MAN Operating Instructions

MAN Diesel & Turbo 3.1.1

Prerequisites/Guarantee Prerequisites

Effects from the past

For a successful operation of the engine/the engine system, specific prereq-
uisites must be fulfilled before the system is commissioned. There are further
prerequisites which must be fulfilled by the engine/plant operator when daily
operation starts.

The prerequisites influencing the future performance include:
▪ the origin of the engine,
▪ qualified production under the supervision of the monitoring authorities/

classification companies,
▪ qualified technicians which have been trained for the precise, reliable

assembly and adjustment of the engine during the build-up and testing
period at the plant,
▪ meticulous planning, design and set-up of the system,
▪ a good cooperation between the purchaser and the main contractor and
the sub-suppliers,
▪ consistent target-oriented work during the start-up and running-in phase.

Prerequisites - To be practised daily

Prerequisites which must be met consistently for the daily operation of the
system:
▪ selecting employees with relevant qualifications and training
▪ availability of technical documentation for the system, especially Operat-

ing Instructions and safety regulations,
▪ ensuring operational availability and reliability, taking into account the

operating targets and results
▪ an effective organisation for monitoring the maintenance and repair work
▪ the commissioning of the systems, auxiliary facilities and engines accord-

ing to a chronologically structured check list and
▪ knowledge of the operating targets and the consequences from striking

a balance between expenditure and benefit
The points mentioned above will be explained in more detail below.

2008-12-08 - de Guarantee Warranty questions are dealt with in accordance with the MAN Diesel & Operation/Operating fluids
Turbo SE "General terms and conditions of sale". We would like to draw your
Point 1 attention to an important section that contains a number of basic principles V28/33D
you can use for orientation when making your daily decisions and in your
handling approach. The entire text, or agreements made in each case, is
binding.
"MAN Diesel & Turbo SE provides assurance of compliance with expressly
stated characteristics and also for flawless engineering design and manufac-
turing and also that materials are free of defects. You can therefore choose
either to have parts which become unserviceable as a result of these kind of
defects, or whose usefulness has been significantly impaired, repaired free of
charge or redelivered at own expense and risk."

6739 3.1.1-01 EN 1 (2)

Prerequisites3.1.1 MAN Diesel & Turbo

Point 4 "The warranty does not cover natural wear and parts that reach the end of
their service life prematurely due to their material qualities or type of use; it
Point 5 also does not cover damage as a result of improper storage, handling or use,
excessive stress, unsuitable operating fluids, substandard construction work
or foundations, unsuitable building ground, chemical, electrochemical or
electrical factors."
"The orderer can only submit warranty claims to MAN Diesel & Turbo SE if
▪ the delivery item has been set up and commissioned by MAN Diesel &

Turbo SE personnel,
▪ a defect which is covered under the warranty is reported to MAN Diesel

& Turbo SE immediately in writing and 2 months following expiry of the
warranty period at the very latest,
▪ the orderer has observed the MAN Diesel & Turbo SE guidelines regard-
ing handling and maintenance of the delivery item and, most importantly,
has had any prescribed checks properly carried out,
▪ no remedial work has been carried out without the consent of MAN Die-
sel & Turbo SE,
▪ no spare parts manufactured by third parties have been installed."

Operation/Operating fluids 2008-12-08 - de

V28/33D

2 (2) 6739 3.1.1-01 EN

MAN Diesel & Turbo 3.1.2

Transport/On site measures Prerequisites

Preparation The following chapters are addressed to the engine plant operator and give
Transport an overview of the work to be done during the engine plant transport.
Scope of supply The contractual agreements between MAN Diesel & Turbo SE and the oper-
ator or its representative shall prevail over the information in this chapter.
2011-11-29 - de It is recommended to have the transport, installation and commissioning of Operation/Operating fluids
the engine plant carried out by MAN Diesel & Turbo.
To ensure trouble-free transport and installation, the customer has to carry General
out or to provide the following items.
▪ Availability of sufficient transport capacities
▪ Check of the scope of supply
▪ Site preparation
▪ Availability of energy and operating fluids

The engine plant will be transported to the site in accordance with the con-
tractual agreements between MAN Diesel & Turbo SE and the customer.
The following items give an overview of the most important tasks to be fulfil-
led in connection with transport.

Prerequisites

Engine plant is ready for transport.

Implementation

▪ Transport to the site will be carried out or provided in accordance with
the contractual agreements between MAN Diesel & Turbo SE and the
customer.

▪ The required suspension devices and transport equipment on site shall
be agreed with MAN Diesel & Turbo and made available in due time.

▪ On site transport must be carried out in accordance with the applicable
transport regulations.

Generally, MAN Diesel & Turbo supplies the engine plant up to a system limit
engine or for skid-mounted units up to a system limit skid-mounted unit with
fully installed piping and cabling. Terminal boxes or transition flanges are
interfaces for corresponding energy and operating fluids.
After receiving the delivery on site, check the scope of supply for complete-
ness and proper condition immediately. Delayed claims shall not be accep-
ted by MAN Diesel & Turbo.
Before each transport, MAN Diesel & Turbo shall mark the delivered compo-
nents and attach a packing list to the delivery.
The following items give an overview of the most important tasks to be fulfil-
led in connection with scope of supply checking.

6680 3.1.2-01 EN 1 (2)

3.1.2 MAN Diesel & Turbo

Prerequisites Prerequisites

Delivery received

Implementation

▪ Check the packages and unpacked parts of the delivery.
▪ Inform MAN Diesel & Turbo about any missing parts or damaged pack-

ages in accordance with the contractual agreements.
▪ Check the delivery for completeness and integrity and report any dam-

age to the shipping company, if necessary.

Installation Site

Installation site of the engine plant must fulfill the requirements for safe instal-
lation of all components.
The following items give an overview of the most important tasks to be fulfil-
led in connection with preparation of the installation site.
▪ The installation site must be prepared in accordance with the contractual

agreements with reference to following items:
– transport and work areas
– tool and material storage place
– adequate lighting
– safety devices
▪ Installation surfaces must be prepared in accordance with the contrac-
tual agreements with reference to the data of the project documentation.
▪ The engine plant must be protected against excessive surroundings
effects (e.g. dust, sand etc.).

Operation/Operating fluids Energy and operating fluids

General The energy supply of the engine plant is provided from external energy sour-
ces. The required energy and operating fluids shall be made available by the
customer.
The following items give an overview of the most important tasks to be fulfil-
led in connection with energy supply and operating fluid availability.
▪ The required energy and operating fluids shall be made available with the

specified quality. To ensure safe operation of the engine plant, observe
the specified requirements.
▪ The supply and disposal of required energy and operating fluids must be
provided and monitored during the operation.
▪ If more than one supply voltage must be available, the differing supply
voltages must be fully isolated from each other.

2011-11-29 - de

2 (2) 6680 3.1.2-01 EN

MAN Diesel & Turbo 3.1.3

Assembly/Installation Prerequisites

Preparation The following items give an overview of the most important tasks to be fulfil-
Erection led in connection with installation and assembly.
▪ The work will be carried out or provided in accordance with the contrac-

tual agreements between MAN Diesel & Turbo SE and the customer.
▪ Use for installation only materials/parts of prescribed quality. Ensure that

no materials/parts are mixed (e.g. bolts or screws).
▪ Never use the safety-related components or any other tasks, to ensure

that their safety-relevant functions are not adversely affected.
▪ For arrangement of the components with safety functions, observe the

specific regulations and principles, particularly concerning the following
items:
– fail safe behavior
– redundancy
– variety
– self monitoring
– maximum achievable pressure
– appropriate response times
▪ For design and installation of pressure equipment and piping, observe
the applicable regulations as well as the contractual agreements to
ensure safe operation. Provide adequate protection of pressure equip-
ment and piping.

The installation of the engine plant incl. alignment will be carried out in
accordance with the contractual agreements between MAN Diesel & Turbo
SE and the customer.
The following items give an overview of the most important tasks to be fulfil-
led in connection with installation of the engine plant.

Prerequisites

The supply and disposal of required energy and operating fluids are provided

2011-11-29 - de Connections Implementation Operation/Operating fluids

▪ Any work related to installation of the engine plant shall only be carried General
out in accordance with the contractual agreements.

▪ Any work prescribed by contractual agreements shall be carried out by
MAN Diesel & Turbo.

The connections of required energy and operating fluids must be provided
on specified interfaces in accordance with engine installation drawing.
The following items give an overview of the most important tasks to be fulfil-
led for connections of the engine plant.

6680 3.1.3-01 EN 1 (2)

3.1.3 MAN Diesel & Turbo

Prerequisites Prerequisites

Engine plant is erected.

Implementation

▪ Determine connection points in accordance with the engine installation
drawing.

▪ Route required energy and operating fluids to the specified connection
points. For this purpose, observe relevant national regulations concerning
the energy and operating fluids to be used.

▪ Install piping and fittings using the following examples to avoid any dan-
ger for people as far as possible:
– Install burst discs so that the ejected jet could not cause any damage
when they are activated.
– Fit piping tension free
– Piping mountings must be performed so that they could not loosen
due to foreseeable exerting forces (e.g. movements due to pressure
changes, vibrations).

Operation/Operating fluids 2011-11-29 - de

General

2 (2) 6680 3.1.3-01 EN

MAN Diesel & Turbo 3.1.4

Commissioning Prerequisites

Check of installation

After installation and prior to the commissioning of the engine plant, check all
performed work as well as the safe condition of the engine plant.
The following items give an overview of the most important tasks to be fulfil-
led in connection with check of the installation of the engine plant.

Prerequisites

Fabrication of all required connections is completed.

Implementation

Guarantee

MAN Diesel & Turbo will refuse any guarantee claims, which are
attributed to an improper installation check.

Commissioning ▪ To prevent damages due to improper installation and connections have
all required checks and tests performed by MAN Diesel & Turbo.
2011-11-29 - de Operation/Operating fluids
▪ In particular, check the following items:
– installation of piping in accordance with layout plan General
– proper installation of cabling
– installation of safety devices
– availability of walkways and working rooms
– installation of all warning notes
– Realization of measures required for engine plant protection by oper-
ator (e.g. installation of safety valves, fitting the protection devices).

▪ Detected defects must be rectified immediately.

For safety reasons, the initial commissioning the engine plant may only be
carried out by MAN Diesel & Turbo.
The following items give an overview of the most important tasks to be fulfil-
led in connection with initial commissioning.

Prerequisites

Installation check is performed.

Implementation

▪ Have the test run carried out by MAN Diesel & Turbo, in order to prevent
damages due to improper commissioning.

▪ Take over the engine plant by MAN Diesel & Turbo based on a take-over
report.

6680 3.1.4-01 EN 1 (2)

3.1.4 MAN Diesel & Turbo

Prerequisites ▪ Prepare with MAN Diesel & Turbo a test plan with all required informa-
tion, e.g. date of preparing, time and scope of the next test, or require-
ments of national legislation.

▪ Have a specific start up procedure for the engine plant prepared by MAN
Diesel & Turbo.

Operation/Operating fluids 2011-11-29 - de

General

2 (2) 6680 3.1.4-01 EN

MAN Diesel & Turbo 3.2

Safety

3.1 Prerequisites
3.2 Safety
3.3 Operating fluids
3.4 Operative management I - Starting the engine
3.5 Operative Management II - Monitoring Operating

Data
3.6 Operative Management III - Operating faults
3.7 Operative Management IV - Shutting down the

Engine

2013-02-19 - de Operation/Operating fluids

6739 3.2-02 EN 1 (1)



MAN Diesel & Turbo 3.2.1

General notes Safety

Safety-related basic principles/their fulfilment

Safe use German laws and standards and also guidelines of the European Union (EU)
require that technical products guarantee their users the necessary level of
safety and also satisfy the generally accepted codes of practise. It must also
be emphasised in this regard that the safe use and safety of machines must
be ensured by proper planning and engineering design, and not by restrictive
rules of conduct.

Intended use The technical documentation must include statements about the "Intended
use" and restrictions governing use.

Residual risks Residual risks must be made disclosed and sources of danger/critical situa-
tions must be identified/named. The purpose of this information is to make
operating personnel aware of the dangers and enable them to act in a
safety-conscious manner.

Signals, symbols, texts or images must be used to communicate these kind
of dangers/critical situations. These must be used on the product and in the
technical documentation following an agreed method. A multi-level system
must be used for safety information.

Contribution of MAN Diesel & MAN Diesel & Turbo SE invests particular effort at the development, engi-
Turbo SE neering design and construction stages, and through appropriate layout
measures in the technical documentation by observing the information in this
section in particular, to ensure these requirements are satisfied. The sum-
mary, some of which is in note form, does not relieve the user of the respon-
sibility of observing the relevant sections in the technical documentation.
Please also observe that incorrect handling may render claims made under
the warranty null and void.

2012-07-20 - de Operation/Operating fluids

V28/33D

6739 3.2.1-01 EN 1 (4)

3.2.1 MAN Diesel & Turbo

Safety Warning signs

Warning sign on engine

Operation/Operating fluids Figure 1: Warning sign - engine 2012-07-20 - de
This warning sign is placed on the engine in a well-visible manner.
V28/33D Personnel who need to enter the danger area within 2.5 m around the
machine for operational reasons must be informed on the existing dangers.
Access to the danger area is only permitted when the operating mode of the
engine is in order and if suitable protective equipment is being worn. Unnec-
essary loitering in the danger area is prohibited.

2 (4) 6739 3.2.1-01 EN

MAN Diesel & Turbo 3.2.1

Safety

Figure 2: Warning sign - explosion in the crankcase Operation/Operating fluids
This warning sign is placed on the engine in a well-visible manner.
V28/33D
Danger of explosion

When opening the crankcase cover, hot components may initiate the
formation of an explosive mixture, consisting of crankcase-generated
oil mist and of inflowing oxygen.
• Carry out any work on the engine only after a period of 20 minutes

Premature entering the crankcase

Danger to life due to oxygen-poor atmosphere and hot components in
case of premature entering the crankcase.
• before entering the crankcase it must be cooled and sufficiently

ventilated
• the engine must be secured against the unintentional start
• an additional person must take corrective action to protect work in the

crankcase

2012-07-20 - de

6739 3.2.1-01 EN 3 (4)

Safety 3.2.1 MAN Diesel & Turbo

Operation/Operating fluids Explanations for the warning sign, meaning of the symbols in the warning notes 2012-07-20 - de

V28/33D Attention!
Warning of a dangerous location!
Flammable materials!
Warning of hand injuries
Danger of crushing!
Hot surface!

Explanations of the warning sign, significance of the prohibitive symbols

Fire, open flame and smoking prohibited!
Entry not allowed to unauthorised persons!

Explanations of the warning sign, meaning of the command symbols

Wear ear protection!
Wear protective helmet!
Use eye protection!
Wear protective clothing!
Wear safety shoes!
Wear protective gloves!
Operating instructions/
Observe working instructions!

4 (4) 6739 3.2.1-01 EN

MAN Diesel & Turbo 3.2.2

Design/suitability of the engine Safety

Intended use

The four-stroke diesel engine delivered is intended for (initial) operation under
the following conditions:
▪ compliance to the Technical Specifications, Section 2.5.1,
▪ compliance to the Technical Specifications, Section 2.1,
▪ compliance to the order confirmation,
▪ it may only be operated using the specified operating media.
▪ The layout/arrangement of the supply, measuring, control and regulating

systems as well as the constraints determined (e.g. disassembly areas/
crane capacities) according to MAN Diesel & Turbo SE recommenda-
tions or state-of-the-art technology need to be taken into account.
▪ Starting, operating and stopping according to the usual technical operat-
ing rules, exclusively by authorised, qualified, trained personnel who are
familiar with the system.

Restrictions of the intended use

The engine is conditionally intended/suitable for:
▪ Operation at operating data for which there is an alarm situation,
▪ Operation with forced speed (marine engines),
▪ passing through barred speed ranges,
▪ idling or low load operation,
▪ operation with generator in "return output" (in parallel operation with the

grid),
▪ operation with reduced maintenance expenditure,
▪ accelerated run-up/sudden loading and unloading to a moderate extent,
▪ emergency operation with 1 or 2 blocked/partly dismantled turbo-

charger(s),
– operation with shut-off fuel pumps,

– with the running gear removed,

– with dismantled rocker arms/push rods.

2009-11-13 - de Not intended/unsuitable for Operation/Operating fluids

The engine is not intended/suitable for: V28/33D
▪ operation with operating values which caused an engine stop or load

reduction,
▪ operation in case of failure of supply equipment (air, compressed air,

water, ..., electric voltage supply, power output),
▪ Operation within barred speed ranges,
▪ operation without appropriate monitoring/supervision,
▪ operation without or with significantly reduced maintenance expenditure,
▪ unauthorised modifications,
▪ use of spare parts which have not been supplied by the original manu-

facturer
▪ long-term shutdown without adopting preservation measures.

6739 3.2.2-02 EN 1 (1)



MAN Diesel & Turbo 3.2.3

Risks/Dangers Safety

Dangers resulting from insufficient qualification/training of the personnel

Expectations in case of Propulsion operation
marine engines Machine officer on board. Operation led by technical officer.

Maintenance work/repair work:
Implementation by engineers, technical assistants or fitters and helpers.
Instruction and, in difficult cases: Technical officer or machine officer.

General operation (in port):
Operation conducted by technical officer.

Maintenance work/repair work in port:
As above.

The following applies in The persons responsible for the operating checks must be in possession of a
addition certificate/proof according to national and international agreements (STCW).
The number of people required and their minimum qualifications are generally
stipulated by national regulations or by international agreements (STCW).

Expectations for stationary During operation:
plants (power plants) Operations manager (engineer) can be contacted. Company management/
monitoring of the engine and the relevant supply systems by trained and
specially instructed engineer or technical assistant.

Maintenance work/repair work:
Implementation by engineers, technical assistants or fitters and helpers.
Instruction and, in difficult cases: Engineer or machine officer

The following applies in For persons responsible for operating checks and for persons carrying out/
addition monitoring maintenance work and repairs, it must be proven in accordance
with the Energy Law (EnWG) in Germany that technical operation is guaran-
teed by an adequate number of qualified employees. In other countries com-
parable laws/guidelines must be observed. Insufficient qualification/training of
employees cannot be compensated for by other means.

Dangers due to components/systems Operation/Operating fluids

Mechanical components can be dangerous under specific operating condi- V28/33D
tions or when carrying out specific actions. These dangers exist in engines
and turbochargers, amongst others, and cannot be eliminated by counter-
measures at the engineering design, development and manufacturing
stages. However, these machines can be operated safely under normal con-
ditions, and also occasionally under unfavourable conditions. Certain dan-
gers exist in every case that cannot be fully eliminated. Some of these are
only potential dangers, and several only occur under specific or unforeseen
circumstances. The purpose of figs. 1 and 2 below and tables 1, 2, 3, 4 and
5 is to draw attention to these kind of danger zones.

2009-11-13 - de

6739 3.2.3-02 EN 1 (6)

Safety 3.2.3 MAN Diesel & Turbo

Operation/Operating fluids Figure 1: Danger zones at the engine according to the EC Machine Directive 2009-11-13 - de
2 (6) 6739 3.2.3-02 EN
V28/33D

MAN Diesel & Turbo 3.2.3

Safety

Figure 2: Danger zones at the engine according to the EC Machine Directive

Dangers due to emissions Danger Defensive/protective measure

Emission Dangerous to the skin and health, Use and dispose of according to the
Prepared cooling water, lubricating water-contaminating instructions of the manufacturers or
oil, fuel suppliers
Cleaning and auxiliary agents
According to the manufacturer's Use and dispose of according to the
Exhaust with harmful components information instructions of the manufacturers or
NOx, SO2, CO, HC, soot suppliers

Sound (structure-borne) Harmful to health1), ecologically harm- Carry out maintenance work in
ful when limit values are exceeded accordance with maintenance sched-
Sound (structure-borne) ule, inform company management of
dangers, critically observe operating
Vibrations results

Dangerous for persons and the envi- Wear hearing protection, limit expo- Operation/Operating fluids
ronment when limit values are excee- sure to the absolutely essential
ded V28/33D

Dangerous for persons and the envi- Limit exposure to the absolutely
ronment when limit values are excee- essential
ded

2009-11-13 - de Hazardous, for maximum allowable Avoid a reinforcement of process-
threshold see Section 2.5.1 related vibrations through additional
interference sources.

1) Information for clients in California:

6739 3.2.3-02 EN 3 (6)

3.2.3 MAN Diesel & Turbo

Safety CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
Table 1: Dangers from emissions originating from the engine and turbocharger

Personal protection measures

The accident prevention regulations (APR) and other regulations issued by
the responsible trade association or comparable institutions must be strictly
observed.
This includes wearing work protection clothes and safety shoes, the use of
safety helmets, goggles, hearing protection and gloves.
The general protection clothing/equipment must comply, as a minimum, with
the following standards and working descriptions:

Subject Standard / Issue date Description of the workplace

Hearing protection DIN EN 352-1 / 04.2003 For the noise range up to 110 dBA

Head protection DIN EN 397 / 05.2000 Sharp edges and corners, danger
from falling objects, high surface tem-
peratures <220 ℃

Eye protection DIN EN 166 / 04.2002 Danger from spurting oil and hot liq-
uids in a temperature range of
approx. 40 to 200 °C

When recording the indicator charac-
teristics: Facial protection against
flash fires

Protective clothing DIN EN 340 / 03.2004 High surface temperatures <220 ℃,
sharp edges and corners

Foot protection DIN EN ISO 20345 / 10.2004 Use of oils, fuels, chemicals and simi-
lar substances, hot surfaces <220 ℃,
sharp edges and corners, danger of
falling objects, danger of impacts

Hand protection DIN EN 420 / 12.2003 Use of oils, fuels, chemicals and simi-
DIN EN 388 / 12.2003 lar substances, hot surfaces <220 ℃,
DIN EN 407 / 11.2004 sharp edges and corners. When
recording the indicator characteris-
tics: hot surfaces < 350 ℃

Table 2: Protection equipment standards and work descriptions

Operation/Operating fluids In addition, observe instructions on special protective clothing/equipment in
the individual Work Cards (see Volume B2/Work instructions)!
V28/33D
The relevant sections of the technical documentation must have been read
and understood.

Hazardous areas on the engine (during designated use) 2009-11-13 - de

Danger zone Source of danger Possible consequences
Engine, complete (1)
Absence of/impaired operational relia- Danger to ship and crew and/or
Flywheel (2) bility emergency situation due to failure of

electrical power supply

Gear ring/Fixing bolts Trapping, crushing, impact to body/
limbs

4 (6) 6739 3.2.3-02 EN

MAN Diesel & Turbo 3.2.3

Danger zone Source of danger Possible consequences Safety

Turning gear (3) Gear ring/Area of gear mesh Trapping, crushing, impact to body/
limbs

Longitudinal sides of engine (4) Danger of explosion due to compo- Parts can be flung out of the engine.
nents being flung out at the side of
the engine.

Turbocharger, especially the radial Parts under internal pressure, parts Parts can be flung out of the
space in relation to the rotor (5) rotating at high speeds machine.

Pipes/pressure vessels, pressurised Parts under internal pressure, filled Spurting/discharge of media, danger
parts/systems, or liquid or gas-filled with liquids/gases of injury, danger of fire, loss of operat-
components/systems (6) ing fluids, contamination, possible
danger to health and the environment

Crankcase cover (7) Moving parts, hot/turbulent oil Danger of explosion, fire and acci-
dents due to spurting of oil and/or
danger of injury in the event of bear-
ing or piston seizures.

Casing of camshaft, rocker arms and Intervention in cam/camshaft, move- Trapping/crushing of garments/limbs,
push rods (8) ment of rocker arms and push rods leaking oil

Insulation and sheathing of fuel and Hot surfaces, flammable medium, Burning, squirting fuel, sometimes
injection pipes (9) parts under high internal pressure discharged as a jet which can pene-
trate the skin

Exhaust pipe and exhaust pipe cas- Hot surfaces, parts under internal Burning, escaping hot gases, fire haz-
ing (10) pressure filled with hot gas ard

Instrumentation and control equip- High voltage Electric shock, fire, arcing; function
ment/systems (electrical) (11) adversely affected in the event of
inappropriate handling.

Instrumentation and control equip- Parts under internal pressure, filled Danger of injury from escaping
ment/systems (hydraulic/pneumatic) with gases medium during depressurisation;
(12) function is adversely affected by inap-
propriate handling.

Threaded connections (14) Parts subject to high compressive/ Danger due to bolts/nuts breaking off
tensile stress or coming loose

Safety valves, pressure setting valves Malfunction/restricted functionality Injuries due to bursting, parts coming
(cylinder head, crankcase, instrumen- and resulting failures off and escaping medium
tation and control systems) (16)

Special tools (17) Vary depending on the application, Danger to persons and damage to
sometimes pose a significant danger property!

Hydraulic tightening devices, high- Parts under high internal pressure Injuries due to parts coming off/loose
pressure hoses, high-pressure pump can burst, break or leak; hydraulic oil or leaking hydraulic oil
(18) may be discharged in the form of jets
that can penetrate the skin (hydraulic Operation/Operating fluids
oil is harmful to health)
V28/33D
Table 3: Danger zones on the engine (during designated use)

2009-11-13 - de Danger situations during proper designated use

Danger zone Source of hazard Possible consequences

Operation with forced speed (marine Increase in torque, negative influence Contamination, wear, overloading of
engines), on operating data components, pumping of the turbo-
charger

Idling operation or low-load operation Operation outside the operation Incomplete combustion, residues in
range, deterioration of operating data the combustion chamber

6739 3.2.3-02 EN 5 (6)

3.2.3 MAN Diesel & Turbo

Safety Danger zone Source of hazard Possible consequences

Operation with generator in "return During return output, the engine is Unplanned operating condition
output" (in the parallel operation with driven by the generator.
the grid)

Overspeed Increased thermal and mechanical Unplanned operating condition
loads, exhaust clouding, turbocharger
overload

Operation in case of failure of speed Remote-controlled manoeuvring is Limited manoeuvrability
governor not possible with marine engines
(communication problems).

Emergency operation with blocked/ Engine's thermal balance affected, Damage to combustion-chamber
partly dismounted turbocharger potential overload condition components

Emergency operation with fuel pump Reduction in output required, operat- Reduced output, ship speed,
switched off ing data could be exceeded manoeuvrability

Emergency operation with cylinder Reduction in output required, operat- Increased attention required
parts removed ing data could be exceeded, starting
difficulties threat, critical vibrations
can occur

Emergency operation with dismantled Reduction in output required, operat- Increased attention required
rocker arms/push rods ing data could be exceeded

Table 4: Danger situations during proper designated use

Danger situations during improper use

Danger zone Source of hazard Possible consequences

Putting into operation of the engine/of Impairment of the running layers, pre- Increased wear, permanent damage,
parts without running in, liminary component damage impact on the oil consumption, piston
seizure in extreme cases

Operation within restricted speed Under certain conditions increased Danger from components and
ranges vibration and mechanical load screwed connections

Operation without appropriate super- Measures in the case of unpredicta- Miscellaneous
vision ble events

Operation with significantly reduced Reduction of operational reliability, Cumulative effects, loss of warranty
maintenance efforts spontaneous failures, increased fuel
consumption, lubricating oil con-
sumption, increased emissions and
costs

Unauthorised modifications Danger from the deterioration in Parts failure, therefore further dam-
operational reliability caused by inad- age, loss of warranty
equate solutions
Operation/Operating fluids
Use of non-genuine spare parts Combination with other parts not Parts failure, therefore further dam-
V28/33D guaranteed, deterioration in operating age, loss of warranty
safety and spontaneous failures to be
expected

Decommissioning over a longer Corrosion, and seizing of parts Corrosion damage, accumulation of 2009-11-13 - de
period of time without preservation corrosion products, start and operat-
ing difficulties

Table 5: Danger situations during improper use

6 (6) 6739 3.2.3-02 EN

MAN Diesel & Turbo 3.2.4
Safety Instructions
Safety

Marking/danger scale Attention is to be drawn to the dangers by the safety instructions, in con-
formance with the relevant laws, guidelines and standards. This applies for
Marking marking on the product and in the technical documentation. This should indi-
cate the following information:
Scale of danger ▪ Type and source of the danger,
▪ Immediacy/magnitude of the danger,
▪ possible consequences,
▪ Measures for avoidance.
The explanations and tables in Section 3.2.3 follow this specification, as well
as other safety instructions in the technical documentation.

The immediacy/magnitude of the danger is identified using a 5-stage scale
as shown below:

Danger

means that death or severe injuries will occur, if the relevant
precautionary measures are not taken.

Warning!

means that death or severe injuries may occur, if the relevant
precautionary measures are not taken.

Caution

with warning triangle means that slight injuries may occur, if the
relevant precautionary measures are not taken.

Caution Operation/Operating fluids

without warning triangle means that material damage may occur, if the General
relevant precautionary measures are not taken.

2011-12-05 - de Note

indicates special user tips and other useful information.

6680 3.2.4-01 EN 1 (2)

Safety3.2.4 MAN Diesel & Turbo

Examples Example of danger

Flywheel can catch, crush, hit body/limbs.
Do not remove covering. Do not reach into the danger area.

Example of caution

Commissioning the engine/components without running-in can
damage components.
Follow the regulations, run in the engine again after a long period of
low load operation.

Operation/Operating fluids 2011-12-05 - de

General

2 (2) 6680 3.2.4-01 EN

MAN Diesel & Turbo 3.2.5
Safety Regulations
Safety

General

2012-07-17 - de Trained staff Operation/Operating fluids

Trained staff in terms of the manufacturer are persons who because of their General
education and/or qualified training have a level of knowledge enabling them
to operate and maintain MAN Diesel & Turbo engines.
MAN Diesel & Turbo offers qualified training (basic and advanced).

Untrained staff

Untrained persons may 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.

Technical documentation

The technical documentation for the plant, especially the Operating and
Working Instructions for the engine and for the accessories required for
engine operation must be read and known.

Lack of information

Lack of information and non-observance of information may cause
serious injury to persons and serious damage to property and the
environment.
• Operating and Working Instructions are to be observed.

Operations log

It is required to meet the regulations of supervising authorities, to keep an
operations log, where all the important work with the completion dates, oper-
ating results and special events are recorded. When the personnel are
changed, the new person should be able to continue the operation in a
proper manner based on this documentation. The machine log also permits
limited analysis of trends and tracing the cause of operational malfunctions.

Accident prevention regulations

When operating the engine, and during maintenance and overhauls, the valid
accident prevention regulations must be observed. It is advisable to post
these specifications in the engine room and to repeatedly indicate the acci-
dent hazards.

6680 3.2.5-01 EN 1 (7)

3.2.5 MAN Diesel & Turbo

Safety During operation MAN Diesel & Turbo engines are put on the market according to latest tech-
nical safety standards. Nevertheless, some hazardous areas cannot be avoi-
Operation/Operating fluids2 (7) ded by design solutions. These hazardous areas are listed and explained 2012-07-17 - de
below.
General
Falling down objects

Falling down objects

Objects placed on the engine and/or on the gallery during operation,
may fall down and cause severe personnel injuries and material
damage.
• Never place objects on the engine and/or on the gallery during operation

Explosion in the crankcase

Explosion in the crankcase

When the relief valve in the crankcase cover is activated through an
explosion in the crankcase, release of a large volume of highly
explosive oil mist is to be expected.
• Leave the engine room immediately.
• Vent the engine room

Fire hazard

Fire hazard

Generally, a potential fire hazard due to fuel and lubricating oil is
present in the engine room.
• Smoking and handling with open fire is prohibited.
• Fuel and oil pipes may not be routed next to uninsulated engine

components (exhaust pipe/turbocharger).
• After overhaul work on the exhaust pipe and turbocharger, all insulation

and coverings must be re-fitted carefully and completely.
• Check all fuel and oil pipes regularly for tightness
• Any leaks are to be rectified immediately
• Make fire extinguishing units available and check them regularly

If fire breaks out, observe the following items:
▪ stay calm;
▪ dial the emergency number;
▪ shut off the fuel and oil supply (stop the engine, turn the feed pumps off,

close the valves);

6680 3.2.5-01 EN

MAN Diesel & Turbo 3.2.5

▪ machine room accessible; Safety
– try to extinguish the fire using hand fire extinguishers;

▪ machine room not accessible;
– close all openings for oxygen inflow (doors, roof-lights, supply and
exhaust fans must be switched off, chimneys);

Asphyxia hazard

Danger to life through flue gases emitted during a fire. Inhalation of
these gases may lead to asphyxia.

• In case of fire, leave the engine room immediately

Works on the engine Temperatures in the engine room

The temperature in the engine-room may not fall below +5 °C. If the temper-
ature falls below this value, the cooling water chambers must be drained - in
any case if the cooling water does not contain antifreeze. Freezing could oth-
erwise cause material cracks / damage to components.

Working on engine

Danger of falling

When the work requires walking around the engine, severe injuries or
fatal accidents due to falling can occur.

• Fall protection devices (e.g. safety harness) must be used and fastened
at suitable points.

• Wear personal protective equipment

Transportation and storage of components and tools

Components and tools falling down Operation/Operating fluids

Components and tools placed down on unclean and uneven surfaces General
may slip or fall down, and thereby may injure a person.

• Put components and tools aside on a clean and flat surface

• Existing grating shall be covered

• Isolate working areas

2012-07-17 - de

6680 3.2.5-01 EN 3 (7)

3.2.5 MAN Diesel & Turbo

Safety Standing and transport under suspended loads

Operation/Operating fluids Improper transport of components and tools may lead to accidents
with severe or fatal person injuries.
General • Use suitable transport equipment as well as suspension devices and

lifting tackles, and operate them as intended
• Do not stand under suspended loads
• Wear protective clothing (protective helmet, safety goggles, protective

gloves)

Residual heat after engine stop

Hot surfaces

High surface temperatures developing during the engine operation
may cause burns at contact.
• Avoid direct contact with hot surfaces
• Wear protective clothing
• When working at certain surface temperatures, it may be helpful to take

special care and to wear heat-resistant personal protective appliances

Opening crankcase cover

Danger of explosion

When opening the crankcase cover, hot components may initiate the
formation of an explosive mixture, consisting of crankcase-generated
oil mist and of inflowing oxygen.
• Carry out any work on the engine only after a period of 20 minutes

Moving parts

Danger of crushing through moving parts

During engine operation or work on the engine, accidents with severe
person injuries by moving parts may occur.
• Do not reach/grasp rotating parts
• Secure or cover the moving parts whenever possible.

2012-07-17 - de

4 (7) 6680 3.2.5-01 EN

MAN Diesel & Turbo 3.2.5

Pipes Safety

Fluids in piping

When opening piping, flanges, screwed connections or pipe fittings,
hot fluids under pressure may be released. These fluids may cause
burns or penetrate skin and tissue.

• Before opening, check whether the system is depressurized or emptied

• Carry out any work on the engine only after a period of 20 minutes

When being removed, all piping to be re-fitted, especially those for fuel, lubri-
cating oil and air, must be closed off carefully. New piping to be fitted must
be checked carefully for cleanliness and flushed out if required. Prevent for-
eign objects from entering the system under any circumstances. If stored for
a long time, all individual parts must be preserved.

Danger of fire through leaks

Leaks from fuel, lubricating oil or gas piping, if not repaired, may cause
fires on the engine.
• After work on relevant piping, make sure that it is shut off carefully
• New piping to be fitted must be checked prior to fitting, and flushed out

if required
• Any leaks are to be rectified immediately

Coverings

After maintenance work, ensure that all coverings are properly mounted
again. Engine operation with removed coverings is generally prohibited!

Missing casings

Due to missing casings, the moving parts are exposed, thus catching
loose clothing and long hair. In case of leaks, operating fluids under
high pressure and at high temperature are released, and can thereby
penetrate and hurt skin and tissue.
• After maintenance work, ensure that all casings or coverings are

mounted again

2012-07-17 - de Operation/Operating fluids

General

6680 3.2.5-01 EN 5 (7)

Safety 3.2.5 MAN Diesel & Turbo

Operation/Operating fluids6 (7) Turning the running gear over 2012-07-17 - de

General Work in drive chamber

Danger to life due to work in the drive chamber during the turning
operation.
• do not work in the drive chamber during the turning operation
• cover any opened drive chamber windows
• prior to start with the turning operation; take into account acoustic and

optical signals

Pressure in the combustion chamber

When turning the running gear, an overpressure will build up in the
combustion chamber if the intake and exhaust valves are closed.
Depending on the running gear position, the piston may be at TDC
after stopping the turning operation.
• Start work on the cylinder head only 1 minute after stopping the turning

operation

Cleaning components

When using high pressure cleaning devices ensure that they are used prop-
erly. Shaft exits (even those with lip-type sealing rings), governors, splash-
proof monitoring systems, cable sockets as well as noise and heat insulation
under non-waterproof coverings must be covered or not cleaned under a
high pressure.

Short-circuit in electronic components

Water in electrical components may cause surface-leakage currents
and fires.
• Never clean switch cabinets and electrical components using high

pressure cleaning devices

Danger of chemical burns

From cleaning agents poisonous gases and fumes can develop, which
may cause light to severe person injuries.
• Wear protective clothing
• Provide adequate ventilation
• Do not inhale developed gases and fumes
• Observe Safety Data Sheets or Operating Instructions of the relevant

manufacturer

6680 3.2.5-01 EN

MAN Diesel & Turbo 3.2.5

Maintenance and repair work on the alarm and safety system Safety

Alarm and safety system

Manipulations or improper work on the alarm and safety system may
lead to failure of the engine safety functions.
• Work on this system may be performed only by authorized qualified

personnel
• After fitting spare parts in the alarm and safety systems, carry out a

complete functional check of the system.

Tools to be used

Tools to be used

Manipulated, defective or improperly used tools may cause severe
personnel injuries and material damages.
• A tool may only be used for its intended purposes.
• Before starting work, check the tool for damage.
• Any repairs or modifications of tools are not permissible
• For work on MAN Diesel & Turbo engines, only MAN Diesel & Turbo

tools are permitted

Insufficient local lighting conditions

Insufficient local lighting conditions

When working on the engine under insufficient local lighting
conditions, a hand lamp should be used.
• The supply voltage of the hand lamp must not exceed 24 volts

2012-07-17 - de Operation/Operating fluids

General

6680 3.2.5-01 EN 7 (7)



MAN Diesel & Turbo 3.3

Operating fluids

3.1 Prerequisites
3.2 Safety
3.3 Operating fluids
3.4 Operative management I - Starting the engine
3.5 Operative Management II - Monitoring Operating

Data
3.6 Operative Management III - Operating faults
3.7 Operative Management IV - Shutting down the

Engine

2013-02-19 - de Operation/Operating fluids

6739 3.3-02 EN 1 (1)



MAN Diesel & Turbo 3.3.1

Gas oil / diesel oil (MGO) specification Operating fluids

Diesel oil Gas oil, marine gas oil (MGO), diesel oil
Gas oil is a crude oil medium distillate and therefore must not contain any
Other designations residual materials.

Military specification

Diesel oils that satisfy specification F-75 or F-76 may be used.

Specification

The suitability of fuel depends on whether it has the properties defined in this
specification (based on its composition in the as-delivered state).
The DIN EN 590 and ISO 8217-2010 (Class DMA or Class DMZ) standards
have been extensively used as the basis when defining these properties. The
properties correspond to the test procedures stated.

Properties Unit Test procedure Typical value
≥ 820.0
Density at 15 °C ISO 3675 ≤ 890.0
≥ 1.5
kg/m3 ISO 3104 ≤ 6.0

Kinematic viscosity at 40 °C DIN EN 116 ≤0
DIN EN 116 ≤ -12
mm2/s (cSt) ≥ 60
ISO 1523
Filtering capability °C ≥ 85
in summer and °C ISO 3405 ≤ 0.01
in winter ISO 3735 ≤ 0.05
ISO 3733 ≤ 1.5
Closed cup flash point according to Abel-Pensky °C ISO 8754 ≤ 0.01
method ISO 6245 ≤ 0.10
ISO CD 10370 ≥ 40
Distillation range up to 350 °C Vol. % ISO 5165
ISO 2160 ≤1
Sediment content (extraction method) Weight %
M1
Water content Vol. % 1D/2D

Sulphur content

Ash Weight %
Coke residue (MCR)

Cetane number -

Copper strip test - Operation/Operating fluids

Other specifications: V28/33D

British Standard BS MA 100-1987

2013-02-05 - de ASTM D 975
Table 1: Diesel fuel (MGO) – properties that must be complied with.

Additional information If distillate intended for use as heating oil is used with stationary engines
instead of diesel oil (EL heating oil according to DIN 51603 or Fuel No. 1 or
Use of diesel oil no. 2 according to ASTM D 396), the ignition behaviour, stability and behav-
iour at low temperatures must be ensured; in other words the requirements
for the filterability and cetane number must be satisfied.

6739 3.3.1-01 EN 1 (2)

Operating fluids3.3.1 MAN Diesel & Turbo

Analyses Improper handling of operating fluids

If operating fluids are improperly handled, this can pose a danger to
health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.

Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at our laboratory (PrimeServLab).

Operation/Operating fluids 2013-02-05 - de

V28/33D

2 (2) 6739 3.3.1-01 EN

MAN Diesel & Turbo 3.3.5

Lubricating oil specification for operation with gas oil (MGO) Operating fluids

General

The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Doped lubricating oils (HD oils) have a proven track record as lubricants for
the drive, cylinder, turbocharger and also for cooling the piston. Doped lubri-
cating oils contain additives that, amongst other things, ensure dirt absorp-
tion capability, engine cleaning, and neutralisation of acidic combustion prod-
ucts.
Only lubricating oils that have been approved by MAN Diesel & Turbo may be
used. These are listed in the table entitled "Approved lubricating oils".

2013-02-07 - de Specifications The base oil (doped lubricating oil = base oil + additives) must have a narrow Operation/Operating fluids
distillation range and be refined using modern methods. If it contains paraf-
Base oil fins, they must not impair the thermal stability or oxidation stability. V28/33D
Compounded lubricating oils The compounded lubricating oil must have the following properties:
(HD oils)
Additives The additives must be dissolved in the oil and their composition must ensure
that as little ash as possible remains following combustion.
Washing ability The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
Neutralisation capability osition in the combustion chamber will be higher, particularly at the outlet
valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
Evaporation tendency ting of the valve seats, and causes valve burn-out, it also increases mechani-
Additional requirements cal wear of the cylinder liners.
Lubricating oil additives Additives must not increase the rate, at which the filter elements in the active
Military specification or used condition are blocked.
The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion.
The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
The base number (BN) must be at least 8.5 mg KOH/g with a fuel sulphur
content of 0.2% or less. The base number (BN) must be at least 12 mg
KOH/g with a fuel sulfur content of between 0.2% and 1.5%.
The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.
The viscosity of the oil must be a monograde oil of SAE40.
The use of other additives with the lubricating oil, or the mixing of different
brands (oils by different manufacturers), is not permitted as this may impair
the performance of the existing additives which have been carefully harmon-
ised with each another, and also specially tailored to the base oil.
Lubricating oils that comply with NATO Code O-278 can be used.

6739 3.3.5-01 EN 1 (2)

3.3.5 MAN Diesel & Turbo

Operating fluids Selection of lubricating oils/ Most of the mineral oil companies are in close regular contact with engine
warranty manufacturers, and can therefore provide information on which oil in their
Oil during operation specific product range has been approved by the engine manufacturer for
the particular application. Irrespective of the above, the lubricating oil manu-
facturers are in any case responsible for the quality and characteristics of
their products. If you have any questions, we will be happy to provide you
with further information.

Manufacturer

BP BP ENERGOL HP-DX40

CASTROL CASTROL HLX 40

CHEVRON (CALTEX, TEXACO) DELO 400 SAE 40
DELO SHP 40

MOBIL MOBIL DELVAC 1640

SHELL SIRIUS X 40

TOTAL FINA TOTAL RUBIA FP40

Table 1: Approved lubricating oils
We will not accept liability for problems that occur as a result of using these
oils.

The intervals between lubricating oil changes are determined by the ageing
rate of the oil. The lubricating oil used must comply with the requirements
stated in the table entitled "Limit values for used engine oil".

Limit value Procedure

Viscosity (at 40 ℃) 100–190 mm2/s ISO 3104 or ASTM D 445

Base number (BN) at least 50 % of fresh oil - ISO 3771
BN

Flash point (PM) At least 170 ℃ ISO 2719

Water content Max. 0.2 % ISO 333 or ASTM D 1744

Soot content Max. 3% DIN 51452

Oxidation Max. 25 A/cm DIN 51453

Table 2: Limit values for used engine oil

Regular analysis of lube oil samples is very important for safe engine opera-
tion. We can analyse fuel for customers at our laboratory (PrimeServLab).

Operation/Operating fluids Improper handling of operating fluids

V28/33D If operating fluids are improperly handled, this can pose a danger to
health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.

2013-02-07 - de

2 (2) 6739 3.3.5-01 EN

MAN Diesel & Turbo 3.3.7

Engine cooling water specifications Operating fluids

Preliminary remarks

As is also the case with the fuel and lubricating oil, the engine cooling water
must be carefully selected, handled and checked. If this is not the case, cor-
rosion, erosion and cavitation may occur at the walls of the cooling system in
contact with water and deposits may form. Deposits obstruct the transfer of
heat and can cause thermal overloading of the cooled parts. The system
must be treated with an anticorrosive agent before bringing it into operation
for the first time. The concentrations prescribed by the engine manufacturer
must always be observed during subsequent operation. The above especially
applies if a chemical additive is added.

Requirements The properties of untreated cooling water must correspond to the following
limit values:
Limit values
Properties/Characteristic Properties Unit
Testing equipment -
Water type Distillate or fresh water, free of foreign matter.
°dH*
Total hardness max. 10 -

pH value 6.5 - 8 mg/l**

Chloride ion content max. 50

Table 1: Cooling water - properties to be observed

*) 1°dH (German hard- ≙ 10 mg CaO in 1 litre of water ≙ 17.9 mg CaCO3/l
ness)

≙ 0.357 mval/l ≙ 0.179 mmol/l

**) 1 mg/l ≙ 1 ppm

The MAN Diesel & Turbo water testing equipment incorporates devices that
determine the water properties referred to above in a straightforward man-
ner. The manufacturers of anticorrosive agents also supply user-friendly test-
ing equipment.

For information on monitoring cooling water, refer to Work Card 000.07.

2013-02-05 - de Additional information If distilled water (from a fresh water generator, for example) or fully desalina- Operation/Operating fluids
ted water (from ion exchange or reverse osmosis) is available, this should
Distillate ideally be used as the engine cooling water. These waters are free of lime V28/33D
and salts which means that deposits that could interfere with the transfer of
Hardness heat to the cooling water, and therefore also reduce the cooling effect, can-
not form. However, these waters are more corrosive than normal hard water
as the thin film of lime scale that would otherwise provide temporary corro-
sion protection does not form on the walls. This is why distilled water must
be handled particularly carefully and the concentration of the additive must
be regularly checked.
The total hardness of the water is the combined effect of the temporary and
permanent hardness. The proportion of calcium and magnesium salts is of
overriding importance. The temporary hardness is determined by the carbo-
nate content of the calcium and magnesium salts. The permanent hardness

6739 3.3.7-01 EN 1 (5)

3.3.7 MAN Diesel & Turbo

Operating fluids is determined by the amount of remaining calcium and magnesium salts (sul-
phates). The temporary (carbonate) hardness is the critical factor that deter-
mines the extent of limescale deposit in the cooling system.
Water with a total hardness of > 10°dGH must be mixed with distilled water,
or softened.

Damage to the cooling water system

Corrosion Corrosion is an electrochemical process that can widely be avoided by
selecting the correct water quality and by carefully handling the water in the
engine cooling system.

Flow cavitation Flow cavitation can occur in areas in which high flow velocities and high tur-
bulence is present. If the steam pressure is reached, steam bubbles form
and subsequently collapse in high pressure zones which causes the destruc-
tion of materials in constricted areas.

Erosion Erosion is a mechanical process accompanied by material abrasion and the
destruction of protective films by solids that have been drawn in, particularly
in areas with high flow velocities or strong turbulence.

Stress corrosion cracking Stress corrosion cracking is a failure mechanism that occurs as a result of
simultaneous dynamic and corrosive stress. This may lead to cracking and
rapid crack propagation in water-cooled, mechanically-loaded components if
the cooling water has not been treated correctly.

Processing of engine cooling water

Formation of a protective The purpose of treating the engine cooling water using anticorrosive agents
film is to produce a continuous protective film on the walls of cooling surfaces
and therefore prevent the damage referred to above. In order for a anticorro-
sive agent to be 100 % effective, it is extremely important that untreated
water satisfies the requirements in the Section Requirements.

Protective films can be formed by treating the cooling water with a chemical
slushing oil.

Treatment prior to initial Treatment with a anticorrosive agent should be carried out before the engine
commissioning of engine is brought into operation for the first time to prevent irreparable initial dam-
age.

Operation/Operating fluids Treatment of the cooling water

V28/33D The engine must not be brought into operation without treating the
cooling water first.

Additives for cooling water 2013-02-05 - de

Required approval A cooling water additive may only be permitted for use if tested and
approved as per the latest directives of the ICE Research Association (FVV)
"Suitability test of internal combustion engine cooling fluid additives.” The test
report must be obtainable on request. The relevant tests can be carried out
on request in Germany at the staatliche Materialprüfanstalt (Federal Institute
for Materials Research and Testing), Abteilung Oberflächentechnik (Surface
Technology Division), Grafenstraße 2 in D-64283 Darmstadt.

2 (5) 6739 3.3.7-01 EN

MAN Diesel & Turbo 3.3.7

Once the cooling water additive has been tested by the FVV, the engine Operating fluids
must be tested in the second step before the final approval is granted.

Biocides

If you cannot avoid using a biocide because the cooling water has been con-
taminated by bacteria, observe the following steps:
▪ You must ensure that the biocide to be used is suitable for the specific

application.
▪ The biocide must be compatible with the sealing materials used in the

cooling water system and must not react with these.
▪ The biocide and its decomposition products must not contain corrosion-

promoting components. Biocides whose decomposition products con-
tain chloride or sulphate ions are not permitted.
▪ Biocides that cause foaming of cooling water are not permitted.
Anti-freeze agents
▪ If anti-freeze agents must be used, consult MAN Diesel & Turbo before-
hand. Anti-freeze solutions reduce the capacity of the cooling water to
absorb heat. In some cases the cooling effect of the coolant may be
insufficient.

2013-02-05 - de Prerequisite for effective use of an anticorrosive agent Operation/Operating fluids

Clean cooling system V28/33D

As contamination significantly reduces the effectiveness of the additive, the
tanks, pipes, coolers and other parts outside the engine must be free of rust
and other deposits before the engine is started up for the first time and after
repairs are carried out on the pipe system. The entire system must therefore
be cleaned with the engine switched off using a suitable cleaning agent (see
Work Cards 000.03 and 000.08 by MAN Diesel).
Loose solid matter in particular must be removed by flushing the system
thoroughly as otherwise erosion may occur in locations where the flow veloc-
ity is high.
The cleaning agents must not corrode the seals and materials of the cooling
system. In most cases, the supplier of the cooling water additive will be able
to carry out this work and, if this is not possible, will at least be able to pro-
vide suitable products to do this. If this work is carried out by the engine
operator, he should use the services of a specialist supplier of cleaning
agents. The cooling system must be flushed thoroughly following cleaning.
Once this has been done, the engine cooling water must be treated immedi-
ately with anticorrosive agent. Once the engine has been brought back into
operation, the cleaned system must be checked for leaks.

Regular checks of the cooling water condition and cooling water
system

Treated cooling water may become contaminated when the engine is in
operation, which causes the additive to loose some of its effectiveness. It is
therefore advisable to regularly check the cooling system and the cooling
water condition. To determine leakages in the lube oil system, it is advisable

6739 3.3.7-01 EN 3 (5)

3.3.7 MAN Diesel & Turbo

Operating fluids to carry out regular checks of water in the compensating tank. Indications of
oil content in water are, e.g. discoloration or a visible oil film on the surface of
the water sample.
The additive concentration must be checked at least once a week using the
test kits specified by the manufacturer. The results must be documented.

Minimum concentration of chemical additives

The chemical additive concentrations must not fall below the minimum
concentrations specified in the table entitled "Chemical agents".

Excessively low concentrations can promote corrosion and must be avoided.
If the concentration is slightly above the recommended concentration this will
not result in damage. Concentrations that are more than twice the recom-
mended concentration should be avoided.
Every 2 to 6 months, send a cooling water sample to an independent labora-
tory or to the engine manufacturer for an integrated analysis.
If chemical additives or anti-freeze solutions are used, the cooling water
should be replaced after 3 years at the latest.
If there is a high concentration of solids (rust) in the system, the water must
be completely replaced and entire system carefully cleaned.
Deposits in the cooling system may be caused by fluids that enter the cool-
ing water, corrosion in the plant and limescale deposits if the water is very
hard. If the concentration of chloride ions has increased, this generally indi-
cates that seawater has entered the system. The maximum specified con-
centration of 50 mg chloride ions per kg must not be exceeded as otherwise
the risk of corrosion is too high. If exhaust gas enters the cooling water this
can lead to a sudden drop in the pH value or to an increase in the sulphate
content.
Water losses must be compensated for by filling with untreated water that
meets the quality requirements specified in the section Requirements. The
concentration of anticorrosive agent must subsequently be checked and
adjusted if necessary.
Subsequent checks of the cooling water are especially required if the cooling
water had to be drained off in order to carry out repairs or maintenance.

Protective measures

Operation/Operating fluids Anticorrosive agents contain chemical compounds that can pose a risk to 2013-02-05 - de
health or the environment if incorrectly used. Comply with the directions in
V28/33D the manufacturer's material safety data sheets.
Avoid prolonged direct contact with the skin. Wash hands thoroughly after
use. If larger quantities spray and/or soak into clothing, remove and wash
clothing before wearing it again.
If chemicals come into contact with your eyes, rinse them immediately with
plenty of water and seek medical advice.
Anticorrosive agents are generally harmful to the water cycle. Observe the
relevant statutory requirements for disposal.

4 (5) 6739 3.3.7-01 EN

MAN Diesel & Turbo 3.3.7

Approved cooling water additives Operating fluids

Chemical agents (chemicals)

Manufacturer Product designation Concentration
BASF Glysacorr G93 10%
CHEVRON, ARTECO Havoline XLI 7.5%
TOTAL WT Supra 7.5%
Q8 Oils Q8 Corrosion Inhibitor 7.5%
Long-Life
Table 2: Chemical agents

2013-02-05 - de Operation/Operating fluids

V28/33D

6739 3.3.7-01 EN 5 (5)



MAN Diesel & Turbo 3.3.8
Analysis of operating fluids
Operating fluids
Checks are important

The engine oil and cooling water must be monitored during operation, as
contamination and acidification limits the performance of the lubricating oil
and damage to the engine could occur if the quality of the water or concen-
tration of slushing oil in the cooling water is too low.
It is also important to check specific fuel characteristics of engines that run
on heavy fuel oil to ensure optimum processing of the heavy fuel oil. It cannot
always be assumed that the values specified in the bunker documents apply
to the delivery.

Test kit

For easy chemical and physical investigation of the operating fluids, we rec-
ommend the following MAN Diesel & Turbo test case:

Medium Type Designation
Fuel and lubricating oil analyser
Heavy fuel oil and lubricating oil A Cooling water tester

Cooling water B

Table 1: Test kit for operating fluids analysis

Laboratory tests Figure 1: Test kit case A for the analysis of fuel and lubricating oil Operation/Operating fluids
Test kit cannot replace a regular laboratory test of operating fluids, but only
2012-11-05 - de supplement it. General
We can analyse engine operating fluids for customers at our laboratory (Pri-
meServLab).

6680 3.3.8-01 EN 1 (4)

3.3.8 MAN Diesel & Turbo

Operating fluids

Figure 2: Test kit case B for the analysis of cooling water

Characteristic value Fuel Water Lubricating oil Characteristic value provides indication of Test
or influences kit
A
Density X X Separator setting A*

Viscosity X X Separating temperature, injection vis- A
cosity, lubricating oil dilution
A
Ignition behaviour CCAI/CII X Ignition and combustion behaviour, A
ignition pressure, rate of pressure A
increase, starting behaviour B
A
Water content X X Fuel delivery and atomisation, corro- B
Test for seawater X X sion susceptibility B
**
Total Base Number (TBN) X existing neutralising capacity
A
pH value X A

Pour point X X Storability and pumpability

Water hardness X Cooling water processing

Chloride ion content X Corrosion potential

Slushing oil in cooling water X Corrosion protection in the cooling
system

Operation/Operating fluids Spot test X Total lubricating oil contamination

General Spot Test (ASTM-D2781) X Compatibility of blended heavy fuel oil
components

Table 2: Characteristic values that can be analysed using the test kits

* Test kit A contains the Viscomar device which measures the viscosity at different reference temperatures. The vis- 2012-11-05 - de
cosity-temperature relationship can be determined in conjunction with the Calcumar computing device (e.g. injection
and pump temperature).
** Not included. Available from the supplier of the slushing oil.

Refill kits are available for the chemicals used. Every test kit contains a com-
prehensive user manual that provides detailed information on each aspect of
the application.

2 (4) 6680 3.3.8-01 EN

MAN Diesel & Turbo 3.3.8

Other testing instruments Operating fluids

Lube Oil Tec Determines the water content, Total Base Number (TBN) and lubricating oil
viscosity (alternative to test kit A with fewer features)

Port-A-lab Figure 3: Lube Oil Tec
Refractometer For test of lubricating oil. Test scope similar to Lube Oil Tec.
For monitoring the anti-freeze solution dosing (in stationary systems).

Sources of supply Item no. Source
09.11999-9005 1, 2
Product 09.11999-9002 1, 2
A Fuel and lubricating oil analyser 09.11999-9003 1, 2
09.11999-9004 1, 2, 3
Chemical refill kit for A
B Cooling water tester 2 Operation/Operating fluids
3
Chemical refill kit for B 4 General
Lube Oil Tec
Port-A-lab 5
Measuring device for determining the concentration
2012-11-05 - de of anticorrosive agent containing nitrite
Refractometer for determining the concentration of
anti-freeze solutions

Addresses Address
MAN Diesel & Turbo SE, Augsburg, Department A-AUG
Source Drew Marine Mar-Tec GmbH, Stenzelring 8, 21107 Hamburg
1
2

6680 3.3.8-01 EN 3 (4)

3.3.8 MAN Diesel & Turbo

Operating fluids Source Address
3 Martechnic GmbH, Schnackenbergallee 13, 22525 Hamburg
4 Supplier of anticorrosive agent
5 Müller Gerätebau GmbH, Rangerdinger Straße 35, 72414 Höfendorf

Operation/Operating fluids 2012-11-05 - de

General

4 (4) 6680 3.3.8-01 EN

MAN Diesel & Turbo 3.3.11
Specifications for intake air (combustion air)
Operating fluids
General The quality and condition of intake air (combustion air) have a significant
Requirements effect on the power output, wear and emissions of the engine. In this regard,
not only are the atmospheric conditions extremely important, but also con-
tamination by solid and gaseous foreign matter.
Mineral dust in the intake air increases wear. Chemicals and gases promote
corrosion.
This is why effective cleaning of intake air (combustion air) and regular main-
tenance/cleaning of the air filter are required.
When designing the intake air system, the maximum permissible overall pres-
sure drop (filter, silencer, pipe line) of 20 mbar must be taken into considera-
tion.
Exhaust turbochargers for marine engines are equipped with silencers
enclosed by a filter mat as a standard. The quality class (filter class) of the
filter mat corresponds to the G3 quality in accordance with EN 779.

Fuel oil engines: As minimum, inlet air (combustion air) must be cleaned in a
filter of the G3 class as per EN779. For engine operation in the environment
with a risk of higher inlet air contamination (e.g. due to sand storms, due to
loading the grain crops cargo vessels or in the surroundings of cement
plants) additional measures must be taken.
Gas engines and dual-fuel engines: As minimum, inlet air (combustion air)
must be cleaned in a filter of the G3 class as per EN779. Gas engines or
dual-fuel engines must only be equipped with a dry filter. Oil bath filters are
not permitted because they enrich the inlet air with oil mist. This is not per-
missible for gas operated engines. For engine operation in the environment
with a risk of higher inlet air contamination (e.g. due to sand storms, due to
loading the grain crops cargo vessels or in the surroundings of cement
plants) additional measures must be taken.
In general, the following applies: The concentration downstream of the air fil-
ter and/or upstream of the turbocharger inlet must not exceed the following
limit values.

Properties Typical value Unit *
mg/Nm3
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 Operation/Operating fluids

Chlorine max. 1.5 General

Sulphur dioxide (SO2) max. 1.25

Hydrogen sulphide (H2S) max. 5

2013-02-04 - de Salt (NaCl) max. 1

* One Nm3 corresponds to one cubic meter of
gas at 0 °C and 101.32 kPa.
Table 1: Intake air (combustion air) - typical values to be observed

6680 3.3.11-01 EN 1 (2)

3.3.11 MAN Diesel & Turbo

Operating fluids Intake air shall not contain any flammable gases

Intake air shall not contain any flammable gases. Make sure that the
combustion air is not explosive.

Operation/Operating fluids 2013-02-04 - de

General

2 (2) 6680 3.3.11-01 EN