MAN Operating Instructions

MAN Diesel & Turbo 3.6.7

Response in the event that operating data are exceeded when alarms occur Operative Management III - Operating faults

General remarks Operating data, e.g. temperatures, pressures, resistance to flow and all other
safety-relevant values/characteristics must be kept within the target range.
Operating data/threshold Threshold values must not be exceeded. Binding reference values are con-
values tained in the test run and commissioning documents and in the "list of meas-
uring and testing devices".
Alarms, reduction and stop Depending on how high the values are exceeded and on the potential risks,
signals alarm or reduction or stop signals for the most important operating data are
triggered. This is achieved with the help of the alarm system and safety con-
Response in the event of trol system. Reduction signals can reduce the engine output in marine sys-
emergencies - technical tems. This is achieved by reducing the pitch in variable-pitch propeller sys-
options tems. Stop signals cause the engine to stop.
Determination of alarm and Acoustic or visual warnings can be reset. The displays remain active until the
limit values fault has been eliminated. In marine systems, speed reduction or stop signals
Examples can be suppressed with the override function "ship gets higher priority than
engine". This option is not provided in stationary systems.
To determine alarm and safety-relevant limit values, the requirements set
forth by the classification institutes and our own evaluation are decisive.
Stop criteria are, for example: overspeed, excessively low lube oil pressure
and excessively high temperatures at the crankshaft main bearing. If the oil
mist detector responds, a stop signal is also triggered. When the cooling
water temperatures are too high, the output of the marine systems is
reduced.

Legal situation

The purpose of alarm, reduction and safety signals is to warn against or
avoid dangers. The causes must be traced back with the necessary careful-
ness. The sources of malfunctions must always be eliminated. They must not
be ignored or suppressed. Exceptions are instructions by management or an
even greater danger.

The ignoring or suppressing of alarms or the deletion of reduction or
stop signals is very dangerous both for persons and for the technical
system.

Liability claims for damage caused by exceeded target values and/or sup- Operation/Operating fluids
pressed/ignored alarm and safety signals will not be recognised under any
circumstances. V28/33D

2008-10-28 - de

6739 3.6.7-01 EN 1 (1)



MAN Diesel & Turbo 3.6.8

Response in the event of a splash oil alarm Operative Management III - Operating faults

General

Checks following a splash-oil The running gear temperatures in the crankcase are transferred to the sur-
alarm/engine stop rounding lube oil. Damage to big-end bearings, piston seizure and blow-bys
from the combustion chamber cause a change in the lube oil temperature.
With the splash-oil monitoring system, part of the splash oil from every crank
pin is collected. The temperature of the splash oil of every crank pin is moni-
tored and compared with the temperatures of the other crank pins. If the
defined maximum temperature is exceeded or if the difference between the
temperatures of the individual running gears is too high, first an alarm is trig-
gered and, if necessary, the engine is switched off automatically.

Danger to persons and
damage to property!

Type and source of danger

Bearing damage, piston seizure and blow-bys increase the formation
of oil mist, which represents an acute risk of injury or material damage.
In the crankcase, an explosion is possible which can severely damage
the engine, crankcase as well as the running-gear components.

In the event of a malfunction of the splash-oil monitoring system, the engine
is not monitored. In this case, starting damage can not be recognized quickly
enough in order to prevent further damage.

Checks following a splash-oil alarm/engine stop

Monitoring the alarms Once an alarm has been output, continue to monitor the splash oil tempera-
tures. If the temperature that triggered the alarm does not fall to a normal
value after a short time, you must stop the engine and check the relevant
crankcase. The crankcase must be checked following an automatic engine
stop.

Checking the running gear All crankcase covers must be removed following a 10 minute waiting period
which is necessary to avert the danger of explosion due to an ingress of air
(see safety regulations). In addition, the following action must be taken:

▪ Measurement of all bearing temperatures,
▪ Visual check of crankcase components and oil sump for swarf, tarnishing

and accumulation of material,

▪ Visual inspection of all piston skirts and cylinder liners. Damage to the Operation/Operating fluids
contact surfaces of aluminium alloy pistons occurs at after a short time,
grey cast iron bottom sections are less susceptible to damage. V28/33D

If no damage is found, extend the diagnosis to include the points on the trou-
bleshooting list that have not yet been checked. Consult your nearest service
outlet if necessary.

2009-03-26 - de Type and source of danger

The engine may only be restarted once you have established that no
damage is present, or once the damage that triggered the alarm has
been repaired.

6739 3.6.8-01 EN 1 (2)

Operation/Operating fluids Operative Management III - Operating faults

V28/33D
3.6.8 MAN Diesel & Turbo

2 (2) 6739 3.6.8-01 EN

2009-03-26 - de

MAN Diesel & Turbo 3.7

3.1 Prerequisites Operative Management IV - Shutting down the Engine
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 3.7-02 EN 1 (1)



MAN Diesel & Turbo 3.7.1

Shutting down/Preserving the engine Operative Management IV - Shutting down the Engine

Shutting down/Preserving the engine

If an engine is switched off for more than a week, it must be turned once a
week for approx. 10 min. During this procedure, the priming pump that lubri-
cates the running gear must be put into operation (oil temperature approx.
40°C).
If the engine is switched off for a longer period (e.g. when putting it into stor-
age), empty it (of lubricating oil, water and diesel oil), clean and preserve it.
You can find relevant information in Work Card 000.14 "slushing oil/preserva-
tion of diesel engines". The necessary conditions, preservation measures and
suitable preservatives are described here.

2010-09-22 - de Operation/Operating fluids

V28/33D

6739 3.7.1-02 EN 1 (1)



MAN Diesel & Turbo 3.7.2

Decommissioning, dismantling and disposal Operative Management IV - Shutting down the Engine

Decommissioning

The following items give an overview of the most important tasks to be fulfil-
led in connection with taking the engine plant out of operation in order to
prevent further use temporarily or finally.

Prerequisites

Measures for shutting down the engine plant are completed.

Implementation

▪ Take measures preventing further use of the engine plant.
▪ Flush all gas-containing spaces and piping with nitrogen (any existing gas

pipes, charge air pipes, exhaust pipes).
▪ Check with a gas detector whether any ignitable gas mixture is present in

the engine plant.
▪ Flush/vent until no more residual gas mixture is contained in the engine

plant.

Danger of explosion due to ignitable gas mixture!

The consequences may be death or severe injuries.

• Flush engine plant with nitrogen.

• Observe safety regulations.

• Use the prescribed personal protective equipment.

• Keep away sources of ignitions.

Dismantling ▪ Disconnect the engine plant from all connected systems completely (e.g.
fuel system, lube oil system, cooling water system, gas system and
2011-11-29 - de energy supply system). Operation/Operating fluids

▪ For later re-commissioning the engine plant it must be long-term pre- General
served. In this case, contact with MAN Diesel & Turbo PrimeServ.

The following items give an overview of the most important tasks to be fulfil-
led in connection with dismantling the engine plant out of operation in order
to reuse it elsewhere or to dispose of.

Prerequisites

Engine plant decommissioning completed.

Implementation

Reuse of the engine plant
Have the engine plant dismantled by MAN Diesel & Turbo PrimeServ.
Disposal of the engine plant

6680 3.7.2-01 EN 1 (3)

Operative Management IV - Shutting down the Engine3.7.2 MAN Diesel & Turbo

Operation/Operating fluids Storage Specialized company for dismantling 2011-11-29 - de
Disposal
General The operator shall order dismantling of the engine plant, and
2 (3) particularly the pressure equipment, only specialized companies
having the required devices and equipment components for safe work
execution and the required qualified personnel.

Order the following work to a specialist company:
▪ disconnecting the network connection;
▪ disconnecting the operating fluid connections;
▪ drainage of all auxiliary agents and operating fluids from the engine plant;
▪ environmentally friendly disposal of all auxiliary agents and operating flu-

ids in accordance with the national disposal regulations;
▪ removal of cables and piping connections to switch cabinets and to

engine plant;
▪ dismantling the individual components of the engine plant in accordance

with the procedure in Operating Instructions for related components;
▪ dismantling the remaining components of the engine plant.

The following items give an overview of the most important tasks to be fulfil-
led in connection with storage of dismantled engine plant intended for future
reuse.

Prerequisites

Dismantling the engine plant is completed.

Implementation

▪ Have the engine plant long-term preserved. For this purpose contact
with MAN Diesel & Turbo PrimeServ.

▪ Store preserved machine components in a dry indoor space.

The following items give an overview of the most important tasks to be fulfil-
led in connection with disposal of the engine plant.
Disposal of packages, operating fluids, wear parts and cleaning agents
▪ Disposal of packages:

always dispose packages environmentally friendly and in accordance
with the local disposal regulations. If necessary, engage a recycling com-
pany.
▪ Disposal of operating fluids:
always dispose of operating fluids according to manufacturer's instruc-
tions, environmentally friendly, and in accordance with the local disposal
regulations. If necessary, engage a recycling company.
▪ Disposal of wear parts:
always dispose of wear parts environmentally friendly and in accordance
with the local disposal regulations. If necessary, engage a recycling com-
pany.

6680 3.7.2-01 EN

MAN Diesel & Turbo 3.7.2

▪ Disposal of cleaning agents: Operative Management IV - Shutting down the Engine
always dispose of cleaning agents according to manufacturer's instruc-
tions, environmentally friendly, and in accordance with the local disposal
regulations. If necessary, engage a recycling company.

Disposal of dismantled engine plant

Prerequisites

Engine plant dismantling completed.

Specialized company for disposal

The operator shall order disposal of the engine plant and particularly of
the pressure equipment only to such specialized companies which
have the required devices and equipment components for safe work
execution and the required qualified personnel.

▪ Engage a specialized company or contact with MAN Diesel & Turbo Pri-
meServ, to dispose of the dismantled engine plant properly.

2011-11-29 - de Operation/Operating fluids

General

6680 3.7.2-01 EN 3 (3)



MAN Diesel & Turbo

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

2013-02-19 - de

Maintenance/repair

6739 4 B1-02 EN 1 (1)



MAN Diesel & Turbo 4.1

General remarks Alongside routine checks maintenance work needs to be carried out regu- Maintenance/repair
larly. This is required to maintain the operational readiness and reliability of
General remarks the system. This work must be carried out in accordance with the mainte-
nance schedule in a timely manner by competent personnel.
General remarks Regular maintenance work helps operating personnel to detect emerging
malfunctions at an early stage. It provides the persons responsible with infor-
Maintenance schedule/ mation on necessary reconditioning work or repairs and influences the plan-
maintenance intervals/ ning of downtimes.
personnel and time Maintenance and repair work can only be carried out properly and correctly if
requirements the required spare parts are available. In addition to spare parts, it is also
Work Cards expedient to keep a stock of parts in reserve to cater for unexpected failures.
Please forward your request for a quotation to MAN Diesel & Turbo SE.
Maintenance schedule for The necessary work is listed in the maintenance schedule. This contains
the turbocharger ▪ a brief description of the work,
▪ the repetition intervals,
▪ the personnel and time requirements and
▪ refers to the relevant Work Cards/working instructions.
The Work Cards, which are part of the engine or turbocharger documents,
can be found in the corresponding working instructions.
They also contain information on
▪ required tools/auxiliary equipment and
▪ detailed descriptions and drawings of the work sequences and steps.
In addition to the printed paper version a foil-laminated copy is available.
These Work Cards are protected against dirt and can therefore be used as a
source of information when carrying out the work.
A separate maintenance schedule is available for the turbocharger(s). It can
be found in the operating manual for the turbocharger.

2008-10-28 - de Maintenance/repair

V28/33D

6680 4.1-04 EN 1 (1)



MAN Diesel & Turbo 4.2
Maintenance schedule (explanatory notes)
Maintenance/repair
Preliminary remarks

Maintenance schedules

Systems 4.7.1

Engine 4.7.2

Turbocharger 4.7.3

The maintenance schedule for the engine includes work on components of
peripheral systems and on engine components/sub-assemblies (see Section
4.7). The maintenance schedule for the turbocharger is part of Volume
010.200 of the Technical Documentation.

Obligation and possibilities for adaptation

Validity of the maintenance Maintenance schedules 4.7.1 and 4.7.2 are jointly applicable. They summa-
schedule rise work that is to be carried out at regular intervals or within an interval
range.

After 30,000 or 36,000 operating hours, a thorough examination of the main
components must be carried out. In particular, the cylinder heads and valves,
the cylinder liners and pistons and the running gear parts and bearings
should be checked for wear and renewed if necessary. It is recommended
that extensive work such as this and the general overhaul is carried out by
one of our customer service support locations.

Adapting the maintenance The maintenance schedules apply to average operating conditions. The stip-
schedule ulations are non-binding recommendations and guideline figures. In order to
obtain data based on experience, it is recommended that the lower interval
ranges are used initially as a guideline. The repeat intervals must be short-
ened following a critical analysis, if the operating results and operating condi-
tions require it, and if the operating schedules permit it (ship timetables/
inspection periods for power stations). It is possible to extend the intervals if
the operating results and operating conditions are favourable.

Favourable operating conditions are:

▪ Uniform loading within the range of 60 to 90 % of rated power,
▪ Observance of the specified temperatures and pressures for operating

media,

▪ Use of specified lubricating oil and fuel qualities,
▪ careful separation of fuel and lubricating oil.
Unfavourable operating conditions are:

▪ Prolonged operation at peak loads or low loads, long periods of idling, Maintenance/repair
frequent severe load changes,
General
2010-03-22 - de ▪ frequent engine starts and repeated warm-up phases without sufficient
preheating,

▪ high engine loads before the specified operating temperatures have been
reached,

▪ lubricating oil, cooling water and charge air temperatures too low,
▪ Use of insufficient fuel qualities and inadequate separation,
▪ insufficient intake air filtering (particularly with stationary engines).

6628 4.2-02 EN 1 (1)



MAN Diesel & Turbo 4.4

Spare parts Maintenance/repair

Tip

Because of its importance we have repeated a sentence here that we have
already used:

Availability of required spare parts

Maintenance and repair work can only be carried out properly and
correctly if the required spare parts are available.

The following notes should help you to confidently use the right information
source for identifying and ordering spare parts when required.

Spare parts for engines and turbochargers

Spare parts for engines and turbochargers can be identified with the aid of
the spare parts catalogues in Volume 010.005 Engine - Spare Parts Cata-
logue or Volume 010.200 Turbocharger. An illustrated sheet is provided in
each case to guide you, using the item number to direct you to the order
number.

2012-10-04 - de Maintenance/repair

Figure 1: Spare parts catalogue for engine components - illustrated sheet General
6680 4.4-01 EN
1 (3)

Maintenance/repair4.4 MAN Diesel & Turbo

Maintenance/repair Figure 2: Spare parts catalogue for engine components - text sheet 2012-10-04 - de

General Spare parts for tools/Ordering of tools (engine and turbocharger)

Complete tools can be ordered with the aid of the tool list in Volume 015.010
Engine Tools of the Technical Documentation or with the aid of the contents
list in the turbocharger tool case. The order numbers can also be obtained
from the corresponding Work Card in Volume 010.005 Engine - Work
Instructions or Volume 010.200 Turbocharger. It is also possible to order
replacement parts for tools in this way.
When ordering tools you must, as usual, quote the engine type, the engine
factory reference number and the 6 digit tool number, which also serves as
the order number. The first 3 digits of the tool number refer to the sub-
assembly where the tool is used. General tools have a number below 010
instead of the sub-assembly number.
To avoid queries, we require the information listed under 1, 2 and 5, as per
the following example.
Explanatory notes
1 Number required
2 Designation
3, 4 Sub-assembly
5 Tool number = Order number

2 (3) 6680 4.4-01 EN

MAN Diesel & Turbo 4.4

Maintenance/repair

Figure 3: Information for ordering tools and parts. Figure - Work Card for sub-assembly 030.

Spare parts for measuring, control and regulation systems and for engine and system
accessories

Information about spare parts for the following systems (accessories) can be
found in the documents in Volumes 010.290 Engine Control and Monitoring
or Volumes 030 ...
▪ Measuring, control and regulating devices, e.g. temperature sensors,

relays, measuring transducers (unless contained in the spare parts cata-
logue for the engine),
▪ Engine accessories, e.g. oil mist detector and
▪ System accessories, e.g. filters, separators, water-softening plants and
similar equipment.

2012-10-04 - de Maintenance/repair

General

6680 4.4-01 EN 3 (3)



MAN Diesel & Turbo 4.5

Replacement of Components on the New-for-Old Principle Maintenance/repair

New-for-old

If components of high value show signs of damage or wear and if the recon-
ditioning or repair of these parts requires special know-how or equipment
they can be replaced in the process "Reconditioned for Old". This includes
▪ Piston crowns,
These components are generally available ex-stock. Otherwise they will be
reworked/repaired and sent back to your address. If necessary, request a
quotation by MAN Diesel & Turbo SE or the next customer-service centre.

2008-12-08 - de Maintenance/repair

V28/33D

6739 4.5-01 EN 1 (1)



MAN Diesel & Turbo 4.6
Services/repair work
Maintenance/repair
Services/repair work

A wide range of services and expert advice is available for routine matters,
and also for more difficult problems
▪ from MAN Diesel & Turbo SE, Augsburg works,
▪ from the MAN Diesel & Turbo SE Service Centre in Hamburg,
▪ from MAN Diesel & Turbo Pte. Ltd., Service Centre Singapore,
▪ from the service centres and authorised repair workshops

This service ranges from the supply of spare parts, advice and support in
operation, maintenance and repair issues, through to the identification and
clarification of defects and dispatch of installers and engineers worldwide.
Some of these services are without doubt provided as standard by manufac-
turers, shipyards, repair workshops or specialised companies. Some can
only be provided as a result of many decades of experience of building diesel
engines, and also operation, maintenance and repair of diesel engine plants.
The latter arises because we feel we have a special professional obligation
towards our engine operators and products.
Please observe the additional information provided in the documents in the
volume entitled "About us" in the technical documentation. This also contains
the addresses and telephone numbers of the nearest support centres you
can contact at any time.

2007-04-20 - de Maintenance/repair

General

6680 4.6-01 EN 1 (1)



MAN Diesel & Turbo 4.7
Maintenance schedule (Signs/Symbols)
Maintenance/repair
Explanation of signs and symbols

Signs and symbols are used instead of bilingual entries in the header of the
maintenance schedule. They have the following meanings:

1, 2, 3 Running number of maintenance task.
The series of numbers contains to accommodate
changes/additions.
Brief description of maintenance task

Corresponding Work Cards.
The Work Cards that are listed contain detailed informa-
tion on the necessary work steps.

___.xx A group of Work Cards is combined in these
Work Cards

A No Work Card required/available
B See manufacturer's maintenance instructions

(see Volume 030 Auxiliary systems, engine-
related)
C Have this work carried out by a MAN Diesel &
Turbo SE Service Centre or a specialised
company
D See corresponding maintenance task
Human resources

Time required per person in hours

per Reference value for the information on time required

24 ... 36000 Repeat interval in operating hours

Sign that is used in the interval columns.
The explanation is repeated on every page.

X, 1 ... 4 With the signs and symbols used in the header on the
other hand, we assume that these are visually sufficient
and do not need to be repeated continuously.

Table 1: Explanation of signs and symbols in the maintenance schedule Maintenance/repair

Groups of maintenance tasks The maintenance tasks are grouped according to systems/function groups in General
the maintenance schedule (systems), and according to sub-assemblies in the
maintenance schedule (engine).

2007-04-20 - de

6680 4.7-03 EN 1 (1)



MAN Diesel & Turbo 4.7.1

Maintenance schedule per 24 (Daily)
(systems) 150 (Weekly)
500
Maintenance schedule 1000
2000
1, 4000
2, 8000
3 12000
16000
Fuel system 32000
64000

Maintenance/repair

003 Check the system components for 000.01 1 0.20 Engine X
leakage (visual inspection)

004 Service tank: Check the fuel level; drain A 1 0.20 Engine X
the service tank and settling tank

005 Clean water separator (if available) 000.01 1 0.20 Filter 1 1 1 1 1 1 1 1 1 1 1

006 Clean fuel oil filter and replace filter 000.01 1 3 Filter 1 1 1 1 1 1 1 1 1 1 1
elements (depending on differential
pressure)

007 Fuel oil module (if available): Maintain B Unit 3 3 3 3 3 3 3 3 3 3 3
according to maintenance instructions
of manufacturer

Lube oil system

012 Check the system components for 000.01 1 0.20 Engine X
leakage (visual inspection)

013 Examine oil sample (drip test) 000.05 1 0.20 Engine X

014 Have the oil sample analysed by the 000.04 1 0.30 Engine X
lube oil supplier

015 Change oil filling (depending on results 000.04 1 2 Engine 1 1 1 1 1 1 1 1 1 1 1
of analysis), clean the tank 011.02

016 Overhaul/replace lube oil pre-lubricating B Unit 3 3 3 3 3 3 3 3 3 3 3
pump

017 Clean oil mist separator for crankcase B Unit 1 1 1 1 1 1 1 1 1 1 1

022 Clean bypass filter (if available) B 13 Filter 1 1 1 1 1 1 1 1 1 1 1

023 Clean the lube oil preheater (if available) B 14 Unit 1 1 1 1 1 1 1 1 1 1 1

024 Check, clean and overhaul the lube oil B 1 Unit 1 1 1 1 1 1 1 1 1 1 1
separator, residue self-discharging (if
available)

Cooling water system

031 Check the system components for 000.01 1 0.20 Engine X
leakage (visual inspection)

032 Expansion tank: Check the cooling 000.01 1 0.20 Engine X
water level
2012-11-16 - de

Maintenance/repair

V28/33D
033 Cooling water: Analyse sample and refill 000.02 1 0.50 Engine X
slushing oil if necessary 000.07

034 Have test of the cooling water sample 000.07 1 0.10 Engine 11
carried out at laboratory

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer

6739 4.7.1-02 EN 1 (2)

4.7.1 MAN Diesel & Turbo

1, per
2,
3
Maintenance/repair
24 (Daily)000.08
150 (Weekly)
500
1000
2000
4000
8000
12000
16000
32000
64000
035 Cooling water heat exchanger: Clean 11111111111
cooling areas, or by a specialist
company

036 HT/LT Cooling water heat exchanger (if C 33333333333
available): Clean cooling areas

Compressed air and control air system

041 Check the system components for 000.01 1 0.20 Engine X
leakage (visual inspection)

042 Drain the water from the compressed A 2 0.20 Unit X
air reservoir (if it is not automatically
drained)

043 Check air cylinders for correct A 3 0.30 Unit X
functioning of automatic drainage

044 Check compressed air reservoir and B 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1
valves according to manufacturer's
specifications

045 Drain the water separator (if available) A 1 0.10 Engine X

046 Clean the water separator (if available) A 1 0.50 Engine 1 1 1 1 1 1 1 1 1 1 1

Engine foundation/pipe connections

082 Foundation bolts: Check firm seating of A 28 Engine 2X
brackets and resilient elements (in case
of marine engines also after collision or
grounding) - see also 402

083 Elastic bearing: Determine the amount A 23 Engine X
of settling of the elastic elements

084 Elastic pipe connections: Check all A 11 Engine X
hoses

085 Elastic pipe connections: Replace A 2 14 Engine 1 1 1 1 1 1 1 1 1 1 1
hoses for fuel, lubricating oil, cooling
water, steam and compressed air

Flexible coupling/turning gear

092 Coupling bolts: check for tight fit/proper 020.02 1 1 Engine X
preload - see also 402

093 Flexible coupling: Check alignment and 000.09 2 8 Engine X
rubber elements

Additionally required

401 New or repaired parts installed and any D X
new working materials used should be
inspected once in a certain period
Maintenance/repair

V28/33D
2012-11-16 - de
402 New or repaired parts installed and any D X
new working materials used should be
inspected once in a certain period

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer

2 (2) 6739 4.7.1-02 EN

MAN Diesel & Turbo 4.7.2

Maintenance schedule per 24 (Daily)
(engine) 150 (Weekly)
500
Maintenance schedule 1000
2000
1, 4000
2, 8000
3 12000
16000
Operating data 32000
64000

Maintenance/repair
000
101 Engine start up (recommendation): After 000.01 1 0.50 Engine X
12 hrs down time, open the sealing 012
plug for the indicator cock and turn the 020
engine over with the turning gear. 021
Check whether there is no fuel, oil or X
cooling water emission.

102 Check the exhaust clouding (visually) A 1 0.10 Engine X

103 Record operating data and compare to 000.02 1 1 Engine X
earlier records.

104 Check ignition pressures (for monthly 000.25 1 0.10 Cyl. X
recording of operating data)

105 Check and test oil mist detector 000.02 1 0.40 Engine 4
emergency stops

106 Check and test metal particle detector 000.02 1 0.40 Engine X

Crankcase

111 Check crankcase pressure A 1 0.10 Engine X

112 Safety valves in crankcase covers: 073.01 1 0.40 Cyl. X
Check all valves for ease of movement

Running gear/Crankshaft

113 Check running gear (visual check) - see A 2 0.20 Cyl. 2 X
also 404

114 Crankshaft: Measure crank web 000.10 2 0.14 Cyl. 2 X
deflection (in the case of marine
engines also after collision or
grounding) - see also 405

Crankshaft bearing

122 Locating bearing: Check axial 021.03 2 0.50 Bearing 2 X
clearance. See also 405

123 Lower one bearing cap and inspect 000.11 2 6 Bearing X
lower bearing shell. If bearing shell 012.02
cannot be used again, check all 021.01
bearings. Check pressure for loosening
bearing bolts.
2013-02-19 - de
2 6 Bearing
Maintenance/repair

V28/33D
124 Replace all bearing shells and check 020.06
crankshaft journals. Replace locating 021.01
bearing and oil seal. 021.03

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer
4 If component/system is available
7 After .... operating hours or after 2 years

6739 4.7.2-02 EN 1 (6)

4.7.2 MAN Diesel & Turbo

1, per
2,
3
Maintenance/repair
24 (Daily) 027
150 (Weekly) X
500
1000 1
2000 X
4000
8000 1
12000 030
16000 X
32000 7
64000
Torsional vibration damper X

131 12V and 16V engines: Check viscosity 027.05 1 1 Engine X
of the liquids in viscose-damper by 034
damper manufacturer. Next sampling X
date has to be recommended by the 7
damper manufacturer.
X
132 12V and 16V engines: Replace 027.05 2 6 Engine
vibration damper of the crankshaft. X
(Depending on results of viscosity
analysis)

133 20V engines: Remove and check 027.03 2 6 Engine
vibration damper of the crankshaft.
Replace worn parts and sealing rings.

134 20V engines: Remove and replace 027.03 2 6 Engine
vibration damper of the crankshaft.

Connecting rod/big-end bearing

142 Remove 1 connecting rod per cylinder 030.04 2 6 Bearing
bank and check. Check big-end 034.01
bearing bore for ovality. Check bearing
surface of the bearing shells and piston
pin bushing. Remeasure bolts on the
big-end bearing cap.

143 Remove all connecting rods and check. 030.04 2 6 Bearing
Check big-end bearing bore for ovality. 034.01
Check the bearing surface of the piston
pin bushing. Remeasure bolts on the
big-end bearing cap. Replace all big-
end bearing shells.

144 Remove connecting rods and replace 034.01 2 2 Cyl.
with overhauled ones.

Piston/piston pin

152 Remove, clean and check 1 piston per 034.01 2 2.50 Cyl.
cylinder bank. Measure the piston rings 034.02
and ring grooves. Check pressure for
releasing bolts on connecting rod
shank. Document data recorded (see
Work Card).

153 Remove, clean and inspect all pistons. 034.01 2 2.50 Cyl.
Measure ring grooves. Replace all 034.02
piston rings. Caution: Re-hone the
cylinder liner when replacing the piston
rings! Replace piston crowns if
necessary. Document data recorded
(see Work Card)Maintenance/repair

V28/33D 034.04 2 0.30 Cyl.
2013-02-19 - de
154 Remove all piston pins, check piston
pin bushing, check clearance

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer
4 If component/system is available
7 After .... operating hours or after 2 years

2 (6) 6739 4.7.2-02 EN

MAN Diesel & Turbo 4.7.2

1, per 24 (Daily)
2, 150 (Weekly)
3 500
1000
157 Replace piston crowns 034.04 2 1.50 Cyl. 2000 X
4000 X
158 Replace complete piston 034.01 2 2 Cyl. 8000
12000 050
Cylinder liner 16000
32000 X
161 Check all cylinder liners during injection 050.07 1 0.30 Cyl. 64000X
nozzle replacement using an interscope X
Maintenance/repair7

162 Measure one cylinder liner (per cylinder 050.02 2 0.30 Cyl.
bank). Document data recorded (see
Work Cards)

163 Remove, clean,measure and hone all 034.01 2 2 Cyl.
cylinder liners. Replace seal rings. If 050.02
necessary, the complete cylinder liners
must be replaced.

164 Replace all cylinder liners. 034.01 2 1.50 Cyl. X
055
Cylinder head

172 Replace the seal of the cylinder head 111.01 1 0.10 Cyl. X
cover X
7
173 Remove, clean and check one cylinder 055.01 2 2.50 Cyl.
head per cylinder bank. Check 055.02
pressure for releasing the cylinder head
bolts.

174 Remove, clean and check all cylinder 055.01 2 2.50 Cyl. X
heads Replace worn parts. 055.02
100
Control device operating mechanism X

202 Check gears, measure the backlash - 100.01 2 1 Engine X
see also 406

203 Remove camshaft drive, check and C 28 Engine
measure, replace individual parts if
necessary

Camshaft/camshaft bearing/cam follower 101/102/112

212 Check cams (visual inspection). See 209.01 1 0.10 Cyl. X
also 405

213 Clean camshaft thrust bearing, replace 102.03 1 3 Engine X
if necessary X

214 Remove drive section pieces on both C 22 Cyl. X
sides and check. Check bearing 111/112
bushes.

215 Remove the camshafts, check them C 22 Cyl.
and replace worn parts. Replace
bearing bushes.
2013-02-19 - de
Valve timing/rocker arms
Maintenance/repair

V28/33D
222 Check rocker arm and associated 111.01 1 0.10 Cyl. X
bolted connections (visually)

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer
4 If component/system is available
7 After .... operating hours or after 2 years

6739 4.7.2-02 EN 3 (6)

4.7.2 MAN Diesel & Turbo

1, per
2,
3
Maintenance/repair
24 (Daily)
150 (Weekly)
500
1000
2000
4000
8000
12000
16000
32000
64000
223 Dismantle rocker arm and check it. 055.02 2 2 Cyl. X
Replace worn parts

225 Check tappet casing and tappets. 112.03 1 0.30 Cyl. X
Replace worn parts

226 Remove and overhaul tappet casing 112.03 1 1 Cyl. X
and tappet

Inlet and exhaust valves 113/114

233 Check the valve clearance - see also 111.01 2 0.20 Cyl. X
405

234 Remove 2 inlet valves (per cylinder C 12 Cyl. X
bank). Check valve seats, valve cones, 7
valve guides and valve rotators.
Replace worn parts.

235 Remove all inlet valves. Replace all C 23 Cyl. X
valve cones, valve seat rings and valve
rotators.

242 Remove 2 exhaust valves (per cylinder C 12 Cyl. X
bank). Check valve seats, valve cones 7
and valve guides. Replace worn parts.

243 Remove all exhaust valves. Replace all C 23 Cyl. X
valve cones, valve guides, valve seat
rings and valve rotators.

Electronic injection/speed sensor 140

266 Check the pulse sensor for A 1 0.20 Engine 1 1 1 1 1 1 1 1 1 1 1
contamination and correct distance

Starter 171

271 Maintain starter according to B 11 Engine 1 1 1 1 1 1 1 1 1 1 1
maintenance instructions of
manufacturer

272 Check starter toothed ring 171.01 1 1 Engine X

273 Replace starter 171.02 1 2 Engine X

274 Check turning gear, overhaul if B 11 Unit 3 3 3 3 3 3 3 3 3 3 3
necessary

Fuel injection pump with drive 200/201

301 Replace fuel injection pumps with 200.03 1 1 Pump X
overhauled pumps

Fuel injection valve/injection pipe 221

322 Remove the injection valves. Replace 221.01 1 2 Valve X
injection nozzles, distance disc and
sealing rings. Alternatively, replace
complete injection valves.
Maintenance/repair
X
V28/33D
2013-02-19 - de
323 Fuel oil system: Replace injection pipes 200.03 1 0.30 Valve

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer
4 If component/system is available
7 After .... operating hours or after 2 years

4 (6) 6739 4.7.2-02 EN

MAN Diesel & Turbo 4.7.2

1, per 24 (Daily)
2, 150 (Weekly)
3 500
1000
Attached fuel supply pump 2000 300
4000
331 Fuel supply pump: Open sealing plug of A 1 0.10 Pump X 8000
leakage bore and check for leakages. 12000
16000
Engine lube oil system 32000
64000
342 Check system components for
tightness (visually) Maintenance/repair
000.01 1 0.20 Engine X

343 Check oil drain (visually) after A 1 0.30 Unit;Cyl. 1 1 1 1 1 1 1 1 1 1 1
overhauling or replacement of: piston,
connecting rod big-end and crankshaft
main bearings, camshaft bearings,
valve gear in the rocker arm casing,
gear drive and the turbocharger - refer
to 404

344 Engine lubrication: Check lube oil level 000.01 1 0.10 Engine X
in oil sump

345 Check the pressure limiting valve A 1 0.10 Pump X
functioning

346 Replace lubricating oil filter, depending 000.01 1 2 Filter 1 1 1 1 1 1 1 1 1 1 1
on differential pressure 310.02

347 Clean the lube oil cooler. Replace if C 2 10 Unit 1 1 1 1 1 1 1 1 1 1 1
necessary

Engine cooling water system

351 Check the cooling water spaces, clean 000.08 X
if necessary

352 Check attached HT/LT water pumps 350.04 1 2.50 Pump 11X
including gear. Replace with service
exchange units if necessary.

353 Check attached sea water pumps 350.04 1 2.50 Pump 11X
including gear. Replace with service
exchange units if necessary.

Engine exhaust gas system

361 Dismantle exhaust gas system on 289.01 2 10 Unit X
engine, check compensators and
replace all seals

Charge air system on engine

362 Charge air cooler/pipe: Check system 000.01 1 0.10 Pipe X
for leakages, condensation water
drainage for quantity/free pass-through

363 Blow-off valve: Dismount and check for 000.34 1 2 Engine 4
cracks. Every 4000 operational hours 322.01
or once a year
2013-02-19 - de

Maintenance/repair

V28/33D
24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer
4 If component/system is available
7 After .... operating hours or after 2 years

6739 4.7.2-02 EN 5 (6)

4.7.2 MAN Diesel & Turbo

1, per
2,
3
Maintenance/repair
24 (Daily)2
150 (Weekly)
500
1000
2000
4000
8000
12000
16000
32000
64000
364 Bypass valve: Dismount and check for 000.34 1 Engine 4
cracks. Every 4000 operational hours 322.01
or once a year

365 Emergency stop shut-off valve: Check 000.34 1 2 Engine X
in accordance with the maintenance 322.01 7
manual

366 Check charge air piping for 322.01 1 1 Engine X
contamination. 7

367 Clean the charge air cooler, depending 322.01 2 15 Engine 1 1 1 1 1 1 1 1 1 1 1
on differential pressure

368 Charge air cooler: Replace cooler insert 322.01 2 15 Engine X

Measuring, control and regulation systems

372 Engine electronic equipment: Check 125.22 2 8 Engine X
and calibrate - refer to 405

373 Dismantle the control valves in the 10 A 1 2.50 Engine X
and 30 bar system, replace wear parts

374 Switch and shut-down devices:<br/> 125.30 2 3 Engine X
Check the functionality and the
switching point - also see 405

Additionally required

403 Bolted connections: Check for tight fit 000.30 2 10 Engine 2 X
(e.g. on exhaust gas and charge air
pipe, charge-air cooler and
turbocharger) and proper fastening
(according to work cards) - refer to 404

404 Check parts installed in new or D X
reconditioned condition and operating
media applied in new or improved
condition once after the time given -
applies to 113, 341 and 403

405 Check parts installed in new or D X
reconditioned condition and operating
media applied in new or improved
condition once after the time given -
applies to 114, 122, 212, 233

406 Check installed new parts or installed D 0 X
overhauled parts/newly added
lubricants once after the indicated
interval - applies to 202

24 (Daily) ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
3 According to specification of manufacturer
4 If component/system is available
7 After .... operating hours or after 2 years
Maintenance/repair

V28/33D
2013-02-19 - de

6 (6) 6739 4.7.2-02 EN

MAN Diesel & Turbo

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

2013-02-19 - de

Appendix

6739 5 B1-02 EN 1 (1)



MAN Diesel & Turbo 5.1

Designations/Terms Appendix

Standards

The conventional designations/terms used in engine manufacture are laid
down in the ISO 1204 standard and the MAN regulation Q10.09121-4611. A
selection of terms, as they appear in the Technical Documentation, are
explained in the following section.

Engines

Engines with supercharging Supercharged engines have one or more exhaust gas turbochargers fitted
(consisting of a turbine and compressor) which are driven by the exhaust
gases. The purpose of the turbochargers is to compress the air required for
combustion.

Dual-fuel engines (DF) Dual-fuel engines can be operated either with liquid fuel or with gas (natural
gas, town gas, digester gas, etc.); for ignition, a small amount of fuel, the
pilot oil as it is known, is injected.

Spark-ignition gas engines Spark-ignition gas engines are operated with gas (natural gas, town gas,
(G) sewer gas, etc.) and external electric ignition.
Common-Rail engines (CR) In engines with a Common-Rail injection system the pressurised fuel is held
in a reservoir and injected under electronic control.

Performance Gas Injection PGI engines are operated with natural gas and auto-ignition.
(PGI)

Type, and direction of rotation

Left-hand engine/right-hand The terms left-hand engine (LM) and right-hand engine (RM) refer to the loca-
engine tion of the engine's exhaust side. When looking towards the coupling side,
the exhaust side is on the left on a left-hand engine, and it is on the right on a
right-hand engine (see figure 1). It is normally only possible to make this dis-
tinction on an in-line engine.

Left-hand engine Right-hand engine

Direction of rotation Figure 1: Determination of left-hand engine/right-hand engine
When looking towards the coupling side, a right-turning engine turns clock-
wise, whilst a left-turning engine turns counterclockwise.
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Appendix

V28/33D

6680 5.1-02 EN 1 (3)

5.1 MAN Diesel & Turbo

Appendix Designations for cylinders and bearings

Designation for cylinders The cylinders are numbered in sequence, from the coupling side, 1, 2, 3 etc.
In V engines, looking from the coupling side, the left hand row of cylinders is
designated A, and the right hand row is designated B. Accordingly, the cylin-
ders are referred to as A1-A2-A3 or B1-B2-B3, etc. (see figure 2).

In-line engine V engine

Designations for crank pins, Figure 2: Cylinder designation
shaft journals and bearings The crank pins and connecting rods are designated 1, 2, 3 etc. from the
coupling side, the crank pins and main bearings are designated 1, 2, 3 etc. If
there is an additional bearing located between the coupling flange and the
gearwheel for the drive of the control system this bearing and the corre-
sponding crank pins are designated 01 (see figure 3). It is of no significance
which bearing is arranged to be the flanged bearing.
On V engines, if 2 connecting rods are acting on one crank pin, the big-end
bearings are designated in the same way as the cylinders, e.g. A1, B1, A2,
etc.

1 Shaft journals A Coupling flange
2 Crank pin B Spur wheel
Appendix

V28/33D
2010-02-05 - de
Figure 3: Designations for crank pins and bearings

2 (3) 6680 5.1-02 EN

MAN Diesel & Turbo 5.1

Designation for engine sides Appendix

Coupling side KS The coupling side is the main power-output side and is the side to which the propel-
Free engine end KGS ler, the generator or other working machine is coupled.
Left side The free engine end is the front end of the engine coupling side.
Right side On a left-hand engine, the left side is the exhaust side and on a V engine it is cylin-
Timing side der bank A.
Exhaust side On a right-hand engine, the right side is the exhaust side and on a V engine it is cyl-
inder bank B.
Exhaust counter side The timing side is the longitudinal side of the engine to which the injection pumps
and the camshaft are attached (opposite the exhaust side).
The exhaust side is the longitudinal side of the engine to which the exhaust pipe is
connected (opposite the timing side). The terms timing side and exhaust side are
only used for in-line engines.
On engines with two camshafts, one on the exhaust side and one on the opposite
side, the term "timing side" is ambiguous. The term exhaust counter side is used in
addition to exhaust side.

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Appendix

V28/33D

6680 5.1-02 EN 3 (3)



MAN Diesel & Turbo 5.2
Formulae
Appendix
Formulae
Engine The selection below contains some of the main formulae used in engine and
installation design. The formulae clarify fundamental correlations.
Effective engine output Pe

Effective mean pressure pe

Swept volume VH

Mean piston speed cm

Torque Md

Efficiency ηe

2008-10-28 - de

Appendix

General

6680 5.2-01 EN 1 (3)

5.2 MAN Diesel & Turbo

Appendix Propeller

Propeller law

Generator

Synchronous speed

Key be Specific fuel consumption kg/kWh

Swept volume cm Average piston speed m/s

2 (3) D Cylinder diameter dm

f Frequency Hz

Hu Lower calorific value of the fuel kJ/kg

Md Torque Nm

n Rotational speed 1/rpm

P Output kW

Pe Effective engine output kW

p Number of pole pairs /

pe Effective mean pressure bar

s Stroke dm

VH Swept volume dm3/Cyl.

z Number of cylinders /

ηe Efficiency /

Appendix

General
2008-10-28 - de
Engine type Swept volume [dm3/cyl.]
20/27 8,48
25/30 14,73
28/33 20,32

6680 5.2-01 EN

MAN Diesel & Turbo 5.2

Engine type Swept volume [dm3/cyl.] Appendix

32/40 32,15

32/44 35,39

40/45 56,52

40/54 67,82

48/60 108,50

51/60 122,57

52/55 116,74

58/64 169,01
Table 1: Swept volume of MAN Diesel & Turbo engines

2008-10-28 - de

Appendix

General

6680 5.2-01 EN 3 (3)



MAN Diesel & Turbo 5.3
Conversion of units
Appendix
Useful facts about units of measurement

Some useful facts about units of measurement can be found in the insert
entitled "SI units" in Section 5.5. It includes explanations of the ISO system of
units, conversion factors for units of measurement and some physical
parameters commonly used in engine design.

2008-10-28 - de

Appendix

General

6680 5.3-01 EN 1 (1)



MAN Diesel & Turbo 5.4

Symbols and abbreviations Appendix

Use

Standard symbols and abbreviations are used for clear representation of
process technology interactions. The following list is a selection tailored to
the needs of engine and energy plant construction. In the Operating Instruc-
tions, the symbols and abbreviations are mainly used in Sections 2 and 3 of
this volume.

Symbols for functional and piping diagrams

Figure 1: Symbols used in functional and pipeline diagrams, 1/4
6680 5.4-02 EN
2011-05-19 - de

Appendix

General

1 (5)

Appendix5.4 MAN Diesel & Turbo

Figure 2: Symbols used in functional and pipeline diagrams, 2/4
2 (5) 6680 5.4-02 EN
Appendix

General
2011-05-19 - de