MAN Diesel

IndexGenSet

L23/30H

Text Index Drawing No.

Engine data 500/600

Warning Description A500 Main data for engine Description 500.00 (11H) Introduction Description 500.01 (02) Safety Description 500.02 (02) Cross section Description 500.05 (06H)-f Cross section Description 500.05 (06H)-s Key for engine designation Description 500.10 (02) Designation of cylinders Description 500.11 (03) Engine rotation clockwise Description 500.12 (02) Code identification for instruments Description 500.20 (03) Introduction to plant maintenance program Description 500.24 (03) Planned maintenance programme Description 500.25 (19H) Planned maintenance programme Description 500.25 (21H) Operation data and set points Description 500.30 (55H) Green Passport Description 500.33 (01) Data for pressure and tolerance Description 500.35 (29H) Data for pressure and tolerance Description 500.35 (22H) Data for tightening torque Description 500.40 (21H) Data for tightening torque Description 500.40 (22H) Declaration of weight Description 500.45 (01H) Ordering of spare parts Description 500.50 (02) Service letters Description 500.55 (01) Conversion table Description 500.60 (01) Basic symbols for piping Description 500.65 (01)

Operation of engine 501/601

Operating Description 501.01 (01H) Out of service Description 501.05 (01H) Starting-up after out of service periods Description 501.10 (01H) Guidelines for longterm low-load operation on HFO Description 501.15 (03) Guidelines regarding MAN Diesel GenSets operating on low sulphur fuel oil

Description 501.16 (01)

Performance and condition 502/602

Engine performance and condition Description 502.01 (01H) Evaluation of reading regarding combustion condition Description 502.02 (01H) Condensate amount Description 502.05 (03) Engine performance data Working card 502-01.00 (01H)

Trouble shooting 503/603

Starting failures Description 503.01 (02) Faults in fuel oil system Description 503.02 (01H) Disturbances during running Description 503.03 (01H) Ignition in crankcase Description 503.04 (03) Trouble shooting guide for centrifugal by-pass filter Description 503.05 (01H) Trouble shooting guide for turbine starter Description 503.06 (01H) Trouble shooting for cooling water system Description 503.09 (03) Trouble shooting for lubricating cooler Description 503.10 (01)

Media specification 504/604

Quality of lube oil (SAE30) for heavy fuel oil operation (HFO) Description 504.01-12

MAN Diesel

Index GenSet

L23/30H

Text Index Drawing No.

Quality of lube oil (SAE30) for operation on gas oil and diesel oil (MGO/MDO)

Description 504.01-13

Lubricating points Description 504.05 (01H) Lubricating oil in base frame Description 504.06 (16H) Lubricating oil in base frame Description 504.06 (17H) Specific lubricating oil consumption - SLOC Description 504.07 (03) Quality of heavy fuel oil (HFO) Description 504.20-08 Quality of marine diesel fuel (MDO) Description 504.20-09 Quality of gas oil / diesel fuel (MGO) Description 504.20-10 Analysis data Description 504.27 (02) Fuel oil cleaning Description 504.30 (01) Fresh water system treatment Description 504.40 (02)

Cylinder head 505/605

Cylinder head Description 505.01 (01H) Dismantling of cylinder head Working card 505-01.00 (01H) Inspection of inlet valve, exhaust valve and valve guide Working card 505-01.05 (01H) Reconditioning of valve spindle seat and valve seat ring Working card 505-01.10 (01H) Valve rotator Working card 505-01.15 (01H) Replacement of valve guide Working card 505-01.20 (01H) Indicator valve Working card 505-01.26 (01H) Replacement of sleeve for fuel injector Working card 505-01.30 (01H) Replacement of valve seat ring Working card 505-01.35 (01H) Mounting of cylinder head Working card 505-01.40 (01H) Inspection of cylinder head cooling water space Working card 505-01.45 (01H) Cylinder head Plate 50501-10H Valve spindles and valve gear Plate 50502-01H Indicator valve Plate 50508-01H Cylinder head, top cover Plate 50510-01H

Piston/connecting rod 506/606

Piston, connecting rod and cylinder liner Description 506.01 (01H) Dismounting of piston and connecting rod Working card 506-01.00 (01H) Separation of piston and connecting rod Working card 506-01.05 (01H) Piston Working card 506-01.10 (01H) Connecting rod Working card 506-01.15 (01H) Criteria for replacement of connecting rod big-end and main bearing shells

Working card 506-01.16 (01H)

Mounting of piston and connecting rod Working card 506-01.20 (01H) Tightening and check of connecting rod screws Working card 506-01.25 (01H) Hydraulic tightening of connecting rod screws Working card 506-01.25 (04H) In-situ inspection of connecting rod big-end bearing Working card 506-01.30 (01H) Inspection and honing of cylinder liner Working card 506-01.35 (01H) Replacement of cylinder liner Working card 506-01.40 (01H) Grinding of seal face on cylinder liner and cylinder head Working card 506-01.45 (01H) Dismounting of piston and cylinder liner at low overhaul height Working card 506-01.50 (01H) Piston and connecting rod Plate 50601-01H Piston and connecting rod Plate 50601-02H Piston and connecting rod (hydraulic tightening) Plate 50601-05H Piston and connecting rod (hydraulic tightening) Plate 50601-06H Cylinder liner Plate 50610-01H Cylinder liner Plate 50610-02H Cylinder liner Plate 50610-05H

Camshaft 507/607

MAN Diesel

IndexGenSet

L23/30H

Text Index Drawing No.

Camshaft and camshaft drive Description 507.01 (01H) Check of camshaft and camshaft drive Working card 507-01.00 (01H) Inspection and replacement of camshaft bearing Working card 507-01.05 (01H) Adjustment of camshaft Working card 507-01.20 (01H) Intermediate wheel Plate 50701-01H Camshaft and camshaft bearing Plate 50705-07H Camshaft and camshaft bearing Plate 50705-17H

Operating gear 508/608

Operating gear for valves and fuel injection pumps Description 508.01 (06H) Inspection of valve roller guide Working card 508-01.00 (07H) Inspection of fuel injector pump roller guide Working card 508-01.05 (01H) Control and adjustment of valve clearance Working card 508-01.10 (01H) Roller guide and push rods Plate 50801-07H

Control/safety 509/609

Control and safety systems Description 509.01 (01H) Instrument and automatics Description 509.05 (01H) Lambda controller Description 509.10 (09H) Starting box Description 509.35 (01H) Converter for engine.- and turbocharger RPM signal Description 509.40 (01H) Functional test and adjustment of safety, alarm and monitoring equipment

Working card 509-01.00 (01H)

Function test and adjustment of overspeed trip Working card 509-01.05 (01H) Adjustment and test of ON/OFF pressostate Working card 509-05.00 (01H) Adjustment and test of ON/OFF thermostate Working card 509-05.01 (01H) Function and test of level switch (LAL 25) Working card 509-05.02 (01H) Adjustment and test of analogous pressure transmitter Working card 509-05.03 (01H) Adjustment and test of analogous temperature transmitter Working card 509-05.04 (01H) Adjustment of lambda controller Working card 509-10.00 (13H) Governor and governor drive Plate 50901-21H Governor and governor drive Plate 50901-22H Governor and governor drive Plate 50901-23H Regulating device Plate 50902-06H Regulating device Plate 50902-07H Overspeed device Plate 50903-02H Instrument panel Plate 50905-07H Instrument panel Plate 50905-11H Instrument panel Plate 50905-12H Instruments Plate 50907-17H Thermometer Plate 50907-09H Pick-up Plate 50908-02H Lambda controller Plate 50910-02H Prelubricating oil alarm (LAL 25) Plate 50919-01H Level switch in oil sump (LAL/LAH 28) Plate 50920-13H Level switch in oil sump (LAL 28) Plate 50920-14H Level switch in oil sump (Dipstick only) Plate 50920-15H Fuel oil leakage alarm (LAH 42) Plate 50925-08H Local starting box - No 1 Plate 50935-11H Local starting box - No 2 Plate 50935-12H Local starting box - No 2 (incl. high lub. oil temp.) Plate 50935-13H Engine control box Plate 50936-13H Terminal box Plate 50936-20H APM motor control Plate 50948-01 Converter Plate 50956-01

MAN Diesel

Index GenSet

L23/30H

Text Index Drawing No.

Crankshaft 510/610

Crankshaft and main bearings Description 510.01 (01H) Checking of main bearing alignment (deflection) Working card 510-01.00 (04H) Checking of main bearing alignment (autolog) Working card 510-01.00 (05H) Inspection of main bearing shells Working card 510-01.05 (01H) Inspection of guide bearing shells Working card 510-01.10 (01H) Vibration damper Working card 510-04.00 (01H) Crankshaft Plate 51001-04H Coupling for central driven lubricating oil pump Plate 51002-01H Resilient gear wheel Plate 51002-02H Flywheel with flexible coupling and gear rim Plate 51003-01H Flywheel with gear rim Plate 51003-02H Flywheel with gear rim Plate 51003-03H Flywheel with gear rim Plate 51003-22H Flywheel with gear rim Plate 51003-23H Flywheel with gear rim Plate 51003-24 Torsional vibration damper Plate 51004-01H Torsional vibration damper Plate 51004-26H Torsional vibration damper Plate 51004-27H Torsional vibration damper Plate 51004-28H Torsional vibration damper Plate 51004-29H Torsional vibration damper Plate 51004-30H Torsional vibration damper Plate 51004-31H Torsional vibration damper Plate 51004-32H Torsional vibration damper Plate 51004-33H Torsional vibration damper Plate 51004-34H Torsional vibration damper Plate 51004-35H Torsional vibration damper Plate 51004-36H Torsional vibration damper Plate 51004-37H Torsional vibration damper Plate 51004-38H Tuning wheel Plate 51004-02H Tuning wheel Plate 51004-39H Tuning wheel Plate 51004-40H Tuning wheel Plate 51004-41H

Engine frame/Oil pan 511/611

Engine frame and base frame Description 511.01 (01H) Functional test of crankcase safety relief valves Working card 511-01.00 (10H) Frame with main bearings Plate 51101-09H Frame with main bearings Plate 51101-10H Mounting of pumps Plate 51102-05H Front cover for lubricating oil pump Plate 51102-10H Mounting of pumps Plate 51102-11H Covers on frame Plate 51106-17H Covers on frame Plate 51106-30H Covers on frame Plate 51106-31H

Turbocharger 512/612

Turbocharger system Description 512.01 (01H) Cleaning the turbocharger in service, water washing of compressor Description 512.05 (01) Cleaning the turbocharger in service, dry cleaning - turbine side Description 512.10 (02H) Cleaning the turbocharger in service, water washing - turbine side Description 512.15 (01H) Overhaul of charging air cooler Working card 512-01.00 (01H) Water washing of compressor side Working card 512-05.00 (01)

MAN Diesel

IndexGenSet

L23/30H

Text Index Drawing No.

Water washing of compressor side - TC type NR15/R Working card 512-05.05 (01H) Water washing of compressor side - TC type NR20/R Working card 512-05.05 (02H) Water washing of turbine side Working card 512-15.00 (01H) Charging air cooler - Freshwater Plate 51201-02H Charging air cooler - Freshwater Plate 51201-03H Charging air cooler - Freshwater Plate 51201-04H Charging air cooler - Freshwater Plate 51201-05H Exhaust pipe arrangement Plate 51202-01H Exhaust pipe arrangement Plate 51202-02H Turbocharger arrangement Plate 51203-09H Turbocharger arrangement Plate 51203-10H Turbocharger arrangement Plate 51203-11H Turbocharger arrangement Plate 51203-12H Water washing of compressor side Plate 51205-01 Steam trap Plate 51208-01H Blowgun for dry cleaning of turbocharger Plate 51210-01

Compressed air system 513/613

Compressed air system Description 513.01 (05H) Air filter Working card 513-01.21 (02) Overhaul, test and inspection of turbine starter Working card 513-01.30 (01H) Main starting valve Working card 513-01.40 (01H) Check of compressed air piping system Working card 513-01.90 (01H) Turbine starter Plate 51309-01H Main starting valve Plate 51310-01H Muffler Plate 51312-01H Emergency starting valve Plate 51313-01H Starting valve Plate 51314-01H Main stop valve Plate 51315-03 Air strainer Plate 51316-01H Safety valve Plate 51319-01H ON-OFF valve for jet system Plate 51320-01H Air filter Plate 51321-03 Pressure reduction valve Plate 51322-02H

Fuel oil system 514/614

Internal fuel oil system Description 514.01 (01H) Fuel injection pump and fuel injection pipe Working card 514-01.05 (12H) Fuel injection valve Working card 514-01.10 (02H) Fuel oil split filter Working card 514-01.15 (01H) Check of fuel oil piping system Working card 514-01.90 (01H) Adjustment of the maximum combustion pressure Working card 514-05.01 (01H) Fuel oil feed pump Working card 514-10.00 (01H) Fuel injection pump Plate 51401-10H Fuel injection valve Plate 51402-16H Fuel injection valve Plate 51402-17H Fuel injection valve - NICO Plate 51402-18H Fuel injection valve - NICO Plate 51402-19H Fuel oil filter duplex Plate 51403-03H Fuel injection pipe Plate 51404-01H Fuel oil feed pump Plate 51410-01H Pipes on cylinder section Plate 51430-01H Pipes on cylinder section Plate 51430-15H Pipes on cylinder section Plate 51430-16H Pipes on cylinder section Plate 51430-17H

MAN Diesel

Index GenSet

L23/30H

Text Index Drawing No.

Lubricating oil system 515/615

Internal lubricating oil system Description 515.01 (11H) Lubricating oil cooler Description 515.06 (01H) Centrifugal by-pass filter Description 515.15 (01H) Lubricating oil pump, engine driven Working card 515-01.00 (01H) Prelubricating pump Working card 515-01.05 (08) Lubricating oil filter Working card 515-01.10 (01H) Lubricating oil, thermostatic valve Working card 515-01.20 (01H) Check of lubricating oil piping system Working card 515-01.90 (01H) Lubricating oil cooler Working card 515-06.00 (02H) Centrifugal by-pass filter Working card 515-15.00 (01H) Lubricating oil pump (central driven) Plate 51501-01H Lubricating oil pump (central driven) Plate 51501-02H Lubricating oil pump (gear driven) Plate 51501-10H Lubricating oil pump (gear driven) Plate 51501-11H Lubricating oil pump (gear driven) Plate 51501-22H Lubricating oil filter (type A) Plate 51502-07H Lubricating oil filter (suppl. for plate 51502-06H/07H) Plate 51502-02H Lubricating oil thermostatic valve Plate 51503-01H Prelubricating oil pump with el-motor Plate 51504-02H Prelubricating oil pump with el-motor Plate 51504-08H Lubricating oil cooler Plate 51506-01H Combined lubricating oil cooler Plate 51506-02H Lubricating oil cooler Plate 51506-11H Lubricating oil cooler Plate 51506-12H Combined lubricating oil cooler Plate 51506-13H Combined lubricating oil cooler Plate 51506-14H Centrifugal by-pass filter Plate 51515-01H Hand wing pump Plate 51525-01H Lubricating oil separator Plate 51530-04H

Cooling water system 516/616

Cooling water system Description 516.01 (01H) Cooling water thermostatic valve Description 516.04 (01H) Check of cooling water system Working card 516-01.90 (04H) Cooling water, thermostatic valve Working card 516-04.00 (01H) Cooling water thermostatic valve Plate 51604-01H High temperature fresh water pump Plate 51610-01H High temperature fresh water pump Plate 51610-02H Low temperature fresh water pump Plate 51610-05H Low temperature fresh water pump Plate 51610-13H Pipes on cylinder head Plate 51625-01H Preheater - fresh water Plate 51635-04H

Specific plant information 519/619

Resilient mounting of generating sets Description 519.03 (07H) Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (27H) Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (28H) Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (29H) Replacement of conicals Working card 519-03.05 (01H) Replacement of conicals Working card 519-03.05 (05H) Maintenance of conicals Working card 519-03.10 (01H) Maintenance of conicals Working card 519-03.10 (05H) Flexible external connections Plate 51902-01H

MAN Diesel

IndexGenSet

L23/30H

Text Index Drawing No.

Conical element Plate 51903-01H Conical element Plate 51903-06H

Tools 520/620

Introduction to spare part plates for tools Description 520.01 (01H) Function of the hydraulic tools Working card 520-01.05 (02) Application of hydraulic tools for connecting rod Working card 520-01.06 (03H) Application of hydraulic tools for cylinder head and main bearing Working card 520-01.06 (04H) Hand lever pump Working card 520-01.07 (01) Maintenance of hydraulic tools Working card 520-01.10 (01H) Tightening with torque spanner Working card 520-01.15 (01H) Tool combinations for tightening of connecting rod screws Working card 520-01.20 (01H) Max. pressure indicator Working card 520-01.25 (01H) Tools for cylinder head Plate 52005-04H Tools for piston, connecting rod and cylinder liner Plate 52006-06H Tools for operating gear for inlet, exhaust valves and fuel injection pumps

Plate 52008-04H

Tools for control and safety system, automatics and instruments Plate 52009-02H Tools for crankshaft and main bearing Plate 52010-04H Tools for fuel oil system and injection equipment Plate 52014-03H Tools for lubricating oil cooler Plate 52015-01H Hydraulic tools Plate 52021-10H Tools for low overhaul height, piston, cylinder liner and connecting rod

Plate 52050-02H

Engine data

500/600

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DescriptionPage 1 (1) Warning A500

Warning !

(Marine engines only)

It is important that all MAN Diesel engines are oper-ated within the given specifi cations and performance tolerances specifi ed in the engines' Technical Files and are maintained according to the MAN Diesel maintenance instructions in order to comply with given emissions regulations.

In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, §94.211 NOTICE is hereby given that Chapter I of the Code of Fed-eral Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specifi ed in MAN Diesel instructions including, but not limited to, the instructions to that effect included in the Technical File.

08.16 - ES0

General

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Main Data for EngineDescriptionPage 1 (1)

L23/30H

05.17 - ES1

500.00Edition 11H

Cycle : 4-stroke

Confi guration : In-line

Cyl. Nos. available : 5-6-7-8

Power range : 650-1280 kW (885-1740 BHP)

Speed : 720/750/900 rpm

Bore : 225 mm

Stroke : 300 mm

Stroke/bore ratio : 1.33:1

Piston area per cyl. : 398 cm2

Swept volume per cyl. : 11.9 ltr.

Compression ratio : 13:1

Max. combustion pressure : 130 bar*

Turbocharging principle : Constant pressure system and inter cool ing

Fuel quality acceptance : HFO up to 700 cSt/50° C (BSMA 100-M9)

Power lay-out

Speed

Mean piston speed

Mean effective pressure

Max. combustion pressure

Power per cylinder

rpm

m/sec.

bar

bar

kW/cyl.BHP/cyl.

900

9.0

17.9

130*

160217

720

7.2

18.2

130

130175

750

7.5

18.1

130

135185

MCR version

Power per cylinder kW/cyl.BHP/cyl.

145190

150205

175239

Overload rating (up to 10%) allowable in 1 hour for every 12 hours

*For L23/30H-900 rpm version a pressure of 135 bar measured at the indicator cock correspond to 130 bar in the combustion chamber.

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DescriptionPage 1 (1) Introduction 500.01

Edition 02

Description

This instruction book serves the purpose to provide general information for operation and maintenance, and to describe the design. It can also be used as a reference when ordering spare parts.

03.36 - ES0

General

Reliable and economical operation of the plant is conditional upon its correct operation and mainte-nance in accordance with MAN B&W Diesel A/S' instructions. Emissions related maintenance of the diesel engine shall be performed as specifi ed in MAN B&W Diesel A/S' instructions and any additional instructions to that effect included in the Technical File. Consequently, it is essential that the engine room personnel are fully acquainted with the con-tents of this book and, in respect of instructions on emissions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.

The book is a basic instruction manual for the particu-lar engine supplied, with plant-adapted infor mation such as basic media-system drawings, electrical wiring diagrams and test bed reports.

The fi rst fi ve sections (500-504) of the book serve as a guide to engine operation, and the next fi fteen sections (505-519) contain technical de scrip tions, spare parts illustrations with appurtenant parts lists, as well as working cards.

The last section (520) comprises tools.

The engine is divided into a number of main com-ponents/as semblies, each of which is described in a section of this book (section 505-519).

Each of these sections starts with technical de-scriptions of the systems/components, followed by working cards and the spare parts illustration plates and parts lists.

Fig. 1 Structure of instruction book.

Description

Section 505-519

Working card

Spare parts plates

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DescriptionPage 1 (2) Safety 500.02

Edition 02

General

Proper maintenance, which is the aim of this book, is a crucial aspect of achieving optimum safety in the engine room. The general measures mentioned here should, therefore, be a natural routine for the entire engine room staff.

Cleanliness

The engine room should be kept clean above and below the fl oor plates. If grit or sand blows into the engine room while the ship is in port, the ventilation should be stopped and ventilating ducts, skylights, and doors in the engine room should be closed.

In particular, welding or work which causes the spread ing of grit and chips must be avoided near the engine, unless this is closed or covered, and the turbo char ger air intake fi lters are covered.

The exterior of the engine should be kept clean and the paintwork maintained, so that leakages can easily be detected.

Fire

If the crankcase is opened before the engine is cold, welding and the use of naked light will involve the risk of explosions and fi re. The same applies to inspection of oil tanks and the space below the cooler. Attention should furthermore be paid to the danger of fi re when using paint and solvents with a low fl ash point. Porous insulating material drenched with oil from leakages is easily infl ammable and should be re newed. See also: "Ignition in Crankcase" in section 503.

Order

Hand tools should be placed to be easily accessible on tool boards. Special tools should be fastened to tool panels (if supplied) in the engine room close to the area of use. No major objects may be left unfastened, and the fl oor and passages should be kept clear.

01.32 - ES0

General

Spares

Large spare parts should, as far as possible, be placed well strapped near the area of use and should be accessible by crane. The spare parts should be well-preserved against corrosion and protected against mechanical damage. Stock should be checked at intervals and replenished in time.

Light

Ample working light should be permanently installed at appropriate places in the engine room, and port-able working light in explosion-proof fi ttings should be available everywhere.

Freezing

If there is a risk of damage due to freezing when the plant is out of service, engines, pumps, coolers and pipe systems should be emptied of cooling water.

Warning

Opening of cocks may cause discharge of hot liquids or gases. Dismantling of parts may cause springs to be released.

The removal of fuel valves (or other valves in the cylinder head) may cause oil to run down to the piston crown, and if the piston is hot an explosion may then blow out the valve.

When testing fuel valves with the hand pump do not touch the spray holes, as the jet may pierce the skin. Consider beforehand which way the liquids, gases or fl ames will move, and keep clear.

Crankcase Work

Check beforehand that the starting air supply to the engine is shut off.

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DescriptionPage 2 (2)

Feeling Over

Whenever repairs or alterations have been made to the running gear, apply the "feel-over sequence" until it is ensured that there is no undue heating, oil-mist formation, blow-by, or failure of cooling water or lubricating oil systems.

Feel-over Sequence

Feel over after 5-15 and 30 minutes' idle running and fi nally when the engine is running at full load. See also "Operation" in the section 501.

Safety

01.32 - ES0

General

500.02Edition 02

Turning

After prolonged out-of-service periods or overhaul work which may involve a risk of accumulation of liquid in the combustion spaces, turning should always be effected through at least two complete revolutions.

Check and Maintain

Lubricating oil condition, fi lter elements and meas-uring equipment, see "Planned Maintenance Pro-gramme".

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99.40 - ES1

Cross Section

L23/30H

DescriptionPage 1 (1)

500.05Edition 06H

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99.40 - ES1

Cross Section

L23/30H

DescriptionPage 1 (1)

500.05Edition 06H

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Key for Engine Designation

General

No of cylinders

5, 6, 7, 8, 9 12, 16, 18

Engine Type

L : In-lineV : V-built

Cyl. diam/stroke

16/24 : 160/24021/31 : 210/31023/30 : 225/30027/38 : 270/38028/32 : 280/32032/40 : 320/400

Design Variant

Rating

MCR : Maximum continuous ratingECR : Economy continuous rating

6 L 28/32 H MCR

04.08 - ES1

DescriptionPage 1 (1)

Engine Type Identifi cation

The engine types of the MAN B&W programme are identifi ed by the following fi gures:

500.10Edition 02

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Designation of Cylinders

General

98.19 - ES1

DescriptionPage 1 (1)

500.11Edition 03

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Engine Rotation Clockwise

General

98.18 - ES1

DescriptionPage 1 (1)

500.12Edition 02

Engine

Direction “Clockwise” of diesel engine seen from flywheel end

Alternator

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Explanation of Symbols

Measuring deviceLocal reading

Temperature IndicatorNo. 40 *

Measuring deviceSensor mounted on engine/unitReading/identifi cation mounted in a panel on the engine/unit

Pressure IndicatorNo. 22 *

Measuring deviceSensor mounted on engine/unitReading/identifi cation outside the engine/unit

Temperature Alarm HighNo. 12 *

Measureing deviceSensor mounted on engine/unitReading/identifi cation in a panel on the engine/unit and reading/indication outside the engine/unit

Pressure TransmittingNo. 22 *

* Refer to standard location and text for instruments on the following pages.

Specifi cation of letter code for measuring devices

1st letter Following letters

F Flow A Alarm

L Level D Differential

P Pressure E Element

S Speed, System H High

T Temperature I Indicating

U Voltage L Low

V Viscosity S Switching, Stop

X Sound T Transmitting

Z Position X Failure

V Valve, Atuator

TI40

TAH12

PI22

PT22

Code Identifi cation for Instruments

04.36 - ES1

DescriptionPage 1 (2)

General

500.20Edition 03

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Standard Text for Instruments

Diesel Engine/Alternator

LT Water System01 inlet to air cooler 04 inlet to alternator 07 inlet to lub. oil cooler02 outlet from air cooler 05 outlet from alternator 08 inlet to fresh water cooler (SW)03 outlet from lub. oil cooler 06 outlet from fresh water cooler (SW) 09

HT Water System10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler10A FW inlet to engine 14A FW inlet to air cooler 18 inlet to fresh water cooler11 outlet from each cylinder 14B FW outlet from air cooler 19 preheater12 outlet from engine 15 outlet from HT system 19A inlet to prechamber13 inlet to HT pump 16 outlet from turbocharger 19B outlet from prechamber

Lubricating Oil System20 inlet to cooler 24 sealing oil - inlet engine 28 level in base frame21 outlet from cooler / inlet to fi lter 25 prelubricating 29 main bearings22 outlet from fi lter / inlet to engine 26 inlet rocker arms and roller guides 23 inlet to turbocharger 27 intermediate bearing / alternator bearing

Charging Air System30 inlet to cooler 34 charge air conditioning 3831 outlet from cooler 35 surplus air inlet 3932 jet assist system 36 inlet to turbocharger33 outlet from TC fi lter / inlet to TC compr. 37 charge air from mixer

Fuel Oil System40 inlet to engine 44 outlet from sealing oil pump 4841 outlet from engine 45 fuel-rack position 4942 leakage 46 inlet to prechamber43 inlet to fi lter 47

Nozzle Cooling System50 inlet to fuel valves 54 58 oil splash51 outlet from fuel valves 55 valve timing 59 alternator load52 56 injection timing53 57

Exhaust Gas System60 outlet from cylinder 64 6861 outlet from turbocharger 65 6962 inlet to turbocharger 6663 compustion chamber 67

Compressed Air System70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system71 inlet to stop cylinder 75 microswitch for turning gear 7972 inlet to balance arm unit 76 inlet to turning gear73 control air 77 waste gate pressure

Load Speed80 overspeed air 84 engine stop 88 index - fuel injection pump81 overspeed 85 microswitch for overload 89 turbocharger speed82 emergency stop 86 shutdown 90 engine speed83 engine start 87 ready to start

Miscellaneous91 natural gas - inlet to engine 94 cylinder lubricating 97 remote92 oil mist detector 95 voltage 98 alternator winding93 knocking sensor 96 switch for operating location 99 common alarm

Code Identifi cation for Instruments

04.36 - ES1

DescriptionPage 2 (2)

General

500.20Edition 03

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MAN Diesel

DescriptionPage 1 (2) Introduction to Planned Maintenance Programme 500.24

Edition 03

General

The overhaul intervals are based on operation on a specifi ed fuel oil quality at normal service output, which means 70-100% of MCR.

In the long run it is not possible to achieve safe and optimum economical running without an effective main tenance system.

The structure and amount of information in the main-tenance programme mean that it can be integrated in the entire ship's/power station's maintenance system or it can be used separately.

The core of the maintenance system is the key dia-gram, see pages 500.25 and 500.26, indicating the inspection intervals for the components/systems, so that the crew can make the necessary overhauls based on the engines' condition and/or the time criteria.

The maintenance system is divided into 2 main groups:

a. Major overhaul / inspection (page 500.25): These works are to be carried out during major overhauls and inspections of the engine.

b. Duty during operation (page 500.26): indicated the works to be carried out by the personnel during the daily operation of the engine.

The stated recommended intervals are only for guidance as different service conditions, the quality of the fuel oil and the lubricating oil, treatment of the cooling water, etc., will decisively infl uence the actual service results and thus the intervals between necessary overhauls.

Experience with the specifi c plant/personnel should be used to adjust the time between overhauls. It should also be used to adjust the timetable stated for guidance in the working cards.

Working Cards

Each of the working cards can be divided into two: a front page and one or several pages describing and illustrating the maintenance work.

98.19 - ES0

General

The front page indicates the following:

1) Safety regulations, which MUST be carried out before the maintenance work can start.

2) A brief description of the work.

3) Reference to any work which must be carried out before the maintenance work can start.

4) Related procedures - indicates other works, depending on the present work - or works which it would be expedient to carry out.

5) Indicates x number of men in x number of hours to accomplish the work.

The stated consumption of hours is only intended as a guide.

1

2

3

4

5

6

7

8

9

Fig. 1 Instruction guide for working cards.

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Experience with the specifi c station/personnel may lead to updating.

6) Refers to data required to carry out the work.

7) Special tools which must be used. Please note that not all tools are standard equip ment.

DescriptionPage 2 (2)Introduction to Planned Maintenance Programme500.24

Edition 03

98.19 - ES0

General

8) Various requisite hand tools.

9) Indicates the components/parts which it is advisible to replace during the maintenance work. Please note that this is a condition for the intervals stated.

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

ck n

ew/

over

haul

ed p

arts

af

ter

hour

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DescriptionPage 1 (4)

06.02 - ES0

50

1200

0

2400

0

6000

200020

0

Obs

erva

tions

Dai

ly

Wee

kly

500.25Edition 19H

L23/30H900 RPM

Planned Maintenance Programme

Operating of Engine:

Readings of data for engine and alternor, with refe-rence to "Engine Performance Data", section 502.01 .....

Cylinder Head:

Inlet and exhaust valve - overhaul and regrinding of spindel and valve seat .....................................................Inspection of inlet, exhaust valves and valve guide .........Check of valve rotators' rotation during engine rotation ..Sleeve for fuel injector .....................................................Safety valve - overhaul and adjustment of opening pressure ..........................................................................Indicator valve .................................................................

Cylinder head cooling water space - inspection ..............Cylinder head nut - retightening ...................................... 200

Piston, Connecting Rod and Cylinder Liner:

Inspection of piston .........................................................Piston ring and scraper ring ............................................

Piston pin and bush for connecting rod - check of clearance ......................................................................... Connecting rod - measuring of big-end bore ...................Inspection of big-end bearing shells ................................

Connecting rod - retightening .......................................... 200Cylinder liner - cleaning, honing and measuring .............Cylinder liner removed - check the water space and wear ring in frame ............................................................

Camshaft and Camshaft Drive:

Camshaft - inspection of gear wheels, bolts, connections etc. ................................................................................... 200Camshaft bearing - inspection of clearance ....................Camshaft adjustment - check the condition .....................

Lubrication of camshaft bearing - check ..........................

■

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■

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502-01.00

505-01.10505-01.05505-01.05505-01.30

505-01.25505-01.26

505-01.45505-01.40

506-01.10506-01.10

506-01.15506-01.15506-01.16

506-01.25506-01.35

506-01.40

507-01.00507-01.05507-01.20

507-01.00

3rd

mon

th

Mon

thly

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

ck n

ew/

over

haul

ed p

arts

af

ter

hour

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DescriptionPage 2 (4)

06.02 - ES0

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200

Obs

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Wee

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6000

1200

0

Dai

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500.25Edition 19H

L23/30H900 RPM

Planned Maintenance Programme

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

Roller guide for valve gear ...............................................Valve gear - valve bridge, spring, push rod, etc ...............Roller guide for fuel injection pump .................................

Roller guide housing ........................................................Inlet and exhaust valve - check and adjustment of valve clearance .........................................................................

Lubricating of operating gear - check ..............................

Control and Safety System, Automatics and Instruments:

Safety, alarm and monitoring equipment ........................

Lambda controller - adjustment .......................................

Governor - check oil level, see governor instruction book, section 509 ............................................................

Crankshaft and Main Bearing:

Checking of main bearings alignment, (autolog) .............Inspection af main bearing ..............................................Inspection of guide bearing .............................................

Vibration damper - check the condition ...........................

Lubricating of gear wheel for lub. oil pump and cooling water pump etc. ...............................................................Counterweight - retightening, see page 500.40............... 900*

Main- and guide bearing cap - retightening ..................... 200

* If screw can be tightened then the screw have to be loosened and retightened after page 500.40.

■ ■ ■

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508-01.00508-01.10508-01.05

508-01.10

508-01.10

508-01.00508-01.05

509-01.00

509-10.00

510-01.00510-01.05510-01.10

510-04.00

510-01.05510-01.10

3rd

mon

th

Mon

thly

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

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ew/

over

haul

ed p

arts

af

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DescriptionPage 3 (4)

06.02 - ES0

500.25Edition 19H

2400

0

200

Obs

erva

tions

Wee

kly50

2000

6000

1200

0

Dai

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L23/30H900 RPM

Planned Maintenance Programme

Engine Frame and Baseframe:

Holding down bolts - retightening, see page 500.40 ....... 200Bolts between engine frame and base frame - retightening, see page 500.40 ......................................... 200

For fl exible mounted engines - check anti-vibration mountings ........................................................................ 200Safety cover - function test ..............................................

Turbocharger System:

Wet cleaning of turbine side ............................................Water washing of compressor side .................................

Cleaning of air fi lter - compressor side (see turbo-charger instruction book) .................................................Turbocharger complete - dismantling, cleaning, inspec-tion etc. (see turbocharger instruction book) ...................Charging air cooler - cleaning and inspection .................

Charging air cooler housing - draining.............................Exhaust pipe - compensator ............................................

Compressed Air System:

Air starter motor - dismantling and inspection .................Function test - main starting valve, starting valve, main valves and emergency start valve ...................................

Dirt separator - dismantling and cleaning ........................Muffl er - dismantling and cleaning ...................................

Compressed air system - draining ...................................Compressed air system - check of the system ................

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■

■

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519-03.00511-01.00

512-15.00512-05.00

512-01.00

513-01.30

513-01.40

513-01.90513-01.90

3rd

mon

th

Mon

thly

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

ck n

ew/

over

haul

ed p

arts

af

ter

hour

s

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06.02 - ES0

DescriptionPage 4 (4)

500.25Edition 19H

2400

0

200

Obs

erva

tions

Wee

kly50

2000

6000

1200

0

Dai

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L23/30H900 RPM

Planned Maintenance Programme

Fuel Oil System and Injection Equipment:

Fuel oil fi lter - dismantling and cleaning ..........................Fuel oil feed pump ...........................................................Fuel oil injection pump - dismantling and cleaning ..........

Fuel injection valve - adjustment of opening pressure .... 200Fuel oil high-pressure pipe - dismantling and check .......Adjustment of the maximum combustion pressure ..........

Fuel oil system - check the system ..................................Nozzle cooling system - check the system if installed .....

Fuel oil - oil samples after every bunkering, see sec.504

Lubricating Oil System:

Lubricating oil pump - engine driven ...............................Lubricating oil fi lter - cleaning and exhange ....................Lubricating oil cooler .......................................................

Prelubricating pump - el.-driven ......................................Thermostatic valve ..........................................................Centrifugal fi lter - cleaning and exhange of paper ...........

Hand pump ......................................................................Lubricating oil - oil samples, see section 504 ..................Lubricating oil system - check the system .......................

Cooling Water System:

Cooling water pump - engine-driven (sea water and fresh water)......................................................................Thermostatic valve ..........................................................Cooling water system - check the system .......................

Cooling water system - water samples, see sec. 504 ......

● ● ●

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● ■ ■

■ ■ ■

■ ■

514-01.15514-10.00514-01.05

514-01.10514-01.05514-05.01

514-01.90514-01.90

515-01.00515-01.10515-06.00

515-01.05515-01.20515-15.00

515-10.00

515-01.90

516-04.00516-04.00516-01.90

3rd

mon

th

Mon

thly

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

ck n

ew/

over

haul

ed p

arts

af

ter

hour

s

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Operating of Engine:

Readings of data for engine and alternator with refe-rence to "Engine Performance Data", section 502.01 .....

Cylinder Head:

Inlet and exhaust valve - overhaul and regrinding of spindle and valve seat .....................................................Inspection of inlet, exhaust valves and valve guide .........Check of valve rotators' rotation during engine rotation ..Sleeve for fuel injector .....................................................Safety valve - overhaul and adjustment of opening pressure ..........................................................................Indicator valve .................................................................

Cylinder head cooling water space - inspection ..............Cylinder head nut - retightening ...................................... 200

Piston, Connecting Rod and Cylinder Liner:

Inspection of piston .........................................................Piston ring and scraper ring ............................................

Piston pin and bush for connecting rod - check of clearance ......................................................................... Connecting rod - measuring of big-end bore ...................Inspection of big-end bearing shells ................................

Connecting rod - retightening .......................................... 200Cylinder liner - cleaning, honing and measuring .............Cylinder liner removed - check the water space and wear ring in frame ............................................................

Camshaft and Camshaft Drive:

Camshaft - Inspection of gear wheels, bolts, connections etc. ................................................................................... 200Camshaft bearing - inspection of clearance ....................Camshaft adjustment - check the condition .....................

Lubrication of camshaft bearing - check ..........................

DescriptionPage 1 (4)

06.02 - ES0

50

1600

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3200

0

8000

200020

0

3rd

mon

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Mon

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500.25Edition 21H

L23/30H720/750 RPM

■

● ■ ■ ■

■ ■ ■

■

■ ●

■ ■ ■

■ ●

■

■ ■ ■

■

502-01.00

505-01.10505-01.05505-01.05505-01.30

505-01.25505-01.26

505-01.45505-01.40

506-01.10506-01.10

506-01.15506-01.15506-01.16

506-01.25506-01.35

506-01.40

507-01.00507-01.05507-01.20

507-01.00

Planned Maintenance Programme

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

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ew/

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haul

ed p

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DescriptionPage 2 (4)

06.02 - ES0

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

Roller guide for valve gear ...............................................Valve gear - valve bridge, spring, push rod, etc ...............Roller guide for fuel injection pump .................................

Roller guide housing ........................................................Inlet and exhaust valve - check and adjustment of valve clearance .........................................................................

Lubricating of operating gear - check ..............................

Control and Safety System, Automatics and Instruments:

Safety, alarm and monitoring equipment ........................

Lambda controller - adjustment .......................................

Governor - check oil level, see governor instruction book, section 509 ............................................................

Crankshaft and Main Bearing:

Checking of main bearings alignment, (autolog) .............Inspection af main bearing ..............................................Inspection of guide bearing .............................................

Vibration damper - check the condition ...........................

Lubricating of gear wheel for lub. oil pump and cooling water pump etc. ...............................................................Counterweight - retightening, see page 500.40............... 900*

Main- and guide bearing cap - retightening ..................... 200

* If screw can be tightened then the screw have to be loosened and retightened after page 500.40.

■ ■ ■

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■

■

■

■

■

■ ■ ■

■

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■

3200

0

200

3rd

mon

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Obs

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tions

Wee

kly50

2000

8000

1600

0

Mon

thly

Dai

ly

500.25Edition 21H

L23/30H720/750 RPM

508-01.00508-01.10508-01.05

508-01.10

508-01.10

508-01.00508-01.05

509-01.00

509-10.00

510-01.00510-01.05510-01.10

510-04.00

510-01.05510-01.10

Planned Maintenance Programme

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

ck n

ew/

over

haul

ed p

arts

af

ter

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s

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DescriptionPage 3 (4)

06.02 - ES0

Engine Frame and Baseframe:

Holdingdown bolts - retightening, see page 500.40 ........ 200Bolts between engine frame and base frame - retightening, see page 500.40 ......................................... 200

For fl exible mounted engines - check anti-vibration mountings ........................................................................ 200Safety cover - function test ..............................................

Turbocharger System:

Wet cleaning of turbine side ............................................Water washing of compressor side .................................

Cleaning of air fi lter - compressor side (see turbo-charger instruction book) .................................................Turbocharger complete - dismantling, cleaning, inspec-tion etc. (see turbocharger instruction book) ...................Charging air cooler - cleaning and inspection .................

Charging air cooler housing - draining.............................Exhaust pipe - compensator ............................................

Compressed Air System:

Air starter motor - dismantling and inspection .................Function test - main starting valve, starting valve, main valves and emergency start valve ...................................

Dirt separator - dismantling and cleaning ........................Muffl er - dismantling and cleaning ...................................

Compressed air system - draining ...................................Compressed air system - check of the system ................

500.25Edition 21H

3200

0

200

Obs

erva

tions

Wee

kly50

2000

8000

1600

0

Dai

ly

L23/30H720/750 RPM

■

■

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● ●

■

● ■

■

■

● ●

● ■

519-03.00511-01.00

512-15.00512-05.00

512-01.00

513-01.30

513-01.40

513-01.90513-01.90

Planned Maintenance Programme

Mon

thly

3rd

mon

th

DescriptionWorking

CardNo

● = Overhaul to be carried out ■ = Check the condition

Time Between Overhaul

Che

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06.02 - ES0

DescriptionPage 4 (4)

Fuel Oil System and Injection Equipment:

Fuel oil fi lter - dismantling and cleaning ..........................Fuel oil feed pump ...........................................................Fuel oil injection pump - dismantling and cleaning ..........

Fuel injection valve - adjustment of opening pressure .... 200Fuel oil high-pressure pipe - dismantling and check .......Adjustment of the maximum combustion pressure ..........

Fuel oil system - check the system ..................................

Fuel oil - oil samples after every bunkering, see sec.504

Lubricating Oil System:

Lubricating oil pump - engine-driven ...............................Lubricating oil fi lter - cleaning and exhange ....................Lubricating oil cooler .......................................................

Prelubricating pump - el. driven .......................................Thermostatic valve ..........................................................Centrifugal fi lter - cleaning and exhange of paper ...........

Hand pump ......................................................................Lubricating oil - oil samples, see section 504 ..................Lubricating oil system - check the system .......................

Cooling Water System:

Cooling water pump - engine-driven (sea water and fresh water)......................................................................Thermostatic valve ..........................................................Cooling water system - check the system .......................

Cooling water system - water samples, see sec. 504 ......

● ● ●

■ ■ ●

■

■ ● ●

■ ■ ●

● ■ ■

■ ■ ■

■ ■

514-01.15514-10.00514-01.05

514-01.10514-01.05514-05.01

514-01.90

515-01.00515-01.10515-06.00

515-01.05515-01.20515-15.00

515-10.00

515-01.90

516-04.00516-04.00516-01.90

500.25Edition 21H

3200

0

200

Obs

erva

tions

Wee

kly50

2000

8000

1600

0

Dai

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L23/30H720/750 RPM

Planned Maintenance Programme

3rd

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Normal Value at Full load Alarm Set point Autostop of engine

90° C100° C

75° C85° C

3 bar

4 bar

1.5 bar

level switch

low levelhigh level

95° C

1.5 bar4 bar

leakage

1.5 bar (B)(B)

0.4 bar + (C)0.4 bar + (C)

90° C93° C

550° C600° C

450° C

average (F)±50° C

500° C

65° C

7 bar

Operation Data & Set Points

L23/30H

08.23 - ES1

DescriptionPage 1 (2)

Lubricating Oil System

Temp. before cooler SAE 30(outlet engine) SAE 40

Temp. after cooler SAE 30(inlet engine) SAE 40

Pressure after fi lter (inlet eng)

Elevated pressure i.g. whencentrifugal fi lter installed

Pressure drop across fi lter

Prelubricating pressurePressure inlet turbocharger

Lub. oil, level in base frame

Temp. main bearings

Fuel Oil System

Pressure after fi lter MDO HFO

Leaking oil

Press. nozz. cool. oil, inlet eng.Temp. nozz. cool. oil, outlet eng.

Cooling Water System

Press. LT-system, inlet enginePress. HT-system, inlet engine

Temp. HT-system, inlet engineTemp. HT-system, outl. cyl.units

Temp. HT-system, outlet engine

Temp. raise across cyl. units

Exhaust Gas and Charge Air

Exh. gas temp. before TC

Exh. gas temp. outlet cyl.

Diff. between individual cyl.

Exh. gas temp. after TC

Ch. air press. after coolerCh. air temp. after cooler

Compressed Air System

Press. inlet engine

TI 20TI 20

TI 22TI 22

PI 22

PI 22

PDAH 21-22

PI 25PI 23

TE 29

PI 40PI 40

PI 50TI 51

PI 01PI 10

TI 10TI 11

TI 62TI 62

TI 60TI 60

TI 61TI 61

PI 31TI 31

PI 70

60-75° C65-82° C

45-65° C50-72° C

3.1-4.5 bar

4.1-5 bar

0.5-1 bar

0.1-0.5 bar1.5 ±0.2 bar

75-85° C

2.5-5 bar5-16 bar (A)

2-3 bar80-90° C

1-2.5 bar (D)1.5-4.6 bar

60-75° C70-85° C

max. 10° C

425-475° C*460-520° C**

280-390° C*320-420° C**

275-350° C*320-390° C**

2-2.5 bar35-55° C

7-9 bar

TAH 20TAH 20

TAH 22TAH 22

PAL 22

PAL 22

PDAH 21-22

LAL 25

LAL 28LAH 28

TAH 29

PAL 40PAL 40

LAH 42

PAL 50

PAL 01PAL 10

TAH 12TAH 12-2

TAH 62TAH 62-2

TAH 60

TAD 60

TAH 61

TAH 31

PAL 70

TSH 22TSH 22

PSL 22

PSL 22

TSH 12

85° C95° C

2.5 bar

2.5 bar

95° C

Specifi c plants will not comprise alarm equipment and autostop for all parameters listed above. For specifi c plants additional parameters can be included. For remarks to some parameters, see overleaf.* for 720/750 rpm ** for 900 rpm.

Acceptable value at shop test or after

repair

<75° C<82° C

<65° C<72° C

>4.0 bar

>4.5 bar

<0.5 bar

>0.2 bar>1.5 bar

<85° C

>1.3 bar>1.8-<6 bar

<85° C

average±25° C

<55° C

>7.5-<9 bar

500.30Edition 55H

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Operation Data & Set Points

E. Limits for Turbocharger Overspeed Alarm (SAH 89)

Remarks to individual Parameters

A. Fuel Oil Pressure, HFO-operation

When operating on HFO, the system pressure must be suffi cient to depress any tendency to gasifi cation of the hot fuel.

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

B. Nozzle Cooling Oil System

The nozzle cooling oil system is only applied for stationary engines.

C. Cooling Water Pressure, Alarm Set Points

As the system pressure in case of pump failure will depend on the height of the expansion tank above the engine, the alarm set point has to be adjusted to 0.4 bar plus the static pressure.

D. Press. LT -system, inlet engine (PI 01)

With two-string cooling water system the normal value can be higher, max. 4.0 bar.

L23/30H

08.23 - ES1

DescriptionPage 2 (2)

Engine type 720 rpm 750 rpm 900 rpm

5L23/30H 55,290 55,290 –

6L23/30H 55,290 55,290 42,680

7L23/30H 42,680 42,680 42,680

8L23/30H 42,680 42,680 42,680

Normal Value at Full load Alarm Set point Autostop of engine

Acceptable value at shop test or after

repair

Speed Control SystemEngine speedMechanicalElec.MechanicalElec.MechanicalElec.

Turbocharger speed

SI 90

SI 90

SI 90

SI 89

720 rpm

750 rpm

900 rpm

(G)

SAH 81

SAH 81

SAH 81

SAH 89

815 rpm

850 rpm

1015 rpm

(E)

SSH 81SSH 81SSH 81SSH 81SSH 81SSH 81

825 rpm815 rpm860 rpm850 rpm1030 rpm1015 rpm

820 rpm

855 rpm

1020 rpm

F. Exhaust Gas Temperatures

The exhaust gas temperature deviation alarm is normally ±50° C with a delay of 1 min., but at start-up the delay is 5 min. Furthermore the deviation limit is ±100° C if the average temperature is below 200° C.

G. Turbocharger Speed

Normal value at full load of the turbocharger is de-pendent on engine type (cyl. no) and engine rpm. The value given is just a guide line. Actual values can be found in the acceptance test protocol.

500.30Edition 55H

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MAN Diesel

"Green Passport"DescriptionPage 1 (1)

List of potentially hazardous materials of MAN four-stroke diesel engines that are relevant to be delivered to recycling facilities according to IMO resolution A.962(23) Adopted on 5 december 2003.

General

07.36 - ES0

500.33Edition 01

Asbestos

Type of asbestos Materials Location Approximate quantity/volume

- - None Plastic Materials

Type Location Approximate quantity/volume

Copolymer, based on acrylnitrile and butadiene: NBR

O-rings (Inside engine) *)

Copolymer, based on vinylidene-fl uoride and hexafl uoro-propene: FPM

O-rings (Inside engine) *)

FPI 155, Flame retardant according to IEC 332-3 cat. 3

Cable jacket < 100 m

Materials containing PCBs, PCTs, PBBs at levels of 50 mg/kg or more

None Gases sealed in the machinery

Argon Exhaust thermometers *) Chemicals in engine

Type Location Approximate quantity/volume

Anti-seize Compounds Used on high temperature screws *)

Engine Additives None

Water Treatment: Nitrite-borate inhibitor Fresh water system See instruction manual Other Substances in engine

Type Location Approximate quantity/volume

Fuel oil Engine F.O. pipe system < 0,020 m3

Lubricating oil Engine frame See instruction manual

Filter cartridge Lub. oil fi lter on engine 2 pcs. 1)

Filter cartridge Lub. oil fi lter on engine/fi lter candles 2 pcs./48 pcs. 2)

Mercury None

Lithium battery (if installed) Electronic cabinet 1 pcs.

Lead Pb - for soldering circuit board Electronic cabinet < 10 g/engine 2) *) The component is most likely bound in an alloy or present at a very low concentration 1) only valid for GenSets 2) only valid for Propulsion engines

MAN Diesel

Section Description mm. / bar

505

506

507

508

509

510

514

Maximum inner diameter, valve guideFor grinding of valve spindle and valve seat ring(see also working card 505-01.10)Minimum height of valve head, inlet valve and exhaust valve, "H" 1Maximum height of spindle above cylinder head, "H" 2

Piston and piston ring grooves (see working card 506-01.10)Clearance in big-end bearingClearance between connecting rod bush and piston pinMaximum clearance between connecting rod bush and piston pinMaximum ovalness in big-end bore (without bearing)New cylinder liner, inside diameterMaximum inside diameter cylinder liner, max. ovalness 0.1 mm

Clearance between camshaft and camshaft bearingMaximum clearance between camshaft and camshaft bearingClearance between teeth on intermediate wheel

Valve clearance, Inlet valve (cold engine 15 - 55°C)Valve clearance, Exhaust valve (cold engine 15 - 55°C)Maximum clearance between rocker arm bush and rocker arm shaft

Clearance between pick-up and impulse wheel

Defl ection of crankchaft (autolog) (see working card 510-01.00)Clearance between crankshaft and sealing ring, (upper and lower part)Clearance in main bearingClearance in connecting rod bearingClearance in guide bearing (axial)Maximum clearance in guide bearing (axial) Clearance between bearing and gearwheel shaft:Clearance when new bearings are mountedMaximum clearance

Maximum combustion pressure at full loadIndividual cylinders; admissible deviation from average

A change of the height of the thrust piece spacer ring of 0.10 mm will change the maximum pressure by 1° turning of camshaft gear wheel changes max. pressure by approx

Measurement "X" between thrust piece and roller guide housing

For L23/30H 900 rpm version a pressure of 135 bar measured at the indicator cock correspond to 130 bar in the combustion chamber

Opening pressure of fuel valve

14.25 mm.

5.0 mm.83.3 mm

0.15-0.20 mm0.15-0.25 mm

0.35 mm0.08 mm

225,000-225,046 mm.225.50 mm

0.11-0.20 mm0.35 mm

0.2-0.3 mm.

0.50 mm.0.90 mm.0.30 mm.

1 ±0.3 mm

0.30 - 0.40 mm.0,2-0,3 mm

0.13 - 0.29 mm0.15 - 0.44 mm

0.8 mm

0.085-0.1350.185

130 ± 3 bar± 3 bar

1 bar3 bar

5.5 ± 2.5 mm

1.5 mm

320 bar

Data for Pressure and ToleranceDescriptionPage 1 (1)

L23/30H

500.35Edition 29H

08.03 - ES0

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Section Description mm. / bar

505

506

507

508

509

510

514

Maximum inner diameter, valve guideFor grinding of valve spindle and valve seat ring(see also working card 505-01.10)Minimum height of valve head, inlet valve and exhaust valve, "H" 1Maximum height of spindle above cylinder head, "H" 2

Piston and piston ring grooves (see working card 506-01.10)Clearance in big-end bearingClearance between connecting rod bush and piston pinMaximum ovalness in big-end bore (without bearing)New cylinder liner, inside diameterMaximum inside diameter cylinder liner, max. ovalness 0.1 mm

Clearance between camshaft and camshaft bearingMaximum clearance between camshaft and camshaft bearingClearance between teeth on intermediate wheel

Valve clearance, Inlet valve (cold engine 15 - 55°C)Valve clearance, Exhaust valve (cold engine 15 - 55°C)Maximum clearance between rocker arm bush and rocker arm shaft

Clearance between pick-up and impulse wheel

Defl ection of crankchaft (autolog) (see working card 510-01.00)Clearance between crankshaft and sealing ring, (upper and lower part)Clearance in main bearingClearance in guide bearing (axial)Maximum clearance in guide bearing (axial) Clearance between bearing and gearwheel shaft:Clearance when new bearings are mountedMaximum clearance

Maximum combustion pressure at full loadIndividual cylinders; admissible deviation from average

A change of the height of the thrust piece spacer ring of 0.10 mm will change the maximum pressure by 1° turning of camshaft gear wheel changes max. pressure by approx

Measurement "X" between thrust piece and roller guide housing

For L23/30H 900 rpm version a pressure of 135 bar measured at the indicator cock correspond to 130 bar in the combustion chamber

Opening pressure of fuel valve

14.25 mm.

5.0 mm.83.3 mm

0.15-0.20 mm0.15-0.25 mm.

0.08 mm.225,000-225,046 mm.

225.50 mm

0.11-0.20 mm0.35 mm

0.2-0.3 mm.

0.50 mm.0.90 mm.0.30 mm.

1 ±0.3 mm

0.30 - 0.40 mm.0,2-0,3 mm

0.15 - 0.44 mm0.8 mm

0.085-0.1350.185

130 ± 3 bar± 3 bar

1 bar3 bar

5.5 ± 2.5 mm

1.5 mm

350 bar

Data for Pressure and ToleranceDescriptionPage 1 (1)

L23/30H

500.35Edition 22H

06.18 - ES0

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505 Cylinder cover stud (in frame) Stud M48 200 Loctite 243 Nut for cylinder cover stud Nut M45 750 Oil/Molykote (Unimol gl 82) Cooling jacket cylinder cover Screw 22 –

506 Connecting rod (see section 506) Molykote Connecting rod screw Stud M 33 x 2 (Unimol gl 82) (hydraulic tightening) Nut M 33 x 2 750 –

507 Camshaft assembly Nut M12 50 – Intermediate wheel shaft Nut M 20 x 1.5 250 – Intermediate wheel gear Nut M 12 40 – Gear wheel on camshaft Screw M 12 50 –

508 Housing for valve gear Screw M 12 60 – Valve gear bracket rocker arm Nut M 16 150 –

510 Main bearing stud (in frame) Stud M 48 200 Loctite 243 Nut for main bearing stud Nut M 45 x 3 750 Molykote (Unimol gl 82) Main bearing side screw Screw M 24 300 – Counterweight on crankshaft Screw M 30 x 2 200 – + 60° turn

Vibrationdamper on crankshaft Nut M 27 400 – Frame / baseframe Nut M 24 500 – Flywheel mounting (fi tted bolt) Nut M 20 140 – Gear rim on fl ywheel Screw 34 – Gear wheel on crankshaft Nut M 10 40 –

514 Fuel pump distribution piece Screw M 8 25 - 30 – Fuel pump top fl ange (barrel) Screw M 10 55 - 65 – Fuel pump caviation plugs Plug M 20 x 1.5 100-120 – Fuel pump mounting (bottom fl ange) Screw M 16 150 –

Fuel valve (nozzle nut) Nut M 26 x 1.5 100 - 120 – Fuel valve mounting Nut M 16 40 – Fuel valve (cap nut) Nut 70 – Fuel valve adjusting (lock nut) Nut 100 – High pressure pipe Nut M 18 x 1.5 40 –

515 Gear wheel on lub. oil pump Nut 300 –

519 Conical elements mounting Upper mounting Screw M 24 150 – Lower mounting Nut M 24 200 –

DescriptionPage 1 (1)

500.40Edition 21H

L23/30H720/750 rpm

Data for Tightening Torque

07.10

DescriptionSection TorqueNm

Tightening

Thread Pressurebar

Lubricant

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505 Cylinder cover stud (in frame) Stud M48 200 Loctite 243 Nut for cylinder cover stud Nut M45 750 Oil/Molykote (Unimol gl 82) Cooling jacket cylinder cover Screw 22 –

506 Connecting rod (see section 506) Molykote Connecting rod screw Stud M 33 x 2 (Unimol gl 82) (hydraulic tightening) Nut M 33 x 2 750 –

507 Camshaft assembly Nut M12 85 – Intermediate wheel shaft Nut M 20 x 1.5 250 – Intermediate wheel gear Nut M 12 40 – Gear wheel on camshaft Screw M 12 50 –

508 Housing for valve gear Screw M 12 60 – Valve gear bracket rocker arm Nut M 16 150 –

510 Main bearing stud (in frame) Stud M 48 200 Loctite 243 Nut for main bearing stud Nut M 45 x 3 750 Molykote (Unimol gl 82) Main bearing side screw Screw M 24 300 – Counterweight on crankshaft Screw M 30 x 2 200 – + 60° turn

Vibrationdamper on crankshaft Nut M 27 400 – Frame / baseframe Nut M 24 500 – Flywheel mounting (fi tted bolt) Nut M 20 140 – Gear rim on fl ywheel Screw 34 – Gear wheel on crankshaft Nut M 10 40 –

514 Fuel pump distribution piece Screw M 8 25 - 30 – Fuel pump top fl ange (barrel) Screw M 10 55 - 65 – Fuel pump caviation plugs Plug M 20 x 1.5 100-120 – Fuel pump mounting (bottom fl ange) Screw M 16 150 –

Fuel valve (nozzle nut) Nut M 26 x 1.5 100 - 120 – Fuel valve mounting Nut M 16 40 – Fuel valve (cap nut) Nut 70 – Fuel valve adjusting (lock nut) Nut 100 – High pressure pipe Nut M 18 x 1.5 40 –

515 Gear wheel on lub. oil pump Nut 300 –

519 Conical elements mounting Upper mounting Screw M 24 150 – Lower mounting Nut M 24 200 –

DescriptionPage 1 (1)

500.40Edition 22H

L23/30H900 rpm

07.10

Data for Tightening Torque

DescriptionSection TorqueNm

Tightening

Thread Pressurebar

Lubricant

MAN Diesel

081019068018055

014,026,038

016

021,104,116

108300019237

181054138

756

381177290

330115242337

114201

L23/30H

505

506

507

508

509

511

512

513

514

515

516

Cylinder Head, complete

Piston, completePiston PinConnecting Rod, complete without bearingCylinder Liner, completeCooling Water Jacket

Camshaft, section

Housing for Roller Guide

Governor, complete

Main Bearing CapGuide Bearing CapFront coverEnd cover, complete

Turbocharger, complete

Intermediate pieceAir CoolerInlet Bend

Air Starter

Fuel Injection PumpFuel Injection ValveFuel Oil Feed Pump

Lubricating Oil PumpThermostatic ValvePrelubricating Oil Pump, incl. el-motorCentrifugal Filter

Thermostatic ValveCooling Water Pump

250

45199510033

29

17

28

7585164179

See special instruction

945093

40

15522

45292024

2930

Plate No.Section Item No.

Declaration of Weight

Weight in Kg.Component

97.06 - ES0U

50501-5050250508-50510

5060150601506015061050610

50705

50801

50901

51101511015110251106

512025120351203

51309

514015140251410

51501515035150451515

5160451610

500.45Edition 01H

DescriptionPage 1 (1)

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MAN Diesel

06

04

01

0809

1011

12

0203

05

07

14

13

60601-13HL/V28/32H

Piston and Connecting Rod

91.46 - ES0S

PlatePage 1 (2)

620

619

618

617

616

615

614

613

612

611

610

609

608

607

DescriptionPage 1 (2) Ordering of Spare Parts 500.50

Edition 02

When spare parts are ordered (or referred to in correspondence, etc.) the following data must be indicated for the engine concerned:

Name of customer/ship IMO number Engine TypeEngine noBuilt byPlate numberItem noDescriptionQty.

•••••••••

07.04

General

These data are necessary to ensure supply of the correct spare parts for a particular engine, even though the spare part illustrations contained in this book may not always be in complete accordance with the individual components of a specifi c engine.

Note: For ordering of spare parts for governor, turbo-charger and alternator, please see the special chapter in the instruction book for these components.

Information found on each plate:

Plate no Edition Item no Description Qty. 50601 13H 10 Piston ring 10 pcs

Information found on page 500.15 or on the name plate of the engine(s)

Example: Name of customer/ship IMO no Eng. type Eng. no Built by DANYARD 705 L9007489 5L28/32H 20433 MAN Holeby

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Ordering of Spare Parts 500.50Edition 02

07.04

General

DescriptionPage 2 (2)

Name of customer/ship IMO no

Engine type Engine number Built by

Plate no Ed. no Item no Description Qty.

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DescriptionPage 1 (1) Service Letters 500.55

Edition 01

Description

In order to ensure the most effi cient, economical and up-to-date operation of our engines, we regularly send out "Service Letters" containing fi rst-hand information regarding accumulated service expe ri ence.

The service letters can either deal with specifi c engine types, or contain general instructions and recommendations for all engine types, and are used as a reference when we prepare up-dated editions of instruc tion books.

97.40 - ES0

General

Since new service letters might be of great impor-tance to the operation of the plant, we recommend that engine staff fi le them as supplements to the relevant chapters of this instruction book.

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Velocity, Speed (m/s) (3.6 km/h = 1 m/s)

1 kn (knot) = 1 nautical mile/h 1.852 km/h = 0.5144 m/sCincerning other conversions, see table for length

Density

1 lb/cub. ft 16.02 kg/m3

Force (1 kg m/s2 = 1 N)

1 kp (kilopound)* 9.807 N1 poundal** 138.3 x 10-3 N1 lbf (pound force) 4.448 N

* Can occasionally be found stated as kgf (kilogram force). Standard acceleration of free fall gn = 9.80665 m/s2

** Unit of force in the ft-lb-s system

Stress ( 1 N/m2 = 10 -6 N/mm2)

1 kp/mm2 = 100 kp/cm2 9.807 N/mm2

1 lbf/sq. in (psi) = 0.07031 at 6.895 x 10-3 N/mm2

Dynamic viscosity (N s/m2)

1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)1 poundal s/sq.ft 1.488 N s/m2

1 lbf/sq.ft 47.88 N s/m2

poise is a special name taken from the CGS system. 1 P = 0.1 Pa s1 cP = 1 mPa s = 10-3 Pa s

Kinematic viscosity (m2/s)

1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *

* 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name taken from the CGS system. 1 St = 10-4 m2/s

Energy, Work (1 Nm = 1 J, Wh)

1 cal I.T* 4.187 J*1 kpm 9.807 J1 hph (metric) 2.648 x 106 J = 0.7355 kWh1 ft. lbf 1.356 J1 hph (UK, US) 2.685 x 106J = 0.7457 kWh1 BTU (UK, US) 1.055 x 103J = 1.055 KJ

* Exact value: 4.1868 J I.T. = International Steam Table

Basic Sl Units

Quantity Name Symbol

length metre mmass kilogram kgtime second selectric current ampere Aabsolute temperature* kelvin Kamount of substance mole molluminous intensity candela cd

* Also named "thermodynamic temperature"

Supplementary SI Units

Quantity Name Symbol

plane angle radian radsolid angle steradian sr

Additional SI Units

Quantity Name Symbol Defi nition

time minute min 1 min = 60 stime hour h 1 h = 60 minplane angle degree ° 1° = (p/180) radvolume litre l 1 l = 1 dm3

pressure bar bar 1 bar = 105 Pa

Length (m)

1 in (inch) 25.40 mm = 0.0254 m1 ft (foot) = 12 inches 0.3048 m1 yd (yard) = 3 ft = 36 inches 0.9144 m1 statute mile = 1760 yds 1609 m1 n mile (international nautical mile) 1852 m

SI Prefi xes

Factor Prefi x Symbol Factor Prefi x Symbol

1018 exa E 10-1 deci d1015 peta P 10-2 centi c1012 tera T 10-3 milli m109 giga G 10-6 micro μ106 mega M 10-9 nano n103 kilo k 10-12 pico p102 hecto h 10-15 femto f10 deca da 10-18 atto a

Area (m2)

1 sq. in (square inch) 0.6452 x 10-3 m2

1 sq. ft (square foot) 92.90 x 10-3 m2

DescriptionPage 1 (3)

500.60Edition 01

04.37 - ES0

Conversion Table

General

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Conversion Table

General

500.60Edition 01

DescriptionPage 2 (3)

04.37 - ES0

Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W)

1 kpm/s 9.807 W1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW1 kcalI.T./h 1.163 W1 ft lbf/s 1.356 W1 hp (UK, US) = 550 ft.lbf/s 745.7 W1 BTU/h 0.2931 W

Moment of Force, Torque (kg m2/s2 = Nm)

Can easily be derived from the above tables.

Moment of Inertia (kg m2)

1 GD2 (old notation) = 4 x I* kg m2

1 WR2 (old notation)* = 1 x I* kg m2

*I = ∫ dmr x r2 mr = mass at the radius rG = W = mass in kg D = Diameter of gyrationR = Radius of gyration

Specifi c fuel consumption* (g/kWh)

1 g/hph (metric) 1.360 g/kWh

* See also table for specifi c fuel oil consumption values

Temperature difference (K)

1 °C (Celsius) 1 K1 °F (Fahrenheit) 5/9 K

Temperature levels (K) (see "Derived SI Units with special Names)

t °C (Celsius) tc + 273.15 = Kt°F (Fahrenheit) 5/9(tf - 32) + 273.15 = KCelsius from Fahrenheit: tc = 5/9(tf - 32)Fahrenheit from Celcius: tf = 9/5 x tc + 32

Specifi c heat capacity (J/(kg K))

1 kcalI.T./(kg x °C) 4.187 x 103 J/(kg K)1 BTU*/(lb x °F) = 1 kcalI.T. /(kg °C) 4.187 x 103 J/(kg K)

* British Thermal Unit (see table for energy conversions)

Heat conductance (W/(m K))

1 calI.T./(cm x s x °C) 418.7 W/(m K)1 kcalI.T./(m x h x °C) 1.163 W/(m K)1 BTU*/(ft x h x °F) 1.731 W/(m K)

* British Thermal Unit (see table for energy conversions)

Heat transmission (W/(m2 K))

1 calI.T./(cm x s x °C) 41.87 x 103 W/(m2 K)1 kcalI.T./(m

" x h x °C) 1.163 W/(m2 K)1 BTU*/(ft2 x h x °F 5.678 W/(m2 K)

Specifi c fuel oil consumption (SFOC)

Reference conditionsSpecifi c fuel oil consumption values refer to brake power, and the following reference conditions:

Reference conditions (ISO)

Blower inlet temperature 25°C 298 KBlower inlet pressure 1000 mbarCharge air coolant temperature 25°C 298 KFuel oil lower calorifi c value (10200 kcal/kg) 42707 kJ/kgk

Derived Si Units with Special Names

Quantity Name Symbol Expressed in basic, supplementary or derived SI units

frequency hertz Hz 1 Hz = 1 s-1

force newton N 1 N = 1 kg m/s2

pressure, stress pascal Pa 1 Pa = 1 N/m2*energy, working quantity of heat joule J 1 J = 1 Nmpower watt W 1 W = 1 J/selectric potential (DC) volt V 1 V = 1 W/Atemperature Celsius °C 1°C = 1 k**

* For mechanical stresses N/mm2 is widely used. 1 N/mm2 = 106 N/m2

** t (°C) = T(K) - T0(K), where T0 = 273.15 K

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DescriptionPage 3 (3)

500.60Edition 01

04.37 - ES0

Conversion Table

General

Volume (1 m3 = 1000 l)

1 cub. in (cubic inch) 16.39 x 10-6 m3

1 cub. ft (cubic foot) 28.32 x 10-3 m3 = 28.32 l1 gallon* (imperial, UK) 4.546 x 10-3 m3 = 4.546 l1 gallon* (US) 3.785 x 10-3 m3 = 3.785 l1 barrel (US petroleum barrel) = 42 gallon (US) 0.1590 m3

1 bbl (dry barrel, US) 0.1156 m3

1 register ton = 100 cub. ft 2.832 m3

* 1 gallon = 4 quarts = 8 pints

Mass (kg)

1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg1 slug* 14.59 kg

* Unit and mass in the ft-lb-s system

Pressure(1 N/m2 = 1 Pa, 1 bar = 105 Pa, 1 mbar = 10-3 bar)

1 kp/cm2 = 1 at = 0.9678 atm 98.07 x 103 Pa = 0.9807 bar1 at = 735.5 mm Hg* = 10 m H2O** (T = 277 K)750 mm Hg* 105 Pa = 1 bar1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar1 mm H2O** (T = 277 K) 10-4 at = 9.807 Pa = 98.07 x 10-3 mbar1 in Hg* (T = 273 K) 3386 Pa = 33.86 mbar1 in H2O** (T = 277 K) 249.1 Pa = 2.491 mbar1 atm (standard atmosphere) 760 mm Hg, 1.013 x 105 Pa = 1013 mbar1 atm = 1.033 at1 lbf/sq.in (psi) 6895 Pa = 68.95 mbar

* Mercury. 1 mm Hg = 1 Torr Values in table provided gn = 9.80665 m/s2

** Water column (WC)

Some physical data in SI units

Nomenclaturet = temp. in °C ΔK = temperature differencer = density in kg/m3 Cp = heat capacity in J/(kg DK)

t ρ Cp t Cp

rangeWater 18 999 4.18 x 103

Lubricating oil (approx.)* 15 900 1.96 x 103

Atmospheric air (dry) (p=1 bar) 0 1.276 998 0-150 1005Exhaust gas 200-400 1080* Viscosity: 100-140 cSt at 40°C 750 mm Hg = 1 bar = 105 Pa1 atm (standard pressure at sea level) = 760 mm Hg = 1013 mbarGas constant for air and exhaust gas = 287 J/(kg x K)Water, heat of evaporation 100°C 1.013 bar 2.256 x 106 J/kgFuel oil. Lower calorifi c value 41-43 x 106 J/kgISO 3046/1-1986 standard reference fuel 43 x 106 J/kgDiesel engine reference fuel (see below)

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DescriptionPage 1 (3) Basic Symbols for Piping

General

05.02 - ES0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

No Symbol Symbol designation

1. GENERAL CONVENTIONAL SYMBOLS

2. PIPES AND PIPE JOINTS

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

2.12

2.13

2.14

2.15

2.16

2.17

2.18.

2.19

No Symbol Symbol designation

3. VALVES, GATE VALVES, COCKS AND FLAPS

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.13

3.14

3.15

3.16

Pipe

Pipe with indication of direction of fl ow

Valves, gate valves, cocks and fl aps

Appliances

Indicating and measuring instruments

High-pressure pipe

Tracing

Crossing pipes, not connected

Crossing pipes, connected

Tee pipe

Flexible pipe

Expansion pipe (corrugated) general

Joint, screwed

Joint, fl anged

Joint, sleeve

Joint, quick-releasing

Expansion joint with gland

Expansion pipe

Cap nut

Blank fl ange

Spectacle fl ange

Orifi ce

Orifi ce

Loop expansion joint

Snap coupling

Pneumatic fl ow or exhaust to atmosphere

Valve, straight through

Valve, angle

Valve, three-way

Non-return valve (fl ap), straight

Non-return valve (fl ap), angle

Non-return valve (fl ap), angle, screw down

Safety valve

Angle safety valve

Self-closing valve

Quick-opening valve

Quick-closing valve

Regulating valve

Ball valve (cock)

Butterfl y valve

Gate valve

Enclosure for several components as-sem-bled in one unit

500.65Edition 01

Non-return valve (fl ap), straight screw down

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DescriptionPage 2 (3)Basic Symbols for Piping

General

05.02 - ES0

No Symbol Symbol designation No Symbol Symbol designation

3.17

3.18

3.19

3.20

3.21

3.22

3.23

3.24

3.25

3.26

3.27

3.28

3.29

3.30

3.31

3.32

3.33

3.34

3.35

3.36

3.37

3.38

3.39

Double-seated changeover valve

Suction valve chest

Suction valve chest with non-return valves

Double-seated changeover valve, straight

Double-seated changeover valve, angle

Cock, straight through

Cock, angle

Cock, three-way, L-port in plug

Cock, three-way, T-port in plug

Cock, four-way, straight through in plug

Cock with bottom connection

Cock, straight through, with bottom conn.

Cock, angle, with bottom connection

Cock, three-way, with bottom connection

Thermostatic valve

Valve with test fl ange

3-way valve with remote control (actuator)

Non-return valve (air)

3/2 spring return valve, normally closed

2/2 spring return valve, normally closed

3/2 spring return valve contr. by solenoid

Reducing valve (adjustable)

4. CONTROL AND REGULATION PARTS

Fan-operated

Remote control

Spring

Mass

Float

Piston

Membrane

Electric motor

Electromagnetic

Manual (at pneumatic valves)

Push button

Spring

Solenoid

Solenoid and pilot directional valve

By plunger or tracer

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

4.15

5. APPLIANCES

5.1

5.2

5.3

5.4

5.5

5.6

Mudbox

Filter or strainer

Magnetic fi lter

Separator

Steam trap

Centrifugal pump

500.65Edition 01

On/off valve controlled by solenoid and pilot directional valve and with spring return

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DescriptionPage 3 (3) Basic Symbols for Piping

General

05.02 - ES0

No. Symbol Symbol designation No. Symbol Symbol designation

5.7

5.8

5.9

5.10

5.11

5.12

5.13

5.14

5.15

5.16

5.17

5.18

5.19

5.20

5.21

5.22

5.23

Gear or screw pump

Hand pump (bucket)

Ejector

Various accessories (text to be added)

Piston pump

Heat exchanger

Electric preheater

Air fi lter

Air fi lter with manual control

Air fi lter with automatic drain

Water trap with manual control

Air lubricator

Silencer

Single acting cylinder with spring returned

Double acting cylinder with spring returned

Steam trap

7. READING INSTR. WITH ORDINARY DESIGNATIONS

7.1

7.2

7.3

7.4

7.5

Sight fl ow indicator

Observation glass

Level indicator

Distance level indicator

Recorder

6. FITTINGS

6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.8

6.9

Funnel / waste tray

Drain

Waste tray

Waste tray with plug

Turbocharger

Fuel oil pump

Bearing

Water jacket

Overspeed device

Fixed capacity pneumatic motor with direc-tion of fl ow

500.65Edition 01

Operation of engine

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DescriptionPage 1 (2) Operating 501.01

Edition 01H

96.02 - ES0U-G

L23/30H

4. Check the pressure in the starting air receiver(s) and open the starting air supply (blow-off water, if any, and drain the starting air system before opening.

5. Regulating gear - please check:

- that all fuel pumps are set at index "0" when the regulating shaft are in STOP position.

- that each fuel pump can be pressed by hand to full index when the regulating shaft are in STOP position, and that the pumps return automatically to the "0" index when the hand is removed.

- that the spring-loaded pull rod is working cor-rectly.

- that the stop cylinder for regulating the shaft works properly, both when stopping normally and at over speed and shut down.

- that testing is made by simulating these situa-tions.

6. Open the indicator valves and turn the engine some few revolutions, check that no liquid is fl owing out from any of the indicator valves during the tur-ning.

Slow-turning must always be carried out, before the engine is started after prolonged out of-service pe-riods and after overhauls, which may involve a risk of liquid having collected in the cylinders.

7. Close the indicator valves.

8. Disengage the turning gear, if fi tted. Check that it is locked in the "OUT" position.

Starting

1. Start the engine by activating the start but-tom.

2. Check the lubricating oil pressure, cooling water pressure, fuel oil feed pressure. Check that the prelubricating oil pump is stopped.

3. Check that all alarms are connected.

See also "checks after starting-up".

Preparations for Starting

The following describes what to do before starting, when the engine has been out of service for a lon-ger period of time, or if major overhauls have been made.

1. Check the oil level in the base frame (or in the lub. oil tank, if the engine is with dry sump), air lubricator and in the govenor.

Start-up the prelubricating pump.

The engine shall be prelubricated at least 2 minutes prior to start.

Check oil pressures before and after the fi lter.

2. Open the cooling water supply, start separate cooling water pumps where installed, and check the cooling water pressure.

Note: To avoid shock effects owing to large tempe-rature fl uctuations just after the start, it is recom-mended:

a) to preheat the engine. Cooling water of at least 60 °C should be circulated through the frame and cylinder head for at least 2 hours before start:

- either by means of cooling water from en gines which are running or by means of a built-in preheater (if installed).

or

b) When starting without preheated cooling wa ter, the engine must only be started on MDO (Ma-rine Diesel Oil).

The engine should not be run up to more than 50% load to begin with, and the increase to 100% should take place gradually over 5 to 10 minutes.

Note: When starting on HFO (Heavy Fuel Oil), only item "a" applies.

3. Open the fuel oil supply to the feed pump.

Starting on HFO: circulate preheated fuel through the pumps until correct working temperatures have been obtained. This normally takes 30-60 minutes.

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Operating DescriptionPage 2 (2)

501.01Edition 01H

Testing during Running

When the engine is running, the planned mainte nance programme and the following should be checked:

1. The lubricating oil pressure must be within the stated limits and must not fall below the stated minimum pressure. The paper fi lter cartridges must be replaced before the pressure drop across the fi lter reaches the stated maximum value, or the pressure after the fi lter has fallen below the stated minimum value. Dirty fi lter cartridges cannot be cleaned for re-use.

2. The lubricating oil temperature must be kept within the stated limits indicated on the data sheet.

3. The fuel oil pressure must be kept at the stated value, and the fi lter must be cleaned before the pressure drop across the fi lter reaches the stated maximum value.

4. The cylinder cooling water temperature must be kept within the limits indicated and the tempera ture rise across the engine should not exceed 10°C.

5. The cooling water temperature at the charging air cooler inlet should be kept as low as possible; however, not as low as to produce condensation water in the charging air space.

Adjustment takes place in the external system outside the engine, and the amount of cooling water must be adjusted so that the temperature rise across the charging air cooler is 3 - 5 °C.

6. The exhaust gases should be free from smoke at all loads. For normal exhaust temperatures, see the test report from shop and sea trials.

7. Keep the charging air pressure and tempera-ture under control. For normal values, see the test report from shop and sea trials.

8. Recharge the starting air receivers when the pressure has dropped to about 20 bar. Stop rechar-ging at 30 bar.

9. To ensure full operational liability, the condition of the engine should be contin uously observed in order for preventive mainte nance work to be carried out before serious break downs occur.

Stopping

1. Before stopping, it is recommended to run the engine at reduced load, or to idle for about 5 minutes for cooling-down purposes.

2. The engine is stopped by keeping the fuel pump delivery rate at "0", by turning the "load- limit" knob on the governor to "0", or by activating the remote stopping device.

Start and Stop on HFO

Start and stop of the engine should take place on HFO in order to prevent any incompatibility problems by change-over to MDO.

MDO should only be used in connection with main-tenance work on the engine or longer periods of engine standstill.

Before starting on HFO the engine must be properly preheated as described in "Preparations for Star ting" and as described below.

Stopping the engine on HFO is no problem, but it should be ensured that the temperature of fuel pipes are not reduced to a level below the pour point of the fuel, otherwise, reestabilishing of the circulation might cause problems.

Starting on MDO

For starting on MDO there are no restrictions except lubricating oil viscosity may not be higher than 1500 cSt (5° C SAE 30, or 10° C SAE 40).

Initial ignition may be diffi cult if the engine and am-bient temperatures are lower than 5° C and 15° C cooling water temperature.

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96.02 - ES0U-G

Out-of Service 501.05Edition 01H

L23/30H

DescriptionPage 1 (2)

1. Stand-by Engines

During engine standstill in stand-by position the media cooling water and fuel oil should be con-tinuously circulated at temperatures similar to the operation conditions.

The engine shall be prelubricated 2 minutes prior to start, if there is not intermittent or continuous pre-lub ricating installed. intermittent prelub. is 2 min every 10 minutes.

2. Maintenance during Standstill

In periods during stand-still of the engine (not in stand-by position) it is recommended to start the pre lub ricating oil pump minimum 10 minutes once every week and totum the engine during the prelu-bricating period by 2-3 revolutions.

3. Laid-up Vessels

During the lay-up period (and also when laying-up the vessel) we recommend that our special in struc tions for preservation of the engines are followed.

4. Work before Major Repairs

4.1 After stopping the engine, while the oil is still warm, start the el-driven prelub. pump, open up the crankcase and camshaft housings and check that the oil is fl owing freely from all bearings. Also, take off the top covers on the cylinder heads and make sure that oil is not supplied for lubrication of rocker arms, as non-return valves are fi tted which do not open until the oil pressure at the inlet to the rocker arms exceeds 1 bar.

After overhaul of pistons, bearings, etc. this check should be repeated before starting the engine.

4.2. After stopping the prelub. pump, check the bottom of the oil sump for fragments of babbitt from bearings

4.3. Open up all fi lters to check that fi lter elements are intact. Filter cartridges in the lub. oil fi lter is to be replaced before start, after repair, or after excessive differential pressure. After removal, dirty elements can be examined for particles of bearing metal at the bottom of the paper lamella. (the elements can not be used again).

4.4. Check the cylinder walls.

4.5. Take defl ection measurements of the crank-shaft.

4.6. A lubricating oil sample should be sent to a laboratory for immediate analysis.

4.7. Drain plugs are unscrewed from the bottom of turbochargers, or the drain cock is opened. If drain facilities are installed in the exhaust gas system this should be opened.

5. Work during Repairs

The following should be made during major re-pairs.

5.1. Retighten all bolts and nuts in the crankcase and check their locking devices. Also, retighten foundation bolts.

5.2. Check the various gear wheel drives for the camshaft(s).

5.3. Remedy leakages of water and oil in the en-gine, and blow through blocked-up drain pipes.

5.4. Drain starting air pipes of water.

5.5. Empty the oil sump of lubricating oil and re move the sludge, if not done within a period of one year. Clean the sump very thoroughly and subse quently coat with clean lubricating oil.

6. Work after Repairs

6.1. If an opening-up of engine or lubricating oil system may have caused ingress of impurities, cleaning should be carried out very carefully before starting the engine.

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DescriptionPage 2 (2)Out-of Service501.05

Edition 01H

The differential pressure across the lub. oil fi lter must be watched very carefully after cleaning and star ting-up the engine. Be sure to replace fi lter cart-ridges in due time.

6.2. After restoring normal lubricating oil circula tion, turn the engine at least two revolutions by means of the turning rod to check the movability of the relevant parts of the engine.

6.3. Close the drain cocks in the turbocharger (or in the exhaust gas system, if mounted).

6.4. Lubricate thebearings and rod connections in the manoeuvring gear. Disconnect the governor and move the rod connections by hand to check that the friction in bearings and fuel pumps is suffi ciently low. If repair of bearings or alignment of engine has been made, check no 1, 2, and 5 should be repated.

6.5. Checks to be made just before starting of the engine are mentioned under 501.01.

6.6. Add cooling water and check the leakage pressure system on at the upper and lower cy-linder liner sealings and at cooling water connec tions.

6.7. Check the governor as follows:Start up the engine and run it at the synchronous number of revolutions.

6.7 a) Speed-setting: Before switching-in the alternator on the switchboard please check that the servomotor adjusts the rpm with a suitable quick-ness after actuation of the synchronizer knob on the switch board. The range from - 5% to + 5% from the syn-chronous rpm should be tested.

6.7 b) Adjustment speed: Switch-in the alternator on the switchboard and set the load to about 40%. On reaching normal oil temperatures in governor and engine, increase the load instantly to about 80% (by starting the major pump or compressor). This must not cause the frequency to fall by more than some 8%, and the engine must return to a constant no rpm after about 3 seconds (although this rpm will be a little lower than before owing to the speed droop of the governor). If the engine is operated in parallel with other engines, an even sharing of load shall be established within about 3 seconds. If the gov-ernor reacts too slowly, compensating adjustment is ef fected as indicated in Woodward's instruction ma nual (Compensating Adjustment).

Note: It is a condition for this test that the engine and turbocharger are in perfect operating condition, so that possible sources of error immediately can be eliminated

6.7 c) Hunting: Run the engine at synchronous rpm, and without load. Provided the governor oil is warm, the regulating lever must not perform any major periodical movments, and neither must there be any variation in the engine speed. If that is the case, repeat the compensating adjustment accord-ing to Woodward's instruction manual.

6.7 d) Speed droop: in case of unsatisfactory load sharing between two ore more engines this can be rectifi ed by increasing the speed droop of the engine that is subject to the greatest load (or by reducing the setting of the other engines).

The setting should not normally be increased beyond 70 on the scale, and satisfactory parallel operation can generally be obtained at settings between 40 and 60.

96.02 - ES0U-G

MAN Diesel

DescriptionPage 1 (1) Starting-up after Out of Service Periods 501.10

Edition 01H

96.30 - ES0U-G

L23/30H

The following enumerate checks are to be made im mediately after starting, during load increase, and during normal running.

In the following it is assumed that the engine has been out of service for some time, for instance due to repairs and that checks during out of service periods have been carried out as described in the previous chap ter.

When starting after such an out-of-service period, the following checks must be made in the stated order in addition to normal surveillance and recor ding.

1. To be Checked immediately after Starting:

1.1. Check that the turbocharger is running.

1.2. Check that the lubricating oil pressure is in order.

1.3. Check that all cylinders are fi ring (see exhaust temperatures).

1.4. Check that everyting is normal for the engine speed, fuel oil, cooling water and system oil.

1.5. Check by simulation of the overspeed shut-down device that the engine stops. The overspeed setting should be according to " Set Points and Operation Data " section 500.

2. To be Checked during Starting-up, but only if Re quired after Repairs or Alterations:

2.1. If the condition of the machinery is not well-known, especially after repairs or alterations, the "feel-over sequence" should always be followed, i.e.:

After 5-15 and 30 minutes' idle running, open the crankcase and the camshaft housing and perform feel-over on the surfaces of all moving parts where friction may arise and cause undue heating.

Feel: Main, crankpin, (alternator), and camshaft bearings, piston pins, cylinder liners, roller guides and gear wheels.

After the last feel-over, repeat check 4 page 501.05, see also Ignition in Crankcase page 503.04 in section 503.

After repair or renewal of cylinder liners, piston rings or bearings, allowance must be made for a running-in period, i.e. the engine load should be increased gradually as indicated in the tables below. The engine output is determined on the basis of the fuel index and the load on the electric switchboard. The turbocharger speed gives some indication of the engine output, but is not directly proportional to the output throughout the service period.

Begin the starting-up sequence at a reduced engine speed, e.g. 400 rpm, until it can be known for cer-tain that there are no hot spots in the engine. Then, increase the speed to the normal rpm and connect to the switchboard and put on load.

The load increase during the starting-up sequence may, for instance, be:

25 % load for 2 hours 50 % load for 2 hours 75 % load for 2 hours 100 % load may be put on.

The pump index indicated in the tables has been given as a percentage of the index at full load. To enable the index to be read directly off the fuel pumps, the following formula can be employed:

I = I% x IF 100

IF = Index at full load (from testbed table)

I% = Index expressed as % of full load index (stated in the preceding starting-up sequence).

Following the alteration of the pump index of the one or two cylinders concerned it must be checked that when in STOP position the governor is able to move all the fuel pumps to an average pump index not exceeding 2 or 3.

After completing the starting-up sequence, make sure that all fuel pumps are set at the same index and that the governor can cause all fuel pumps to move to "0" index.

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DescriptionPage 1 (1) Guidelines for Longterm Low-Load Operation on HFO

General

08.20 - ES1

Part load/low load operation

In certain ship and power station operation modes the diesel generating sets are exposed to part load/low load operation.

During manoeuvring of the ship all diesel generating sets are often started up for safety reasons, result-ing in lowload operation of all the engines. During harbour stay one diesel generator could be low-loaded when only hotel purposes are consuming electricity.

Island mode operation of diesel generating sets in power stations is frequently exposed to low load operation like on a ship.

At part load/low load it is important to maintain constant media temperatures, i.e. for cooling water, lubricating oil and fuel oil in order to ensure adequate combustion chamber temperature and thus complete combustion.

At loads lower than 20% MCR there is a risk of time dependant retardation of the engine performance condition due to fouling of the exhaust gas channels and combustion air channels, combustion chambers

and turbocharger. HFO-operation at loads lower than 20% MCR should therefore only take place within certain time limitations according to the curves.

After a certain period of HFO-operation at loads lower than 20% MCR, a change to MDO should take place in order to prevent further retardation of the engine performance condition. Alternatively, the engine load should be raised to 70% MCR over a period of 15 minutes and maintained here for some time in order to burn off the carbon deposits, thus re-establishing adequate performance condition. After such a "clean burning period" low load operation on HFO can be continued.

However, the operator must be aware of the fact that fouling in the combustion air inlet channels, if any, will not be cleaned at high load operation. Extensive low load running can therefore result in the need for manual cleaning of the combustion air inlet channels.

If special application conditions require continuous HFO-operation at loads lower than 20% MCR and occasionally performed "clean-burning" periods are inconvenient or impossible, special equipment andarrangements must be established.

Fig 1 Low-load operation.

Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to MDOor b) operate engine for approx. 1.2 hours with 70% rating minimum, in order to burn off residues. Afterwards low load operation on HFO can be continued.

20

15

10

5

Load %

a

a b

b

Operating period (h) Operating period (h)

Necessary operating period with min. 70% load after low-load operation on HFO.

Running-up period to 70% load: approx. 15 min.

70% load HFO or MDO

Admissible low-load operation (load percent/period) on HFO.

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DescriptionPage 1 (1)

Guidelines Regarding MAN DIesel GenSets Operating on Low Sulphur Fuel Oil

General

07.12 - ES1

Exhaust emissions from marine diesel engines have been the focus of recent legislation. Apart from nitrous oxides (NOx), sulphur oxides (SOx) are considered to be the most important pollution factor. A range of new regulations have been implemented and others will follow (IMO, EU Directive, and CARB). These regulations demand reduction of SOx emissions by restricting the sulphur content of the fuel. That is to say sulphur limits for HFO as well as mandatory use of low sulphur distillate fuels for particular ap-plications. This guideline covers the engine related aspects of the use of such fuels.

Low sulphur HFO

From an engine manufacturer’s point of view there is no lower limit for the sulphur content of HFO. We have not experienced any trouble with the currently available low sulphur HFO, that are related to the sulphur content or specifi c to low sulphur HFO. This may change in the future if new methods are applied for the production of low sulphur HFO (desulphuriza-tion, uncommon blending components). MAN Diesel will monitor developments and inform our customers if necessary.

If the engine is not operated permanently on low sulphur HFO, then the lubricating oil should be se-lected according to the highest sulphur content of the fuels in operation.

Low sulphur distillates

In general our GenSet is developed for continuous operation on HFO as well as on MDO/MGO. Occa-sionally changes in operation mode between HFO and MDO/MGO are considered to be within normal operation procedures for our engine types and do thus not require special precautions.

Running on low sulphur fuel (< 0.1% S) will not cause problems, but please notice the following restrictions:

In order to avoid seizure of the fuel oil injection pump components the viscosity at engine fuel oil inlet must be > 1.5 cSt (except for L32/40 - required viscosity at engine fuel oil inlet > 2.0 cSt). In order achieve this it may be necessary to install a fuel oil cooler, when the engine is running on MGO. This is both to ensure correct viscosity and avoid heating up the service tank, which is important as the fuel oil injection pumps are cooled by the fuel.

When operating on MDO/MGO a larger leak oil amount from fuel oil injection pumps and fuel oil injection valves can be expected compared to op-eration on HFO.

In order to carry out a quick change between HFO and MDO/MGO the change over should be carried out by means of the valve V1-V2 installed in front of the engine.

For the selection of the lubricating oil the same ap-plies as for HFO. For temporary operation on distillate fuels including low sulphur distillates nothing has to be considered. A lubricating oil suitable for operation on diesel fuel should only be selected if a distillate fuel is used continuously.

501.16Edition 01

Performance and condition

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DescriptionPage 1 (3) Engine Performance and Condition

L23/30HV28/32S

Performance Data and Engine Condition

During operation small alterations of the engine condition continuously take place as a result of com-bustion, including fouling of airways and gasways, formation of deposits, wear, corrosion, etc. If conti-nuously recorded, these alterations of the condition can give valuable information about the operational and maintenance condition of the engine. Continual observations can contribute to forming a precise and valuable basis for evaluation of the optimal operation and maintenance programmes for the individual plant.

We recommend taking weekly records of the most important performance data of the engine plant. Du-ring recording (working card 502-01.00 can be used), the observations are to be continually compared in order to ascertain alterations at an early stage and before these exert any appreciable infl uence on the operation of the plant.

As a reference condition for the performance data, the testbed measurements of the engine or possibly the measurements taken during the sea trial at the delivery of the ship can be used. If considerable deviations from the normal condition are observed, it will, in a majority of cases, be possible to diagnose the cause of such deviations by means of a total evaluation and a set of measurements, after which possible adjustment/overhauls can be decided and planned.

Evaluation of Performance Data

For example, fouling of the air side of the air cooler will manifest itself in an increasing pressure drop, lower charge air pressure and an increased exhaust temperature level (with consequential infl uence on the overhaul intervals for the exhaust valves).

Fouling of the turbine side of the turbocharger will, in its fi rst phase, manifest itself in increasing turbo-charger revolutions on account of increased gas velocity through the narrowed nozzle ring area. In the long run, the charging air quantity will decrease on account of the greater fl ow resistance through the nozzle ring, resulting in higher wall temperatures in the combustion chambers.

502.01Edition 01H

02.47 - ES0

An increase of charge air temperature involves a cor-responding increase of the exhaust gas temperature level in a ratio of about 1:1.5, i.e. 1°C higher charge air temperature causes about 1.5°C higher exhaust gas temperature.

Reduction of the charge air pressure results in a corresponding reduction of the compression pres-sure and max. combustion pressure. When checking the max. pressure adjustment of the engine, it is therefore to be ensured that the existing charge air pressure is correct.

The injected amount of fuel is equivalent to supplied energy and is thus an expression of the load and mean pressure of the engine. The fuel pump index can therefore be assumed to be proportional to the mean pressure. Consequently, it can be assumed that the connected values of the pump index are proportional to the load.

The specifi c fuel consumption, SFOC (measured by weight) will, on the whole, remain unaltered whether the engine is operating on HFO or on MDO, when considering the difference in calorimetric combustion value. However, when operation on HFO, the combi-nation of density and calorifi c value may result in an alteration of up to 6% in the volumetric consumption at a given load. This will result in a corresponding alteration in the fuel pump index, and regard should be paid to this when adjusting the overload preven-tative device of the engine.

Abrasive particles in the fuel oil result in wear of fuel pumps and fuel valve nozzles. Effective treatment of the fuel oil in the purifi er can limit the content of abrasive particles to a minimum. Worn fuel pumps will result in an increase of the index on account of an increased loss in the pumps due to leakage.

When evaluating operational results, a distinction is to be made between alterations which affect the whole engine (all cylinder units) and alterations which occur in only one or a few cylinders. Deviations occuring for a few cylinders are, as a rule, caused by malfunctioning of individual components, for example, a fuel valve with a too low opening pressure, blocked nozzle holes, wear, or other defects, an inlet or exhaust valve with wrongly adjusted clearance, burned valve seat etc.

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Engine Performance and Condition

L23/30HV28/32S

502.01Edition 01H

DescriptionPage 2 (3)

02.47 - ES0

The operational observations supplemented by the daily routine monitoring contribute to ensuring that faulty adjustments and other deviations in the performance of individual components are observed in time to avoid operational disturbances and so that normal routine overhauls can be carried out as scheduled.

If abnormal or incomprehensible deviations in the operation are recorded, expert assistance for the evaluation of these should be obtained.

Turbochargers

Service experience has shown that the turbine side is exposed to increased fouling when operating on HFO.

The rate of fouling and thereby the infl uence on the operation of the engine is greatest for small turbo-chargers where the fl ow openings between the guide vanes of the nozzle ring are relatively small. Deposits especially occur on the guide vanes of the nozzle ring and on the rotor blades. In the long run, fouling will reduce the effi ciency of the turbocharger and thereby also the quantity of air supplied for the combustion of the engine. A reduced quantity of air will result in higher wall temperatures in the combustion spaces of the engine.

Detailed information and instructions regarding water washing of the turbocharger are given in the section 512.

Fuel Valves

Assuming that the fuel oil is effectively purifi ed and that the engine is well maintained, the operational conditions for the fuel valves and the overhaul in-tervals will not normally be essentially altered when operating on HFO.

If, for any reason, the surface temperature of the fuel valve nozzle is lower than the condensation tempe-rature of sulphuric acid, sulphuric acid condensate can form and corrosion take place (cold corrosion). The formation of sulphuric acid further depends on the sulphur content in the fuel oil.

Normally, the fuel nozzle temperature will be higher than the approx. 180°C, at which cold corrosion starts to occur.

Abrasive particles in the fuel oil involve a heavier wear of the fuel valve needle, seat, and fuel nozzle holes. Therefore, abrasive particles are, to the greatest pos-sible extent, to be removed at the purifi cation.

Exhaust Valves

The overhaul intervals of exhaust valves is one of the key parameters when reliability of the entire engine is to be judged. Operation on HFO has a negative effect on these intervals. The performance of the exhaust valves is therefore extremely informative.

Especially under favourable conditions, fuel quali-ties with a high vanadium and sodium content will promote burning of the valve seats. Combinations of vanadium and sodium oxides with a corrosive effect will be formed during the combustion. This adhesive ash may, especially in the case of increased valve temperatures, form deposits on the seats. An increa-sing sodium content will reduce the melting point and thereby the adhesive temperature for the ash, which will involve a greater risk for deposits. This condition will be especially unfavourable when the weight ratio Na increases beyond 1:3.Va

The exhaust valve temperature depends on the actual maintenance condition and the load of the engine. With correct maintenance, the valve temperature is kept at a satisfactory low level at all loads. The air supply to the engine (turbocharger/air cooler) and the maximum pressure adjustment are key parameters in this connection.

It is important for the functioning of the valves that the valve seats are overhauled correctly in accordance with our instructions.

The use of rotocaps ensures a uniform distribution of temperature on the valves.

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DescriptionPage 3 (3) Engine Performance and Condition

L23/30HV28/32S

502.01Edition 01H

02.47 - ES0

Air Inlet Valves

The operational conditions of the air inlet valves are not substantially altered when using residual fuel.

Fuel Pumps

Assuming effective purifi cation of the fuel oil, the operation of the fuel pumps will not be very much affected.

The occurrence of increasing abrasive wear of plun-ger and barrel can be a consequence of insuffi cient purifi cation of the fuel oil, especially if using a fuel which contains residues from catalytic cracking. Water in the fuel oil involves an increased risk of cavitation in connection with pressure impulses occurring at the cutting-off of the fuel pump. A fuel with a high asphalt content has deteriorating lubricating properties and can, in extreme cases, result in sticking of the fuel pump plungers.

Engine Room Ventilation, Exhaust System

Good ventilation of the engine room and a suita-ble location of the fresh air intake on the deck are important. Seawater in the intake air might involve corrosive attack and infl uence the overhaul intervals for the exhaust valves.

The fresh air supply (ventilation) to the engine room is to correspond to approximately 1.5 times the air consumption of the engines and possible boilers in operation. Sub-pressure in the engine room will involve an increased exhaust temperature level.

The exhaust back-pressure measured after the turbochargers at full load should not exceed 250-300 mm water gauge. An increase of the exhaust back-pressure will also involve an increased exhaust valve temperature level.

MAN Diesel

DescriptionPage 1 (1)

L23/30H

502.02Edition 01H

92.03 - ES0S-G

Evaluation of Readings RegardingCombustion Condition

T

T

TEMP. DIFFERENCE

TOO LARGE

Water fl ow too small

TEMP. DIFFERENCE

TOO LARGE

Air cooler fouled.

Pcomp and Pmax are measured by means

of max. pressure gauge.

Pcomp too low: Leaky combustion chamber,

charging air pressure too low.

Pmax too low:

P comp too low, ignition too late.

See also:

Engine Performanceand condition 501.01

ALL CYLINDERS

Exhaust temp. increasing:

Air system fouled

(Air fi lter-blower-cooler).

Exhaust system fouled

(nozzle ring, turbine wheel).

PRESSURE DROP

INCREASING

(limit 50%)

Air side of

cooler fouled.

PRESSURE DROP

INCREASING

(limit 50%)

Air fi lters

fouled.

DECREASING CHARGE AIR

PRESSURE:

Decreasing air amount.

Fouled turbocharger,

air fi lter or charge

air cooler (air side).

ONE CYLINDER

Exhaust temp. in-

creasing: Fuel valve

needs overhaul.

Compression too low

owing to leakage of

exhaust valve or piston

ring blow-by.

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Fig. 1 Nomogram for calculation of condensate amount.

General

There is always a certain amount of water in air. When the air is saturated with aqueous vapour, the humidity is said to be 100% and there is as much water in the air as it can absorb with out con dens ing. The amount of water in kg/kg air can be found from the diagram. The ability to ab sorb water de pends on the pressure and tem pe ra tu re of the air.

Amount of Condensation Water in the Charge Air Receiver

Both higher pressure and lower temperature reduce the ability to absorb water. A turbocharged diesel engine takes air from outside, compresses and cools the air.

Condensate Amount

General

Then normally, the air cannot absorb the same amount of water as before.

Condensation of water in the engine's charge air receiver is consequently dependent on the humidity and the temperature of the ambient air. To fi nd out if condensation in the charge air receiver will occur the diagram can be used.

Example:

Diesel engine 1000 kWAmbient air condition: air temperature 35 C relative air humidity 90 %Charge air temperature 50 CCharge air pressure 2.6 bar

502.05Edition 03

DescriptionPage 1 (2)

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Condensate Amount

General

502.05Edition 03

DescriptionPage 2 (2)

04.31 - ES2

p x V 31 x 105 x 4 R x T 287 x 313

As a guidance, an air consumption of 8.2 kg/kWh (Le) at full load can be used for MAN B&W engines.

Solution according to diagram:

Water content of air (I) 0.033 kg/kgMax. water cont. of air (II) 0.021 kg/kg

Amount of condensate in charge air receiver.

= (I-II) x le x P= (0.033 - 0.021) x 8.2 x 1000 = 123 kg/h

Draining of Condensation Water

This phenomenon will occur on all turbocharged engines. For MAN B&W Four-stroke engine, there is no risk with a small amount of water in the charge air receiver. But if the charge air receiver is fi lled with water, there is a risk of getting water into the cylinder. This water have to be drained away. As standard a valve is mounted on the charge air receiver/cooler on the engine. This valve is to be used for draining of the water. If there is a great amount, the valve can be left half-open. If the amount is small, the charge air receiver can be drained periodically.

Amount of Condensate Water in Air Tanks

The volume of condensate in the air tank is determi-ned by means of the curve at the bottom to the right of the diagram, representing an operating pressure of 30 bar.

Example:

Amount of condensate in air tank.

Volumetric capacity of tank (V) 4000 dm³Temperature in tank (T) 40 °C=313KInternal press. of tank (p) 30 bar = 31 x 105 N/m²(abs.)Gas constant for air (R) 287 Nm/kg.KAmbient air temperature 35 °CRelative air humidity 90 %Weight of air in tank

m = = = 138 kg

Solution acc. to above diagram:

Water content of air (l) 0.033 kg/kgMax. water cont. of air (lll) 0.0015 kg/kg

Amount of condensate in air tank

= (I - III) x m= (0.033 - 0.0015) x 138 = 4.35 kg

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Safety precautions:

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

Description:

Measuring of engine performance data.

Starting position:

Engine is running.

Related procedure:

Man power:

Working time : ½ hourCapacity : 1 man

Data:

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

L23/30H

Special tools:

Plate no. Item no. Note.

52005-01 109 Max. pressure indicator

Hand tools:

Replacement and wearing parts:

Plate no. Item no. Qty. /

502-01.00Edition 01HEngine Performance DataWorking Card

Page 1 (4)

96.37 - ES0U-G

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22 23 24

L23/30H

Engine Performance Data Working CardPage 2 (4)

96.37 - ES0U-G

502-01.00Edition 01H

M/V Engine Type Engine No Date/Year Hour Total Engine Running Hours 1 2 3 4 5 6

Engine Performance Data

Engine RPM Fuel Type Turbocharger Turbocharger Visc. Density Type Serial No RPM 7 8 9 10

Switchboard Effect (kW) Voltage (V) Current (A) cos ϕ /kVAr11 12 13 14

15 Cylinder No. 1 2 3 4 5 6 7 8 9 16

17 Fuel Pump Index

18 Maximum Pressure (bar)

19 Compress. Pressure (bar)

20 Exhaust Temp. (° C)

21 Cooling Water (°C)

Cylinder DataAve-rage

Temp. inlet blower (° C) Pressure before blower (mmWC) Temp. after blower (° C)

Turbocharger

Press. air cooler (mmWC) Temp. charge air (° C) Press. charge air (bar)

∇

Temp. exhaust gas before TC (° C) Temp. exhaust gas after TC (° C) Press. exhaust gas after TC (mmWC)

25 26 27

28 29 30

Lubricating Oil System Temp. after engine (° C) Press. before fi lter (bar) Press. after fi lter (bar)31 32 33

Temp. inlet engine (° C) Press. before TC (bar)34 35 36

Cooling Water System LT temp. inlet air cooler (° C) LT temp. outlet air cooler (° C) LT press. inlet air cooler (bar)

43 44 45 LT temp. outlet alternator (° C) HT FW temp. inlet engine (° C) HT FW press. inlet engine (bar)

37 38 39

40 41 42 LT temp. inlet lub. oil cooler (° C) LT temp. outlet lub. oil cooler (° C) LT temp. inlet alternator (° C)

Fuel Oil System Fuel oil temp. inlet engine (° C) Fuel oil press. before engine (bar)46 47

Sign.48 49 50

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502-01.00Edition 01H

Working CardPage 3 (4) Engine Performance Data

96.37 - ES0U-G

L23/30H

13. Current (A) - can be read on the switch-board.

14. Cos ϕ/kVAr - can be read on the switch-board.

Cylinder Data

15. Cylinder No. - can be read on engine plate. A/B is used for V-engines.

16. Average for all engine cylinders for point: 17-18-19-20-21.

17. Fuel pump index - can be read on each of the high pressure fuel oil injection pumps.

18. Max pressure (bar) can be read for each cylinder by means of indicator or Pmax gauge.

19. Compression pressure (bar) - can be read for each cylinder by means of the indicator measure-ment, which is carried out during idling by nominal RPM.

20. Exhaust temperature (°C)- thermometer TI 60.

21. Water outlet cylinder (°C) (jacket cooling)- thermometer TI 11.

Turbocharger

22. Thermometer inlet blower (°C) can be read by means of a thermometer placed in the engine room near the air fi lter of the TC.

23. Pressure before blower (mmWC) - can be read by means of a mmWC instrument placed in the engine room near the TC.

24. Temperature after blower (°C) - can be read by means of a thermometer TI 30.

25. Δ Pressure air cooler (mm/WC).

26. Charge air temperature (°C). Temperature of the charge air in the charge air receiver.- thermometer TI 31.

Instruction for Filling in the Diagram "Engine Performance Data"

The numbers in the instruction are commensurate with the numbers in the diagram.

The automatic symbols mentioned in the instruction (TI 01, TI 03, PI 01 etc) refer to the diagrams prin-ted in the instruction books for specifi ed plants and page 500.20.

Engine Performance Data

1. Name of ship, if stationary name of plant.

2. Engine type.

3. Engine No.

4. Date/year of observations.

5. Hour, time of observations.

6. Total engine running hours - engineer's log-book.

7. Engine revolutions per minute (RPM) - can be read on tachometer SI 90.

8. Fuel oil type: the viscosity must be stated (in cSt) and the temperature by which the viscosity has been measured, f.inst. 180 cSt/50°C. Density must be stated: g/cm³.

9. Turbocharger: type and serial number are stated on the rating plate of turbocharger and page 500.00.

10. Turbocharger revolutions per minute (RPM) - can be read on the tachometer SI 89.

Switchboard.

11. Alternator output (kW) - can be read on the main switchboard.

12. Voltage (V) - can be read on the switch-board.

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L23/30H

Engine Performance Data Working CardPage 4 (4)

96.37 - ES0U-G

502-01.00Edition 01H

27. Pressure charge air (bar). Pressure of the charge air in the charge air receiver.- pressure gauge PI 31.

28. Gas before temperature exhaust TC (°C) - thermometer TI 62.

29. Exhaust gas temperature after TC (°C) - thermometer TI 61.

30. Exhaust gas pressure after the TC (bar)- pressure gauge PI 61.

Lubricating Oil System

31. Lub. oil inlet cooler temperature (°C)- thermometer TI 20.

32. Lub. oil pressure before the fi lter (bar)- pressure gauge PI 21.

33. Pressure of the lub. oil after the fi lter (bar)- Pressure gauge PI 22.

The fi lter element should be replaced with a pres-sure drop across the fi lter of 1.5 bar (see section 615).

34. Lub. oil inlet engine temperature (°C)- thermometer TI 22.

35. Lub. oil pressure before the turbocharger (bar).- pressure gauge PI 23.

Cooling Water System

37. Low temperature (LT) cooling water tempera-ture (sea, raw or fresh) at inlet charge air cooler (°C)- thermometer TI 01.

38. Low temperature (LT) cooling water tempera-ture (sea, raw or fresh) at outlet charge air cooler (°C)- thermometer TI 02.

39. Low temperature (LT) cooling water pressure (sea, raw or fresh) at inlet charge air cooler (bar)- pressure gauge PI 01.

40. Low temperature (LT) cooling water tempera-ture (sea, raw or fresh) at inlet lub. oil cooler (°C)- thermometer TI 07.

41. Low temperature (LT) cooling water tempera-ture (sea, raw or fresh) at outlet lub. oil cooler °C)- thermometer TI 03.

42. Low temperature (LT) cooling water tempera-ture (sea, raw or fresh) at inlet alternator (°C)- thermometer TI 04.

43. Low temperature (LT) cooling water tempera-ture (sea, raw or fresh) at outlet alternator (°C)- thermometer TI 05.

44. High temperature (HT) fresh water tempera-ture (FW) at inlet engine (°C)- thermometer TI 10.

45. High temperature (HT) fresh water tempera-ture (FW) of outlet engine (°C)- thermometer TI 10.

Fuel Oil System

46. Fuel oil temperature at inlet engine (°C)- thermometer TI 40.

47. Fuel oil pressure before engine (bar)- pressure gauge PI 40.

48.

49.

50. Signature.

Trouble shooting

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DescriptionPage 1 (1) Starting Failures 503.01

Edition 02

04.31 - ES0

General

Troubleshooting

Check electrical parts.

Start compressors, re-charge air receiver.

Open valve at receiver and stop valve interposed in line between receiver and engine.

Check the air starter.

Check the air motor for broken shafting, bearing or clutch jaws,see Working Card 513-01.30.

Check electrical parts.

Remove and disassemble the air motor. Examine all parts and replace any that are worn or damaged. Use the guidelines for determining unserviceable parts, see Working Card 513-01.30.

Check start valve.

Raise the air receiver pres-sure.

Dismantle the air starter and repair it.

Possible cause

Faults in electrical system.

Air pressure in starting air receiver too low.

Main valve(s) closed.

Pinion does not engage with the fl ywheel.

Air motor runs, pinion engages but does not rotate.

Faults in electrical system.

Worn air motor parts.

Start valve is sticking in closed position.

Low air pressure.

Clutch or drive shaft broken.

Trouble

Engine turns as soon as shut-off valve is opened, without start button being activated.

Engine does not turn when start button is activated.

Engine turns too slowly or ir-regularly when start button is activated.

Air starter works, but the drive shaft does not rotate.

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DescriptionPage 1 (3) Faults in Fuel Oil System 503.02

Edition 01H

96.37 - ES0U-G

L23/30H

Trouble Shooting

Lubricate and mobilize rod con-nections in manoeuvering gear.

Adjust governor, see special in-struction manual.

Cancel overspeed stop.

Check that piston is not sticking. Check that pressure in cylinder is relieved. Check that the over-speed trip is not actuated.

Check pressures and tempera-tu-res. Check for faults in shut-down devices.

Check that governor is working properly. For further fault location, see special instr. manual.

Check rod connec. Check that fuel pump index is corresponding to "Adjustments after trials" in testbed chart.

Adjust setting of limiter cylinder.

Pump oil into the tank.

Vent the fuel pumps with fuel with-out air bubbles appears. If ignition fails in just one cyl., vent the re-spective fuel injection valve. If igni-tion still fails, install a spare valve before attempting to start the engi-ne again.

Change fuel pumps.

Change defective fuel valves.

Increase the fuel oil feed pump pressure.

Drain off water and repeat venting of fuel pumps.

Change defective fuel valves,see Working Card 514-01.10.

Possible Cause

Sluggish movement of manoeuve-ring gear.

Governor setting incorrect.

Overspeed stop tripped.

Piston in stop cylinder is actuated.

Piston in stop cylinder is actuated owing to uncancelled shutdown function (1).

Failures in governor.

Incorrect adjustment of manoeuve-ring gear.

Incorrect adjustment of limiter cylinder.

Fuel oil service tank empty.

Air in fuel pumps and fuel injection valves (2).

Worn-out fuel pump.

Defective fuel injection valves or valve nozzles (4).

Too low pressure before fuel injec-tion pumps (3).

Water in the fuel.

Fuel valves or nozzles defective (4).

Trouble

Engine turns on starting air, but ignition fails. Fuel pumps are not actuated.

Engine turns on starting air, but no fuel is injected owing to failu-res in fuel system.

Engine turns on starting air, fuel is injected, but ignition fails.

Cont.

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DescriptionPage 2 (3)Faults in Fuel Oil System

L23/30H

Trouble ShootingPossible CauseTrouble

503.02Edition 01H

First ignitions are too violent (sa-fety valves are opening). Engine runs erratically.

Compression during start too low (5).

Incorrect timing of camshaft (6).

Oil has collected on piston crown (7).

Sluggish movement of manoeuve-ring gear.

Fuel pump index too high.

Check intake and exhaust valve for tight closing. Check cyl. wear and piston rings.

Check fuel pump timing advance, and fuel valve opening pressure as well as camshaft adjustment.

Slow turning with open indicator valves. To locate defective fuel val-ve, remove oil.

Lubricate and mobilize rod connections and bearings in manoeuvering gear.

Check rod connection is manoeu-vering gear. Check that governor is working properly. Limiter cylin-der to be set lower.

4) If the fuel is forced into the cylinder through a defective fuel valve or through worn-out atomizer holes, no or too sluggish atomi zation may prevent ignition, possibly followed by too violent ignition.

5) To obtain ignition temperature in the cylinders, the compression pressure during star ting should be normal, see the testbed report. This can be checked by measuring the compression pressure during starting. Cylinders having too low compres-sion should be inspected.

6) Major alterations of the com bustion charac-teristics of the fuel may demand adjustment of the timing of the fuel pumps. One or more camshaft sections may be incorrectly fi tted (after dis mantling). Too high opening pressure of the fuel valves will also delay the injection.

Remarks

1) If the shutdown function is due to overspeed, the shutdown impulse is cancelled by setting the overspeed governor and thus venting the stop cy-linder.

2) Whenever air is present in the fuel oil system repeat venting of fuel pumps. The cause may be that a fuel valve is kept in open position (spindle sticking or spring broken). Heating of fuel to a too high temperature may have a similar effect owing to formation of gas in the fuel. If a sticking valve is found, it should be changed and overhauled. It should be cheked that no oil has collected on the piston crown. Air in the fuel oil system may also be the result of the fuel oil feed pump suckingin air through a defective stuffi ng box or a leaky seal.

3) If the fuel oil pressure drops, the fi lter may be clogged up, or the by-pass at the feed pump may have opened.

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Faults in Fuel Oil System 503.02Edition 01H

96.27- ES0U-G

L23/30H

DescriptionPage 3 (3)

7) Oil on the piston crown will in most cases have leaked down from a defective fuel valve. As these oil accumulations are dangerous, the leakage should be found and remedied before the engine is started again.

Turbocharger Failure

If heavy vibrations, bearing failure or other trouble arise in a turbocharger, the engine load must be reduced until the vibrations cease. When possible, the engine is stopped in order to locate and remedy the fault (see turbocharger instr. manual).

If a repair cannot be made on the spot, it is decided if running may continue, with or without the defective charger blanked off.

When continuing the running with the turbocharger out of operation, the engine output must be redu-ced. The exhaust temperature must not exceed the nor mal valve, for full load running with an intact turbo charger. For further details see the separate turbo charger instr. manual.

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DescriptionPage 1 (3) Disturbances during Running 503.03

Edition 01H

96.37 - ES0U-G

L23/30H

Trouble Shooting

See Working Card 512-01.00.

Reduce load and water-wash tur-bine. Clean air fi lters and coolers.

See Description 504.25.

Check Pmax. Check camshaft ad-justment.

See Working Card 514-01.10.

Check the valve clearance. Repla-ce cyl. head with defective valve.

See Working Card 506-01.00.

Replace the single camshaft section.

Check that thermostatic valve (by-pass valve) in cold water system is working properly and correctly set.

Venting of fuel pump(s) until fuel without air bubbles appears. Check feed pump pressure.

Change and overhaul defective fuel valve.

Change fuel pump plunger/barrel assembly.

Raise fuel oil feed pump pressure to normal. Check fi lter.

Change defective valve or pump.

Drain off water and vent the fuel pumps.

Replace defective governor.

See "Ignition in Crankcase".

Possible Cause

(All cyls.) Increased charging air temperature due to ineffective air coolers.

(All cyls.) Fouling or air and gas passages.

(All cyls.) Insuffi cient cleaning of fuel oil or changed combustion characteristics.

(All cyls.) Wrong position of cam-shaft (maladjustment).

(single cyls.) Fuel valve or valve nozzle defective.

(Single cyls.) Leaky exhaust valves (1).

(Single cyls.) Blow-byleaky com-bustion chamber (2).

(Single cyls.) Damaged fuel pump cam.

(All cyls.) Decreased charging air temperature.

(Single cyls.) Air in fuel pump(s) and fuel injection valve(s).

(Single cyls.) Spindle in fuel valve sticking (3).

(Single cyls.) Fuel pump plunger sticking or leaking.

Pressure before fuel pumps too low.

Fuel valve or fuel pump defective.

Water in the fuel.

Governor defective (4).

Increased internal friction in engine (5).

Trouble

Exhaust temperature(s) increase(s)

Exhaust temperature(s) decrease(s)

Engine RPM decreases

Cont.

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Disturbances during Running

96.37 - ES0U-G

Trouble ShootingPossible CauseTrouble

503.03Edition 01H

Remarks

1) This manifests itself by the exhaust tempe-rature rising and falling of the compression and maximum combustion pressure of the respective cylinder dropping.

To limit the damage to the valves these should be changed immediately, if possible, or the fuel pump of the cylinder concerned should be put out of opera tion by moving the index to stop and locking it in this position.

DescriptionPage 2 (3)

L23/30H

Check pressure and temperatures. If OK, check for faults in shut-down devices. See also Starting Failures.

Reasonably smoke is normal when RPM increases; no measures cal-led for. If smoky exhaust during normal running, clean turbine(s) and check valves.

Fouling of air and gas passages, see section 512.

See Working Card 514-01.10.

Overhaul fuel valves.

Inspect and replace defective parts as necessary.

Stop the engine. Check the cooling water. Find cause of incre-ased friction and remedy fault.

Stop the engine. For further details, see "Ignition in crankcase". See also Working Card 515-01.00 for lub. oil pump and Working Card 515-01.10 for the lub. oil fi lter

2) Blow-by means a serious danger of piston seizure, and the engine must, if possible, be stop-ped and the piston in question pulled. If this is not possible, the fuel pump index must, as described above, be moved to stop. Leaky piston rings will normally result in a heavy excess pressure in the crankcase.

Shutdown.

Turbine RPM lagging behind en-gine RPM.

Air supply too low.

Fuel valves or nozzles defective.

"Trumpets" at nozzle holes. Failure of cooling (especially during hea-vy-oil operation) (6).

Adjusting screw for valve setting loose. Push rod thrust disc da-maged.

Pump stopped. Increased friction (7).

Lubricating oil pump defective. Filters/cooler fouled.

Engine stops.

Smoky exhaust.

Exhaust valve knocking.

Rising cooling water tempera-ture.

Lubricating oil pressure fails.

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Disturbances during Running 503.03Edition 01H

96.37 - ES0U-G

L23/30H

DescriptionPage 3 (3)

6) If the cooling water temperature for the entire engine has risen to 90-100° C, it should be checked whether steam has de veloped by opening the test cocks, if fi tted on the discharge from cylinders. If this is the case, there is no water on the cooling surfaces, which may therefore be heated unduly. To avoid heat stresses arising in cylinder liners and cylinder heads, if the water returns too early, the engine should be stopped and left to cool, while the discharge valve is closed. After 15 minutes it is opened a little to allow the water to rise slowly in the cooling jackets. Check fi lling at test cocks. Make crankcase inspection to ascertain that internal water leakage has not arisen. Remember slow turning with open indicator valves at subsequent starting-up.

7) If the lubricating oil pressure drops below the minimum mentioned in "Data" fi nd the cause of the pressure drop and remedy the defect before re-st-arting the engine. Feel over 5-15-30 minutes after starting, and again when full load is obtained. See section 502.

3) If this happens the fuel pump barrel and plunger must be changed, and if, it is necessary to increase the fuel pump index by more than 10 index degrees, to obtain full load of the respective cylinder, the fuel pump is worn out in most cases. Usually this is confi rmed by inspection of the fuel pump plunger on which the helical cut-off edge will show a pitted and corroded area where material is plucked out. In that case the pump can be provided with a new barrel and plunger.

4) The governor will not reduce the fuel pump delivery to zero in case of, for instance, failure of the governor oil pump, but the engine speed will start fl uctuating.

When the governor is defective the engine is pro-tected against racing by the overspeed trip, i.e. the engine is stopped automatically in case of excessive speed. It is therefore, essential, that the overspeed trip is kept in perfect order. Regarding governor failure, see special instruction book.

5) Usually a bearing failure will not slow down the engine appreciably, but the seizure of a piston in the cylinder liner might do so. Repair is necessary before starting the engine again. Feelover and look out for oil mist.

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DescriptionPage 1 (1)

503.04Edition 03

00.12 - ES0

General

Cause

During running the atmosphere in the crankcase contains the same gases (N2-O2-CO2) in the same proportions as in the ambient air, but an intense spray of oil drops is slung around everywhere. If undue friction, and thus heating, arises between sliding surfaces, or heat is otherwise transmitted to the crankcase, the heated surface will cause eva-poration of the lubricating oil splashed onto it. When the oil vapours condense they form milky white oil mist which can ignite. Such ignition may be caused by the same "hot spot" that produced the oil mist. If a large quantity of oil mist has developed before ignition, the burning may cause considerable pres-sure rise in the crankcase, forcing the relief valves to open. In a few cases, presumably when the whole crankcase has been fi lled with oil mist, a subsequent explosion has thrown off the crankcase doors and caused fi re in the engine room.

Every precaution should therefore be taken to (A) avoid "hot spots" and (B) discover oil mist in time.

"Hot spots" in Crankcase

Overheating of bearings is a result of inadequate or failing lubrication, possibly caused by pollution of the lubricating oil.

It is therefore important that the lubricating oil fi ltra tion equipment is in perfect condition. Filter cartrid ges may not be used again if they have been removed from the fi lter. Checking of the oil condition by analysis is recommended.

Oil Mist in Crankcase

The presence of oil mist may be noted at the vent pipe which is usually fi tted to the top of the engine frame.

Measures (in case of white oil mist).

Warning: Keep away from doors and relief valves on crankcase. Do not stay unnecessarily in door ways near the doors of the engine room casing.

Ignition in Crankcase

1) Stop the Engine

2) Leave the engine room. Shut doors and keep away from them. Make ready fi re-fi ghting equip-ment.

Warning: Do not open crankcase until 10 minutes after stopping the engine. When opening up, keep clear of possible fl ames. Do not use naked light and do not smoke.

3) Cut off starting air. Set the control panel in "Blocking Mode" see

description 501.01. Take off all doors on one side of the crank-

case.

4) Locate the hot spot. Powerful lamps should be employed at once (in explosion-proof fi ttings). Feel over all sliding surfaces (bearings, liners, pistons, roller guides, etc.).

Look for squeezed-out bearing metal and discol-oration by heat (blistered paint, burnt oil, heated steel).

5) Prevent further heating, preferably by making a permanent repair. Special attention should be paid to ensuring lubricating oil supply and the satisfac tory condition of the frictional surfaces involved. It is equally important to replace fi lter elements in time.

6) Start electrically driven lubricating oil pump and check oil fl ow from all bearings and spray pipes in crankcase while turning the engine through at least two revolutions.

7) Stop and feel over. Look out for oil mist.

Especially the frictional surfaces that caused the heating should be felt over (5-15-30 minutes after starting, and again when full load is obtained). Sec-tion 501.10.

8) If it has not been possible to locate the hot spot, step 7 should be intensifi ed and repeated until the cause of the oil mist has been found and remedied. In very rare cases oil mist could be due to "atomization" of lubricating oil by the action of an air jet (for instance blow-by, or blow-by through cracked piston).

MAN Diesel

DescriptionPage 1 (1) Trouble Shooting Guide for Centrifugal By-pass Filter 503.05

Edition 01H

96.30 - ES0U

L23/30H

Tabulated below are the corresponding remedial actions to be taken, if the following faults are obser-ved:

Trouble Shooting

Replace O-ring.

Replace O-ring.

Replace O-ring.

Replace rotor assembly.

Tighten and bring to notice of main-tenance staff.

Re-fi t or replace if damaged.

Clean and bring to notice of main-tenance staff.

Replace rotor assembly.

Follow sequence in Working Card 515-15.00 in section 515.

Fit new bearing tube assembly.

Possible Cause

Missing or damaged O-ring (see Item 291, Plate 51515).

Seal face damaged.

Rotor out of balance owing to un-even build-up of deposit on rotor walls resulting from:

Missing or damaged O-ring (see Item 230, Plate 51515), allowing leakage.

O-ring seat on rotor joint faces damaged.

Rotor assembly inadequately tight ened.

Standtube incorrectly seated or damaged.

Dirt deposit not completely remo-ved.

Rotor castings distorted through maltreatment.

Rotor assembly components fi tted in wrong sequence.

Bushes loose or worn in tube as-sembly.

Trouble

Oil leakage through cover nut.

Excessive vibrations.

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DescriptionPage 1 (2)

503.06Edition 01H

96.38 - ES0U-G

L23/30H

Trouble Shooting

Check for blockage or damage to air supply lines or tank.

Inspect motor assembly and power train and repair power train or re-place motor assembly, if necessary.

Remove motor assembly and piping and remove the blockage.

Remove housing exhaust cover (1) and check for blockage.

Replace control valve or relay valve.

Check air supply.

Check for blockage or damage to air lines.

Clean or replace lines or relay valve. Lubricate relay valve.

Check for blocked or damaged piping. Clean or replace piping. Check for dirt or foreign material and clean or remove. Check for ice build-up. Melt ice and reduce moisture build-up to starter.

Replace motor assembly.

Check air supply.

Remove blockage.

Remove fl uid.

Replace damaged or worn parts.

Relubricate O-rings and seals.

Disassemble drive train and replace worn or damaged parts.

Inspect drive pinion and fl ywheel and replace, if necessary.

Inspect drive components and replace worn or damaged parts.

Cont. ....

Possible Cause, see working card

No air supply.

Damaged motor assembly (12).

Foreign material in motor and/or piping.

Blocked exhaust system.

Defective control or relay valve.

Low air pressure to starter.

Restricted air supply line.

Relay valve malfunctioning.

Exhaust fl ow restricted.

Damaged motor assembly.

No pressure to drive housing port.

Internal drive housing ports blocked.

Fluid in drive unit components.

Damaged or worn piston assembly (54), O-rings or seals.

O-rings and seals dry.

Damaged or broken drive train.

Damaged drive pinion (63) or fl ywheel.

Damaged starter drive (57) com-ponents.

Trouble Shooting Guide for Turbine Starter

Trouble

Motor will not run.

Loss of power.

Drive (57) will not engage.

Motor runs, pinion engages, but does not rotate fl ywheel.

Excessive butt engagement.

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DescriptionPage 2 (2)

503.06Edition 01H

Check air supply.

Replace with proper drive pinion.

Inspect air line and remove source of oil.

Install splash defl ector retaining screw or pipe plug.

Replace static seals on outside of motor or send motor to Ingersoll Rand to be rebuilt.

Replace O-rings.

Make sure that joints fi t properly and starter assembly cap screws are tightened to 60 ft-lb (81 Nm) torque. Make sure all seals and O-rings fi t and seal properly at their perimeters. If they do not replace with new seals and O-rings.

Operate according to recommen-dations.

Replace worn components.

Tighten or replace pipe plugs using Ingersoll-Rand No SMB-441 pipe sealant.

Tighten splash defl ector retaining screw or replace pipe plug.

Make sure that joints fi t properly and starter assembly cap screws are tightened to 60 ft-lb (81 Nm) torque. Make sure all seals and O-rings fi t and seal properly at their perimeters. If they do not, replace with new seals and O-rings.

Operate according to recommen-dations.

Replace worn components.

Tighten or replace pipe plugs.

Tighten splash defl ector retaining screw or replace pipe plug.

Trouble Possible Cause, see working card Trouble Shooting

Low air pressure.

Wrong drive pinion.

Oil in air supply line.

Splash defl ector retaining screw (5) or pipe plug missing.

Worn or damaged rotor seals or static O-rings.

Worn or damaged O-rings.

Loose joints.

Excessive high-speed operation.

High number of start cycles.

Loose or leaking pipe plugs (10) or (11).

Splash defl ector retaining screw loose or pipe plug missing.

Loose joints.

Excessive high-speed operation.

High number of start cycles.

Loose or leaking pipe plugs.

Splash defl ector retaining screw loose or pipe plug missing.

Trouble Shooting Guide for Turbine Starter

L23/30H

Oil blowing out of exhaust.

Oil leaking from gear case (28).

Air or gas leakage.

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DescriptionPage 1 (1) Trouble Shooting for Cooling Water System 503.09

Edition 03

Description

The built-on fresh water pumps in the high and low temperature circuits are of the centrifugal type. They are mounted in the front end box and are driven through the gearing.

98.20 - ES0

General

The pump bearings are lubricated automatically with oil from the lubricating oil system of the engine.

If the pump leaks and the shaft sealing rings are worn, it is recommended to replace the shaft seal, see Working card 516-02.00.

Troubleshooting

See working card 502-05.00.

Check packings and pipes for tightness.

Check the level in the expansion tank.

Vent the system.

Check the shaft seal.

Overhaul the shaft seal.

Clean the impeller.

Open the suction valve.

Replace the seals.

Overhaul the pump.

Possible cause

Worn rotating sealing.

Pump draws in air at suction side.

The system is not fi lled-up.

Air cannot escape on delivery side.

Leaking shaft seal.

Air leakages from shaft seal.

Fouled impeller.

Suction valve not fully open.

Defective seals.

Worn impeller and worn wear rings.

Trouble

Oil or water fl ows out of the inspec-tion holes.

The pump does not work after start.

Pump capacity drops after normal operation.

Pump does not give maximum delivery.

Note: Running trouble with the pump, apart from mechanical faults, is most often due to leaks in the suction line. It is therefore essential that all pack ings and gaskets are in order and that they are renewed when necessary. Even a tiny hole in the suction line will reduce the pump capacity.

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DescriptionPage 1 (2)

503.10Edition 01

98.20 - ESO

Trouble Shooting for Lubricating Oil Cooler

General

Trouble Shooting

It is necessary to replace damaged plates or ga-skets.

First examine the external conditions around the plate heat exchanger in order to localize the cause of the damage. Do this very carefully.

Fatigue fracture will normally necessitate replace-ment of all plates and gaskets as there may be a risk of fatigue fracture in all the material.In case of corrosion, all plates must be examined carefully!Concerning the work to be carried out see Working card 515-06.00.

Visible Leakage

Trouble TroubleshootingPossible cause

Reduce the pressure to the correct work-ing pressure, see page 500.30 "Operating Data & Set Points".

Tighten up the plate heat exchanger, but not below the minimum dimension and never when the plate heat exchanger is under pressure or over 40°C.

If the plate heat exchanger is still leaky, proceed to phase 2.

Separate the plate heat exchanger and check if the plates are deformed or fouled.Check that the gaskets are elastic and non-deformed, and that the faces of the joints are clean.Replace deformed plates and gaskets, if any.Before assembling clean all plates and gaskets very carefully.Assemble the plate heat exchanger and start it up again.Note: Even tiny impurities such as sand grains may cause leakage.

Separate the plate heat exchanger.Clean the plates very carefully.Replace the gaskets.Assemble the plate heat exchanger and start it up again.

Separate the plate heat exchanger.Replace defective plates and gaskets, if any.Assemble the plate heat exchanger and start it up again.

Too high pressure.

Insuffi cient tightening.

Fouled or deformed plates.Inelastic or deformed gaskets.

Gaskets.

Defective gasket or badly corroded plate.

Leakage.

Leakage.(Phase 1)

Leakage.(Phase 2)

Leakage.(Even after tightening of the plate heat exchanger to minimum dimension.)

Leakage. (Through the drain holes of the gas-kets.)

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503.10Edition 01

DescriptionPage 2 (2)

98.20 - ES0

Troubleshooting for Lubricating Oil Cooler

General

Reduced heat transmission and/or increasing pressure drop.

Leakage.(The fl uids get mixed.)(Phase 1)

Leakage.(The fl uids get mixed.)(Phase 2)

Fouled plates or choked plate chan-nels.

Holes in plates.Corrosion or fatigue fracture.

Holes in plates.Corrosion or fatigue fracture.

Separate the plate heat exchanger and check if the plates are fouled.Clean the plates very carefully.Assemble the plate heat exchanger and start it up again.

A suspected leakage can be localized in the following way:Remove one of the lower pipe connec-tions.Then put the opposite side under pres-sure.If the medium continues to run out of the lower pipe connections after the pressure has stabilized one or several plates are leaking.Close down the plate heat exchanger.Separate the plate heat exchanger and check the plates very carefully.Check suspected plates with a dye pen-etrant.Check defective plates and gaskets.Before assembling, clean all plates and gaskets.Assemble the plate heat exchanger and check to fi nd more defective plates, if any, by putting one side under press.Start up again.

Close down the plate heat exchanger.Separate the plate heat exchanger.Put all plates to dry. Suspend the plates in the plate heat exchanger again and tighten it.Circulate medium at full capacity on one plate side (every second plate channel). Keep the other plate channels unpres-surised and free from liquid!Stop the circulation after a few minutes of operation and open the plate heat ex-changer again. Take care to avoid water spraying onto the dry plate side!By a careful study of the plates it will be possible to fi nd moist areas, if any, on the otherwise dry plate sides.Check these areas with a dye penetrant!Replace defective plates and gaskets.Before assembling, clean all plates and gaskets.Assemble the plate heat exchanger and check to fi nd more defective plates, if any, by putting one side under press.Start up again.If the unit is still leaking, check all plates with a dye penetrant!

Non-Visible Leakage

Trouble Possible cause Troubleshooting

Media specification

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L23/30H

504.01Edition 12

DescriptionPage 1 (4)

08.19 - ES1

Quality of Lube Oil (SAE30) forHeavy Fuel Oil Operation (HFO)

The specifi c power output offered by today’s Die-sel engines and the use of fuels which more and more often approach the acceptable limit in quality increase the requirements placed on the lube oil and make it imperative that the lube oil is chosen carefully. Medium-alkaline lube oils have proven to be suitable for lubricating the running gear, the cylinders, the turbocharger and for the cooling of the pistons. Medium-alkaline oils contain additives which, amongst other things, provided them with a higher neutralising capacity than blended (HD) en-gine oils have.

No international specifi cations exist for medium-al-kaline lube oils. An adequately long trial operation in compliance with the manufacturer’s instructions is therefore necessary.

Only lube oils, which have been approved by MAN Diesel, are to be used. These are listed in Table 5.

Requirements

Base oil

The base oil (medium-alkaline lube oil = base oil + additives) must be a narrow distillation cut and must be refi ned in accordance with modern procedures.

Bright stocks, if contained, must neither adversely affect the thermal nor the oxidation stability.

The base oil must meet the limit values given in Table 1, particularly as concerns its ageing tenden-cies.

Medium-alkaline lube oil

The fi nished oil (base oil with additives) must dem-onstrate the following characteristics.

Additives

The additives must be dissolved in the oil and must be of such a composition that an absolute minimum of ash remains as residue after combustion, even though the engine were run on distillate fuel tem-porarily. The ash must be soft. If this prerequisite is not complied with, increased deposits are to be expected in the combustion spaces, especially the exhaust valves and the inlet housing of the turbo-chargers. Hard additive ash promotes pitting on the valve seats, as well as burnt-out valves and in-creased mechanical wear in the cylinder liners.

Additives must not facilitate clogging of the fi lter el-ements, neither in their active nor in their exhaust-ed state.

Table 1 Lube oil (HFO operation) - specifi ed values* in-house method

Properties/characteristics Unit Test method Limit valuesStructure � � preferably paraffi n–basicBehaviour in cold, still fl ows

°CASTM�D2500 � 15

Flash point (as per Cleveland) ASTM�D92 > 200Ash content (oxide ash)

Weight %

ASTM�D482 < 0.02Coke residue (as per Conradson) ASTM�D189 < 0.50Aging tendency after being heated up to 135 °C for 100 hrs.

MAN Dieselageing cabinet *

�

n�heptane insolubles ASTM�D4055 orDIN 51592

< 0.2

Evaporation loss � < 2

Drop test (fi lter paper)MAN Diesel test

Must not allow to recognize precipitation of resinous or asphalt�like ageing products

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DescriptionPage 2 (4)

08.19 - ES1

Engine SAE–Class

23/30H, 28/32H, 23/30A, 28/32AAt cooling water temperatures > 32° C a SAE40 oil can be used.In this case please contact MAN Diesel

30

Table 2 Viscosity (SAE class) of lube oils

Detergency

The detergency must be so high that coke and tar-like residues from fuel combustion must not build-up. The lube oil must be able to avoid fuel derived deposits.

Dispersancy

The dispersancy must be selected such that com-mercially available lube-oil cleaning equipment can remove the detremental contaminations from the used oil, i.e. the used oil must have good separat-ing and fi ltering properties.

Diesel-Performance

The Diesel performance (without taking the neu-tralisation ability into consideration) must, at least, comply with MIL-L-21014 D resp. API-CD.

Neutralisation capacity

The neutralisation capacity (ASTM-D2896) must be so high that the acidic products of combustion are neutralised at the lube oil consumption rate that is specifi c for the engine. The reaction time of the additives must be matched to the process in the combustion chamber. Hints concerning the selec-tion of the BN are given in Table 3.

Evaporation tendency

The tendency to evaporate must be as low as pos-sible, otherwise the oil consumption is adversely affected.

Further conditions

The lube oil must not form a stable emulsion with water. Less than 40 ml emulsion are ac-ceptable in the ASTM-D1410 test after one hour.The foaming behaviour (ASTM-D892) must meet the following conditions: after 10 minutes < 20 ml.The lube oil must not contain agents to improve vis-cosity index. Fresh oil must not contain any water or other contamination.

Lube oil selection

Quality of Lube Oil (SAE30) forHeavy Fuel Oil Operation (HFO)

Neutralisation property (BN)

Medium-alkaline lube oils having differently high levels of neutralisation capacity (BN) are available on the market. According to the present-day state of knowledge, operating conditions to be expected and BN can be correlated as shown in Table 3. The operating resulting will in the essence be the deci-sive criterion as to which BN will ensure the most economic mode of engine operation.

Operation on low sulphur fuel

In order to meet the emission regulations, fuels with different sulphur content are used today. In en-vironmental sensitive areas (SECA) a low sulphur fuel must be used. Outside the SECA a fuel with a high sulphur content can be used. In this case the lube oil BN should be selected to meet the re-quirements of the operation on high sulphur fuel. Only for permanent operation on low sulphur fuel, the lube oil with the lower BN should be selected.Ultimately, the operating results are the decisive criterium as to which content of additives ensures the most economic mode of engine operation.

Speed governor

In case of mechanic-hydraulic governors with sep-arate oil sump, multi grade oil 5W-40 is preferably used. If this oil is not available as refi ll, an oil 15W-40 may exceptionally be used. In this context it is not important, if multi grade oils based on synthetic or mineral oil are used.

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L23/30H

504.01Edition 12

DescriptionPage 3 (4)

08.19 - ES1

The oil quality specifi ed by the manufacturer is to be used for the remaining equipment fi tted to the engine.

Lube-oil additives

It is not allowed to add additives to the lube oil, or mixing the different makes (brands) of the lube oil, as the performance of the carefully matched pack-age of additives which is suiting itself and adapted to the base oil, may be upset. Also, the lube oil company (oil supplier) is no longer responsible for the oil.

Selection of lube oils / warranty

Most of the mineral oil companies are in close and permanent consultation with the engine manufac-turers and are therefore in a the position to quote the oil from their own product line that has been approved by the engine manufacturer for the given application. Independent of this release, the lube oil manufacturers are in any case responsible for quality and performance of their products. If you have further questions, we are more than willing to provide you with further information.

Quality of Lube Oil (SAE30) forHeavy Fuel Oil Operation (HFO)

approx. BN (mg KOH/g oil)

Engines / Operating conditions

20Marine Diesel Oil (MDO) of poor quality (ISO�F�DMC) or heavy fuel oil with a sulphur content of <0.5 %.

30

23/30H and 28/32H in general. 23/30A, 28/32A and 28/32S under normal operating conditions.16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 and 58/64 and 51/60DF in pure HFO mode only if fuel sulphur content is < 1.5 %.51/60DF in alternating mode (HFO/Gas).

40

23/30A, 28/32A and 28/32S in case of severe operating conditions and in case of necessity regarding oil life and engine cleanliness.16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 and 58/64 and 51/60DF in pure HFO mode generally, provided the sulphur content is >1.5%.

5032/40, 32/44CR, 40/54, 48/60, and 58/64 if BN 40 is inadequate in terms of oil life or engine cleanliness (high sulphur content of the fuel, very low lube oil consumption.

Table 3 Determining the Base Number for operating conditions

Oil in service

There are no defi ned oil change intervals for MAN Diesel medium-speed engines. The oil has to be analysed on a regular basis. As long as the oil char-acteristics are within the specifi ed limits of Table 4 the oil is suitable for further use. An oil sample has to be analysed every 1-3 months (see maintenance plan). The quality of the oil can only be maintained if the oil is cleaned by an appropriate device (e.g. separator).

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L23/30H

504.01Edition 12

DescriptionPage 4 (4)

08.19 - ES1

Table 4 Limit value

Quality of Lube Oil (SAE30) forHeavy Fuel Oil Operation (HFO)

Limit value Method

Viscosity at 40 °C 75 � 160 mm2/s ISO 3104 or ASTM D445

Base Number (BN) min. 50% of fresh oil BN ISO 3771

Flash Point (PM) min. 185 °C ISO 2719

Water Content max. 0.2% (for a short period max. 0.5%) ISO 3733 or ASTM D1744

n�Heptan Insoluble max. 1.5% DIN 51592 or IP 316

Metal Contentdependent upon the engine type and

operating condition

only for guidanceFeCrCuPbSnAlSi

max. 50 ppmmax. 10 ppmmax. 15 ppmmax. 20 ppmmax. 10 ppmmax. 20 ppmmax. 10 ppm

Manufacturer Base Number [mg KOH/g]

20 30 40

AGIP � Cladium 300 - SAE30 Cladium 400 - SAE30

BP Energol IC�HFX 203 Energol IC�HFX 303 Energol IC�HFX 403

CASTROL TLX Plus 203 TLX Plus 303 TLX Plus 403

CEPSA Troncoil 3030 Plus Troncoil 4030 Plus

CHEVRON(TEXACO, CALTEX)

Taro 20DP30 Taro 30DP30 Taro 40XL 30

EXXON MOBIL Mobilgard M 330EXXMAR 30 TP 30

Mobilgard M 340EXXMAR 40 TP 30

PETROBRAS Marbrax CCD�320 Marbrax CCD�330 Marbrax CCD�340

REPSOL Neptuno NT 2030 Neptuno NT 3030 Neptuno NT 4030

SHELL Argina S 30 Argina T 30 Argina X30

TOTAL Lubmarine Aurelia XL 3025 Aurelia XL 3030Aurelia TI 3030

Aurelia XL 3040Aurelia TI 3040

Table 5 Lubricating oils (SAE30), which have been approved for the use in MAN Diesel four�stroke engines running on heavy fuel oil

ExaminationsWe carry out the investigations on lube oil in our laboratories for our customers. A representative sample of about 0.5 litre is required for the exami-nation.

Note!MAN Diesel SE do not take any responsibility for diffi culties that might be caused by these oils!

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L23/30H

504.01Edition 13

DescriptionPage 1 (4)

08.19 - ES1

Quality of Lube Oil (SAE30) for Operation onGas Oil and Diesel Oil (MGO/MDO)

The specifi c power output offered by today’s Die-sel engines and the use of fuels which more and more often approach the limit in quality increase the requirements placed on the lube oil and make it imperative that the lube oil is chosen carefully. Blended lube oils (HD oils) have proven to be suit-able for lubricating the running gear, the cylinder, the turbocharger and for the cooling of the pistons. Blended lube oils contain additives which, amongst other things, provide them with sludge carrying, cleaning and neutralisation capabilities.

Only lube oils, which have been released by MAN Diesel, are to be used. These are listed in Table 3.

Specifi cations

Base oil

The base oil (blended lube oil = basic oil + addi-tives) must be a narrow distillation cut and must be refi ned in accordance with modern procedures. Bright stocks, if contained, must neither adversely affect the thermal nor the oxidation stability. The base oil must meet the limit values as specifi ed in Table 1, particularly concerning the ageing stabil-ity.

Blended lube oils (HD-oils)

The base oil for which additives have been mixed (blended lube oil) must demonstrate the following characteristics:

Additives

The additives must be dissolved in the oil and must be of such a composition that an absolute minimum of ash remains as residue after combustion. The ash must be soft. If this prerequisite is not complied with, increased deposits are to be expected in the combustion chamber, especially at the outlet valves and in the inlet housing of the turbochargers. Hard additive ash promotes pitting on the valves seats, as well as burnt-out valves and increased mechani-cal wear.

Additives must not facilitate clogging of the fi lter el-ements, neither in their active nor in their exhaust-ed state.

Detergency

The detergency must be so high that coke and tar-like residues from fuel combustion must not build-up.

Table 1 Lube oil (MGO/MDO) - specifi ed values* in-house method

Characteristic features Unit Test method Limit valueStructure � � preferably paraffi n�basic

Behaviour in cold, still fl ows°C

ASTM–D2500 �15

Flash point (as per Cleveland) ASTM–D92 > 200

Ash content (oxide ash)Weight %

ASTM–D482 < 0.02

Coke residue (as per Conradson) ASTM–D189 < 0.50

Ageing tendency after being heated up to 135 °C for 100 hrs. �

MAN Diesel ageing cabinet *

�

n–heptane insolublesWeight %

ASTM–D4055or DIN 51592

< 0.2

Evaporation loss Weight % � < 2

Drop test (fi lter paper)� MAN Diesel test

Must not allow to recognise precipitation of resin or asphalt�like ageing products

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L23/30H

504.01Edition 13

DescriptionPage 2 (4)

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Engine SAE–Class

23/30H, 28/32H, 23/30A, 28/32AAt cooling water temperatures > 32° C a SAE40 oil can be used.In this case please contact MAN Diesel

30

Table 2 Viscosity (SAE class) of lube oils

Dispersancy

The dispersancy must be selected such that com-mercially available lube-oil cleaning equipment can remove the detrimental contamination from the used oil, i.e. the oil must have good separating and fi ltering properties.

Neutralisation capacity

The neutralisation capacity (ASTM-D2896) must be so high that the acidic products which result dur-ing combustion are neutralised. The reaction time of the additives must be matched to the process in the combustion chamber.

Evaporation tendency

The tendency to evaporate must be as low as pos-sible, otherwise the oil consumption is adversely affected.

Further conditions

The lube oil must not form a stable emulsion with water. Less than 40 ml emulsion are acceptable in the ASTM-D1410 test after one hour.

The foaming behaviour (ASTM-D892) must meet the following conditions: after 10 minutes < 20ml.

The lube oil must not contain agents to improve vis-cosity index. Fresh oil must not contain any water or other contamination.

Lube oil selection

Blended grade

Blended lube oils (HD oils) corresponding to inter-national specifi cations MIL-L 2104 or API-CD, and having a Base Number (BN) of 10 – 16 mg KOH/g are recommended by us (Designation for armed forces of Germany: O-278).

The content of additives included in the lube oil de-pends upon the conditions under which the engine is operated, and the quality of fuel used. If marine Diesel fuel is used, which has a sulphur content of up to 2.0 weight % as per ISO-F DMC, and coke residues of up to 2.5 weight % as per Conradson, a BN of approx. 20 is preferred. Ultimately, the op-erating results are the decisive criterion as to which content of additives ensures the most economic mode of engine operation.

Speed governor

In case of mechanic-hydraulic governors with sep-arate oil sump, multi grade oil 5W-40 is preferably used. If this oil is not available for topping-up, an oil 15W-40 may exceptionally be used. In this context it makes no difference whether multicoloured oils based on synthetic or mineral oil are used. (Desig-nation for armed forces of Germany: O-236)

The oil quality specifi ed by the manufacturer is to be used for the remaining equipment fi tted to the engine.

Lube-oil additives

It is not allowed to add additives to the lube oil, or mixing the different makes (brands) of the lube oil, as the performance of the carefully matched pack-age of additives which is suiting itself and adapted to the base oil, may be upset. Also, the lube oil company (oil supplier) is no longer responsible for the oil.

Quality of Lube Oil (SAE30) for Operation onGas Oil and Diesel Oil (MGO/MDO)

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DescriptionPage 3 (4)

08.19 - ES1

Approved SAE30 lube oils

Manufacturer Base Number 10�161) [mgKOH/g]

AGIP Cladium 120 � SAE 30Sigma S SAE 30 2)

BP Energol DS 3�153

CASTROL Castrol MLC 30Castrol MHP 153Seamax Extra 30

CHEVRON(Texaco, Caltex)

Taro 12 XD 30Delo 1000 Marine SAE 30

EXXON MOBIL Exxmar 12TP30Mobilgard 312Mobilgard ADL 30 2)

Delvac 1630

PETROBRAS Marbrax CCD�310

Q8 Mozart DP30

REPSOL Neptuno NT 1530

SHELL Gadinia 30Sirius FB 30 2)

Sirius/Rimula X30 2)

Gadinia AL30

STATOIL MarWay 1530MarWay 1030

TOTAL Lubmarine Disola M3015

Selection of lube oils / warranty

Most of the mineral oil companies are in close and permanent consultation with the engine manufac-turers and are therefore in a position to quote the oil from their own product line that has been approved by the engine manufacturer for the given applica-tion. Independent of this release, the lube oil manu-facturers are in any case responsible for quality and performance of their products. If any questions, we are more than willing to provide you with further in-formation.

Oil in service

There are no defi ned oil change intervals for MAN Diesel medium-speed engines. The oil has to be analysed on a regular basis. As long as the oil char-acteristics are within the specifi ed limits of Table 4, the oil is suitable for further use. An oil sample has to be analysed every 1-3 months (see maintenance plan). The quality of the oil can only be maintained if the oil is cleaned by an appropriate device (e.g. separator).

Examinations

We carry out the investigations on lube oil in our laboratories for our customers. A representative sample of about 0.5 litre is required for the exami-nation.

1) If Marine Diesel fuel of poor quality (ISO-F-DMC) is used, a Base Number (BN) of ap-prox. 20 is of advantage.

2) If the sulphur content of the fuel is < 1 %.

MAN Diesel SE do not take any reponsibility for dif-fi culties that might be caused by these oils.

Table 3 Lubricating oils (SAE30) which have been approved for the use in MAN Diesel four-stroke engines running on gas oil and Diesel oil

Quality of Lube Oil (SAE30) for Operation onGas Oil and Diesel Oil (MGO/MDO)

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DescriptionPage 4 (4)

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Limit value Method

Viscosity at 40 °C 75 � 160 mm2/s ISO 3104 or ASTM D445

Base Number (BN) min. 50% of fresh oil BN ISO 3771

Flash Point (PM) min. 185 °C ISO 2719

Water Content max. 0.2% (for a short period max. 0.5%) ISO 3733 or ASTM D1744

n�Heptan Insoluble max. 1.5% DIN 51592 or IP 316

Metal Contentdependent upon the engine type and

operating condition

only for guidanceFeCrCuPbSnAlSi

max. 50 ppmmax. 10 ppmmax. 15 ppmmax. 20 ppmmax. 10 ppmmax. 20 ppmmax. 10 ppm

Table 4 Limit value

Quality of Lube Oil (SAE30) for Operation onGas Oil and Diesel Oil (MGO/MDO)

MAN Diesel

Lubricating Oil Types Used in the Engine.

96.02 - ES0U-G

Description Lub. Oil Type

Engine system lubricating oil SAE 30 oil according to lubricating oil specifi cation on page 504.01.

Turbocharger Engine system lubricating oil.

Governor See governor instruction in section 509.

Air lubricator SAE 10W non-detergent oil.

Alternator See special instructions in section 518 or separate instruction.

Hydraulic tools Hydraulic oil or turbine oil (with a viscocity of about SAE 20).

Lubricating PointsDescriptionPage 1 (1)

L23/30H

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DescriptionPage 1 (1)

504.06Edition 16HLubricating Oil in Base Frame

L23/30H

Type L23/30H

Min. level alarm H2 (mm)

Max. level alarm H3 (mm)

Min. litre H2

Max. litre H3

8 cyl.

200

250

450

577

7 cyl.

200

250

397

509

6 cyl.

200

250

344

441

5 cyl.

200

250

291

373

MAN Diesel

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06.39 - ES1

L23/30H900 rpm

DescriptionPage 1 (1)

Type L23/30H

Min. level H2 (mm)

Max. level H3 (mm)

Min. litre H2

Max. litre H3

7 cyl.

275

325

685

814

8 cyl.

275

325

706

859

6 cyl.

275

325

540

657

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Engine type RPM SLOC [g/kWh]

L16/24 1000/1200 0.4 - 0.8

L21/31 900/1000 0.4 - 0.8

L23/30H 720/750/900 0.6 - 1.0

L27/38 720/750 0.4 - 0.8

L28/32H 720/750 0.6 - 1.0

V28/32H 720/750 0.6 - 1.0

V28/32S 720/750 0.4 - 0.8

L32/40 720/750 0.8 - 1.0

DescriptionPage 1 (2) Specifi c Lubricating Oil Consumption - SLOC 504.07

Edition 03

General

06.25 - ES0

Please note that only maximum continuous rating (PMCR (kW)) should be used in order to evaluate the SLOC.

Please note, during engine running-in the SLOC may exceed the values stated.

The following formula is used to calculate the SLOC:

SLOC [g/kWh] =

(lubricating oil added - A1 - A2 [dm3]) * ρlubricating oil [kg/m3] run.hrs period * PMCR [kW]

In order to evaluate the correct engine SLOC, the following circumstances must be noticed and subtracted from the engine SLOC:

A1:Desludging interval and sludge amount from the lubricating oil separator (or automatic lubricating oil fi lters). The expected lubricating oil content of the sludge amount is 30%.

The following does also have an infl uence on the SLOC and must be considered in the SLOC evaluation:

A2:Lubricating oil evaporationLubricating oil leakagesLubricating oil losses at lubricating oil filter exchange

The lubricating oil density, ρ @ 15°C must be known in order to convert ρ to the present lubricating oil temperature in the base frame. The following formula is used to calculate ρ:

ρlubricating oil [kg/m3] =

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

The engine maximum continuous design rating (PMCR) must always be used in order to be able to compare the individual measurements, and the running hours since the last lubricating oil adding must be used in the calculation. Due to inaccuracy *) at adding lubricating oil, the SLOC can only be evaluated after 1,000 running hours or more, where only the average values of a number of lubricating oil addings are representative.

Note *)A deviation of ± 1 mm with the dipstick measurement must be expected, witch corresponds uptill ± 0.1g/kWh, depending on the engine type.

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General

504.07Edition 03Specifi c Lubricating Oil Consumption - SLOCDescription

Page 2 (2)

Date Run. hrs Add. Lube oil A1 + A2 L.O.Temperature SLOC Remarks [h] [dm³] [dm³] [°C] [g/kWh]

Plant / ShipLube oil consumption

Engine type:___________________ Engine # :__________________

Lube oil brand/type:__________________________________________

Density @15 C:_____________ [kg/m3]

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DescriptionPage 1 (10)

08.19 - ES1

Quality of Heavy Fuel Oil (HFO)

Prerequisites

MAN Diesel four-stroke engines can be operated on any crude-oil based heavy fuel oil meeting the requirements listed in Table 3-24, Page 3-37 , pro-vided the engine and the fuel treatment plant are designed accordingly. In order to ensure a well-bal-anced relation between the costs for fuel, spare parts and maintenance and repair work, we recom-mend bearing in mind the following points.

Heavy fuel oil (HFO)

Provenance/refi ning process

The quality of the heavy fuel oil is largely deter-mined by the crude oil grade (provenance) and the refi ning process applied. This is the reason why heavy fuel oils of the same viscosity may differ con-siderably, depending on the bunker places. Heavy fuel oil normally is a mixture of residue oil and distil-lates. The components of the mixture usually come from state-of-the-art refi ning processes such as visbreaker or catalytic cracking plants. These proc-esses may have a negative effect on the stability of the fuel and on its ignition and combustion proper-ties. In the essence, these factors also infl uence the heavy fuel oil treatment and the operating results of the engine.

Bunker places where heavy fuel oil grades of stand-ardised quality are offered should be given prefer-ence. If fuels are supplied by independent traders, it is to be made sure that these, too, keep to the international specifi cations. The responsibility for the choice of appropriate fuels rests with the en-gine operator.

Specifi cations

Fuels that can be used in an engine have to meet specifi cations to ensure a suitable quality. The limit-ing values for a heavy fuel oil are listed in Table 1 Fuel oil specifi cations and associated characteris-tic values.

Please note the entries in the last column of Table 1 Fuel oil specifi cations and associated character-istic values, because they provide important back-ground information.

Several international specifi cations for heavy fuel oils are existing. The most important specifi cations are ISO 8217-2005 and CIMAC-2003. These two specifi cations are more or less equivalent. Table 2 CIMAC Recommendations for residual fuels for diesel engines (as bunkered) shows the specifi -cations CIMAC-2003. All qualities of these specifi -cations up to K700 can be used provided the fuel treatment system is designed for these fuel grades e.g. fuels with a maximum density of 1010 kg/m3 can only be used with modern separation.

Important

Fuel oil characteristics as stated in analysis results - even if they meet the above mentioned require-ments - may be not suffi cient for estimating the combustion properties and the stability of the fuel oil. This means that service results depend on oil properties which cannot be known beforehand. This especially applies to the tendency of the oil to form deposits in the combustion chamber injection system, gas passages and turbines. It may, there-fore, be necessary to rule out some oils that cause diffi culties.

Blends

The admixing of engine oils (ULO:used lube oil), of non-mineral oil constituents (such as coal oil) and of residual products from chemical or other proc-esses (such as solvents, polymers or chemical waste) is not permitted. The reasons are, for ex-ample: the abrasive and corrosive effects, the ad-verse combustion properties, a poor compatibility with mineral oils and, last but not least, the nega-tive environmental effects. The order letter for the fuel should expressly mention what is prohibited, as this constraint has not yet been incorporated in the commonly applied fuel specifi cations.

The admixing of engine oils (ULO: used lube oil) to the fuel involves a substantial danger because the lube oil additives have an emulsifying effect and keep dirt, water and catfi nes fi nely suspended. Therefore, they impede or preclude the necessary cleaning of the fuel. We ourselves and others have made the experience that severe damage induced by wear may occur to the engine and turbocharger components as a result.

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General

DescriptionPage 2 (10)

08.19 - ES1

Quality of Heavy Fuel Oil (HFO)

A fuel shall be considered to be free of used lube oil (ULO) if one or more of the elements Zn, P and Zn are below the specifi c limits (Zn: 15 ppm; P: 15 ppm; Ca: 30 ppm).

The admixing of chemical waste materials (such as solvents) to the fuel is for reasons of environmen-tal protection prohibited by resolution of the IMO Marine Environment Protection Committee of 1st January 1992.

Fuel�system related characteristic values

Viscosity (at 50° C)

mm2/s (cSt)

max.700 »Viscosity/injection viscosity«

Viscosity (at 100° C)

max.55 »Viscosity/injection viscosity«

Density (at 15° C)

g/ml max.1.010 »Heavy fuel oil treatment«

Flash point °C min.60 »Flash point (ASTMD�93)«

Pour point (summer)

max.

30 »Low temperature behaviour (ASTM D�97)«, and »Pump ability«

Pour point (winter)

max.

30 »Low temperature behaviour (ASTM D�97)«, and »Pump ability«

Engine–related characteristic values

Carbon residues (Conradon)

% wt.

max.22 »Combustion properties«

Sulphur 54.5 in marine operation

»Sulphuric acid corrosion«

Ash0.20 »Heavy fuel oil treatment«

Vanadium mg/kg600 »Heavy fuel oil treatment«

Water % vol.1 »Heavy fuel oil treatment«

Sediment (potential)

% wt.0.1

Supplementary characteristic values

Aluminium and silicon

mg/kg max.80 »Heavy fuel oil treatment«

Asphalts % wt. 2/3 of carbon residues (Conradson)

»Combustion properties«

Sodium mg/kg Sodium < 1/3 vanadium, sodium < 100

»Heavy fuel oil treatment«

Cetane number of low–viscosity constituent minimum 35

»Ignition quality«

Fuel free of admixtures not based on mineral oil, such as coal oils or vegetable oils; free of tar oil and lubricating oil (used oil), free of any chemical waste and of solvents or

polymers Table 1 Fuel oil specifi cations and associated characteristic values

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DescriptionPage 3 (10)

08.19 - ES1

Quality of Heavy Fuel Oil (HFO)

Test

met

hod

re

fere

nce

ISO

367

5 or

ISO

121

85

ISO

310

4

ISO

310

4

ISO

271

9

ISO

301

6IS

O 3

016

ISO

103

70

ISO

624

5

ISO

373

3

ISO

145

96 o

r IS

O 8

754

ISO

145

96or

IP 5

01

ISO

1030

7�2

ISO

104

78

IP50

1 or

IP47

0IP

501

or IP

500

IP50

1 or

IP47

0

CIM

AC

K 7

00

1010

.0

700.

0

� 60 30 30 22 0.15 0.5

4.5

600

0.10 80

The

fue

l sha

ll b

e fr

ee o

f U

LO. A

fuel

sha

ll b

e co

nsid

ered

to

be

free

of U

LO if

one

ore

mor

e of

the

ele

men

tsl Z

inc,

Pho

spho

rus

and

Cal

cium

are

bel

ow o

r at

the

sp

ecifi

ed li

mits

. All

thre

e el

emen

ts m

ust

exce

ed t

he s

ame

limits

bef

ore

a fu

el s

hall

be

dee

med

to

cont

ain

ULO

.

15 15 30

CIM

AC

H 7

00

991.

0

CIM

AC

K 3

80

1010

.0

380.

0

� 60 30 30

22

0.15 0.5

4.50

600

0.10 80

CIM

AC

H 3

80

991.

0

CIM

AC

G 3

80

18 300

CIM

AC

F 18

0

991.

0

180.

0

� 60 30 30

20 0.15

0.5

4.50

500

0.10 80

CIM

AC

E 1

80 15 0.10

200

CIM

AC

D80 98

0.0

80.0 � 60 30 30 14 0.10 0.5

4.00

350

0.10 80

CIM

AC

B30 97

5.0

30.0

60

24 24

10 0.10 0.5

3.5

150

0.10 80

CIM

AC

A30 96

0.0

22.0 0 6

Lim

it

max

.

max

.

min

.2)

max

.

max

.m

ax.

max

.

max

.

max

.

max

.

max

.

max

.

max

.

� � �

Uni

t

kg/m

3

mm

2 /s1)

°C °C % (m/m

)

% (m/m

)

% (V/V

)

% (m/m

)

mg/

kg

% (m/m

)

mg/

kg

mg/

kgm

g/kg

mg/

kg

Cha

ract

eris

tics

Den

sity

at

15 û

C

Kin

emat

ic

visc

osity

at

50 û

C

Flas

h p

oint

Pou

r p

oint

(up

per

)�w

inte

r q

ualit

y�s

umm

er q

ualit

y� C

arb

on r

esid

ue

Ash

Wat

er

Sul

fur

3)

Vana

diu

m

Tota

l sed

imen

t p

oten

tial

Alu

min

ium

plu

s s

ilico

n

Use

d lu

bric

atin

g o

il (U

LO)

Zin

cP

hosp

horu

sC

alci

um

1) 1

mm

2/s

= 1

cSt

2) F

uels

with

den

sity

clo

se to

the

max

imum

, but

with

ver

y lo

w v

isco

sity

, may

exh

ibit

poor

igni

tion

qual

ity.

3) A

sul

phur

lim

it of

1,5

% m

m w

ill a

pply

in S

Ox

Em

issi

on C

ontr

ol A

reas

des

igna

ted

by th

e IM

O, w

hen

its r

elev

ant P

roto

col c

omes

into

forc

e. T

here

may

be

loca

l var

iatio

ns.

Table 2 CIMAC Recommendations for residual fuels for diesel engines (as bunkered)

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General

Leaked oil collectors

Leaked oil collectors into which leaked oil and resi-due pipes as well as overfl ow pipes of the lube oil system, in particular, must not have any connection to fuel tanks. Leaked oil collectors should empty into sludge tanks.

Supplementary remarks

The following remarks are thought to outline the re-lations between heavy fuel oil grade, heavy fuel oil treatment, engine operation and operating results.

Selection of heavy fuel oil

Economic operation on heavy fuel oil with the limit values specifi ed in Table 1, is possible under nor-mal service conditions, with properly working sys-tems and regular maintenance. Otherwise, if these requirements are not met, shorter TBO’s (times between overhaul), higher wear rates and a higher demand in spare parts must be expected. Alterna-tively, the necessary maintenance intervals and the operating results expected determine the decision as to which heavy fuel oil grade should be used.

It is known that as viscosity increases, the price ad-vantage decreases more and more. It is therefore not always economical to use the highest viscosity heavy fuel oil, which in numerous cases means the lower quality grades.

Heavy fuel oils ISO-RM A/B 30 or CIMAC A/B 30 ensure reliable operation of older engines, which were not designed for the heavy fuel oils that are currently available on the market. ISO-RMA 30 or CIMAC A30 with a low pour point should be pre-ferred in cases where the bunker system cannot be heated.

Viscosity/injection viscosity

Heavy fuel oils if having a higher viscosity may be of lower quality. The maximum permissible viscosity depends on the existing preheating equipment and the separator rating (throughput).

The specifi ed injection viscosity of 12-14mm2/s (for GenSets 16/24, 21/31, 23/30H, 27/38 and 28/32H: 12 - 18 cSt) and/or fuel oil temperature upstream of the engine should be adhered to. Only then will an appropriate atomisation and proper mixing, and hence a low-residue combustion be possible. Besides, mechanical overloading of the injection system will be prevented. The specifi ed injection viscosity and/or the necessary fuel oil temperature upstream of the engine can be seen from the vis-cosity/temperature diagram.

Heavy fuel oil treatment

Trouble-free engine operation depends, to a large extent, on the care which is given to heavy fuel oil treatment. Particular care should be taken that in-organic, foreign particles with their strong abrasive effect (catalyst residues, rust, sand) are effectively separated. It has shown in practice that with the aluminium and silicon content > 15 mg/kg abrasive wear in the engine strongly increases.

The viscosity and density will infl uence the clean-ing effect, which has to be taken into consideration when designing and setting the cleaning equip-ment.

• Settling tank

The heavy fuel oil is precleaned in the settling tank. This precleaning is all the more effective the lon-ger the fuel remains in the tank and the lower the viscosity of the heavy fuel oil is (maximum preheat-ing temperature 75° C to prevent formation of as-phalt in the heavy fuel oil). One settling tank will generally be suffi cient for heavy fuel oil viscosity below 380mm2/s at 50° C. If the concentration of foreign matter in the heavy fuel oil is excessive, or if a grade according to ISO-F-RM, G/H/K380 or H/K700 is preferred, two settling tanks will be re-quired, each of which must be adequately rated to ensure trouble-free settling within a period of not less than 24 hours. Prior to separating the content into the service tank, the water and sludge have to be drained from the settling tank.

DescriptionPage 4 (10)

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Quality of Heavy Fuel Oil (HFO)

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• Separators

A centrifugal separator is a suitable device for ex-tracting material of higher specifi c gravity, such as water, foreign particles and sludge. The separators must be of the self-cleaning type (i.e. with automati-cally induced cleaning intervals).

Separators of the new generation are to be used ex-clusively; they are fully effi cient over a large density range without requiring any switchover, and are ca-

pable of separating water up to a heavy fuel oil density of 1.01 g/ml at 15° C.

Table 3, shows the demands made on the separa-tor. These limit values which the manufacturers of these separators take as a basis and which they also guarantee.

The manufacturer’ specifi cations have to be ad-hered to in order to achieve an optimum cleaning effect.

100% 100%

Marine and stationary appli-cation; connected in parallel

1 separator for 100% throughput

1 separator (standby) for 100% throughput

Layout of the separators is to be in accordance with the latest recommendations of the separator manu-facturers, Alfa Laval and Westfalia. In particular, the density and viscosity of the heavy fuel oil are to be taken into consideration. Consulting MAN Diesel is required if other makes of separators come up for discussion.

If the cleaning treatment prescribed by MAN Die-sel is applied, and if the correct separators are se-

lected, it can be expected that the results given in Table 3, for water and inorganic foreign particles in the heavy fuel oil are reached at the entry into the engine.

The results obtained in practical operation reveal that adherence to these values helps to particularly keep abrasive wear in the injection system and in the engine within acceptable limits. Besides, opti-mal lube oil treatment must be ensured.

Figure 1 Heavy fuel oil cleaning/separator arrangement

Defi nition Particle size Quantity

Inorganic foreign particlesincl. catalyst residues < 5 μm

< 20 mg/kg Al+Si content <1 5 mg/kg

Water � < 0.2 % by volume

Table 3 Obtainable contents of foreign matter and water (after separation)

DescriptionPage 5 (10)

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Quality of Heavy Fuel Oil (HFO)

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General

• Water

Attention is to be paid to very thorough water sep-aration, since the water is not a fi nely distributed emulsion but in the form of adversely large droplets. Water in this form promotes corrosion and sludge formation also in the fuel system, which has an ad-verse effect on the delivery and atomisation and thus also on the combustion of the heavy fuel oil. If the water involved is sea water, harmful sodium chloride and other salts dissolved in the water will enter the engine.

The water-containing sludge must be removed from the settling tank prior to each separating process, and at regular intervals from the service tank. The venting system of the tanks must be designed in such a way that condensate cannot fl ow back into the tanks.

• Vanadium/sodium

Should the vanadium/sodium ratio be unfavour-able, the melting temperature of the heavy fuel oil ash may drop into the range of the exhaust valve temperature which will result in high-temperature corrosion. By precleaning the heavy fuel oil in the settling tank and in the centrifugal separators, the water, and with it the water-soluble sodium com-pounds can be largely removed.

If the sodium content is lower than 1/3 of the vadi-um content, the risk of high-temperature corrosion will be small. It must also be prevented that sodium in the form of sea water enters the engine together with the intake air.

If the sodium content is higher than 100 mg/kg, an increase of salt deposits is to be expected in the combustion space and in the exhaust system. This condition will have an adverse effect on engine op-eration (among others, due to surging of the turbo-charger).

Under certain conditions, high-temperature corro-sion may be prevented by a fuel additive that raises the melting temperature of the heavy fuel oil ash (also refer to “Additives to heavy fuel oils”.

• Ash

Heavy fuel oils with a high ash content in the form of foreign particles such as sand, corrosion and catalyst residues, promote the mechanical wear in the engine. There may be catalyst fi nes (catfi nes) in heavy fuel oils coming from catalytic cracking processes. In most cases, these catfi nes will be aluminium silicate, which causes high wear in the injection system and in the engine. The aluminium content found multiplied by 5 - 8 (depending on the catalyst composition) will approximately cor-respond to the content of catalyst materials in the heavy fuel oil.

• Homogeniser

If a homogeniser is used, it must not be installed between the settling tank and the separator on any account, since in that case, harmful contaminants, and in particular seawater, cannot be separated out suffi ciently.

Flash point (ASTMD-93)

National and international regulations for transport, storage and application of fuels must be adhered to in respect of the fl ash point. Generally, a fl ash point of above 60° C is specifi ed for fuels used in Diesel engines.

Low temperature behaviour (ASTM D-97)

• Pourpoint

The pour point is the temperature at which the fuel is no longer fl uid (pumplike). Since many of the low-viscosity heavy fuel oils have a pour point greater than 0° C, too, the bunkering system has to be pre-heated unless fuel in accordance with CIMAC A30 is used. The entire bunkering system should be de-signed so as to permit preheating of the heavy fuel oil to approx. 10° C above the pour point.

DescriptionPage 6 (10)

08.19 - ES1

Quality of Heavy Fuel Oil (HFO)

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Pump ability

Diffi culties will be experienced with pumping if the fuel oil has a viscosity higher than 1,000mm2/s (cSt) or a temperature less than approx. 10° C above the pour point. Please also refer to “Low temperature behaviour (ASTM D-97)”.

Combustion properties

An asphalt content higher than 2/3 of the carbon residue (Conradson) may lead to delayed combus-tion, which involves increased residue formation, such as deposits on and in the injection nozzles, increased smoke formation, reduced power and in-creased fuel consumption, as well as a rapid rise of the ignition pressure and combustion close to the cylinder wall (thermal overloading of the lube oil fi lm). If the ratio of asphaltenes to carbon residues reaches the limit value 0.66, and the asphaltene content also exceeds 8 %, additional analyses of the heavy fuel oil by means of thermogravimetric analysis (TGA) must be performed by MAN Diesel to evaluate the usability. This tendency will also be promoted by the blend constituents of the heavy fuel oil being incompatible, or by different and in-compatible bunkering being mixed together. As a result, there is an increased separation of asphalt (also see “Compatibility”).

Ignition quality

Cracked products which nowadays are preferred as low-viscosity blend constituents of the heavy fuel oil in order to achieve the specifi ed reference vis-cosity may have poor ignition qualities. The cetane number of these constituents should be > 35. An in-creased aromatics content (above 35 %) also leads to a decrease in ignition quality.

Fuel oils of insuffi cient ignition qualities will show extended ignition lag and delayed combustion, which may lead to thermal overloading of the oil fi lm on the cylinder liner and excessive pressures in the cylinder. Ignition lag and the resultant pressure rise in the cylinder are also infl uenced by the fi nal temperature and pressure of compression, i.e. by the compression ratio, the charge-air pressure and charge-air temperature.

Preheating of the charge-air in the part-load range and output reduction for a limited period of time are possible measures to reduce detrimental infl u-ences of fuel of poor ignition qualities. More effec-tive, however, are a high compression ratio and the in-service matching of the injection system to the ignition qualities of the fuel oil used, as is the case in MAN Diesel trunk piston engines.

The ignition quality is a key property of the fuel. The reason why it does not appear in the international specifi cations is the absence of a standardised testing method. Therefore, parameters such as the Calculated Carbon Aromaticity Index (CCAI) are resorted to as an aid, which are derived from de-terminable fuel properties. We have found this to be an appropriate method of roughly assessing the ignition quality of the heavy fuel oil used.

A test instrument utilising a constant-volume combustion technology (FIA fuel ignition analy-ser) has been developed and is currently be-ing evaluated at a number of testing laboratories.The ignition quality of a fuel is determined as an ig-nition delay in the instrument that is converted to an instrument-related cetan number (FIA-CN or ECN). It has been observed that fuels with a low FIA ce-tan number or ECN could, in some cases, lead to operational problems.

As the fl uid constituent in the heavy fuel oil is the determining factor for its ignition quality and the vis-cous constituent is decisive for the combustion qual-ity, it is the responsibility of the bunkering company to supply a heavy fuel oil grade of quality matched to the Diesel engine. Please refer to Figure 2.

DescriptionPage 7 (10)

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Quality of Heavy Fuel Oil (HFO)

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General

Figure 2 Nomogram for the determination of CCAI � assignment of CCAI ranges to engine types

A

B

C

16/2420/2721/3123/3025/3027/3828/32

32/3632/4040/45

52/55A

32/44CR40/5448/60

52/55B58/64

1

2

CCAIDV800

810

820

830

840

850

860

870

880

890

900

910

920

8001

2

3

45

10

2030

50

100

200

400

1000

5000

2000050000

820

840

860

880

900

920

940

960

980

1000

1020

1040

930

V Viscosity mm²/s (cSt) at 50° CD Density [kg/m³] at 15° CCCAI Calculated Carbon Aromaticity IndexA Normal operating conditionsB Diffi culties may be encounteredC Problems encountered may increase up to engine damage after a short time of operation1 Engine type2 The combining straight line across density and viscosity of a heavy fuel oil results in CCAI.

CCAI can also be calculated with the aid of the following formula: CCAI = D - 141 log log (V+0.85) - 81

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Quality of Heavy Fuel Oil (HFO)

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Pre�combustion • Dispersants/stabilisers

• Emulsion breakers

• Biocides

Combustion • Combustion catalysts (fuel economy, emissions)

Post�combustion • Ash modifi er (hot corrosion)

• Carbon remover (exhaust system)

Table 4 Additives to heavy fuels � Classifi cation/effects

Sulphuric acid corrosion

The engine should be operated at the cooling water temperatures specifi ed in the operating manual for the respective load. If the temperature of the com-ponent surface exposed to the acidic combustion gases is below the acid dew point, acid corrosion can no longer be suffi ciently prevented even by an alcaline lubricating oil.

If the lube oil quality and engine cooling meet the respective requirements, the BN values (see “Qual-ity of lube oil (SAE40) for heavy fuel oil operation (HFO)”) will be adequate, depending on the sulphur concentration in the heavy fuel oil.

Compatibility

The supplier has to guarantee that the heavy fuel oil remains homogenous and stable even after the usual period of storage. If different bunker oils are mixed, separation may occur which results in sludge formation in the fuel system, large quantities of sludge in the separator, clogging of fi lters, insuf-fi cient atomisation and high–residue combustion.

In such cases, one refers to incompatibility or insta-bility. The heavy fuel oil storage tanks should there-fore be emptied as far as possible prior to rebunker-ing in order to preclude incompatibility.

Blending heavy fuel oil

If, for instance, heavy fuel for the main engine and gas oil (MGO) are blended to achieve the heavy fuel oil quality or viscosity specifi ed for the auxil-iary engines, it is essential that the constituents are compatible (refer to “Compatibility above).

Additives to heavy fuel oils

MAN Diesel engines can be economically operated without additives. It is up to the customer to decide whether or not the use of an additive would be ad-vantageous. The additive supplier must warrant that the product use will have no harmful effects on engine operation.

The use of fuel additives during the guarantee pe-riod is rejected as a matter of principle.

Additives currently in use for Diesel engines are listed in Table 4, together with their supposed ef-fect on engine operation.

Low sulphur HFO

From an engine manufacturer‘s point of view there is no lower limit for the sulphur content of HFO. We have not experienced any trouble with the currently available low sulphur HFO, that are related to the sulphur content or specifi c to low sulphur HFO. This may change in the future if new methods are applied for the production of low sulphur HFO (de-sulphurization, uncommon blending components). MAN Diesel will monitor developments and inform our customers if necessary.

If the engine is not operated permanently on low sulphur HFO, then the lubricating oil should be se-lected according to the highest sulphur content of the fuels in operation.

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General

Examinations

Sampling

To be able to check as to whether the specifi cation indicated and/or the stipulated delivery conditions have been complied with, we recommend a mini-mum of one sample of each bunker fuel to be re-tained, at least during the guarantee period for the engine. In order to ensure that the sample is rep-resentative for the oil bunkered, a sample should be drawn from the transfer pipe at the start, at half the time and at the end of the bunkering period. “Sample Tec”, supplied by Messrs Mar-Tec, Ham-burg is an appropriate testing kit for taking samples continuously during the bunkering.

Analyse samples

The samples received from the bunkering company are frequently not identical with the heavy fuel oil bunkered. It is also appropriate to verify the heavy fuel oil properties stated in the bunker documents, such as density, viscosity. If these values should de-viate from those of the heavy fuel oil bunkered, one runs the risk that the heavy fuel oil separator and the preheating temperature are not set correctly for the given injection viscosity. The criteria for an eco-nomic engine operation with regard to heavy fuel oil and lubricating oil may be determined with the help of the MAN Diesel Fuel and Lube Analysis Set.

Our department for fuels and lube oils (Augsburg Works, Department GQC) will be glad to furnish further information if required.

Analysis of fuel oils are carried out by our chemical laboratory for customers. For examination a sample of approx. 0.5 litre is required.

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DescriptionPage 1 (2)

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Quality of Marine Diesel Fuel (MDO)

Other designations

Diesel Fuel Oil, Diesel Oil, Bunker Diesel Oil, Ma-rine Diesel Fuel.

Marine Diesel Oil (MDO) is offered as heavy distil-late (designation ISO-F-DMB) or as a blend of distil-late and small amounts of residual oil (designation ISO-F-DMC) exclusively for marine applications. The commonly used term for the blend, which is of dark brown to black colour, is Blended MDO. MDO is produced from crude oil and must be free from organic acids and any non-mineral oil products.

Specifi cation

The usability of a fuel depends upon the engine design and available cleaning facilities as well as on the conformity of the key properties with those listed in the table below which refer to the condition on delivery.

The key properties have been established to a great extent on the basis of ISO 8217-2005 and CIMAC-2003. The key properties are based on the test methods specifi ed.

Property/feature Unit Test method Designation

Specifi cation ISO�F DMB DMC

Density at 15° C kg/m3 ISO 3675 900 920

Cinematic viscosity at 40° C mm2/s cSt ISO 3104 >2.5 < 11 >4 < 14

Pour Point winter quality

°C

ISO 3016 < 0 < 0

summer quality < 6 < 6

Flash point Pensky Martens ISO 2719 > 60 > 60

Total content of sediments % by weight ISO CD 10307 0.10 0.10

Water content % by weight ISO 3733 < 0.3 < 0.3

Sulphur content % by weight ISO 8754 < 2.0 < 2.0

Ash content % by weight ISO 6245 < 0.01 < 0.03

Coke residue (MCR) % by weight ISO CD 10370 < 0.30 < 2.5

Cetane number�

ISO 5165 > 35 > 35

Copper�strip test ISO 2160 < 1 < 1

Vanadium contentmg/kg

DIN 51790T2 0 < 100

Content of aluminium and silicon ISO CD 10478 0 < 25

Visual inspection � 1) �

Other specifi cations:

British Standard BS MA 100 –1987 Class M2 Class M3

ASTM D 975 2D 4D

ASTM D 396 No. 2 No. 4

Table 1 Marine Diesel Oil (MDO) – key properties to be adhered to

1) With good illumination and at room temperature, appearance of the fuel should be clear and transparent.

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DescriptionPage 2 (2)

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Supplementary information

At transshipment facilities and in transit MDO is handled like residual oil. Thus, there is the possibil-ity of oil being mixed with high-viscosity fuel oil or Interfuel, for example with remainders of such fuels in the bunkering boat, which may adversely affect the key properties considerably.

The fuel shall be free of used lubricating oil (ULO). A fuel shall be considered to be free of ULO if one or more of the elements Zn, P and Ca are below the specifi ed limits (Zn: 15 ppm; P: 15 ppm; Ca: 30 ppm).

The Pour Point indicates the temperature at which the oil will refuse to fl ow. The lowest temperature the fuel oil may assume in the system, should lie approx. 10° C above the pour point so as to ensure it can still be pumped.

A minimum viscosity at the fuel injection pump is re-quired to ensure a suffi cient lubricity. Therefore the temperature of the fuel must never exceed 60° C.

If Blended MDOs (ISO-F-DMC) of differing bunker-ing are being mixed, incompatibility may result in sludge formation in the fuel system, a large amount of sludge in the separator, clogging of fi lters, insuf-fi cient atomization and a large amount of combus-tion deposits. We would therefore recommend to run dry the respective fuel storage tank as far as possible before bunkering new fuel.

Sea water, in particular, tends to increase corrosion in the fuel oil system and hot corrosion of exhaust valves and in the turbocharger. It is also the cause of insuffi cient atomization and thus poor mixture formation and combustion with a high proportion of combustion residues.

Solid foreign matter increase the mechanical wear and formation of ash in the cylinder space.

If the engine is mainly run on Blended MDO i.e. ISO-F-DMC, we recommend to provide a centrifu-gal separator upstream of the fuel oil fi lter. Sepa-rator throughput 65 % with relation to the rated throughput. Separating temperature 40 to 50 °C. Solid particles (sand, rust, catalyst fi nes) and water can thus largely be removed and the intervals be-tween cleaning of the fi lter elements considerably extended.

Investigations

Fuel analyses are carried out in our chemical labo-ratory for our customers. For examination a sample of approx. 0.5 litre is required.

Quality of Marine Diesel Fuel (MDO)

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DescriptionPage 1 (2)

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Quality of Gas Oil / Diesel Fuel (MGO)

Property/feature Unit Test method Characteristic value

Density at 15° Ckg/m3 ISO 3675

≥ 820.0≤ 890.0

Cinematic viscosity / 40° C mm2/s (cSt) ISO 3104≥ 1.5≤ 6.0

Filter ability1) in summerin winter °C

DIN EN 116≤ 0

≤ �12

Flash point Abel�Pensky in closed crucible

ISO 1523 ≥ 60

Distillation range up to 350° C % by volume ISO 3405 ≥ 85

Content of sediment (Extraction method) % by weight ISO 3735 ≤ 0.01

Water content % by volume ISO 3733 ≤ 0.05

Sulphur content

% by weight

ISO 8754 ≤ 1.5

Ash ISO 6245 ≤ 0.01

Coke residue (MCR) ISO CD 10370 ≤ 0.10

Cetane number � ISO 5165 ≥ 40 2)

Copper�strip test � ISO 2160 ≤ 1

Other specifi cations:

British Standard BS MA 100�1987 M1

ASTM D 975 1D/2D

Table 1 Diesel fuel oil (MGO) � key properties to be adhered to

1) Determination of fi lter ability to DIN EN 116 is comparable to Cloud Point as per ISO 3015.

2) L/V 20/27 engines require a cetane number of at least 45

Other designations

Gas oil, Marine Gas Oil (MGO), High Speed Diesel Oil.

Diesel fuel is a medium class distillate of crude oil which therefore must not contain any residual com-ponents.

Specifi cation

Suitability of the fuel depends on the conformity with the key properties as specifi ed hereunder, per-taining to the condition on delivery.

On establishing the key properties, the standards of DIN EN 590 and ISO 8217-2005 (Class DMA), as well as CIMAC-2003 were taken into considera-tion to a large extent. The key property ratings refer to the testing methods specifi ed.

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DescriptionPage 2 (2)

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Quality of Gas Oil / Diesel Fuel (MGO)

Supplementary information

Using fuel oil

If, in case of stationary engines a distillate intended for oil fi ring (for instance Fuel Oil EL to DIN 51603 or Fuel Oil No 1 or No 2 according to ASTM D-396, resp.), is used instead of Diesel fuel, adequate ignition performance and low-temperature stability must be ensured, i.e. the requirements as to prop-erties concerning fi lter ability and cetane number must be met.

A minimum viscosity at the fuel pump is required to ensure a suffi cient lubricity. The required maximum temperature to keep the viscosity before the fuel pump above 2 mm2/s is dependent on the fuel vis-cosity. But in all cases the temperature of the fuel before the injection pump must not exceed 50° C.

Investigations

Fuel analysis are carried out in our chemical labo-ratory for our customers at cost price. For examina-tion a sample of approx. 0.5 litre is required.

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General

Analysis Data

Asphaltenes also infl uences the lubricating properties of the fuel oil and, in extreme cases, high asphalteness content may lead to fuel injection pump sticking.

Fuel oils with a high asphalteness content will have a tendency to form sludge, especially if the water content is also high. The asphaltenes content of a fuel oil is infl uenced by pre-treatment. The heaviest semi-solid asphaltenes, and asphaltenes bound to water as sludge, can be separated by centrifuging.

Diesel Index

Diesel index is a calculated value to determine the ignition quality of a fuel oil. The ignition quality is re-lated to the hydrocarbon composition, paraffi n being of high quality, n-heptanes of moderate quality and aromatics of low quality.

With certain exceptions the properties of the aniline point and the specifi c gravity refl ect the hydrocarbon composition of a fuel oil, and are therefore used in the following simple formula as an expression of ignition quality:

Diesel index = (aniline point °F x API gravity) x 0.01.

The aniline point is the lowest temperature at which equal volumes of the fuel and aniline become just miscible. The test relies on the fact that aromatic hydrocarbons mix completely with aniline at compara-tively low temperatures, whereas paraffi ns require considerably higher temperatures before they are completely miscible.

A high aniline point thus indicates a highly paraffi nic fuel, and consequently a fuel oil of good ignition qual-ity. Similarly, a high API gravity number denotes a low specifi c gravity and high paraffi nicity, and again a good ignition quality.

The diesel index provides a reasonable idea of the ignition quality, but generally gives fi gures slightly above the cetane number.

Fuel oils with poor ignition quality and a low diesel index might in particular cause problems in starting diesel engines and running at low load.

Comments on Analysis Data for Fuel Oils

Carbon Residue

The carbon residue of a fuel oil indicates its coke-forming tendency and can be used to determine the tendency to form deposits in the combustion chamber and gasways. The higher the carbon residue value, the higher the fouling tendency.

Some changes in the combustion process, requir-ing adjustment of the maximum pressure, may also be attributed to a high carbon residue content. The value is measured by standardized tests, such as the Conradson or Ramsbottom tests which give similar results.

The non-vaporized residue from the carbonizing test consists of carbonaceous material and inorganic im-purities and is expressed as percentage weight of the fuel sample tested. Carbon residue and asphaltenes content generally move in parallel, both in relation to the carbon-to-hydrogen ratio, with increasing values for a higher ratio.

The carbon-to-hydrogen ratio and thus also the carbon residue depends on the source of the crude oil and the type of refi nery processing used.

The effect of carbon residue is impossible to coun-teract by pre-treatment of the fuel oil, as centrifuging only infl uences solid inorganic contaminants and hard asphalts, which are only small amounts of the percentage weight called carbon residue.

Asphaltenes

Asphaltenes is defi ned as the part of a fuel oil sam-ple which is insoluble in heptane. The content of asphalteness is expressed as percentage weight of the fuel oil sample tested.

Asphaltenes, which is aromatic, slow-burning, semi-solid hydrocarbon compounds dispersed in the fuel oil, has a similar effect on the combustion process to the carbon residue, the main impact being fouling of gasways. The stability of the fuel oil is related to the asphaltenes content.

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In addition to starting diffi culties, a prolonged ignition delay may give rise to alternations in the maximum pressure, leading to increased mechanical or ther-mal load.

Furthermore, fuel oils with poor ignition quality may cause retarded combustion and subsequent fouling of gasways.

Sulphur

Sulphur is present in fuel oil, mainly as organic compounds, the amount present being expressed as percentage weight of an oil sample tested. If free sulphur is present it may cause corrosion in the fuel system. The main problem caused by sulphur is low temperature corrosion. During combustion, sulphur oxides are produced in the form of gases. Since humidity is also present sulphur and sulphuric acid may be formed on components in the combustion chamber and in the gasways, where the temperature is below that of the dew point for sulphuric acid.

The detrimental effect of sulphur in fuel oil is coun-teracted by maintaining an adequate temperature of the combustion chamber components and by using alkaline lubricating oil to neutralize the sulphuric acid produced during combustion.

Vanadium and Sodium

Vanadium and sodium are constituents of the ash content. The amounts of these are measured by analyzing the residue from the combustion test used for determination of the ash content. The amount of vanadium and sodium present is expressed in ppm, parts per million, by weight in relation to the fuel oil sample being tested for ash content. Vanadium de-rives from the crude oil itself and, being oil soluble, cannot be removed from the fuel oil by conventional pre-treatment. Sodium derives from the crude oil, and also from contamination with salt water during storage and transport of the fuel oil. Sodium is water- soluble and, regardless of derivation, tends to combine with the water present in the fuel oil.

Owing to its water solubility, it is possible to remove or reduce the amount of sodium present in the fuel oil. During combustion, corrosive ash is formed from vanadium and sodium.

Analysis Data

General

Especially if the weight ratio of sodium to vanadium exceeds 1:3, ash with a very low melting point and stiction temperature is formed, giving rise to high temperature corrosion of exhaust valves and deposit formation in turbochargers.

It is possible to reduce the tendency for formation of detrimental vanadium-sodium ash by effective centrifuging, which will remove sodium salts to-gether with water. If a very low content of sodium is ensured, a relatively high vanadium content might be acceptable.

Water

The water content of fuel oil is measured by a standardized distillation test and is expressed as percentage volume of the sample tested. Water in the fuel oil may lead to several detrimental effects on the fuel oil system, and corrosion and cavitation of fuel injection pumps and fuel valves, and cause fouling of exhaust systems and turbochargers.

Due to its content of sodium, salt water in combina-tion with vanadium contributes to the formation of low-melting corrosive ash, which attacks exhaust valves and turbochargers. When it disturbs the fuel atomization, water will lead to poor combustion, resulting in higher heat load on the combustion chamber components.

It is possible to reduce the water content of a fuel oil primarily by centrifuging, and this should be done to the widest possible extent in order to avoid the detrimental effects of water in the fuel oil.

Ash

Ash content is a measure of the non-combustible material present in the fuel oil. The ash content is determined by a combustion test and it is expressed as a percentage weight residue from complete com-bustion of the oil sample tested.

Ash-forming materials are present in the fuel oil as natural components of crude oil and due to external contamination of the fuel oil.

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Ash-forming materials exist both as solid contami-nants and in soluble compounds. The solid contami-nants may lead to abrasive wear in the fuel injection system. Ash formed during combustion may lead to abrasive as well as corrosive wear of combustion chamber components and give rise to formation of detrimental deposits. It is therefore essential, to the greatest possible extent, to reduce the amount of ash-forming materials by centrifuging.

Solid contaminants such as sand, rust, certain metal oxides and catalyst fi nes can be removed by centrifuging, and the same goes for water-soluble salts such as sodium.

Some of the components included in the ash content have been found to be particularly harmful and are therefore stated individually in the analysis data.

Silicium and Aluminium Oxides

Residual fuels produced by refi neries using fl uid catalytic cracking may be contaminated by catalyst particles in the form of silicium and aluminium oxides. Any catalyst particles are shown by the ash content value. Separate values for silicium oxide content and aluminium oxide content are measured by analyzing the ash content.

The amount of silicium and aluminium oxides is ex-pressed in ppm in relation to the weight of the original fuel oil sample being tested for ash content.

As catalyst particles are very hard and abrasive, they can cause extreme mechanical wear of the fuel injection system, cylinder liners and piston rings.

Catalyst particles, being solid and insoluble, can be removed from the fuel oil. The guidelines for dimen-sioning the centrifuge size are based on the fact that approx. 1/3 of the catalyst particles in terms of weight is removed.

Viscosity

Basically viscosity is a measure of the internal friction or resistance of a liquid to fl ow.

02.16 - ES0 - G

Analysis Data

General

Viscosity of Marine Gas Oil (MGO) and Marine Diesel Oil (MDO) are expressed in centistokes (cSt) at 40° C.

Viscosity is an important parameter in connection with pumping, pre-treatment and injection of fuel oil, since the possibility and effi ciency of these processes to a large extent depend on adequate viscosity.

Adjustment of viscosity to adequate values is possible by taking advantage of the interdependence between the temperature and viscosity index of the fuel oil.

The nominal viscosity of a fuel oil is the factor de-termining the preheating temperatures necessary to obtain adequate viscosity for pumping, centrifuging and injection of the fuel oil, and thus also the factor determining the capacity of the preheating equipment in the fuel oil system.

Density

Density is defi ned as the mass of a unit volume and is expressed in g/cm³ at a temperature of 15°C (59°F).

Specifi c gravity is the ratio of the mass of a given volume of liquid at 60°F (15.6°C) and the mass of an equal volume of water at the same temperature. For a given liquid, the specifi c gravity will generally give the same numerical value as the density.

API gravity is an arbitrary scale calibrated in de-grees and related to specifi c gravity by the following formula:

° API gravity = + 131.5

As the formula indicates, the API gravity is in inverse proportion to density and specifi c gravity.

Density is an important parameter in the centrifuging process, where separating water and water-dissolved impurities from the fuel oil is based on the difference in densities. If the density of the fuel oil approaches that of water, centrifuging thus becomes less effec-tive, necessitating a reduced fl ow rate and therefore increased centrifuge capacity.

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141.5specifi c gravity/50°F

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Analysis Data for Fuel Oils

Carbon Residue % weight Asphaltenes % weight Diesel Index Engine- FIA Relevant Ash % weight Properties Sulphur % weight Water % volume Vanadium ppm Sodium ppm Silicium Oxide ppm Aluminium Oxide ppm

Viscosity cSt/50°C Installation- Density g/ml Relevant Flash Point °C Properties Pour Point °C

The water separation ability of fuel oil is increased by preheating the fuel oil prior to centrifuging since the densities of fuel oil and water change with the temperature at different rates, thus making it possible to optimize density differences.

To some extent the quality of a fuel oil can be judged by the density, since this is directly proportional to the carbon-to-hydrogen ratio, which again is in direct pro-portion to aromativity, carbon residue and asphaltene content, but in reverse ratio to calorifi c value.

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Analysis Data

General

DescriptionPage 4 (4)

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Table 2 Analysis data for fuels.

Pour Point

The pour point is the lowest temperature at which an oil will fl ow or can be poured. The pour point is meas-ured under specifi c test conditions. Fuel oil must be stored, handled and pumped at temperatures above the pour point to avoid wax crystallization, which may result in precipitation in storage tanks, blocking of fi lters and pipe lines and prevention of pumpability. Normally, the pour point of residual fuel oil does not create any problems, since the temperature needed to reduce the viscosity to pumpable levels will be adequately in excess of the pour point.

Flash Point

The fl ash point of an oil is defi ned as the temperature at which it gives off suffi cient vapour to create an infl ammable mixture with air. This mixture will ignite or fl ash under the infl uence of an open fl ame, but will not support combustion itself. The fl ash point of fuel oil is normally tested by the Pensky-Martens closed-up method.

In order to provide a suffi cient margin of safety from fi re risk during storage, handling and transportation, fuel oils for shipboard use must meet the classifi ca-tion societies' requirements of fl ash point, limited to a minimum of 60°C (140°F).

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Cleaning of HFO by Centrifuging

Single centrifuge as purifi er.

Two centrifuges in parallel.

Two centrifuges in series.

Optimum Operating Confi gurations

Water content Parallel operation

below 1 % Purifi er / Purifi er

or

Density at 15°C Series operation

below 0.991 Purifi er + Clarifi er

Water content

below 1 % Parallel operation

Density at 15°C Purifi er / Purifi er

below 0.991

High content Series operation

of catalyst fi nes Purifi er + Clarifi er

Purifi cation Recommendations

Fuel oils are always contaminated and should there-fore be cleaned thoroughly of solid as well as liquid contaminants before use. The solid contami-nants in the fuel are mainly rust, sand, dust and re-fi nery catalysts. Liquid contaminants are mainly water, i.e. either fresh water or sea water.

The impurities can cause damage to fuel injection pumps and fuel valves, result in increased cylinder liner wear and cause the exhaust valve seats to deteriorate. Increased fouling of gasways and tur-bocharger blends may also result from the use of inadequately cleaned fuel oils.

Effective cleaning can only be ensured by means of a centrifuge. We recommend that the capacity of the centrifuges installed be at least according to the centrifuge maker's recommendations. To obtain optimum cleaning it is of the utmost importance to operate the centrifuge with as low a viscosity of the fuel oil as possible and to allow the fuel oil to remain in the centrifuge bowl for as long as possible.

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DescriptionPage 1 (2) Fuel Oil Cleaning

504.30Edition 01

General

Especially for fuels above 180 cST/50°C (1500 sec. RW/100°F) the highest possible temperature of 98°C (208°F) should be maintained in the centrifuge oil preheater.

The fuel is kept in the centrifuge for as long as pos-sible by adjusting the fl ow rate through the centrifuge so that it corresponds to the amount of fuel required by the engine without excessive re-circulating. Con-sequently, the centrifuge should operate for 24 hours a day except during necessary cleaning.

Taking today's fuel qualities into consideration the need to clean centrifuges ("shooting frequency") should not be underestimated. Correct choice and adjustment of the regulating screws and/or the grav-ity discs are of special importance for effi cient water removal. The centrifuge manual states the disc or screw adjustment which should be chosen on the basis of the specifi c gravity of the fuel.

Normal practice is to have at least two centrifuges available for fuel cleaning. Results from experimen-tal work on centrifuges, treating today's qualities of residual fuel, have shown that the best cleaning ef-fect, especially as regards removal of catalyst fi nes, is achieved when the centrifuges are operated in series, in purifi er/clarifi er mode.

Therefore series operation of centrifuges to ensure maximum safety is a fully accepted alternative to the previously recommended parallel operation, provided the operating capacity of each individual centrifuge can handle the total amount of fuel required by the engine, without exceeding the fl ow rate recommended by the centrifuge maker for the operating mode in question.

If the centrifuge capacity installed is on the low side, corresponding to the specifi c viscosity of the fuel oil used, and if more than one centrifuge is avail-able, parallel operation may be considered in order to obtain an even lower fl ow rate. However, in view of the above results and recommendations serious consideration should be given to installing new equip-ment in accordance with today's fuel qualities and fl ow recommendations.

Table 1. Cleaning of HFO.

Operatingoptions

Normal conditions

Extremeconditions

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15

30

200

60

400

80

600

180

1500

380

3500

600

6000

25 45

100

13075

cST/50°C

sec. RI/100°F

cSt/80°C

Log scales

212

194

176

158

140

122

104

100

100

90

80

80

70

60

60

50

40

40

°C°F

Separation Temperature

20

%

Related to Rated Capacity of Centrifuge

Flow Rate

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Fuel Oil Cleaning DescriptionPage 2 (2)

General

Fig. 1 Flow rate through centrifuge related to nominal capa- city of centrifuge.

To determine centrifuging capacity we generally advise to follow the recommendations of the cen-trifuge maker, but the curves in fi g. 1, can be used as a guideline.

A homogenizer may be installed in the fuel oil sys-tem as a supplement to the centrifuges in order to homogenize possible water and sludge still present in the fuel after centrifuging.

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DescriptionPage 1 (5) Freshwater System Treatment 504.40

Edition 02

General

00.11- ES1

Cleaning agents emulsifi ed in water as well as slight ly alkaline cleaning agents can be used for the de grea-sing process, whereas ready-mixed cleaning a gents which involve the risk of fi re must obviously not be used. For descaling with acid, especially products based on amino-sulphonic acid, citric acid, and tar-taric acid are recommendable, as these acids are usually obtainable as solid substances, easily soluble in water, and do not emit poisonous vapours.

The cleaning agents should not be directly admixed, but should be dissolved in water and then added to the cooling water system.

Normally, cleaning can be executed without any dis-mantling of the engine. We point out that the water should be circulated in the engine to achieve the best possible result.

As cleaning can cause leaks to become apparent in poorly assembled joints or partly defective gaskets, inspection should be carried out during the cleaning process. The acid content of the system oil should also be checked immediately after cleaning, and 24 hours afterwards.

Cooling Water - Inhibitors

The fi lling-up with cooling water and the admixture of the inhibitor is to be carried out directly after the clea ning in order to prevent formation of rust on the cleaned surfaces.

Raw Water

The formation of lime stone on cylinder liners and in cylinder heads may reduce the heat transfer, which will result in unacceptably high temperatures in the material.

Therefore, it is recommended that deionized or di stil-led water (for example from the freshwater genera-tor) is used as cooling water. However, on account of its lack of hardness, this water will be relatively corro sive, and a corrosion inhibitor should therefore al ways be added.

Protection against Corrosion in Freshwater Cooling System

The engine fresh water must be carefully treated, maintained and monitored so as to avoid corrosion or the formation of deposits which can result in insuf-fi cient heat transfer, it is necessary to treat the cooling wa ter. MAN B&W recommend that this treatment is car ried out according to the following procedure:

– Clean the cooling water system.

– Fill up with deionized or distilled cooling water (for example from the freshwater generator) with corrosion inhibitor added.

– Carry out regular checks of the cooling water system and the condition of the cooling wa-ter.

Observance of these precautions, and correct ven ting of the system, will reduce service diffi culties caused by the cooling water to a minimum.

Cleaning of the Cooling Water System

Before starting the inhibition process, any existing deposits of lime or rust, or any oil sludge, should be removed in order to improve the heat transfer and to ensure uniform protection of the surface by means of the inhibitor.

The cleaning should comprise degreasing to remove oil sludge, and descaling with acid afterwards to remove rust and lime deposits.

Ready-mixed cleaning agents, specially made for cleaning the cooling water system, can be obtained from companies specializing in cooling water treat-ment. These companies offer assistance and con trol of the treatment in all major ports. A number of these companies are mentioned on the enclosed list. We point out that the directions given by them should be closely followed. It is of particular importance to fl ush the system completely after cleaning.

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DescriptionPage 2 (5)Freshwater System Treatment504.40

Edition 02

General

00.11- ES1

If deionized or distilled water cannot be obtained, nor mal drinking water can be used in exceptional cases. If so, the total hardness of the water must not exceed 9° dH (German hardness degrees). The chlo ride, chlorine, sulphate, and silicate contents are also to be checked. These contents should not ex ceed the following values:

Chloride 50 ppm (50 mg/litre) Chlorine 10 ppm (10 mg/litre) Sulphate 100 ppm (100 mg/litre) Silicate 150 ppm (150 mg/litre)

There should be no sulphide and ammonia con tent. Rain water must not be used, as it may be heavily contaminated.

It should be noted that softening of water does not reduce its sulphate and chloride contents.

Corrosion Inhibitors

To protect freshwater cooling systems in marine diesel engines against corrosion, various types of in hibitors are available.

Generally, only nitrite-borate based inhibitors are recommended.

A number of the products marketed by major compa-nies are specifi ed on the enclosed list, together with the necessary dosages and admixing procedures. We recommend that these directions are strictly ob served.

Treatment of the cooling water with inhibting oils is not recommended, as such treatment involves the risk of oil adhering to the heat transmitting surfaces.

Chromate inhibitors must not be used in plants connected to a freshwater generator.

Evaporated cooling water is to be replaced with non inhibited water, whereas a loss of water through leakage must be replaced with inhibited water.

When overhauling individual cylinders, a new dosage of inhibitor must, if necessary, be added im-mediate ly after completing the job.

Checking of the Cooling Water System and the Cooling Water during Service

If the cooling water is contaminated during service, sludge or deposits may form. The condition of the cooling water system should therefore be regularly checked, especially if deionized or distilled water is not used. If deposits are found in the cooling spa ces, these spaces or, if necessary, the entire system should be cleaned.

According to experience, a zinc galvanized coating in the freshwater cooling system is often very sus cep-tible to corrosion, which results in heavy for mation of sludge, even if the cooling water is cor rectly inhibited. The initial descaling with acid will, to a great extent, remove the galvanized coa ting. Generally, therefore, we advise against the use of galvanized piping in the freshwater cooling sys tem.

The quality of the cooling water is to be checked re-gularly, if possible once a week. Basically the in hi bitor concentration, the pH value and the chlori de con cen-tration should be in accordance with limits sta ted by inhibitor manufacturer. For this purpose the in hi bitor manifactures normally supply simple test kits.

As a general guidance values the pH value should be 7-10 measured at 20° C and the chloride concentra-tion should not exceed 50 ppm (50 mg/litre).

The water sample for these tests is to be taken from the circulating system, and not from the expansion tank or the pipe leading to it.

The concentration of inhibitor must under no circumstances be allowed to fall below that re commended by the producer, as this would in crease the risk of corrosion.

A clear record of all measuring results should be kept, so that the actual condition and trend of the sys tem may be currently ascertained and evaluated.

A sudden or gradual increase in the chloride con tent of the cooling water may be indicative of salt water leakages. Such leakages are to be traced and repai-red at the fi rst opportunity.

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DescriptionPage 3 (5) Freshwater System Treatment 504.40

Edition 02

General

00.11- ES1

A chloride content in the cooling water higher than the 50 ppm specifi ed might, in exceptional cases be tolerated. However, in that case the upper limit speci fi ed by the individual inhibitor supplier must not be exceed.

A clear record of all measuring results should be kept, so that the actual condition and trend of the sys tem may be currently ascertained and evaluated.

A sudden or gradual decrease in pH value, or an in crease of the sulphate content, may indicate ex-haust gas leakage. The pH value can be increased by adding inhibtor; however, if major quantities are ne cessary, the water should be replaced.

Every third month a cooling water sample should be sent ashore for laboratory analysis, in particular to ascertain the contents of inhibtor, sulphate, and iron, as well as the total salinity of the water.

Cleaning and Inhibiting Procedure

The engine must not be running during the cleaning procedure, as this may involve the risk of overhea ting when draining.

Degreasing

Use clean tap water for fi lling-up. The cooling water in the system can be used, if it does not contain inhibitors.

Heat the water to 60° C and circulate the water con tinuously.

Drain to lowest water level in expansion tank.

Add the amount of degreasing chemical specifi ed by the supplier, preferably from the suction side of the freshwater pump.

Drain to lowest water level in the expansion tank directly afterwards.

Circulate the cleaning chemical for the period speci-fi ed by the supplier.

The cooling water system must not be kept under pressure.

Check, and repair any leaks.

Drain the system and fi ll up completely with clean tap water, in order to fl ush out any oil or grease from the tank.

Circulate the water for 2 hours, and drain again.

Descaling with Acid Solution

Fill up with clean tap water and heat to 70-75° C.

Dissolve the necessary dosage of acid compound in a clean iron drum with hot water.

Fill the drum half up with water and slowly add the acid compound, while stirring vigorously. Then fi ll the drum up completely with hot water while conti nuing to stir (e.g. using a steam hose).

Be careful - use protective spectacles and gloves.

For engines which have been treated before the trial trip, the lowest concentration recommended by the supplier will normally be suffi cient.

For untreated engines, a higher concentration - de-pending on the condition of the cooling system - will normally be necessary.

Drain some water from the system and add the acid solution via the expansion tank.

The cooling water system must not be put under pressure.

Keep the temperature of the water between 70° C and 75° C, and circulate it constantly. The duration of the treatment will depend on the degree of foul-ing. Normally, the shortest time recommended by the supplier will be suffi cient for engines which are treated before the trial trip. For untreated engines, a longer time must be reckoned with. Check every hour, for example with pH-paper, that the acid in the solution has not been used up.

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DescriptionPage 4 (5)Freshwater System Treatment504.40

Edition 02

General

00.11- ES1

A number of descaling preparations contain colour indicators which show the state of the acid solution. If the acid content is exhausted, a new acid solution can be added, in which case, the weakest recom-mended concentration should be used.

The solubility of acids in water is often limited. There fore if, in exceptional cases, a large amount is re quired, descaling can be carried out in two stages with a new solution of compound and clean water. Normally the supplier will specify the maximum solubility.

After completing the descaling, drain the system and fl ush with water. Acid residues can be neutralized with clean tap water containing 10 kg soda per ton of water. Circulate the mixture for 30 minutes, then drain and fl ush the system.

The cooling water system must not be put under pressure.

Continue to fl ush until water used is neutral (pH approx. 7).

Adding of Inhibitors

Fill up the cooling water system with water from the evaporator to the lowest water level in the expan-sion tank.

Weight out the quantity of inhibitors specifi ed by the supplier and dissolve in a clean iron drum with hot water from the evaporator.

Add the solution via the expansion tank to the system. Then fi ll up to normal water level with water from the evaporator.

Allow the engine to run for not less than 24 hours to ensure that a stable protection of the cooling surfa-ces is formed.

Subsequently, test the cooling water with a test kit (available from the inhibitor supplier) to ensure that an adequate inhibitor concentration has been obtai ned.

This should be checked every week.

The acid content of the system oil is to be checked directly after the descaling with acid, and again 24 hours afterwards.

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DescriptionPage 5 (5) Freshwater System Treatment 504.40

Edition 02

General

00.11- ES1

Company

Castrol LimitedSwindonWiltshire, England

Drew AmeriodMarineBoonton, N.J./U.S.A

Houseman Scandinavia3660 StenløseDenmark

Nalfl eet Marine ChemicalsNorthwich,Cheshire CW8DX, England

Rohm & Haas(ex Duolite)Paris, France

Unitor RochemMarine ChemicalsOslo, Norway

CastrolSolvex WT4CastrolSolvex WT2

DEWT-NCLiquidewtMaxiguard

Cooltreat 651

Cooltreat 652

Nalfl eet EWT Liq(9-108)Nalfl eet EWT 9-131CNalfl eet EWT 9-111Nalcool 2000

RD11 DIA PROSIMRD25 DIA PROSIM

Dieselguard NBRocor NB Liquid

Powder

Liquid

PowderLiquidLiquid

Liquid

Liquid

LiquidLiquidLiquidLiquid

PowderLiquid

PowderLiquid

3 kg/1000 l

20 l/1000 l

3.2 kg/1000 l8 l/1000 l16 l/1000 l

5 l/1000 l

5 l/1000 l

3 l/1000 l10 l/1000 l10 l/1000 l10 l/1000 l

3 kg/1000 l50 l/1000 l

3 kg/1000 l10 l/1000 l

Name of Inhibitor Delivery Form

* Initial dosage may be larger

The list is for guidance only and must not be consid-ered complete. We undertake no responsibility for diffi culties that might be caused by these or other water inhibitos/chemicals.

The suppliers are listed in alpabetical order.

Suitable cleaners can normally be supplied by these fi rms.

Maker's minimum Recommended

Dosage*

Nitrite-borate corrosion inhibitorsfor cooling water treatment

Cylinder head

505/605

MAN Diesel

DescriptionPage 1 (1) Cylinder Head 505.01

Edition 01H

Cylinder Head

The individual cast-iron cylinder heads, one for each cylinder unit, are equipped with a centrally situated fuel injection valve, two inlet valves, two exhaust valves and one indicator cock.

The head has a thick, bore-cooled fl ame plate for satisfactory control of mechanical and thermal loads and stress.

The cylinder head is attached by means of 4 nuts and 4 studs screwed into deep bosses in the engine frame top plate. The nuts are tightened by means of hydraulic tools.

95.50 - ES0U-G

L23/30H

Inlet and Exhaust Valves

The inlet and exhaust valve spindles are identical and therefore interchangeable.

The valve spindles are made of heat-resistant ma-terial. Hard metal is welded on to the valve spindle seats.

The valve spindles are fi tted with valve rotators which turn the spindles a little each time the valves open.

The cylinder head is equipped with replaceable seat rings for inlet and exhaust valves.

The seating surfaces are hardened in order to mi-nimize wear and prevent dent marks, on the inlet seat by induction hardening, on the exhaust seat by hard metal armouring.

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Safety precautions:

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

Description:

Dismantling of cylinder head for inspection and/or overhaul.

Starting position:

Cooling water has been drained from engine.

Related procedure:

Dismounting of piston and connecting rod 506-01.00Dismounting and inspection of inlet valve, exhaust valve and valve guide 505-01.05Dismantling, overhaul and testpressure of fuel oil valve 514-01.10

Manpower:

Working time : 1 hourCapacity : 2 men

Data:

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

505-01.00Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52021 011 Oil injector, 52021 011 (Complete) 52021 501 4 pieces 52021 513 1 piece 52021 155 52005 014 52021 251 Hydraulic tools

Hand tools:

Ring and open-end spanner, 17 mm.Ring and open-end spanner, 19 mm.Ring and open-end spanner, 27 mm.Allen key, 8 mm.

Replacement and wearing parts:

Plate no Item no Qty/

Dismantling of Cylinder HeadWorking CardPage 1 (2)

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L23/30H

Draining of cooling water, disconnection of pipes etc.

1) Open the drain cock and vent cock for cool-ing water.

2) Take off the top cover.

3) Take off the front cover which gives access to the injection pump.

4) Disconnect the fuel oil high-pressure pipe.

5) Disconnect the rocker arm lubricating oil pi-pe.

6) Remove the thermometer attachment bran-ch (cooling water outlet pipe).

7) Remove the exhaust pipe fl ange screws.

8) Remove the cylinder head nuts, see Fig 1, by means of hydraulic jacks. See working card 520-01.05.

Fig 2

Fig 1

Mounting of Lifting Tool while the Fuel Injection Valve is Placed in the Cylinder Head.

9) Disconnect the two nuts which is holding down the fuel injection valve.

10) Remove the two distance pieces.

11) Mount the lifting tool by means of the two nuts. See Fig 2.

Mounting of Lifting Tool with the Fuel Injection Valve is Removed from the Cylinder Head.

12) Mount the two-distance pieces to the studs.

13) Mount the lifting tool by means of the two nuts. See Fig 3.

Fig 3

Dismantling of Cylinder HeadWorking Card

Page 2 (2)

14) Attach the hook to the lifting tool and lift the cylinder head away.

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Safety precautions:

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

Description:

Dismounting of inlet and exhaust valve, inspec-tion of valve guide and mounting of inlet and exhaust valve.

Starting position:

Cylinder head, dismantled from engine 505-01.00

Related procedure:

Reconditioning of valve spindle seat and valve seat ring 505-01.10Valve rotator 505-01.15Replacement of valve guide 505-01.20Replacement of valve seat ring 505-01.35Mounting of cylinder head 505-01.45

Manpower:

Working time : 1 hourCapacity : 1 man

Data:

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

95.50 - ES0S

Special tools:

Plate no. Item no. Note.

52005 014 52005 051 52005 254/301 Extra tools 52005 553

Hand tools:

Ring and open-end spanner, 24 mm.Small screwdriver.Measuring tools.

Replacement and wearing parts:

Plate no Item no Qty/

60501 363 4/cyl.

505-01.05Edition 01HInspection of Inlet Valve, Exhaust Valve and Valve GuideWorking Card

Page 1 (3)

L23/30H

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505-01.05Edition 01H

Working CardPage 2 (3)

Dismantling of Inlet and Exhaust Valve Spind-les

1) Land and fasten the cylinder head upon the spe cial work table and remove the lifting tool.

Or as an Alternative:

Land the cylinder head on the fl oor upon wood en supports and remove the lifting tool.

2) Mount the supporting devices for the valve spindle heads on the work table.

Or as an alternative:

Place wooden blocks under the valve spindle heads.

3) Turn back the rocker arm and remove the

Inspection of Inlet Valve, Exhaust Valve and Valve Guide

Fig 2.

9) Remove valve rotator and springs.

10) Remove the supporting devices under the work table and take out the valve spindle.

11) Repeat point 4 - 10 to remove the two other valve spindles.

Inspection of Valves/Valve Seats

A slight grinding of valve/valve seat can be carried out by means of the handle as shown, see fi g 3.

If the valve seat is heavily burnt or scarred, it should be ground using the valve seat grinder, see working card 505-01.10.

95.50 - ES0S

A

B

Fig 1.

spring-loaded valve bridge over the valve spind-les.

4) Mount the tool for mounting af valves, see fi g 2.

5) Compress the valve springs by tightening nut A, see fi g 1.

6) Remove the cone rings, see fi g 2.

7) Release the springs again.

8) Remove nut A and traverse B, see fi g 1.

Fig 3.

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95.50 - ES0S

L23/30H

Inspection of Inlet Valve, Exhaust Valve and Valve GuideWorking CardPage 3 (3)

505-01.05Edition 01H

Inspection of Valve Guide

Too much clearance between valve spindle and spindle guide may cause:

- in creas ed lub. oil consumption. - fouling up of the spindle guide and thus give

the risk of a sticking valve spindle.

Too much clearance also means in suf fi cient guid-ance of the valve spindle, and thus bad alignment between spind le head and valve seat ring.

In con nec tion with overhaul of the cylinder head, the valve spindle guides should be cleaned, inspected and measured for wear.

If the inner diameter of the valve spindle guide exceeds the tolerance, see page 500.35, the valve spindle guide must be replaced. See working card 505-01.20.

Mounting of Valve Spindle

12) For mounting of valve spindle follow the in-structions in point 4 - 10 in reversed order.

Max inner diameter,see page 500.35.

Fig 4.

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Safety precautions:

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

Description:

Reconditioning of valve spindle seat and valve seat ring, with special grinding machine.

Starting position:

Valve spindle has been removed 505-01.05

Related procedure:

Mounting of valve spindle 505-01.05

Manpower:

Working time : 6 hoursCapacity : 1 man

Data:

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

505-01.10Edition 01H

95.50 - ES0S

L23/30H

Working CardPage 1 (3)

Special tools:

Plate no Item no Note

52005 408 Grinding machine for valve spindle. 52005 350 Grinding machine for valve seat ring (extra tools).

Hand tools:

All the hand tools and new stones are included in the tools box for grinding machine.

Replacement and wearing parts:

Plate no Item no Qty/

Reconditioning of Valve Spindle Seatand Valve Seat Ring

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Reconditioning of Valve Seat Ring

Reconditioning of valve seat rings by machining is carried out by means of a grinding machine, the pilot spindle of which is to be mounted in the valve spindle guide. For operation of the grinding machine, see separate instructions.

Grinding of Valve Seats

Grinding of valve seat rings should be carried out according to the following sequence:

1) Grind the seating surface with a feed at an angle "A" of 30° ± 0,10°.

2) Continue the grinding until a clean and uniform surface condition has been obtained.

3) Carry out the fi nal grinding with a feed in the direction inside and outwards. Normally, the best surface quality is obtained this way.

L23/30H

505-01.10Edition 01H

Working CardPage 2 (3)

Reconditioning of Valve Spindle Seatand Valve Seat Ring

0.

"A" 30 ± 0,10°

"R"0

"S"

Fig 1. Valve Seat Ring

Scrapping of Valve Seat Rings

Normally, the valve seat ring can be re con di tion ed several times.

However, when the seat "S" has been ground to such an extent that the recess "R" disappears, see fi g 1, the valve seat ring has to be scrapped and a new one must be installed, see working card 505-01.35

Reconditioning of Valve Spindle

Reconditioning by machining is carried out with the valve spindle being rotated in a turning lathe and a special grinding machine mounted on the tool post of the turning latch.

Grinding of Valve Spindle

For operation of the grinding machine, see se pa ra-ted instructions.

1) Grind the seating surface with a feed at an angel "A" of 30° ± 0.

2) Continue the grinding until a clean and uniform surface condition has been obtained.

3) Check the height "H"1 after completing the grinding, see fi g 2.

"H"1 has as a minimum to be as indicated on page 500.35.

If measured to be less, the spindle has to be scrap-ped.

0,25°.

"H"1

"A" 30° ± 00,25°

Fig 2. Valve Spindle

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505-01.10Edition 01H

L23/30H

Working CardPage 3 (3)

Reconditioning of Valve Spindle Seatand Valve Seat Ring

Fig 3.

"H"2

4) After assembling the valves, check - on account of the valve motion - that distance "H"2 between the upper edge of the cylinder head and the upper edge of the valve spindle, see fi g 3, does not exceed the maximum value, see page 500.35.

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Safety precautions:

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

Description:

Dismantling, inspection and mounting of valve rotator.

Starting position:

Valve spindle has been removed 505-01.05

Related procedure:

Mounting of valve spindles 505-01.05

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

505-01.15Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52005 051

Hand tools:

Small screwdriver.Ring and open-end spanner 24 mm.

Replacement and wearing parts:

Plate no Item no Qty/

Valve RotatorWorking CardPage 1 (2)

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L23/30H

Inspection of Rotocap

Dirt especially in the ball pockets due to residues in the oil (abrasives, combustion products), can cause the individual parts to become stuck, and hinders the movement of the balls.

Rotocap valve rotators need no servicing under normal operating conditions.

Rotator performance is satisfactory when the valve rotates visibly and evenly.

Dismantling of Rotocap

See working card 505-01.05, point 3 to 9.

Overhaul of Rotator

1) Clean the valve rotator.

2) Inspect for wear and ball impressions.

3) Remove the retaining ring and disassemble the individual parts.

4) Replace parts showing wear grooves or de-pressions formed by the balls.

5) Insert the balls and the tangential springs.

Note! All balls on the inclined races of the ball pockets must point in the same direction, see fi g. 1.

The inner ring of the spring washer should rest on the retainer body.

95.50 - ESOS

5 05-01.15Edition 01H Valve Rotator Working Card

Page 2 (2)

Fig 1.

Note! Having assembled the valve rotator in dry condition it should be placed in clean lubricating oil for a short period of time.

Mounting of Rotocap

See working card 505-01.05, point 3 to 9, opposite direction.

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Safety precautions:

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

Description:

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

Starting position:

Valve spindle has been removed 505-01.05

Related procedure:

Mounting of valve spindles 505-01.05

Manpower:

Working time : 3/4 hourCapacity : 1 man

Data:

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

505-01.20Edition 01H

Special tools:

Plate no Item no Note

Hand tools:

Hammer.Nitrogen (N2), or similar.Mandrel for knocking out the valve guide.

Replacement and wearing parts:

Plate no. Item no. Qty/

50501 363 4/cyl 50501 218 4/cyl

Working CardPage 1 (2) Replacement of Valve Guide

95.50 - ES0S

L23/30H

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L23/30H

505-01.20Edition 05H

Working CardPage 2 (2)

When to Replace the Valve Guide

If the clearance exceeds the max. limit, see page 500.35, the valve guide must be replaced.

Dismounting of Valve Guide

1) Knock the valve guide out from the bot tom of the cylinder head, by means of a mandrel, which has a shoulder turning that fi ts into the valve guide, see fi g 1.

4) Before mounting - cool down the new valve guide to approx. -70°C with nitrogen or similar.

5) Insert the valve guide into the bore.

6) Knock slightly with the mandrel and a ham-mer.Note! The shoulder of the valve guide must bear against the cylinder head, by knocking slightly with the mandrel and a hammer.

Replacement of Valve Guide

Valve guide

Mandrel

Valve seat ring

Fig 1.

2) Clean the bore of the cylinder head carefully.

3) Inspect for marks that can prevent mounting of new valve guide.

Fig 2.

7) Before mounting of the valve spindle insert a new O-ring in the valve guide.

Correct mounting can easily be done by the use of two valve spindles as mounting tool, one spindle to be used as support and the other spindle to be used for pushing the O-ring downwards.

Screw-drivers or other sharp tools should never be used for this purpose.

8) For mounting of valve spindle, see working card 505-01.05.

95.50 - ESOS

MAN Diesel

Safety precautions:

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

Description:

Dismounting, inspection and mounting of indi-cator valve.

Starting position:

Related procedure:

Man power:

Working time : 1/2 hourCapacity : 1 man

Data:

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

505-01.26Edition 01H

95.50 - ES0S-G

L23/30H

Indicator ValveWorking CardPage 1 (2)

Special tools:

Plate No Item No Note

Hand tools:

Ring and open-end spanner 10 mmRing and open-end spanner 27 mmSteel brushCopaslip

Replacement and wearing parts:

Plate No Item No Qty./

50508 037 1/Cyl.

MAN Diesel

L23/30H

95.50 - ES0S-G

505-01.26Edition 01H Indicator Valve Working Card

Page 2 (2)

Maintenance

Under normal working conditions the indicator valve requires very little maintenance except inspection in connection with the normal cylinder cover over-haul.

Inspection of the Indicator Valve

1. Disassemble the indicator valve.

2. Check the valve seat and the cone for "burning through".

If the valve seat in the housing is "burned", the entire valve is to be replaced.

3. Clean and lubricate all components before remounting.

4. Ensure that the spindle is in "OPEN" position when assembling the valve.

NOTE: Otherwise, cone and seat may be dama-ged.

1. Indicator valve, complete 2. Connecting piece

Fig 1 Indicator valve.

MAN Diesel

Safety precautions:

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

Description:

Dismounting, inspection and mounting of sleeve for fuel injector.

Starting position:

The cylinder head has been dis-mounted from engine 505-01.00The fuel injector has been removed 514-01.10

Related procedure:

Mounting of fuel valve 514-01.10

Man power:

Working time : 1 hourCapacity : 1 man

Data:

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

505-01.30Edition 01H

96.19 - ES0S

L23/30H

Special tools:

Plate No Item No Note

Hand tools:

Brass mandrel.Hammer.Lub. oil.Two small screw-drivers.Loctite 572.

Replacement and wearing parts:

Plate No Item No Qty/

50501 039 1/cyl. 50501 040 1/cyl. 50501 052 1/cyl.

Replacement of Sleeve for Fuel InjectorWorking CardPage 1 (2)

MAN Diesel

L23/30H

96.19 - ES0S

505-01.30Edition 01H Replacement of Sleeve for Fuel Injector Working Card

Page 2 (2)

Dismounting of Sleeve for Fuel Injector

1) Remove the snap ring by means of two screw-drivers.

2) The sleeve can now be driven out of the bo-re by use of a brass mandrel and a hammer.

Fig 1.

4) Coat the sealing ring zone in the bore with grea se or lub. oil.

Fig 2.

5) Install new sealing rings on the sleeve.

6) Coat the sealing surfaces on the sleeve with loctite 572.

7) Insert the sleeve in the bore.

8) Mount the snap ring.Inspection of Bore in Cylinder Head and Mount-ing of the Sleeve:

3) Clean and inspect the bore in the cylinder head. Any marks which could pre vent mounting of the sleeve, should be gent ly smoothed.

Brass mandrel

Snap ring

O-ring

Sleeve

Loctite 572

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Replacement of valve seat ring for inlet and exhaust valve.

Starting position:

Inlet and exhaust valves have beenremoved 505-01.05

Related procedure:

Mounting of valve spindles 6505-01.05

Man power:

Working time : 1 1/2 hoursCapacity : 1 man

Data:

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

505-01.35Edition 01H

05.02 - ES0

L23/30H

Special tools:

Plate no Item no Note

52021 011 52021 501 1 piece 52005 457 Extra tools 52005 504 Extra tools 52021 466 1 piece

Hand tools:

Ring and open-end spanner, 36 mmHammer.Loctite, 572.Lub. oil.

Replacement and wearing parts:

Plate no Item no Qty. /

50501 351 4/cyl. 50501 064 2/cyl. 50501 076 2/cyl.

Replacement of Valve Seat RingWorking CardPage 1 (4)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

505-01.35Edition 01H Replacement of Valve Seat Ring Working Card

Page 2 (4)

Dismounting of Valve Seat Rings

When reconditioning of a valve seat ring no longer is possible due to dimensions exceeding the scrapping criteria, the seat ring has to be replaced.

Dismounting of a valve seat ring is carried out by means of a special extractor tool set comprising the components, see fi g 1.

Dismounting of a Valve Seat Ring is Carried out According to the Following Procedure

1) By means of the guide pin (7) the guide disc (5) is led vertically through the valve seat ring. Then the guide disc (5) is lifted with the guide pin (7) until the latter is guided by the valve seat ring. The stud (1) is then screwed in until it rests in the valve guide.

Fig 1.

Fig 2.

2) The guide disc (3) is positioned so that it bears against the bottom of the cylinder head, and the hydraulic jack is clamped with the disc (4) and the collar nut hexagon (2), see fi g 1. The hydraulic jack is the one used for main bearing caps.

05.02 - ESO

1 Stud 6 Eye screw 2 Collar nut hexagon 7 Guide pin 3 Guide disc 8 Valve guide 4 Disc 9 Hydraulic jack 5 Guide disc 10 Valve seat ring

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

505-01.35Edition 01H

L23/30H

Replacement of Valve Seat RingWorking CardPage 3 (4)

3) By pumping up the pack, see working card 520-01.05 for the use of hydraulic tools, the valve seat is pressed out max. 6 mm, and the pressure is released again. The collar nut hexagon is tightened and the operation is continued until the valve seat ring can be removed.

Mounting of Valve Seat Rings

1) Prior to mounting of a new valve seat ring, the bore must be cleaned thoroughly and inspected for marks. Marks that can hinder mounting of the valve seat ring must be removed.

2) Tools for mounting of valve seat rings are shown in fi g 3.

3) To facilitate mounting the valve seat ring is it cooled down, however, a min. of -25°C otherwise, the o-ring can be damaged.

4) Place the o-ring on the valve seat ring and coat with oil/loctite as shown in fi g 4, just before positioning it in the bore.

Fig 4.

Coat with loctite 572

Valve seat ring

O-ring

Fig 5.

5) The valve seat ring is positioned in the bore, the handle with stud is inserted as shown in fi g 5, and the washer with screw is screwed tight.

1 Handle 2 Stud

2

1

Coat with oil

Fig 3.

05.02 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

6) By knocking on the handle and at the same time tightening the nut (4), the valve seat ring slides in place in the bore and it is felt on the knocks when it bears in the bore.

7) Prior to mounting of the valve spindle the valve seat ring must be ground, to ensure correct centering af the valve guide and the valve seat ring. This can be done according to working card 505-01.05 or 505-01.10.

L23/30H

505-01.35Edition 01H Replacement of Valve Seat Ring Working Card

Page 4 (4)

05.02 - ESO

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Mounting of cylinder head after inspection and/or overhaul.

Starting position:

Cylinder head is completely assembled 505-01.05 to 505-01.35Valve gear of respective cylinder is in right posi-tion (valve closed)Control of the surface on the cylinder liner 506-01.45

Related procedure:

Adjustment of valve clearance 508-01.10

Manpower:

Working time : 1 1/2 hourCapacity : 2 men

Data:

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

505-01.40Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52021 011 52021 501 4 Pieces 52021 155 52005 014 52010 011 52021 251

Hand tools:

Ring and open-end spanner, 14 mm.Ring and open-end spanner, 17 mm.Ring and open-end spanner, 24 mm.Lub. oil and copaslip.

Replacement and wearing parts:

Plate no Item no Qty/

50501 338 2/cyl 50510 075 1/cyl 50610 079 8/cyl 51202 024 2/cyl 51625 097 1/cyl 51625 132 1/cyl

Mounting of Cylinder HeadWorking CardPage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Check to be Done before Lifting

1) Check the jointing surfaces of the cylinder head/cylinder liner to see that they are clean and without damage marks, see working card 506-01.45. Fit new O-rings on the water passage, lubricate the O-rings with a little oil.

2) Check all contact faces on the cylinder head and nuts, including threads, and make sure that these are level and smooth and absolutely free from foreign particles.

Mounting of Cylinder Head

3) Attach the lifting tool, see fi g 1, to the cylinder head that has been made ready for installation, and position it carefully on the cylinder liner.

95.50 - ES0S

505-01.40Edition 01H Mounting of Cylinder Head Working Card

Page 2 (2)

Place the spacer ring around the nuts with the slot insuch a position that the tommy bar can be used.

Tighten the hydraulic jacks and make sure that the cylinder of the jacks bears fi rmly against the spacer ring. Tighten up all the nuts, see page 500.40. For using the hydraulic tools, see working card 520-01.05.

Fig 1.

Tightening of Cylinder Head Nuts

4) Make sure that the nuts run easily on the threads and that they bear on their entire contact surfaces.

5) Coat threads and contact faces with copaslip before fi tting the nuts.

6) Screw nuts onto the studs and tighten lightly with the tommy bar.

Fig 2.

7) If new studs or nuts have been fi tted, the nuts must be tightened and loosened three times, in order to compensate for deformation of the thread and in order to ensure a safe minimum load of the studs through the tightening.

Adjustment of Valve Clearance

8) Adjust the valve clearance, see working card 508-01.10.

9) Fit the pipes for fuel oil, lub. oil, cooling water and the fl ange for exhaust pipe.

Before Starting

10) Prior to starting up check for leakages. After starting up check for leakages and oil fl ow.

11) Mount the cover for rocker arm and the front cover for fuel pump.

MAN Diesel

Safety precautions:

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

Description:

Inspection of cylinder head cooling water space.

Starting position:

The cylinder head dismantledfrom engine 505-01.00

Related procedure:

Manpower:

Working time : ¼ hourCapacity : 1 man

Data:

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

95.50 - ES0S

Special tools:

Plate no Item no Note

Hand tools:

Steel brush

Replacement and wearing parts:

Plate no Item no Qty/

Working CardPage 1 (2)

L23/30H

Inspection of Cylinder Head Cooling Water Space 505-01.45Edition 01H

MAN Diesel

Working CardPage 2 (2)

Inspection of Cylinder Head Cool. Water Space

1) Inspect the cooling water inlet at the bottom and the cooling water outlet at the top of the cylinder head, see fi g 1.

2) Remove all possible deposits.

3) Pour water into the cooling water outlet and make sure that water is coming out of all the cooling water inlet bores at the bottom of the cylinder head.

4) If necessary, clean the cooling water inlet and outlet by means of a steel brush. Flush the cooling water space after cleaning.

5) Should the cylinder head cooling water space, contrary to expectation, be blocked with deposits, please contact MAN B&W Diesel, Holeby for further instructions.

Inspection of Cylinder Head Cooling Water Space

L23/30H

505-01.45Edition 01H

Fig 1. Cylinder Head

95.50 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Cylinder HeadPlatePage 1 (2)

07.32 - ES0

50501-10H

338

351123

111

159

135

231040

039

052

363

218

280292

267

279302

243

255

147

351

064

015

649

637

076

184

172

160

196

184

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Cylinderdæksel (som 649) monteret med bukke og vippearne.

Foring

O-ring

Låsering

Ventilsædering,(indstrømning)

Ventilsædering,(udstødning)

Propskrue

Tætningsring

Propskrue

Tætningsring

Fjederstift

Kølekappe

Skrue

O-ring

Kølevandsovergang

Ventilstyr

Tap

Afstandsstykke

Møtrik

Tap

Møtrik

Fjederstift

Tap

Trykstykke

O-ring

O-ring

Designation BenævnelseBenævnelseDesignation

L23/30H

Cylinder Head PlatePage 2 (2)

Item No.

Cylinder head (as 649) with brackets and rocker arms installed

Sleeve

O-ring

Snap ring

Valve seat ring,(inlet)

Valve seat ring,(exhaust)

Plug screw

Sealing ring

Plug screw

Sealing ring

Spring pin

Water guide jacket

Screw

O-ring

Cooling water con-nection

Valve Guide

Stud

Distance pipe

Nut

Stud

Nut

Spring pin

Stud

Thrust piece

O-ring

O-ring

015

039

040

052

064

076

111

123

135

147

159

160

172

184

196

218

231

243

255

267

279

280

292

302

338

351

1/C

1/C

1/C

1/C

2/C

2/C

2/C

2/C

8/C

8/C

2/C

1/C

4/C

8/C

4/C

4/C

2/C

2/C

2/C

2/C

2/C

1/C

3/C

2/C

2/C

4/C

Qty. Qty.

Item No.

07.32 - ES0

50501-10H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

363

637

649

O-ring

Cylinder head with valve guide sleeve for fuel valve and valve seat rings

Cylinder head (as 637) with valve spindles, spring and rotocap installed

O-ring

Cylinderdæksel mon-teret med spindelstyr, foring for br. ventil og ventilsæderinge

Cylinderdæksel (som 637), monteret med ventilspindler, fjeder og rotocap

4/C

1/C

1/C

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (2) Valve Spindles and Valve Gear

02.38 - ES0

50502-01H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

010

022

034

046

071

083

095

105

117

129

130

178

201

237

249

262

286

298

345

357

441

453

465

477

Designation BenævnelseBenævnelseDesignation

Valve bridge, compl. incl. item 022, 034, 046, 071, 083, 095, 105, 117, 129 and 130

Valve bridge

Spring

Ball guide

Thrust piece

Thrust screw

Nut

Thrust piece

Circlip

Thrust piece

Spring pin

Rocker armbracket

Plug

Rocker arm, exhaust, compl. incl. item 095, 249, 262, 286, 298, 585

Rocker arm, exhaust

Plug

Thrust piece

Thrust screw

Rocker arm inlet, com-plete incl. item 095, 249, 262, 286, 298, 585

Rocker arm, inlet

Disc

Securing ring

Conical ring in 2/2

Rotocap, compl.

Ventilbro komplet inkl. item 022, 034, 046, 071, 083, 095, 105, 117, 129 og 130

Ventilbro

Fjeder

Kuglestyr

Trykstykke

Trykskrue

Møtrik

Trykstykke

Fjederring

Trykstykke

Fjederstift

Buk for vippearm

Prop

Vippearm udst. komplet inkl. item 095, 249, 262, 286, 298 og 585

Vippearm, udstødning

Prop

Trykstykke

Trykskrue

Vippearm inds. komplet inkl. item 095, 249, 262 286, 298 og 585

Vippearm, indsugning

Skive

Sikringsring

Konisk ring 2/2

Rotationsgiver, kom-plet

Itemno.

Qty.

2/C

2/C

2/C

2/C

2/C

2/C

4/C

4/C

4/C

2/C

4/C

1/C

1/C

1/C

1/C

4/C

2/C

2/C

1/C

1/C

2/C

2/C

4/C

4/C

Qty.Itemno.

02.38 - ES0

50502-01H Valve Spindles and Valve Gear PlatePage 2 (2)

L23/30H

489

490

512

524

536

548

573

585

607

4/C

4/C

4/C

28/C

28/C

4/C

2/C

4/C

1/C

Inner spring

Outer spring

Valve spindle, inletand outlet

Spring

Ball

Spring washer

Bearing bush

Retainer ring

Rocker arm shaft

Indvendig fjeder

Udvendig fjeder

Ventilspindel, inds. og uds.

Fjeder

Kugle

Fjederskive

Lejebøsning

Låsering

Aksel for vippearm

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./C = Qty./CylinderQty./ = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/CylinderAntal/ = Antal/Individuelt

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

025

050

013

037

049

Handwheel for indicatorvalve, see plate 52005

L23/30H

PlatePage 1 (2) Indicator Valve

06.41 - ES0

50508-01H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

013

025

037

049

050

Designation BenævnelseBenævnelseDesignation

Connecting piece

Gasket

Gasket

Indicator valve

Insulation glove

Forbindelsesstykke

Gasket

Gasket

Indikatorventil

Beskyttelseshætte

Item No.

Qty.

1/C

3/C

1/C

1/C

1/C

Qty.Item No.

06.41 - ES0

Indicator Valve PlatePage 2 (2)50508-01H

L23/30H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Cylinder Head, Top Cover

94.22 - ES0S

50510-01HPlatePage 1 (2)

087

063

075

038

122

014

026

099

110

051

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Karm

Pakning

Skrue

Fjederstift

Topdæksel

Pakning

Håndtag

O-ring

Møtrik

Skive

Coaming

Gasket

Screw

Spring pin

Top cover

Gasket

Handle

O-ring

Nut

Washer

Designation BenævnelseBenævnelseDesignation

014

026

038

051

063

075

087

099

110

122

1/C

1/C

13/C

4/C

1/C

1/C

3/C

3/C

3/C

13/C

Item No.

Qty.

Item No. Qty.

94.22 - ES0S

50510-01H PlatePage 2 (2)Cylinder Head, Top Cover

L23/30H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

Piston/connecting rod

506/606

MAN Diesel

DescriptionPage 1 (1) Piston, Connecting Rod and Cylinder Liner 506.01

Edition 01H

Piston

The piston, which is oil-cooled and of the monobloc type made of nodular cast iron, is equipped with 3 compression rings and 1 scraper ring.

By use of a combination of compression rings with different barrel-shaped profi les and chrome-plated running surface on all rings, the piston ring pack is optimized for maximum sealing effect and minimum wear rate.

The piston has a cooling oil space close to the piston crown and the piston ring zone. The heat transport, and thus the cooling effect are based on the sha-ker effect arising during the piston movement. Oil from the engine's lubricating oil system is used as cooling oil.

The piston is provided with a turned edge at the top due to the fl ame ring mounted in the cylinder liner.

Piston Pin

The piston pin is fully fl oating which means that it can turn freely in the pin bosses of the piston as well as in the connecting rod bush. The piston pin is turned in place upwords in axial direction by two circlips (seeger rings).

96.19 - ES0U

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

Connecting Rod

The connecting rod is die-forged. The big-end has an inclined joint in order to facilitate the piston and connecting rod assembly to be withdrawn up through the cylinder liner. The joint faces on the connecting rod and the bearing cap are serrated to ensure precise location and to prevent relative movement of the parts.

The big-end bearing is of the trimetal type, i.e. steel shells lined with tin-aluminium or lead-bronze coa-ted with a running layer. Designed as plain type or rillen type. The bearing shells are of the precision type and are therefore to be fi tted without scraping or any other kind of adaption.

The small-end bearing is of the trimetal type and is pressed into the connecting rod.

Cylinder Liner

The cylinder liner is made of fi ne-grained, pearlite cast iron and is fi tted in a bore in the engine frame. Repla-ceable cast iron sealing rings are fi tted between the liner and the cylinder head and be tween the liner and the frame. The liner is clamped by the cylinder head and is guided by a bore at the bottom of the cooling water space of the engine frame. The liner can thus expand freely downwards, when heated during the running of the engine. Sealing for the cooling water is obtained by means of silicone rubber rings which are fi tted in grooves machined in the liner.

The cylinder liner is of the socalled "stepped cylin-der" type, provided with fl ame ring inserted in the top of the liner.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Dismounting of piston and connecting rod as-sembly, for inspection and/or overhaul.

Starting position:

Cylinder head has been dismountedfrom engine 505-01.00Crankcase open.

Related procedure:

Separation of piston and connectingrod 506-01.05Inspection and honing of cylinder liner 506-01.35

Manpower:

Working time : 1 hourCapacity : 2 men

Data:

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

506-01.00Edition 01H

96.20 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 021 52006 033 52006 094 2 pieces 52006 224 52006 273 80-360 Nm 52010 011

Tool combination for dismounting of connecting rod screw, see working card 520-01.20.

Hand tools:

Threaded pin M12.Open-end spanner 24 mm.Wire.Scraper or similar.Small adjustable spanner.

Replacement and wearing parts:

Plate no Item no Qty/

Dismounting of Piston and Connecting RodWorking CardPage 1 (3)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

96.20 - ES0S

506-01.00Edition 01H Dismounting of Piston and Connecting Rod Working Card

Page 2 (3)

2) Remove the gangway, if any installed, in order to improve the access conditions.

3) Turn the crankshaft to bring the crank throw concerned into a position of approx. 50 degrees before TDC.

This position is identifi able by the connecting rod shaft being very close to the cylinder liner shirt, see fi g. 1.

4) Clean the threaded hole in the piston top, and mount the eye screw.

5) Mount the tube (for holding down the cylinder liner during the piston withdrawal) on one of the cylinder head studs, screw on the nut and tighten it slightly.

6) Attach a wire rope to the eye bolt by means of a shackle, hook the wire on to a tackle and pull the wire rope tight.

Note! If minor adjustments of the crank throw posi-tion appear necessary for access to the connecting rod screws, the wire rope must be slackened before turning of the crankshaft and tightened up again in the new crank throw position.

Preparations before Dismounting

1) Clean the upper part of the cylinder. If not, the piston may get stuck during removal in the carbon deposited in this area.

a) Turn the piston to the buttom.

b) Place a used piston ring on top of the piston.

c) Mount the tube (for holding down the cylinder liner during the piston withdrawal) on one of the cylinder head studs, screw on the nut and tighten it slightly.

d) Turn the piston in top, in order to push the fl ame ring out of the cylinder by means of the piston ring.

Info: It is the used piston ring which pushes the fl ame ring out of the cylinder.

Fig 2. Removal of bearing cap.Fig 1. Mounting of tools (placing).

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

506-01.00Edition 01H

96.20 - ES0S

L23/30H

Dismounting of Piston and Connecting RodWorking CardPage 3 (3)

Fig 3. Removal of upper big-end bearing shell.

Fig 4. Lift of piston and connecting rod assembly.

Dismounting of Bearing Cap

7) Unload the connecting rod screws and un screw one of the upper screws.

8) Mount the guide pin for the bearing cap in one of the threaded holes and fi t a screwdriver or similar in the hole in the guide pin, and unscrew the screws.

Note! The purpose of the guide pin is to prevent any damage of crank journal, joint faces or bearing sur face to occur during dismounting of the bearing cap, and to facilitate easy handling when removing the bearing cap from the crankcase.

9) Remove the screwdriver from the guide pin, and dis mount the bearing cap by sliding it along the guide pin, see fi g 2.

10) Remove the guide pin from the connecting rod.

Dismounting of Upper Big-end Bearing Shell

11) Pull the piston and connecting rod assembly upwards and remove the upper big-end bearing shell, see fi g 3.

12) Lift the piston and connecting rod assembly up through the cylinder liner and out of the engine, see fi g 4.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

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

Starting position:

Piston and connecting rod are dismountedfrom engine 506-01.00

Related procedure:

Inspection or/and overhaul of piston 506-01.10Inspection or/and overhaul ofconnecting rod 506-01.15Inspection of connecting rodbig-end bearing 506-01.16

Manpower:

Working time : 1/4 hourCapacity : 1 man

Data:

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

506-01.05Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 021 52006 033 52006 200

Hand tools:

Open-end spanner, 24 mm.Wooden wedge, 2 pieces.Wooden support.Wire.

Replacement and wearing parts:

Plate no Item no Qty/

Separation of Piston and Connecting RodWorking CardPage 1 (2)

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506-01.05Edition 01H Separation of Piston and Connecting Rod Working Card

Page 2 (2)

Landing of Piston and Connecting Rod

1) Land the piston and connecting rod carefully on wooden supports to prevent damage of piston and scraper ring, see fi g 1.

Separation of Piston and Connecting Rod

6) Take out the securing ring, (seeger circlips), push out the piston pin and lift the connecting rod away.

Assembly of Piston and Connecting Rod

7) For assembly of piston and connecting rod, see point 1-6 in reversed order.

8) Lubricate the piston pin before assembling.

Fig 1. Landing of Piston and Connecting Rod.

2) The bearing cap should be mounted with the screws tightened only by hand, in order to protect the serrated joint faces during handling of the assembly, see fi g 1.

3) Remove the shackle and eye screw from the piston crown, see fi g 1.

4) Place the piston and connecting rod assembly in upright position resting on the top face of the piston crown, see fi g 2.

Note: Wooden wedges should be used to prevent the connecting rod from swinging out and thus impact the piston skirt during the lifting into upright position.

5) Place a wire around the big-end of the con-necting rod. Attach a tackle and tighten the wire rope, see fi g 2. Fig 2. Removal of Connecting Rod and Piston Pin.

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Safety precautions:

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

Description:

Cleaning and inspection of piston. Control of piston ring, scraper ring and ring grooves.

Starting position:

Piston has been dismantled fromconnecting rod 506-01.05

Related procedure:

Mounting of piston and connecting rod 506-01.20

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

506-01.10Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 141 52006 153 52006 165

Hand tools:

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

Replacement and wearing parts:

Plate no Item no Qty/

PistonWorking CardPage 1 (4)

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Working CardPage 2 (4)

Inspection of Piston

1) Remove the piston and scraper rings.

2) Clean and examine the piston rings to determine if reuse is acceptable, see page 3.

3) Clean the piston on the outside and on the inside.

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

Removal of Piston Ring

For removal of piston rings, which are to be used again, and for all mounting of rings, only the special ring opener which prevents local over stressing of the rings should be used.

Straps to expand the ring gap or tools working on the same principle must not be used, as this would result in permanent deformation which might cause blow-by or broken rings.

95.50 - ES0S

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Working CardPage 3 (4) Piston 506-01.10

Edition 01H

L23/30H

The piston has to be scrapped if:

A) The wear limit on the testing mandrel is ex-ceeded, see fi g 1A

or

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

Note! At each piston overhaul:

- The piston and scraper ring must be ex-changed.

- The cylinder liner must be honed according to the instructions.

A) Testing Mandrel for Ring Grooves

If the wear limit (2 mm mark) on the testing mandrel is exceeded, the specifi ed max. wear limits are ex ce ed ed, and the piston must be scrapped.

The handle is marked with the nominal size.

Wear limit line.

Fig 1. Wear limits for ring grooves.

B) Clearance Ring/Groove

0.45 mm

Maximum vertical clearance between new piston ring/scraper ring and ring groove: 0.45 mm.

+0.14+0.12

+0.11+0.09

+0.11+0.09

+0.10+0.08

New ring grooves.

Tolerances.

Ring grooves.Max. wear limit.

Table 1. Nominal size, new ring groove tolerance and wear limit for ring grooves.

4.43 mm

4.43 mm

4.43 mm

7.43 mm

4.0 mm

4.0 mm

4.0 mm

7.0 mm

Piston and oilscraper ring.Nominal size.

New4.0 mm

New4.0 mm

New4.0 mm

New7.0 mm

Piston ring1

Piston ring2

Piston ring3

Scraper ring

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L23/30H

PistonWorking Card

Page 4 (4)

95.50 - ES0S

Position of Piston and Scraper Rings

Scraper ring:marked with ident.No "top 881503-9"or "0120".

Piston Ring No 1:marked with ident.No "top 881500-3"or "0946".

Piston Ring No 3:marked with ident.No "top 881501-5"or "0945".

Piston Ring No 2:marked with ident.No "top 881502-7"or "0947".

Marking of Piston and Scraper Rings

Marking

Identifi cation marks to face upwards against the piston crown when mounted.

Note! The marking may include other fi gures than mentioned above, for instance trade mark and production codes.

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Safety precautions:

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

Description:

Cleaning, inspection and test measurement of connecting rod.

Starting position:

Connecting rod has been dismantled from piston 506-01.05

Related procedure:

Mounting of piston andconnecting rod 506-01.20

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

506-01.15Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 273 80-360 Nm 52006 618 225-250 Nm

Hand tools:

Inside micrometer (195 mm).Feeler gauge 0.15 - 0.20 mm.

Replacement and wearing parts:

Plate no Item no Qty /

Connecting RodWorking CardPage 1 (4)

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506-01.15Edition 01H Connecting Rod Working Card

Page 2 (4)

Cleaning of Connecting Rod

1. Clean all machined surfaces on the connecting rod.

2. Degrease the serrated joint faces, tapped holes and connecting rod screws with a volatile solvent and blow dry with working air.

Visual Inspection of Serrated Faces

3. Inspect the serrated joint faces.

Damages, in the form of visible wear marks and pit-tings or even cracks, may be in the serration due to relative movements between the surfaces.

Wear marks and cracks are visible, but not perceptible with a fi ngernail. Pittings and impact marks are both visible and perceptible.

Note!! Handle the connecting rod with care. In case of damaged serration caused by improper handling, the bearing cap can no longer be tightened to the con-necting rod without ovalness of the big-end bore.

4. Register observed damages in the scheme "Connecting Rod Inspection" for historic use only. See page 4.

5. Carefully smooth single raised spots in the serration caused by pitting and impact marks with a fi lesmall.

Inspection of Connecting Rod Screws

6. Inspect the connecting rod screws for seizures in the threads and pittings on the contact surfaces of the screwheads.

7. Turn the connecting rod screws into bottom position in the threaded screw holes by hand.

If screws Then

have seizures in Renew the screwsthreads or pittings on contact surface

cannot be turned into Renew the screwsbottom position by hand

Measurement of Big-end Bore

For check of ovalness the bearing cap has to be mounted onto the big-end bore without bearing shells.

Note !! The ident. No on the connecting rod and the bearing cap must always be the same, see fi g 3.

Fig. 1. Point of measurement

8. Mount the bearing cap onto the connecting rod by means of the connecting rod screws.

9. Tighten the screws with the prescribed torque, see working card 506-01.25.

10. Measure fi ve different diameters in the middle of the boring, see fi g 1.

11. Register the measurements in the scheme "Con nec ting Rod Inspection". See page 4.

12. Calculate the maximum ovalness as the dif-ference between biggest and smallest diameter measured.

13. Check if maximum ovalness is exceeded, see page 500.35.

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L23/30H

Connecting RodWorking CardPage 3 (4)

If Then

maximum ovalness is Renew the completeexceeded connecting rod, screws and bearing shells.

maximum ovalness is Reuse the connecting rod not exceeded

Connecting Rod Inspection for L23/30H

Cylinder no.

Connecting rod ident no.

Running hours for connecting rod

NominaldiameterØ195 mm

0,01 mm1/100 mm

Tightening for measurement seeinstruction.

Serration

Connecting rodIdent no.

Note ! The ident no. on the con-necting rod and on the bearingcap, must always be the same.

Ovalness: Diff. between min./max.

Condition of serration

A

B

C

D

E

Serration OK

Wear

Cracks

Corrosion/Pitting

Impact mark

Remarks:

Serration OK

Wear

Cracks

Corrosion/Pitting

Impact mark

Remarks:

Serration OK

Wear

Cracks

Corrosion/Pitting

Impact mark

Remarks:

+++++

+

A BC

D

E

1 2

- 0,5 - 3,0 - 2,0 - 7,0 - 1,5 - 5,0 + 5,0 + 5,5 + 3,0 + 3,5 7,0 12,5

to be to be reused rejected

Fig 2. "Connecting Rod Inspection".

Example of Measurement Results

The example, see fi g 2, shows measurements and da ma ge observations for two connecting rods on the scheme "Connecting Rod Inspection" (in case the specifi ed maximum ovalness is exceeded, contact MAN B&W Diesel A/S, Holeby for overhaul).

For connecting rod No 1 the maximum ovalness is 0.07 mm and thus reuse is acceptable.

For connecting rod No 2 the maximum ovalness is 0.125 mm and therefore the connecting rod is rejected.

Inspection of Connecting Rod Bush

1. Inspect the surface of the piston pin and the con nec ting rod bush.

2. Measure the clearance between the piston pin and bush.

3. Check if max clearance is exceeded, see page 500.35.

If the specifi ed clearance is exceeded, con tact MAN B&W Diesel A/S, Holeby for replacement.

Inspection of Bearing Shells for Big-end

Criteria for replacement of connecting rod big-end bearing, see working card 506-01.16.

Fig 3.

Connecting rodIdent No

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Connecting Rod506-01.15Edition 01H

L23/30H

Working CardPage 4 (4)

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Safety precautions:

Stopped engineShut-off starting airShut-off cooling waterShut-off fuel oilShut-off cooling oilStopped lub. oil circul.

Description:

Inspection of bearing shells.

Starting position:

Bearing shells removed from engine:Big-end bearing, 506-01.00 and 506-01.30orMain bearing, 510-01.05Guide bearing, 510-01.10

Related procedure:

Mounting af bearing shells:Big-end bearing, 506-01.20 and 506-01.30Main bearing, 510-01.05Guide bearing, 510-01.10

Man power:

Working time : 1/4 HourCapacity : 1 man

Data:

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

506-01.16Edition 01H

91.07 - ES0S-G

L23/30H

Working CardPage 1 (8)

Special tools:

Plate no. Item no. Note.

Hand tools:

Magnifier (x30).

Replacement and wearing parts:

Plate no. Item no. Qty. /

Criteria for Replacement ofConnecting Rod Big-end and Main Bearing Shells

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506-01.16Edition 03H

Working CardPage 2 (8)

Criteria for Replacement ofConnecting Rod Big-end and Main Bearing Shells

This paper gives information about the evaluation ofthe connecting rod big-end and main bearing shellswhen wear appears on the running surface undernormal operating conditions.

Bearing damages caused by incorrect running con-ditions, like

- Scoring of the running surface due to foreignparticles in the lubricating oil.

- Cavitation.- Corrosion- Overloading, overheating a.s.o.

are not described in this paper.

In these cases, the bearing shells must be exchang-ed, of course, and in order to avoid further bearingfailures, the cause of the failure must be found andeliminated.

Wear of the bearings running surface starts primarilyin the soft overlay, where the overlay in the slots isreduced approx. 0.001 mm. The difference betweenthe light-alloy metal and the overlay is by furtherwear almost constant, i.e. approx. 0.005 mm.

The gravity of the running surface’s wear must bedetermined with a magnifier (x30), hereby the over-lay can be seen as the dark area and the light-alloymetal as the light area.

The ratio between the width of the light-alloy metaland the width of the slot as well as the dimension ofthe worn area are important for determining the wearof the bearing.

The bearing can also operate although part of theoverlay is missing in the slots. Practice has shown,that bearings with partly empty slots can run withoutany negative influence on the operation of the bea-ring.

By determining the condition of the bearing shell, theoverlay at a minor stressed area must be used ascomparison.

The valuation of the bearing shell condition is dividedinto 5 groups:

1. Re-use2. Limiting case - wear3. Limiting case - local levelling4. Limiting case - permanent breakage on the

overlay5. Empty slots.

In case of a combination of the above mentionedconditions, the lowest possible limits are valid.

Overlay(~75%)

Light metal(~25%)

Nickel strike(max.5%)

Fig. 1. Running surface of the bearing shell.

A new bearing shell has a running surface withapprox. 75 % galvanic overlay and approx. 25 %light-alloy metal, see fig. 1.

MAN Diesel

MAN Diesel

MAN Diesel

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506-01.16Edition 03H

Working CardPage 6 (8)

Criteria for Replacement ofConnecting Rod Big-end and Main Bearing Shells

3. Limit Case - Levelling

Condition: The slots are locally totally levelled asshown in fig. 10.

Valuation: If the limits shown in fig. 11 and 12 areexceeded the bearing shells must be exchanged.

Fig. 10.

Fig. 12.

max. 10% of width

max.

5%

of

exte

nt

max. 10% of width or

max. 5 mm

Fig. 11.

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506-01.16Edition 03H

Working CardPage 8 (8)

Criteria for Replacement ofConnecting Rod Big-end and Main Bearing Shells

5. Limit Case - Empty Slots

Condition: In some areas there is no overlay in theslots, see fig. 17.

Fig. 17.

Valuation: If the limits shown in the below fig. 18 and19, are exceeded, the bearing shells must be ex-changed.

max. 10% of width or

max. 5 mm

Fig. 19.

max

.15

%of

exte

nt

max. 30% of width

Fig. 18.

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Safety precautions:

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

Description:

Mounting of piston and connecting rod assembly, after overhaul and/or inspection.

Starting position:

Piston mounted on the connecting rod, crank-shaft turned in the right position and the cylinder liner is OK, see working card 506-01.35.

Related procedure:

Tightening of connecting rod screws 506-01.25Mounting of cylinder head 505-01.40

Manpower:

Working time : 1 1/2 hoursCapacity : 2 men

Data:

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

506-01.20Edition 01H

95.50 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 021 52006 033 52006 116 52006 141 52006 224

Hand tools:

Open-end spanner 24 mm.Clean lubricating oil.

Replacement and wearing parts:

Plate no Item no Qty/

50601 093 1/cyl 50601 103 1/cyl 50601 115 1/cyl 50601 127 1/cyl

Mounting of Piston and Connecting RodWorking CardPage 1 (4)

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Mounting of Piston and Connecting Rod Working CardPage 2 (4)

Mounting of Tools

1) Mount the lifting device comprising eye screw, shackle and wire rope on the piston.

2) Lift up the piston and connecting rod and mount the piston and scraper rings, see point 14, and working card 506-01.10.

3) Remove the backstop for cylinder liner and place the piston guide ring on top of the cylinder liner, see fi g 1.

Note: A crank throw position of approx 50 degrees before TDC will ensure this and also be suitable for the further mounting procedure.

Mounting of Big-end Bearing

6) Lower the piston further down, lubricate the ends of the bearing shells (as in fi g. 2) with copaslip, molycote pasta or similar and mount the upper shell of the big-end bearing.

Fig 2.

Fig 1.

Lowering of Piston and Connecting Rod

4) When the piston approaches the guide ring, stop the lowering, coat guide ring, piston, piston rings and scraper ring, with clean lubricating oil in order to minimize friction during the subsequent lowering of the assembly.

5) Make sure that the crank throw is in a position allowing the connecting rod to go clear of both crank journal and cylinder liner skirt during further low er-ing.

7) Coat the crank journal with clean lubricating oil.

8) Lower the piston and connecting rod slow ly into correct landing on the journal.

During this the connecting rod must be guided by hand to ensure correct approach and landing on the journal, see fi g 3.

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Mounting of Bearing Cap

9) Mount the bearing cap with inserted lower shell of the big-end bearing, using the guide pin, see fi g 4.

506-01.20Edition 01H

L23/30H

Fig 3.

Con. Rod - Ident No.

Fig 4.

Note: The ident. No. on the connecting rod and on the bearing cap must always be the same, see fi g 4.

10) Lubricate threads and contact face of the con-necting rod screws with copaslip, molycote pasta or similar.

11) Mount the screws and tighten them slightly using an open end spanner.

12) Slacken the tackle and dismount the eye screw/shackle from the piston.

Fig 5.

Tightening of Connecting Rod Screws

13) Tighten the screws according to "Tightening Procedure for Connecting Rod Screws", see work ing card 506-01.25.

Fitting of Piston and Scraper Rings

14) Piston rings should only be removed from and fi tted to the piston by the use of a special tool, the socalled piston ring opener.

Working CardPage 3 (4) Mounting of Piston and Connecting Rod

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Before fi tting the coil spring loaded scraper ring, the coil spring is dismantled from the ring by removal of the joint pin. The coil spring is placed and assembled in the ring groove. Then the scraper ring is fi tted in the groove in such a way that the ring joint is ap prox-i ma te ly 180° offset to the spring joint.

Ascertain correct assembling by checking the back clearance.The back clearance is suffi cient when the face of the ring is below the groove edge when the ring is pressed against the bottom of the groove.

When installed on the piston the rings should be pushed back and forth in the grooves to make sure that they can move freely. It is also advisable to insert a feeler gauge of adequate thickness between ring and groove.

Adequate clearance is present so the feeler gauge can be moved all the way round.

To prevent gas leakage through coinciding ring joints the piston rings should be turned into positions off-setting the ring joint 180° to each other.

L23/30H

If the rings are opened further than necessary there is a risk of overstressing, which means that rings will become permanently distorted and will not confi rm to the inner running surface of the cylinder.

The piston rings should be installed with the iden ti-fi ca tion mark, which is stamped into the ring close to the ring joints, facing upwords, see working card 506-01.10 "Piston".

Joint coil spring to beplaced opposite to ring joint

Ring joint

Joint pin forcoil spring

Fig 6.

Mounting of Piston and Connecting Rod506-01.20

Edition 01HWorking Card

Page 4 (4)

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Safety Precautions:

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

Description:

Tightening procedure for connecting rod screws.Check of connecting rod screws, tightening condition.

Starting Position:

Piston, connecting rod, bearing shells and bearing cap preassembled. 506-01.20

Related Procedure:

Man Power:

Working time : 1/2 HourCapacity : 2 men

Data:

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

506-01.25Edition 01H

95.50 -ES0S

L23/30H

Special Tools:

Plate No Item No Note

52006 273 80 - 360 Nm

Tool combinations for tightening of connecting rod screws, see working card 520-01.20.

Hand Tools:

Open-end spanner, 24 mm.

Replacement and Wearing Parts:

Plate No Item No Qty./

Tightening and Check of Connecting Rod ScrewsWorking CardPage 1 (3)

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506-01.25Edition 01H Tightening and Check of Connecting Rod Screws Working Card

Page 2 (3)

Tool combinations for tightening of connecting rod screws, see working card 520-01.20.

Tightening of Connecting Rod Screws

1st Step:

Tightening the screws in tightening order, illustrated in fi g 1, using an initial torque of 250 Nm.

Mark on screw collar

Mark on bearing cap

60°

Fig 2.

4th Step:

Check the screw tightening in prescribed order using a torque of 325 Nm.

Proper tightening condition is present, if the screws are not turned further during this test.

5th Step:

Check that the bearing can easily be moved on the journal.

Check of Connecting Rod Screws, Tightening Condition:

Check of the tightening condition of connecting rod screws has to be executed within a short running period after remounting/mounting of the connecting rod.

This check can be fulfi lled after only a few running hours at max. rpm at full load, but has to be fulfi lled not later than 200 running hours after starting-up.

The tightening condition is checked with a torque of 325 Nm, executed in prescribed screw tightening order, see fi g 1.

Proper tightening condition is present, if the screws are not turned further during the test.

Fig 1.

2nd Step:

Once more, tightening the screws in prescribed tightening order, still using a torque of 250 Nm.

3rd Step:

Mark the four screws and the bearing cap felt-tippen, illustrated in fi g 2.

Tightening order by turning through a 60° ± 2° angle, i.e. until the marks on the screw collar and the con-necting rod coincide radially.

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In order to ensure observation of any movement, the screws and the connecting rod should be applied with coinciding fi lt-pen marks prior to the test, see fi g 3.

Any turning of the screws during the 325 Nm test indicates insuffi cient tightening condition, and in this case the big-end assembly has to be dismantled and investigated for evaluation and correction of failure.

As part of recommended overhaul and routine work, the tightening condition of connecting rod screws should also be checked, at certain running hours intervals, see page 500.24.

Mark on screw collar

Fig 4.

325 Nm

506-01.25Edition 01H

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Tightening and Check of Connecting Rod ScrewsWorking CardPage 3 (3)

Coincidingmark on bearing cap

Fig 3.

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Safety Precautions:

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

Description:

Tightening procedure for connecting rod screws.Check of connecting rod screws, tightening condition.

Starting Position:

Piston, connecting rod, bearing shells and bearing cap preassembled. 506-01.20

Related Procedure:

Man Power:

Working time : 1/2 HourCapacity : 2 men

Data:

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

506-01.25Edition 04H

00.28 -ES0

L23/30H

Special Tools:

Plate No Item No Note

52021

Hand Tools:

Replacement and Wearing Parts:

Plate No Item No Qty./

Hydraulic Tightening of Connecting Rod ScrewsWorking CardPage 1 (2)

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506-01.25Edition 04H Hydraulic Tightening of Connecting Rod Screws Working Card

Edition 2 (2)

1) Screw the studs pos. 3 down by hand into the connecting rod body pos. 1.

2) Fit the upper part of the connecting rod pos. 2 and hold it with nuts pos. 4.

Note. Remember to fi t the bearing shells (unless the mounting is carried out for fi nish-machining).

3) Screw the studs to the bottom. Check the distance 81 from surface of upper part pos. 2 to the end of the studs pos. 3 and hand-tighten the nuts pos. 4.

4) Mount the hydraulic jacks pos. 5.

Note. Turn the thrust piece of the jack so that the slots for the ball handle pos. 6 are unloaded when pressurizing the jack.

5) Connect the jacks to the hydraulic system/pumpby using the angle piece pos. 7.

6) Load the studs with the hydraulic pressure and tighten the nuts with the ball handle pos. 6

7) Relieve the tool pressure.

8) Re-apply the tool pressure.

9) Tighten the nuts again.

Note. Item 8 and 9 are carried out in order to elemi-nate any harmful stresses.

10) If any clearance is still visible and the nut can be turned, then repeat item 7, 8 and 9.

11) The pressure to be relieved and the tool to be dismantled.

Fig. 1 Hydraulic tightening of connecting rod.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

In-situ inspection and/or replacement of con-necting rod big-end bearing, dismounting and moun-ting.

Starting position:

Fuel injection valve dismounted, 514-01.10Crankcase open.Top cover for cylinder head removed.

Related procedure:

Inspection of connecting rod big-end bearing 506-01.16Tightening and check of connecting rod screws 506-01.25

Manpower:

Working time : 1 1/2 hoursCapacity : 1 man

Data:

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

506-01.30Edition 01H

96.30 - ES0S

L23/30H

Working CardPage 1 (3)

Special tools:

Plate no Item no Note

52006 070 52006 224 52006 273 80-360 Nm

Tool combination for tightening of connecting rod screw, see working card 520-01.20.

Hand tools:

Open-end spanner 24 mm.

Replacement and wearing parts:

Plate no Item no Qty/

In-situ Inspection of Connecting Rod Big-end Bearing

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

506-01.30Edition 01H In-situ Inspection of Connecting Rod Big-end Bearing Working Card

Page 2 (3)

Turning the Piston in Correct Position

1) Turn the crankshaft into a position allowing the connecting rod to be losened.

2) Turn the crankshaft in a position allowing the connecting rod bearing cap to be dismounted, see fi g 1.

Fig 1.

Dismounting of Bearing Cap

3) Remove the fuel injector.

4) Insert the long-eye bolt and screw it into the thread hole in the piston, see fi g 2.

5) Tighten it slightly by means of a tackle, see fi g 2.

Removal of Bearing Shells

6) Dismount the bearing cap and bearing shell. For use of guide pin, see working card 506-01.00.

a

a

Fig 2.

7) Lift the piston/connecting rod from the bearing journal.

Note: the piston/connecting rod should be lifted further then, just to allow dismounting of the upper bearing shell, see fi g 2.

Inspection of Bearing Shells

8) Inspect the bearing shells, see working card 506-01.16.

96.30 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Cleaning of Components before Mounting.

9) Clean all components, see working card 506-01.20.

Mounting of Upper Bearing Shells

10) The bearing shell is placed in the bore, the contact surfaces of the shells to be in parallel to the contact surface of the connecting rod and the bearing cap respectively.

506-01.30Edition 01H

L23/30H

In-situ Inspection of Connecting Rod Big-end BearingWorking CardPage 3 (3)

Fig 3.

11) Ascertain that the crank throw concerned is in a position of approx 50 degrees before TDC.

12) Coat the journal with clean lubricating oil and lower the piston and connecting rod assembly slowly into correct landing on the journal.

While lowering the connecting rod, it must be guided by hand to ensure a correct approach and landing on the journal, see fi g 4.

13) Lubricate the ends of the bearing shells (as in fi g 2) with copaslip, molycote or simular.

Mounting of Bearing Cap

14) Mount the bearing cap with inserted lower big-end bearing shell, using the guide pin.

15) Lubricate threads and contact face of the con-necting rod screws with copaslip or similar.

16) Mount the screws and tighten them slightly using an open-end spanner.

17) Slacken the tackle and dismount the eye screw from the piston crown.

Tightening of Connecting Rod Screws

18) Tighten the screws according to "Tightening Procedure for Connecting Rod Screw", see working card 506-01.25.

96.30 - ES0S

☛Push

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Inspection and honing of cylinder liner with ho-ning brush.

Starting position:

Piston and connecting rod is removed 506-01.00

Related procedure:

Mounting of piston and connecting rod 506-01.20Replacement of cylinder liner 506-01.40Grinding of seal face on cylinderhead and cylinder liner 506-01.45

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

506-01.35Edition 01H

96.04 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 488 52006 511 52006 606 275-300 mm

Hand tools:

Drilling machine 60-180 rpm.Honing oil.Gas oil.

Replacement and wearing parts:

Plate no Item no Qty/

Inspection and Honing of Cylinder LinerWorking CardPage 1 (4)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

506-01.35Edition 01H Inspection and Honing of Cylinder Liner Working Card

Page 2 (4)

Fig 1.

The measurements should normally be taken in transverse as well as in longitudinal direction.

When measuring, take care that the measuring tool has the approximately same temperature as the liner. When the wear of a cylinder liner exceeds the value indicated on page 500.35, i.e. when it becomes too troublesome to maintain satisfactory service conditions, the cylinder liner in question should be exchanged.

Honing the Cylinder Liner

The renovation can be made either with dismantled liner in the workshop or with liner mounted in the engine frame and by the use of the belonging fun-nel.

Fig 2.

The honing is made by means of a fl ex-honer with fi neness grains 80-120. A revolution speed between 80 and 160 rpm is chosen.

80-160 rpm.

Measurement of Cylinder Diameter

While the piston is removed from the cylinder, the latter is measured to record the wear. The mea sure-ments are taken by means of an inside micrometer, with measuring points at TDC-position for up per-most piston ring, halfway down and at the bottom of the cylinder liner, see fi g 1 and page 4.

Prior to honing, deposits of coke and possible wear edges in the top of the liner must be removed by scraping.

If the cylinder is of the fl ame ring type, the used fl ame ring has to be cleaned in water. Subsequently, the fl ame ring is remounted in the cylinder before carrying out the honing process.

Note: After the honing process has taken place the used fl ame ring is discarded. A new fl ame ring is always mounted in the cylinder when replacing a piston ring.

96.04 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

In order to achieve the required angle between the honing grooves, see fi g 2, the vertical speed is ad-justed to about 1 m/sec. which corresponds to about 2 sec. for one double movement (the fl ex- honer is led from below up and down in 2 sec.)

The procedure is to be continued until the cylinder wall is covered by honing grooves and the surface has a slight matt appearance without any signs of glaze.

During the honing it is important to lubricate freely with honing oil or cutting oil.

After the honing, the liner is carefully cleaned with gas oil. Make sure that all abrasive particles have been removed.

506-01.35Edition 01H

96.04 - ES0S

L23/30H

Inspection and Honing of Cylinder LinerWorking Cardpage 3 (4)

Fig 3.

60°

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

506-01.35Edition 01H

Measu

remen

to

fC

ylind

erL

iner

Cyl.

No.

Cyl.liner

ident.No.

Running

hours

LengthwiseCrosswiseLinertem

p.˚C

Rem

arks...

12

34

56

78

Engine

type

Engine

No.

Running

hours

Fuel

Report

No.

Encl.

No.

Insp.date

Sign.

ABCABC

Plant

ABC

63

194

362

96.04 - ES0S

Inspection and Honing of Cylinder Liner

L23/30H

Working CardPage 4 (4)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Replacement of cylinder liner.

Starting position:

Cylinder head and piston/connecting rod dis-mantled,working card 505-01.00 and 506-01.00.

Related procedure:

Mounting of piston andconnecting rod 506-01.20Grinding of seal face on cylinderhead and cylinder liner 506-01.45

Manpower:

Working time : 11/2 hoursCapacity : 2 men

Data:

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

506-01.40Edition 01H

96.27 - ES0S

Replacement of Cylinder Liner

Special tools:

Plate no Item no Note

52006 452

Hand tools:

Adjustable spanner.

Replacement and wearing parts:

Plate no Item no Qty/

50610 079 8/cyl 50610 031 1/cyl 50610 043 2/cyl

See also plate 50610.

Working CardPage 1 (2)

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Dismounting of Cylinder Liner

1) Prior to mounting of the lifting tool and dis moun-ting from the frame, it must be ensured that the liner and frame have been marked to match, for the sake of a possible remounting of the liner, see fi g 1.

96.27 - ES0S

506-01.40Edition 01H Replacement of Cylinder Liner Working Card

Page 2 (2)

Mounting of Cylinder Liner

6) Check that the sealing surfaces on engine frame, cylinder liner, and sealing rings are perfectly clean.

7) Mount the lifting tool, attach a tackle hook to the eye nut or to the wire in the cross bar and lift the liner.

8) Check that the O-ring grooves are clean. Mount the O-rings and lubricate with a little oil.

9) Lower the cylinder liner carefully into the en gine frame.

When the fi rst O-ring touches the sealing face, align the liner so that the scratch mark on the liner fl ange points to the scratch mark on the frame as illustrated.

10) Mount the piston/connecting rod and cylinder head according to working card 506-01.20 and 505-01.40.

Fig 1.

2) Mount the lifting tool as shown, see fi g 2.

3) Turn the lifting eye nut to pull out the liner until the upper edge of the liner lie aligned against the copper protecting pieces of the cross bar.

4) Attach a tackle hook to the eye nut or the wire and the cross bar, and lift the liner out from the engine frame and put it down onto wooden supports.

5) Clean all parts and inspect for damage and wear according to the description. For mea su re ment of cylinder liner, see working card 506-01.35.

Fig 2.

Hole for charging air

Marking scratch frame

Marking scratch liner

Hole for roller guide house

MAN Diesel

Safety precautions:

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

Description:

Grinding of seal face on cylinder liner and cylinder head by hand with grinding tools and grinding pasta.

Starting position:

Cylinder head has been removedfrom the engine 505-01.00Cooling water guide jacket removed.

Related procedure:

Mounting of cylinder head 505-01.40

Man power:

Working time : 1 hourCapacity : 1 man

Data:

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

506-01.45Edition 01H

95.50 - ES0S-G

L23/30H

Special tools:

Plate no. Item no. Note.

52005 205

Hand tools:

Grinding pasta.

Replacement and wearing parts:

Plate no. Item no. Qty. /

50610 031 1/cyl.

Working CardPage 1 (2)

Grinding of Seal Face onCylinder Liner and Cylinder Head

MAN Diesel

L23/30H

Note! The grinding tool is used for both grinding the groove in the liner fl ange (1) and the sealing surface on the cylinder head (2), see Fig 1.

95.50 - ES0S-G

506-01.45Edition 01H

Working CardPage 2 (2)

Grinding of Seal Face onCylinder Liner and Cylinder Head

Fig 1.

Grinding

1) Loosen the sealing ring in liner fl ange and take it out.

2) Face-grind the sealing grooves in the cylinder liner fl ange, see Fig 2, and the sealing surface on the cylinder head, see Fig 3, with the use of grinding pasta and the grinding tool.

Fig 2.

To do so, move the tool back and forth and lift it out from time to time to allow the grinding compound to distribute evenly.

Fig 3.

3) After grinding, remove all traces of abrasives and grinding compound.

4) When having ground the contact faces, it must be observed that the gap between cylinder head and liner is no less than 0.5 mm, i.e. the difference between measurements y and z must not be less than 0.5 mm, see Fig 4.

y - z = min. 0.5 mm

Fig 4.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Dismounting of piston, connecting rod and cylinder liner for inspection and/or overhaul.

Starting position:

Cylinder head has been dismounting from the engine. Crankcase open.

Related procedure:

Separation of piston and connecting rod.Inspection and honing of cylinder liner.

Manpower:

Working time : 2 ½ hoursCapacity : 2 men

Data:

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

506-01.50Edition 01H

03.34 - ES0

L23/30H

Special tools:

Plate no Item no Note

52050 52006 094 2 pieces 52006 224 52010 011 If necessary

Tool combination for dismounting of connecting rod screw, 520-01.20

Hand tools:

Inside micrometer (195 mm).Feeler gauge 0.15 - 0.20 mm.

Replacement and wearing parts:

Plate no Item no Qty /

Working CardPage 1 (2)

Dismantling of Piston and Cylinder Liner at Low Overhaul Heights

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

03.34 - ES0

Dismantling of Piston at Low Overhaul Heights

1) Lift up the piston and the connecting rod through the cylinder liner until the piston is clear of the liner.

2) Mount the collar on the connecting rod, see plate 52050, item no 045.

3) Place the piston with the collar on the cylinder liner.

4) Mount pull-lifts on the collar.

If Then

the overhaul height is dismount the piston fromtoo low to pull out piston the connecting rod, re-and connecting rod in move the piston and pullone piece. out the connecting rod by the pull-lifts.

the overhaul height is remove the piston andsuffi cient to pull out the connecting rod bypiston and the connect- means of the pull-lifts.ing rod in one piece.

Dismantling of Cylinder Liner at Low Overhaul Heights

1) Mount the normal lifting tool for cylinder li-ners.

2) Carefully pull the cylinder liner half-way out of the frame.

3) Mount a special lifting tool for cylinder liners at low overhaul heights, see plate 52050, item no 033.

4) Attach pull-lifts on the lifting tool for the cylinder liner, see plate 52050, item no 033.

5) Take out the liner over the camshaft side.

506-01.50Edition 01H

L23/30H

Dismantling of Piston and Cylinder Liner at Low Overhaul Heights

Working CardPage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H720/750 RPM

PlatePage 1 (2) Piston and Connecting Rod

97.05 - ES0S

50601-01H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Piston pin incl.item No 020

Socket screw

Retaining ring

Plug screw

Bush forconnecting rod

Connecting rodincl. item Nos 044, 056, 152, 140

Piston

Piston ring

Piston ring

Piston ring

Oil scraper ring

Connecting rodbearing 2/2

Plug screw

Screw forconnecting rod

Designation BenævnelseBenævnelseDesignation

L23/30H720/750 RPM

Item No. Qty.

Item No.

Qty.

019

020*

032

044*

056

068

081

093

103

115

127

139

140*

152

1/C

4/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

4/C

Stempelpind inkl.pos. nr. 020

Kraterskrue

Sikringsring

Propskrue

Plejlstangs-bøsning

Plejlstang inkl.pos. nr. 044, 056, 152, 140

Stempel

Stempelring

Stempelring

Stempelring

Olieskrabering

Plejlstangs-leje 2/2

Propskrue

Plejlstangs-skrue

97.05 - ES0S

Piston and Connecting Rod PlatePage 2 (2)50601-01H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H900 RPM

PlatePage 1 (2) Piston and Connecting Rod

97.05 - ES0S

50601-02H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Piston pin incl.item No 020

Socket screw

Retaining ring

Plug screw

Bush forconnecting rod

Connecting rodincl. item Nos044, 056, 152, 140

Piston

Piston ring

Piston ring

Piston ring

Oil scraper ring

Connecting rodbearing 2/2

Plug screw

Screw forconnecting rod

Designation BenævnelseBenævnelseDesignation

L23/30H900 RPM

Item No. Qty.

Item No.

Qty.

019

020*

032

044*

056

068

081

093

103

115

127

139

140*

152

1/C

4/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

4/C

Stempelpind inkl.pos. nr. 020

Kraterskrue

Sikringsring

Propskrue

Plejlstangs-bøsning

Plejlstang inkl.pos. nr. 044, 056, 152, 140

Stempel

Stempelring

Stempelring

Stempelring

Olieskrabering

Plejlstangs-leje 2/2

Propskrue

Plejlstangs-skrue

97.05 - ES0S

Piston and Connecting Rod PlatePage 2 (2)50601-02H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H720/750 RPM

PlatePage 1 (2) Piston and Connecting Rod (Hydraulic Tightened)

00.27 - ES0

50601-05H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Piston pin incl.item No 020

Socket screw

Retaining ring

Plug screw

Bush forconnecting rod

Connecting rodincl. item Nos044, 056, 140, 152and 164

Piston

Piston ring

Piston ring

Piston ring

Oil scraper ring

Connecting rodbearing 2/2

Plug screw

Connecting rod stud

Nut

Designation BenævnelseBenævnelseDesignation

L23/30H720/750 RPM

Item No. Qty.

Item No.

Qty.

019

020*

032

044*

056

068

081

093

103

115

127

139

140*

152

164

1/C

4/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

2/C

2/C

Stempelpind inkl.pos. nr. 020

Kraterskrue

Sikringsring

Propskrue

Plejlstangs-bøsning

Plejlstang inkl.pos. nr. 044, 056, 140, 152 og 164

Stempel

Stempelring

Stempelring

Stempelring

Olieskrabering

Plejlstangs-leje 2/2

Propskrue

Plejlstangs-bolt

Møtrik

00.27 - ES0

Piston and Connecting Rod (Hydraulic Tightened) PlatePage 2 (2)50601-05H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H900 RPM

PlatePage 1 (2) Piston and Connecting Rod (Hydraulic Tightened)

00.27 - ES0

50601-06H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Piston pin incl.item No 020

Socket screw

Retaining ring

Plug screw

Bush forconnecting rod

Connecting rodincl. item Nos044, 056, 140, 152and 164

Piston

Piston ring

Piston ring

Piston ring

Oil scraper ring

Connecting rodbearing 2/2

Plug screw

Connecting rod stud

Nut

Designation BenævnelseBenævnelseDesignation

L23/30H900 RPM

Item No. Qty.

Item No.

Qty.

019

020*

032

044*

056

068

081

093

103

115

127

139

140*

152

164

1/C

4/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

2/C

2/C

Stempelpind inkl.pos. nr. 020

Kraterskrue

Sikringsring

Propskrue

Plejlstangs-bøsning

Plejlstang inkl.pos. nr. 044, 056, 140, 152 og 164

Stempel

Stempelring

Stempelring

Stempelring

Olieskrabering

Plejlstangs-leje 2/2

Propskrue

Plejlstangs-bolt

Møtrik

00.27 - ES0

Piston and Connecting Rod (Hydraulic Tightened) PlatePage 2 (2)50601-06H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H720/750 RPM

Cylinder LinerPlatePage 1 (2)

97.05 - ES0S

50610-01H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

018

031

043

Cylinder liner

Sealing ring

O-ring

Designation BenævnelseBenævnelseDesignationItem No. Qty.

Item No.

Qty.

Cylinderforing

Tætningsring

O-ring

1/C

1/C

2/C

97.05 - ES0S

Cylinder Liner50610-01H PlatePage 2 (2)

L23/30H720/750 RPM

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H900 RPM

Cylinder LinerPlatePage 1 (2)

97.05 - ES0S

50610-02H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

018

031

043

092

Cylinder liner

Sealing ring

O-ring

Flame ring

Designation BenævnelseBenævnelseDesignationItem No. Qty.

Item No.

Qty.

Cylinderforing

Tætningsring

O-ring

Flammering

1/C

1/C

2/C

1/C

97.05 - ES0S

Cylinder Liner50610-02H PlatePage 2 (2)

L23/30H900 RPM

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Cylinder LinerPlatePage 1 (2)

01.08 - ES0

50610-05H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

018

031

043

092

Cylinder liner

Sealing ring

O-ring

Flame ring

Designation BenævnelseBenævnelseDesignationItem No. Qty.

Item No.

Qty.

Cylinderforing

Tætningsring

O-ring

Flammering

1/C

1/C

2/C

1/C

01.08 - ES0

Cylinder Liner50610-05H PlatePage 2 (2)

L23/30H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

Camshaft

507/607

MAN Diesel

General

The camshaft which controls the actuation of inlet valves, exhaust valves and fuel injection pumps is driven by a gear wheel on the crankshaft through an intermediate wheel, and rotated by a speed which is half of that of the crankshaft, see fi g. 1.

The camshaft is located in a high level housing in the engine frame.The camshaft runs in replaceable, identical, steel-backed bronze bushings fi tted into borings of the transverse girders in the housing.

The camshaft is built-up of sections, one for each cylinder unit. Each section is equipped with fi xed cams for operation of fuel injection pump, air inlet valve and exhaust valve. The sections are assem-bled by bolting of the ample dimensioned and pre-cision made fl ange connections, which also act as bearing journals.

Except for the foremost and the aftmost ones, the sections are identical and therefore interchange able. The foremost section is equipped with a clutch for driving the fuel oil feed pump (if mounted). The gear wheel for driving the camshaft as well as a gear wheel connection of governor are screwed on the aftmost section.

DescriptionPage 1 (1) Camshaft and Camshaft Drive 507.01

Edition 01H

94.26 - ES0S

L23/30H

Engine seen from aft - fl y wheel end

Clockwise rotation direction

Fig. 1. Intermediate wheel

The lubricating oil pipes for the gear wheels are equipped with nozzles which are adjusted to apply the oil at the points where the gear wheels are in mesh. The position of the nozzles is determined by direction of rotation of the engine.

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Safety precautions:

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

Description:

Checking of gear wheels, bolted connections and lubricating system.

Starting position:

Related procedure:

Man power:

Working time : 3 HoursCapacity : 1 man

Data:

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

507-01.00Edition 01H

97.06 - ES0U-G

L23/30H

Special tools:

Plate no Item no Note.

52006 261 20 - 120 Nm.

Hand tools:

Allen key, 12 mm.Ring and open end spanner, 19 mm.Socket spanner, 19 mm.

Replacement and wearing parts:

Plate no Item no Qty./

50705 099 10/eng. 50705 146 6/eng. 50705 195 1/eng. 50705 183 2/eng. 50705 205 2/eng. 51106 237 1/cyl. 51106 058 1/cyl. 51106 693

Check of Camshaft and Camshaft DriveWorking CardPage 1 (2)

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1) Dismount the covers which give access to the gear wheels, camshaft and crankcase.

Examine all gear wheels for cracks, wear and de for-ma tions. While turning the engine to enable in spec-tion allover the circumference of the gear wheels.

2) Check all screws, nuts and bolted con nec tions, including locking devices everywhere in the gear wheel housing, camshaft housing and crank case to check that they have not worked loose. Tigh te ning torques, see page 500.40.

97.06 - ES0U-G

507-01.00Edition 01H Check of Camshaft and Camshaft Drive Working Card

Page 2 (2)

3) Examine all lubricating oil spray pipe nozz-les.

4) Start the electrical lubricating oil pump and check the oil fl ow everywhere. Be particularly care ful to check that the oil jet hits the gear wheels correctly at the points where the wheels mesh.

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Safety precautions:

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

Description:

Check of roller path of cams and check of cam-shaft bearing. Replacement of camshaft bearing.

Starting position:

Cover for camshaft and gear wheel has been removed.

Related procedure:

Camshaft and camshaft drive, 507-01.00

Man power:

Working time : 2 HoursCapacity : 2 men

Data:

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

507-01.05Edition 01H

95.02 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note.

52006 261 20 - 120 Nm.

Hand tools:

Ring and open end spanner, 19 mm.Socket spanner, 19 mm.Feeler gauge.Big screw driver.

Replacement and wearing parts:

Plate no Item no Qty. /

50705 038 1/eng. 50705 051 1/eng.

Inspection and Replacement of Camshaft BearingWorking CardPage 1 (2)

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To Check Roller Path of Cams.

1) While turning the engine, examine the cam discs and in particular, check the roller path of all cams for cracks, crackles and ruffl e. Also examine the rollers of the roller guides.

Note: if there are fl at spots on the roller and if some of the rollers may be blocked, the roller must be repla-ced by a new one, see working card 508-01.00.

To Check Camshaft Bearings.

2) The wearing surface of the camshaft bear-ings cannot be checked without dismounting the cam shaft. However, ab-normal wear of one or more bearings will become apparent in the form of burrs of white metal at the circumference of the camshaft journal, and in that case the bearing will in no doubt be discoloured, as well.

The bearing clearance is measured with a feeler gauge, see data sheet 500.35.

To Replace Camshaft Bearing.

3) If one or several of the camshaft bearings should be replaced, the camshaft must be wholly or partly dismantled.

Dismount the fuel oil feed pump, if mounted, and check that the camshaft sections are marked in relation to each other. Disassemble the camshaft aft (toward fl y wheel) of the bearing that is to be replaced. Dismount all roller guides that are located forward of the disassembling position, see working card 508-01.00 and 508-01.05.

Pull the disconnected sections of the camshaft so far a head that the bearing which is to be replaced is free.

Take out the locating screw of the camshaft bearing concerned and push the bearing out of the bore in the engine frame, see fi g 1.

Check the lubricating oil ducts to the bearing for free fl ow.

95.02 - ES0S-G

507-01.05Edition 01H Inspection and Replacement of Camshaft Bearing Working Card

Page 2 (2)

Camshaft bearing

Hole for lubricating oil

Locating screw

Frame

Fig 1.

Mount a new camshaft bearing in the bore and make sure that the hole for insertion of the locating screw in the bearing is in a correct position. Lock the bea-ring by means of the locating screw, which is to be provided with a new gasket. To facilitate the fi tting of the bearing it can be cooled down with Co2.

Inspect the camshaft journal for seizures.

If necessary, the camshaft section must be entirely removed from the engine, and the journal concerned must be polished.

Coat all the journals of the camshaft section with clean lubricating oil and push the camshaft into position, making sure that the marks on the fl anges coincide.

Assemble the sections and fi t the bolts (coated with copaslip or similar).

Tighten the nuts with a torque spanner, see data sheet 500.40.

Mount all roller guides as well as the fuel oil feed pump.

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Safety precautions:

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

Description:

Nominal adjustment of camshaft. (Adjustment of camshaft in relation to crankshaft).

Starting position:

Camshaft assembled as per timing order, mounted in frame and roller gear house.

Related procedure:

Adjustment of the maximum combustion pressure, 514-05.01

Manpower:

Working time : 3 hoursCapacity : 1 man

Data:

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

507-01.20Edition 01H

96.30 - ES0S-L

L23/30H

Adjustment of CamshaftWorking CardPage 1 (2)

Special tools:

Plate no Item no Note.

Hand tools:

Depth gauge.

Replacement and wearing parts:

Plate no Item no Qty. /

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96.30 - ES0S-L

507-01.20Edition 01H Adjustment of Camshaft Working Card

Page 2 (2)

If the intermediate wheel has been dismantled a nominal adjustment of the camshaft compared to the crankshaft (timing) must be made as follows:

1) The crankshaft is turned to TDC (top dead centre) for cylinder no 1.

Cylinder numbering, see page 500.11.

2) Roller guide for fuel oil pump cylinder no. 1 is mounted and the camshaft is turned in a position where the roller guide rests on the cicular part af the cam, see fi g 1.

Cam for exhaust valve

Cam for fuel oil pump

Roller guide

Seen from front edge

Fig 1.

Fig 2.

"Nominal size"

3) The "nominal size" is measured with a depth gauge, i.e. the distance from the upper edge of the roller guide house to the thrust gauge pressed into the roller guide, see fi g 2.

4) The camshaft is turned - in the engines direc-tion of rotation (see page 500.12) - until the "nominal size" (as described in item 3) is reduced with the lead, mentioned in "Lead of Fuel Pump".

Note: "Lead of fuel pump" is shown in the table "Ad-jusment after the trail" in the Shop Test Protocol.

5) When items 1 - 4 are completed and correct the intermediate wheel can be mounted and tightened up again (torque moment, see page 500.40).

For adjustment of the single fuel oil pumps (separately and assembled), see working card 514-05.01.

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L23/30H

Intermediate WheelPlatePage 1 (2)

94.22 - ES0S

50701-01H

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L23/30H

94.22 - ES0S

50701-01H Intermediate Wheel PlatePage 2 (2)

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

Tandhjul, kompletinkl. item 119, 120, 132, 144, 156

Lejetap

Pasbolt

Selvlåsende møtrik

Tandhjul

Tandhjul

Lejebøsning

Pasbolt

Selvlåsende møtrik

Rør

Sikringsplade

Pakning

Mellemstykke

Sikkerhedsskive

Prop

Rør

Prop

Mellemstykke

Pakning

Dæksel

Skrue

+ Item nr. 061 og 073 kræver en individuel tilpasning, før monte-ring kontakt MAN B&W, Holeby

Gear wheel, complete incl. item 119, 120, 132, 144, 156

Axle journal

Fitted bolt

Self locking nut

Gear wheel

Gear wheel

Bearing bush

Fitted bolt

Self locking nut

Pipe

Locking plate

Gasket

Connection piece

Securing washer

Nipple plug

Pipe

Nipple plug

Connection piece

Gasket

Cover

Screw

+ Item No. 061 and 073 require an indivi-dual matching, before mounting, contact MAN B&W, Holeby

Designation BenævnelseBenævnelseDesignation

024

048

061+

073+

119

120

132

144

156

168

181

193

203

215

227

239

240

252

264

276

288

1/E

1/E

3/E

3/E

1/E

1/E

1/E

4/E

4/E

1/E

6/E

2/E

1/E

2/E

1/E

1/E

1/E

1/E

3/E

1/E

6/E

Item No.

Qty.

Qty.

Item No.

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Camshaft and Camshaft BearingPlatePage 1 (2)

99.41 - ES0

50705-07H

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MAN Diesel

Styreaksel agter/mel-lem, 5 cyl. motor

Styreaksel "for"5 cyl. motor

Styreakselleje

Styreakselleje5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Tandhjul

Skrue

Fjederskive

Skrue

Selvlåsende møtrik5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Nav

Skrue

Fjederskive

Sikringsring

Skrue5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Fjedertap

Kobling

Skrue

Styreaksel komplet,5 cyl. motor, inkl. item 026, 038, 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 374

Styreaksel, agter6 cyl. motor

Camshaft, aft/interme-diate, 5 cyl. engine

Camshaft "fore"5 cyl. engine

Camshaft bearing

Camshaft bearing5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Gear wheel

Screw

Spring washer

Screw

Self locking nut5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Hub

Screw

Disc spring

Guide ring

Screw5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Spring pin

Coupling

Screw

Camshaft, complete for 5 cyl. engine, incl. item 026, 038, 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 374

Camshaft "aft"6 cyl. engine

Designation BenævnelseBenævnelseDesignation

026

038

051

063

075

087

099

109

110

122

134

146

158

171

183

195

205

217

229

4/E

1/E

1/E

5/E6/E7/E8/E

1/E

10/E

10/E

10/E

50/E40/E52/E66/E

1/E

6/E

6/E

1/E

40/E30/E42/E56/E

2/E

1/E

2/E

1/E

1/E

Item no Qty. Qty.

Item no

99.41 - ES0S

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

Camshaft and Camshaft Bearing PlatePage 2 (2)50705-07H

L23/30H

230

242

254

266

278

291

301

313

325

337

349

350

362

374

1/E

1/E

4/E

5/E

6/E

1/E

1/E

1/E

1/E

1/E

1/E

6/E7/E8/E9/E

6/E7/E8/E9/E

1/E

Camshaft "aft"7 cyl. engine

Camshaft "aft"8 cyl. engine

Camshaft , intermed-iate, 6 cyl. engine

Camshaft , intermed-iate, 7 cyl. engine

Camshaft , intermed-iate, 8 cyl. engine

Camshaft "fore"6 cyl. engine

Camshaft "fore"7 cyl. engine

Camshaft "fore"8 cyl. engine

Camshaft complete,6 cyl. eng. incl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 229, 254, 291, 374

Camshaft complete,7 cyl. eng. incl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 230, 266, 301, 374

Camshaft complete,8 cyl. eng. incl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 242, 278, 313, 374

Guide screw5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Packing ring5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Shaft

Styreaksel, agter7 cyl. motor

Styreaksel, agter8 cyl. motor

Styreaksel mellem6 cyl. motor

Styreaksel mellem7 cyl. motor

Styreaksel mellem8 cyl. motor

Styreaksel "for"6 cyl. motor

Styreaksel "for"7 cyl. motor

Styreaksel "for"8 cyl. motor

Styreaksel komplet,6 cyl. motor inkl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 229, 254, 291, 374

Styreaksel komplet,7 cyl. motor inkl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 230, 266, 301, 374

Styreaksel komplet,8 cyl. motor inkl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 242, 278, 313, 374

Styreskrue5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Pakningsring5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Aksel

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L23/30H

Camshaft and Camshaft BearingPlatePage 1 (2)

05.24 - ES0

50705-17H

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MAN Diesel

Styreaksel agter/mel-lem, 5 cyl. motor

Styreaksel "for"5 cyl. motor

Styreakselleje

Styreakselleje5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Tandhjul

Skrue

Fjederskive

Skrue

Selvlåsende møtrik5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Nav

Skrue

Fjederskive

Sikringsring

Skrue5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Fjedertap

Kobling

Skrue

Styreaksel komplet,5 cyl. motor, inkl. item 026, 038, 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 374

Styreaksel, agter6 cyl. motor

Camshaft , aft/interme-diate, 5 cyl. engine

Camshaft "fore"5 cyl. engine

Camshaft bearing

Camshaft bearing5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Gear wheel

Screw

Spring washer

Screw

Self locking nut5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Hub

Screw

Disc spring

Guide ring

Screw5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Spring pin

Coupling

Screw

Camshaft, complete for 5 cyl. engine, incl. item 026, 038, 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 374

Camshaft "aft"6 cyl. engine

Designation BenævnelseBenævnelseDesignation

026

038

051

063

075

087

099

109

110

122

134

146

158

171

183

195

205

217

229

4/E

1/E

1/E

5/E6/E7/E8/E

1/E

10/E

10/E

10/E

50/E40/E52/E66/E

1/E

6/E

6/E

1/E

40/E30/E42/E56/E

2/E

1/E

2/E

1/E

1/E

Item no Qty. Qty.

Item no

05.24 - ES0

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

Camshaft and Camshaft Bearing PlatePage 2 (2)50705-17H

L23/30H

230

242

254

266

278

291

301

313

325

337

349

350

362

374

1/E

1/E

4/E

5/E

6/E

1/E

1/E

1/E

1/E

1/E

1/E

6/E7/E8/E9/E

6/E7/E8/E9/E

1/E

Camshaft "aft"7 cyl. engine

Camshaft "aft"8 cyl. engine

Camshaft , intermed-iate, 6 cyl. engine

Camshaft , intermed-iate, 7 cyl. engine

Camshaft , intermed-iate, 8 cyl. engine

Camshaft "fore"6 cyl. engine

Camshaft "fore"7 cyl. engine

Camshaft "fore"8 cyl. engine

Camshaft complete,6 cyl. eng. incl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 229, 254, 291, 374

Camshaft complete,7 cyl. eng. incl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 230, 266, 301, 374

Camshaft complete,8 cyl. eng. incl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 242, 278, 313, 374

Guide screw5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Packing ring5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Shaft

Styreaksel, agter7 cyl. motor

Styreaksel, agter8 cyl. motor

Styreaksel mellem6 cyl. motor

Styreaksel mellem7 cyl. motor

Styreaksel mellem8 cyl. motor

Styreaksel "for"6 cyl. motor

Styreaksel "for"7 cyl. motor

Styreaksel "for"8 cyl. motor

Styreaksel komplet,6 cyl. motor inkl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 229, 254, 291, 374

Styreaksel komplet,7 cyl. motor inkl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 230, 266, 301, 374

Styreaksel komplet,8 cyl. motor inkl. item 109, 110, 122, 134, 146, 158, 171, 183, 195, 205, 242, 278, 313, 374

Styreskrue5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Pakningsring5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Aksel

Operating gear

508/608

MAN Diesel

DescriptionPage 1(1) Operating Gear for Valve and Fuel Injection Pumps 508.01

Edition 06H

Roller Guides

The fuel injection pumps and the rocker arms for inlet and exhaust valves are operated by the cams, on the camshaft through roller guides. The roller guides for fuel pump, inlet and exhaust valves are located in bores in a common housing for each cylinder, this housing is bolted to the engine frame.

The roller runs on a bush fi tted on a pin that is pres-sed into the roller guide and secured by means of a lock screw.

Operating Gear for Fuel Injection Pumps

The injection pumps which are mounted directly on the roller guide housing are activated via thrust pieces from the roller guide.

The roller is pressed down on to the cam by a spring, which is fi xed between the roller guide and the foot plate of the fuel injection pump.

Operating Gear for Inlet and Exhaust Valves

The movment from the roller guides for inlet and exhaust is transmitted via the push rods the rocker arms and spring-loaded valve bridges to each of the two valve seats. The bridge is placed between the valve spindles and in the one end it is provided with a pressed-on thrust shoe and in the other end it is fi tted with a thrust screw for adjustment of the valve clearance.

On its top the bridge is controlled by a spherical thrust shoe on the rocker arm and at the bottom by a guide which rests in a spherical socket in the cylinder head.

08.17 - ES0S

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Valve bridge Rocker arm

Valve spindle

Push rod

Roller guide housing

Roller guide

Pin

Roller

Camshaft

Fig. 1. Valve Operating Gear.

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Safety precautions:

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

Description:

Dismounting, inspection and/or overhaul, and mounting of valve roller guides.Inspection of roller guide housing.

Starting position:

Top cover for cylinder head and cover for fuel injection pump removed.

Related procedure:

Inspection of fuel injection pump roller guide, 508-01.05Control and adjusting of valveclearance, 508-01.10

Manpower:

Working time : 2 hoursCapacity : 1 man

Data:

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

Special tools:

Plate no Item no Note.

52006 261 20 - 120 Nm

Hand tools:

Ring and open end spanner, 19 mm.Ring and open end spanner, 24 mmSocket spanner, 19 mm.Socket spanner, 10 mmAllen key, 3 mm.Allen key, 10 mmRatchet spanner.Hammer.Drift.

Replacement and wearing parts:

Plate no Item no Qty/

50801 185 4/cyl 50801 220 2/cyl 50801 232 1/cyl

08.17- ES0

Inspection of Valve Roller Guides

L23/30H

508-01.00Edition 07H

Working CardPage 1 (2)

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08.17 - ES0S

Working CardPage 2 (2)

Dismounting of Roller Guide.

1) Turn the engine so that the roller, rests on the circular part of the cam.

2) Unscrew the nuts which secure the rocket arm brackets, and lift off the rocker arm with brackets.

3) Remove the push rods (1), see fi g 1.

5) Dismount the screws (3) which secure the roller guide top cover, take off the cover lift out the roller guide (5).

Disconnect any pipes that may be in the way (lub. oil and fuel oil pipes).

6) If the roller guide housing is to be dismantled, the fuel injection pump and the fuel injection pump roller guide are to be dismounted, see working card 514-01.05 and a number af lubricating oil and fuel oil pipes are also to be disconnected.

The roller guide housing (6) cannot be dismantled with the roller guides fi tted.

7) If the event of any marks or scores from sei-zures, these must be polished away.

8) Inspect the spherical stud for deformations (replace as necessary).

Examine the surface of the roller for marks and other deformations.

Make sure that there is free ply between the roller and the bush and the shaft pin, and replace the bush, if necessary.

Replacement of Roller, Bush and Shaft Pin.

9) Remove the lock screw which secures the roller guide shaft pin and push out the shaft pin.

The roller, shaft pin, and bush can now be replaced as required.

10) Blow through the lubricating ducts in roller guide and roller guide housing, and clean the lu bri ca ting grooves.

Mounting of Roller Guide.

11) When assembling the parts, which is carried out in the reverse order to the above care must be exercised not to damage the o-rings when mounting the proctecting tube.

12) Adjusting of valve clearance, see working card 508-01.10.

4) Loosen the lock screw for the push rod pro tec-ting tube, see plate 50801, item 207, on the roller guide top cover and lift up and remove the protecting tube (2).

Fig 1.

6

4

5

3

2

1

Inspection of Valve Roller Guides508-01.00Edition 07H

L23/30H

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Safety precautions:

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

Description:

Dismounting, inspection and/or overhaul, and mounting af roller guide for fuel injection pump.

Starting position:

Cover for fuel injection pump removed.Fuel injection pump has been removed, 514-01.05

Related procedure:

Adjustment and/or check of max. combustion pressure, 514-01.20

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

508-01.05Edition 01H

96.03 - ES0S

Special tools:

Plate no Item no Note

Hand tools:

Allen key, 3mm.Hammer.Drift.

Replacement and wearing parts:

Plate no Item no Qty/

Working CardPage 1 (2) Inspection of Fuel Injection Pump Roller Guide

L23/30H

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508-01.05Edition 01H Inspection of Fuel Injection Pump Roller Guide Working Card

Page 2 (2)

L23/30H

Dismounting of Roller Guide.

1) Remove the support ring (1) and spring (2) and take up the roller guide (3), see fi g 1.

3

2

1

Fig 1.

Inspection of Roller Guide.

2) If the event of any marks or scores from sei-zures, these must be polished away.

3) Inspect the spherical stud for deformations (replace as necessary).

Examine the surface of the roller for marks and other deformations.

Make sure that there is free ply between the roller and the bush and the shaft pin, and replace the bush if necessary.

Replacement of Roller, Bush and Shaft Pin.

4) Remove the lock screw which secures the roller guide shaft pin and push out the shaft pin.

The roller, shaft pin, and bush can now be replaced as required.

5) Blow through the lubricating ducts in roller guide and roller guide housing, and clean the lub ri ca ting grooves.

Mounting of Roller Guide.

6) When assembling the parts which is carried out in the reverse order.

7) For adaption of the thrust piece of the roller guide, see working card 514-01.20.

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Safety precautions:

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

Description:

Control and/or adjusting of valve clearance.

Starting position:

Cover for rocker arm are removed.All indicator valves open.

Related procedure:

Manpower:

Working time : 1/4 hourCapacity : 1 man

Data:

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

508-01.10Edition 01H

L23/30H

Special tools:

Plate no Item no. Note

52008 022 Exhaust 52008 010 Inlet 52010 011

Hand tols:

Ring and open end spanner, 24 mm.Big screw driver.

Replacement and wearing parts:

Plate no Item no Qty/

See also plate 50502.

Control and Adjusting of Valve ClearanceWorking CardPage 1 (3)

96.38 - ES0S

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Adjusting of Inlet Valve Clearance.

1) Turn the engine so that the roller, rests on the circular part of the cam, i.e. the inlet valves and the exhaust valves are closed.

2) Loosen the adjustment screws on valve bridge and rocker arm, see fi g 1.

508-01.10Edition 01H Control and Adjusting of Valve Clearance Working Card

Page 2 (3)

Fig. 1.

3) Clearance between valve bridge and valve spindle, see page 500.40.

4) Place the feeler gauge marked with "correct" 0,50 mm above the valve spindle nearest to the rocker arm bracket, see fi g 1.

5) Adjust the clearance between valve bridge and valve spindle by means of the adjustment screw on the rocker arm (above the push rod) and tighten the lock nut.

Fig 2.

The feeler gauge is to remain in this position when adjusting the clearance of the other valve.

6) Place another feeler gauge, at the same size 0,50 mm above the other valve spindle, see fi g 2.

7) Adjust the clearance between valve bridge and valve spindle by means of the adjusment screw on the valve bridge, and tighten the lock nut, see fi g 2.

8) Check that the clearance is correct si mul ta neo-us ly at both valve spindles.

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Control and Adjusting of Valve ClearanceWorking CardPage 3 (3)

Fig 3.

96.38 - ES0S

Adjusting af Exhaust Valve Clearance.

9) Carry out adjustment in the same way as described for the inlet valves, but using the feeler gauge for exhaust valve clearance 0,90 mm.

10) The feeler gauges for checking the clearance have two gauges which are marked "incorrect" and "correct", the latter to be used when adjusting the valve clearance, see fi g 3.

After tightening up the counter nuts on rocker arms and valves bridge, be sure that the feeler gauges marked "correct" can be inserted into the two clear-anc es simultaneously as where it must not be pos si ble to insert the gauges marked "incorrect".

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PlatePage 1 (2) Roller Guide and Push Rods

08.16 - ES0

50801-07H

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Hus forrullestyr

Rullestyr for pumpe

Tap

Foring

Rulle

Pinolskrue

Tryktap

Skive for fjeder

Fjeder

Tryktap

Skive

Skrue

Kugletap

Skive

Skærmrør

O-ring

Dæksel

Pinolskrue

Skrue

Pakning

Pakning

Styrestift

Skrue

Tryktap

Rullestyr for ventil

Stødstang

Stødstang komplet, inkl. item 268 og 293

08.16 - ES0

Housing forroller guides

Roller guide forpump

Pin

Bush

Roller

Lock screw

Thrust pin

Washer for spring

Spring

Thrust pin

Washer

Screw

Ball pin

Washer

Protecting tube

O-ring

Cover

Lock screw

Screw

Gasket

Gasket

Guide pin

Screw

Thrust pin

Roller guide forvalve

Push rod

Push rod comp., incl. item 268 and 293

Designation BenævnelseBenævnelseDesignation

Roller Guide and Push Rods

L23/30H

016+

028

041

053

065

077

089

090

100

112

124

136

148

161

173

185

197

207

219

220

232

244

256

268

281

293

303

1/C

1/C

3/C

3/C

3/C

3/C

1/C

1/C

1/C

1/C

1/C

2/C

2/C

8/C

2/C

4/C

2/C

2/C

4/C

2/C

1/C

2/C

8/C

4/C

2/C

2/C

2/C

Item No.

Qty.

Qty.

Item No.

50801-07H PlatePage 2 (2)

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/C = Antal/Cylinder

315 1/C Valve gear complete, as shown on plate 50801 except item 161, 173, 185, 220, 232, 244, 256, 303

+ Item No 016 require an individual match-ing before mounting, contact MAN Diesel

Ventilbevægelsekomplet, som vist på plate 50801 undtagen item 161, 173, 185, 220, 232, 244, 256, 303

+ Item nr. 016 kræveren individuel tilpasningfør montering, kontaktMAN Diesel

Control/safety

509/609

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509.01Edition 01H

96.38 - ES0S-G

DescriptionPage 1 (2) Control and Safety Systems

Governor

The engine speed is controlled by a hydraulic go-vernor. The purpose of the governor is to regulate the rate of delivery from the fuel pumps, so that the engine speed is kept within certain limits, indepen-ding on the load.

Information about the design, function and operation of the governor is found in the special governor instruction book.

The governor is mounted on the fl ywheel end of the engine and is driven from the camshaft via a cy lindrical gear wheel and a set of bevel gears.

Pick-up for Engine RPM

The pick-up for transfer of signal to the tacho meter instrument for engine RPM is mounted on the fl ywheel end cover of the engine.

A signal varying proportionally to engine RPM is created in the pick-up by the rotating toothed im-pulse wheel mounted on the camshaft end.

Pick-up for Turbocharger RPM

See turbocharger instruction book, section 512.

Regulating Shaft

The governor movements are transmitted through a spring-loaded pull rod to the fuel pump regulating shaft which is fi tted along the engine.

The spring-loaded pull rod permits the governor to give full defl ection even if the stop cylinder of the manoeuv ring system keeps the fuel pump regulating shaft at "no fuel" position.

Each fuel pump is connected to the common, lon-gitudinal regulating shaft by means of a two-piece, spring-loaded arm.

L23/30H

Should a fuel pump plunger seize in its barrel, thus blocking the regulating guide, governing of the re-maining fuel pumps may continue unimpede owing to the spring-loaded linkage be tween the blocked pump and the regulating shaft.

Stop Screw for Max. Delivery Rate

The bracket for stop cylinder/limiting cylinder is fi tted with a stop screw which prevents the fuel pumps from being set to a higher delivery rate than what corresponds to the permissible overload rating.

This is effected by the arm on the regulating shaft being stopped by the stop screw, see fi g. 1.

Mechanical Overspeed (SSH 81)

The engine is protected against overspeeding in the event of, for instance, governor failure by means of an overspeed trip.

The engine is equipped with a stopping device which starts to operate if the maximum permissible revo lution number is exceeded.

The overspeed tripping device is fi tted to the end cover of the lubricating oil pump and is driven through this pump.

If the pre-set tripping speed is exceeded, the spring-loaded fl yweight (1), see fi g. 1, will move outwards and press down the arm (2).

The arm is locked in its bottom position by the lock pin (3) which is pressed in by the spring (4).

At the same time the arm (2) presses down the spindle (5), and the pneumatic valve (6) opens, whereby compressed air will be led to the Lambda cylinder, see description 509.10, in which the piston is pressed forward and, through the arm, turns the fuel pump regulating rod to STOP position, thereby the engine stops, the spring-loaded pull rod con-nection to the governor being compressed.

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DescriptionPage 2 (2)Control and Safety Systems509.01

Edition 01H

L23/30H

The engine can be stopped manually by pressing down the button (7), see fi g. 1, which will activate the spring-loaded fl y weight (1) through the lever (8).

If the overspeed has been activated the overspeed must be reset before the engine can be started. Reset is done by means of the button (10).

The overspeed alarm (SAH 81) is activated by means of the micro switch (9).

7

1

83

52

6

1

9

Normal poisition

1. Flyweight

2. Arm

3. Lock pin

4. Spring

5. Spindle

6. Pneumatic valve

7. Button

8. Lever

9. micro switch

10. Button

Overspeed activated

Fig 1. Mechanical overspeed (SSH 81).

2 5 3 4 10 10

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509.05Edition 01H

Push button

Valves

Flexible hose

Rubber element

On the engine is as standard mounted an instrument panel.

The following incorporating pressure gauges for the most essential pressures.

Pressure gauge for:

PI 01 LT fresh water, inlet to air cooler PI 10 HT fresh water, inlet engine PI 21/22 Lubricating oil, inlet/outlet to fi lter PI 23 Lub. oil, inlet to turbocharger PI 31 Charge air, outlet from cooler PI 40 Fuel oil, inlet to engine

Fig. 2. Cross section of instrument panel

Instruments and Automatics

L23/30H

DescriptionPage 1 (3)

Main Instrument Panel

As standard the engine is equipped with an instru-ment panel, comprising instruments for visual indi-ca tion of the most essential pressures.Illu strated on fi g. 1.

The instrument panel is mounted fl exibly on rubber elements and all manometer connections are con-nec ted to the panel by means of fl exible hoses, as shown on fi g. 2.

Fig. 1. Lay-out of instrument panel

The connecting pipes to the manometers are equip-ped with valves which make it possible to replace the manometers during operation.

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Instruments and Automatics509.05Edition 01H

L23/30H

DescriptionPage 2 (3)

Instrumentation

As standard the engine is supplied with the following instrumentation mounted local on the engine:

Thermometer TI 01 LT water - inlet air cooler

Thermometer TI 02 LT water - outlet from air cooler

Thermometer TI 03 LT water - outlet from lub. oil cooler

Thermometer TI 10 HT fresh water - inlet to engine

Thermometer TI 11 HT fresh water - outlet each cylinder

Thermometer TI 20 Lubricating oil - inlet to cooler

Thermometer TI 22 Lubricating oil - outlet from fi lter

Thermometer TI 30 Charge air - inlet to cooler

Thermometer TI 31 Charge air - outlet from cooler

Thermometer TI 40 Fuel oil - inlet to engine

Thermometer TI 60 Exhaust gas - outlet each cylinder

Thermometer TI 61 Exhaust gas - outlet turbocharger

The actual number of the instrumentation for the plant can be seen on the diagrams for the specifi c plant in the sections 512-513-514-515-516.For code identifi cation see 500.20.

Pressostates and Thermostates

The engine is supplied with a number of alarm- and shut-down functions. The alarms shall via the alarm panel worn against an abnormal working condition, which can lead to break down and the shut-down functions shall stop the engine before a break down. I.e. a shut-down is "worse" than an alarm because a shut-down is given if the engine could be severe damage by running on these conditions.

As standard the engine is equipped with:

Shut-down Switches for

- too low lubricating oil pressure - inlet engine - too high HT FW temperature - outlet engine - too high engine speed (over speed)

Alarm Switches for

- leaking fuel oil - too low lubricating oil pressure - inlet engine - too low prelubricating oil pressure (level alarm)

- too high press. drop across lub. oil fi lter - too high HT FW temperature - outlet engine - too low starting air pressure - inlet engine - too high engine speed (overspeed)

The actual number and type of the alarm- and shut-down switches for the plant can be seen in the list "Engine Automatic part list" in this section.

Leakage Alarm (LAH 42)

Waste and leak oil from the comparement, for the injection equipment, fuel valves, high-pressure pipes and engine feed pump (if mounted) is led to a fuel leakage alarm unit.

Fig. 4. Fuel oil leakage alarm.

Normal leakage

High level

Waste oil outlet

AlarmNormal

C

B

A

Leakoil

Leak alarmNormal level

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DescriptionPage 3 (3)

96.03 - ES0S

Alarm for Prelubricating (LAL 25)

Alarm for missing prelubricating, when the engine is stopped is given by means of a level switch (LAL 25) mounted in the main lubricating oil pipe.

Alarm and Shut-down for Overspeed

When the mechanical overspeed is activated, see 509.01 fi g. 2, a micro-switch will release the alarm for overspeed (SAH 81) and activate the shut-down solenoid in the governor.

The latter function is a back-up for the mechanical overspeed.

The alarm unit consists of a box with a fl oat switch for level monitoring, see fi g. 4.

The supply fuel oil to the engine is led through the unit in order to keep heated up, thereby ensuring free drainage passage even for high-viscous wa-ste/leak oil.

Under normal conditions there will always be a smal-ler amount of waste/leak oil from the compare ment, this will be led out through the bore "A" in the pipe "B" as illustrated.

In case of a larger than normal leakage, the level in the box will rise and the level switch "C" will be activated. The larger amount of leak oil will be lead out through the top of the pipe "B".

509.05Edition 01H

Instruments and Automatics

L23/30H

MAN Diesel

DescriptionPage 1 (2)

509.10Edition 09H

Lambda Controller

04.15 - ES0-G

L23/30H

Purpose

The purpose with the lambda controller is to prevent injection of more fuel in the combustion chamber than can be burned during a momentary load in-crease. This is carried out by controlling the relation between the fuel index and the charge air pressure.

The Lambda controller is also used as stop cylin-der.

Advantages

The lambda controller has the following advan-tages:

- Reduction of visible smoke in case of sud- den momentary load increases.

- Improved load ability.

- Less fouling of the engine's exhaust gas ways.

- Limitation of fuel oil index during starting procedure.

Principles for functioning

Figure 1 illustrates the controller's operation mode. In case of a momentary load increase, the regulat-ing device will increase the index on the injection pumps and hereby the regulator arm (1) is turned, the switch (2) will touch the piston arm (3) and be pushed downwards, whereby the electrical circuit will be closed.

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Thus the solenoid valve (4) opens. The jet system is activated, the turbocharger accelerates and increases the charge air pressure, thereby pressing the piston (3) backwards in the lambda cylinder (5). When the lambda ratio is satisfactory, the jet system will be de-activated.

At a 50% load change the system will be activated for about 3-8 seconds.

If the system is activated more than 10 seconds, the solenoid valve will be shut off and there will be a remote signal for "jet system failure".

Fuel oil limiting during start procedure

During the start procedure the lambda controller is used as an index limiter.

Hereby heavy smoke formation is prevented during start procedure and further the regulating device cannot over-react.

Air Consumption

At 50% step load the air consumption will be as follows:

Cyl. no. 5 6 7 8

Nm3 0.70 0.84 0.98 1.12

MAN Diesel

509.10Edition 09H

Fig 1 Lambda controller incl. start limitation

~

Charge airreceiver

Engine'scompressionair system

4

1

2

3

5

6

1. Regulating arm2. Switch (Pick-up)3. Piston4. Solenoid valve5. Lambda controller6. Overspeed device

(mecanical activated 3/2 valve)

DescriptionPage 2 (2)Lambda Controller

L23/30H

04.15 - ES0

MAN Diesel

L23/30H

509.35Edition 01H

94.26 - ES2S-G

Starting Box

Engine / Turbocharger RPM

By activating the "Engine RPM/TC RPM" button, the indication is changed.

Engine RPM indication is green light-emitting diodes and turbocharger RPM indication is red light-emit-ting diodes.

External Indications

There are output signals for engine RPM and tur-bocharger RPM.Engine: 0 - 1200 RPM ~ 4-20 mATC: 0 - 60000 RPM ~ 4-20 mA

The pushbuttons for "Remote", "Local" and "Block-ing" have potential free switches for external indi-cation.

All components in the starting box are wired to the built-on terminal box.

DescriptionPage 1 (1)

Description

The starting box is mounted on the engine's control side. On front of the box there are the following indications/pushbuttons:

- Indication of engine or turbocharger RPM - Indication of electronic overspeed - Pushbutton for "Manual Start" - Pushbutton for "Manual Stop" - Pushbutton for "Remote" * - Pushbutton for "Local" * - Pushbutton for "Blocking" * - Pushbutton for change-over between engine and turbocharger RPM

* The function chosen is indicated in the pushbut- ton. See fi g 1.

Manual Start

The engine can be started by means of the start button, but only if the button "Local" is activated.

The manual, local start is an electrical, pneumatic start, i.e. when activating the start button a sole-noid valve opens for air to the air starter, thereby engaging the starter and starting the diesel engine. Throughout the starting cycle the start button must be activated.

The air starter is automatically disengaged when the diesel engine exceeds 140 RPM. If the start button is disengaged before the diesel engine has exceeded 140 RPM, further starting cycles are blocked, until 5 sec. after the engine is at standstill.

Remote Start

Remote start can only take place if the pushbutton for "Remote" is activated.

Manual Stop

The "Manual Stop" button is connected to the stop coil on the governor.

Blocking

If "Blocking" is activated, it is not possible to start the diesel engine. Fig 1. Starting box

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DescriptionPage 1 (1) Converter for Engine- and Turbocharger RPM Signal

L23/30H

Engine RPM signal

For measuring the engine's RPM, a pick-up mounted on the engine is used giving a frequency depending on the RPM. To be able to show the engine's RPM on an analogue tachometer, the frequency signal is sent through an f/I converter (frequency/current converter), where the signal is transformed into a proportional 4-20 mA ~ 0-1200 RPM signal.

Further, the converter has following signals:

- overspeed - engine run - safe start - tacho fail

96.30 - ES2S-G

The "engine run" signals will be given through a relay. One for synchronizing and one for start/stop of pre. lub. oil pump or alarm blocking at start/stop.

Safe start

When the safe start signal is activated the engine can start. When the engine reach 140 RPM the air starter will be shut-off.

Further, the safe start signal is a blocking function for the air starter during rotation.

Tacho fail

The tacho fail signal will be on when everything is normal. If the pick-up or the converter fails the signal will be deactivated. E.g. if there is power supply failure.

The converter for engine RPM signal is mounted in the terminal box on the engine.

Turbocharger RPM signal

For measuring the turbocharger RPM, a pick-up mounted on the engine is used giving a frequency depending on the RPM. To be able to show the turbocharger's RPM on an analogue tachometer, the frequency signal is sent through a f/I converter (frequency/current converter), where the signal is transferred into a proportional 4-20 mA ~ 0-60000 RPM.

The converter is mounted in the terminal box on engine.

509.40Edition 01H

Fig 2. Converter for TC RPM.

Fig 1. Converter for engine RPM.

Overspeed

When the engine speed reach the setpoint for elec-tronic overspeed the converter gives a shutdown signal and a alarm signal through a relay.

Engine run

When the engine speed reach 710 RPM or 200 RPM + 10 seconds the converter gives a "engine run" signal.

The engine run signal will be deactivated when the speed is 640 RPM. If the engine speed haven't been over 710 RPM the signal will be deactivated at 200 RPM.

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509-01.00Edition 01H

03.32 - ES0

L23/30H

Working CardPage 1 (2)

Special tools

Plate No Item No Note.

See Related Procedure

Hand tools

See Related Procedure

Replacement and wearing parts

Plate No Item No Qty. /

Functional Test and Adjustment of Safety, Alarm and Monitoring Equipment

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

Description

Function test and adjustment of safety, alarm and monitoring equipment.

Starting position

Related procedure

Overspeed trip 509-01.05Pressostate 509-05.00Thermostate 509-05.01Level switch (LAL 25) 509-05.02Analog pressure transmitter 509-05.03Analog temperature transmitter 509-05.04

Man power

Working time : hoursCapacity : man

Data

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

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L23/30H

03.32 - ES0

509-01.00Edition 01H

Working CardPage 2 (2)

Functional Test and Adjustment of Safety,Alarm and Monitoring Equipment

Maintenance of monitoring and safety sy-stems

One of the most important parameters in the pre-ventive work is that the alarm system as well as the shutdown and overspeed devices are functioning100%.

If some of these functions are out of operation, they have to be repaired immediately. If this is not possible because of the present working situation, the engine has to be under constant observation until it can be stopped.

It is recommended that all functions are tested every three months according to the mentioned workingcards.

The extent of the alarm and safety functions is vari- able from plant to plant.

For check of these functions use the working cards mentioned under related procedure on page 1.

Alarm System

It is important that all alarms lead to prompt investi-gation and remedy of the error.No alarm is insignifi cant. It is therefore important that all engine crew members are familiar with and well trained in the use and importance of the alarm system.The most serious alarms are equipped with slowdown and/or shutdown functions.

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Safety precautions:

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

Description:

Functional test and adjustment of overspeed trip.

Starting position:

Functional test and adjustment of safetyalarm and monitoring equipment, 509-01.00

Related procedure:

Manpower:

Working time : 1 hourCapacity : 1 man

Data:

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

509-01.05Edition 01H

96.03 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note

52009 016

Hand tools:

Allen key, 4 mm.Allen key, 2 mm.

Replacement and wearing parts:

Plate no Item no Qty/

Functional Test and Adjustment of Overspeed TripWorking CardPage 1 (2)

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96.03 - ES0S-G

509-01.05Edition 01H Functional Test and Adjustment of Overspeed Trip Working Card

Page 2 (2)

Turn the engine until the adjusting screw is opposite the opening on the side of the housing. Now loosen the lock screw and turn the adjusting screw, using the tubular pin spanner supplied, see fi g 2.

1) The engine is run up manually, (on governor "synchronizer") and at no load, while watching the tachometer.

On reaching the revolution number indicated on page 500.30 or in "Test Report", the overspeed trip-ping device must function, thus actuating the stop cylinders. The fuel injection pump control rods are now moved to zero index, and the engine stops.

2) If the overspeed device trip at a revolution number different from that stated on page 500.30 or in the "Test Report" the overspeed device must be adjusted.

Fig 1.

Adjustment of Overspeed Trip.

3) Remove both covers on the housing of the overspeed tripping device, see fi g 1.

Turn the adjusting screw outwards (slacken fl y weight spring) to reduce the revolution number. Be careful not to screw the adjusting screw so far out that it may touch the release arm. Tighten the lock screw and test the overspeed device again.

4) Refi t the covers when the overspeed device functions at correct revolution number.

5) The overspeed device can be tested manually by depressing the button on top af the housing, see fi g 1. This will activate the fl yweight and the arm for release of the air valve for the stop cylinders and the engine should thus stop. (This test must also be carried out without load).

6) It is recommended now and then, while the engine is at a standstill, to move the fl yweight by means of the push button to ensure that the fl y weight can always move with suffi cient ease.

Fig 2.

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Safety precautions:

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

Description:

Adjustment and test of on/off pressostate. (lub. oil,fuel oil, water etc.).

Starting position:

Functional test and adjustment of safetyalarm and monitoring equipment, 509-01.00

Related procedure:

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

509-05.00Edition 01H

91.45 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note

Hand tools:

Screw driver.Testing pump.Ring and open end spanner, 10 mm.

Replacement and wearing parts:

Plate no Item no Qty/

Adjustment and Test of On/Off PressostateWorking CardPage 1 (2)

0802

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MAN Diesel

L23/30H

Adjustment:

1) When the pressostate cover is removed and locking screw pos. 5, fi g 1 is loosened, the range can be set with the spindle pos. 1 while at the same time the scale pos. 2 is read.

91.45 - ES0S-G

509-05.00Edition 01H Adjustment and Test of On/Off Pressostate Working Card

Page 2 (2)

1. Range spindle. 2. Range scale. 3. Differential spindle. 4. Differential scale. 5. Locking screw.

Fig 1.

2) In pressostates having an adjustable dif fe ren-ti al, the spindle pos. 3 must be used to make the adjusment. The differential obtained can be read directly on the scale pos. 4.

Set points, see page 500.30.

Test:

It is possible to make a functional test of the pres-sure switch. This is to be carried out according to the following procedure.

3) Shut off system pressure with the valve pos 3, fi g 2.

1. Trial fl ange. 2. Drain screw. 3. Valve.

Fig 2.

4) Remove the screw pos. 2.

5) Mount the testing pump on the trial fl ange pos. 1.

Alarm for Falling Pressure:

6) Pump up the pressure until the switch has changed. The pressure will slowly be relieved and it must be checked that the switch change back to the pressure stated as the alarm point.

Alarm for Rising Pressure:

7) Pump up the pressure until the switch chang-es, and check that it happens at the stated alarm point.

8) After the fi nal check and adjustment, remove the testing pump, mount the screw pos 2 and open the valve pos 3.

0802

8-0D

/H52

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.12

MAN Diesel

Safety precautions:

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

Description:

Adjustment and test of on/off thermostate. (lub. oil, fuel oil, water etc.).

Starting position:

Functional test and adjustment of safetyalarm and monitoring equipment, 509-01.00

Related procedure:

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

509-05.01Edition 01H

96.26 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note

Hand tools:

Screw driver.Special testing devices.

Replacement and wearing parts:

Plate no Item no Qty/

Adjustment and Test of On/Off ThermostateWorking CardPage 1 (2)

0802

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.12

MAN Diesel

Test:

3) The funcional test of the thermostate is to be carried out according to the following procedure.

4) Take out the sensor of the pocket.

5) Test the sensor in a water bath, where the temperature can be controlled.

Alarm for Falling Temperature:

6) Raise the temperature until the switch has changed.

Then the temperature must slowly be reduced, and check that the switch changes back at the tem pe ra-ture stated in the list page 500.30.

Alarm for Rising Temperature:

7) Raise the temperature until the switch chang-es and check that is happens at the stated alarm points.

8) Adjust if necessary.

9) The sensor is mounted again.

L23/30H

Adjustment:

1) When the thermostate cover is removed and locking screw pos. 5, fi g 1 is loosened, the range can be set with the spindle pos. 1 while at the same time the scale pos. 2 is read.

96.26 - ES0S-G

509-05.01Edition 01H Adjustment and Test of On/Off Thermostate Working Card

Page 2 (2)

1. Range spindle. 2. Range scale. 3. Differential spindle. 4. Differential scale. 5. Locking screw.

Fig 1.

2) Thermostates having an adjustable dif fe ren ti al, the spindle pos. 3 can be used while the scale pos. 4 is read.

Set points, see page 500.30.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Function and test of level switch, LAL 25, in lubricating oil system.

Starting position:

Functional test and adjustment of safetyalarm and monitoring equipment, 509-01.00

Related procedure:

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

509-05.02Edition 01H

91.03 - ES0S-G

L23/30H

Special tools:

Plate no. Item no. Note

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty/

Function and Test of Level Switch (LAL 25)Working CardPage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

The level switch LAL 25, which is mounted on the main lubricating oil pipe of the engine, gives alarm for missing prelubricating oil.

Function.

1) By starting the prelubricating oil pump the main lubricating oil pipe will be fi lled with lubricating oil, which means that the level switch is lifted and the alarm is disconnected.

2) When the prelubricating is interrupted, the lub. oil will run out of the system through the bearings, which means that level switch is lowered and the alarm starts.

Test:

The test is carried out when the engine is stop-ped.

3) Start the lubricating oil pump, and let the pump run about 5 min.

4) Stop the prelubricating oil pump. The alarm must be released after 0 - 5 min., depending of the oil viscosity.

91.03 - ES0S-G

509-05.02Edition 01H Function and Test of Level Switch (LAL 25) Working Card

Page 2 (2)

Level switch

Main lubricating oil pipe

Vent pipe

Fig 1.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Adjustment and test of analogous pressure trans mit ter.

Starting position:

Functional test and adjustment of safetyalarm and monitoring equipment, 509-01.00

Related procedure:

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

509-05.03Edition 01H

91.45 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note

Hand tools:

Ring and open end spanner, 10 mm.Testing pump.

Replacement and wearing parts:

Plate no Item no Qty/

Working CardPage 1 (2) Adjustment and Test of Analogous Pressure Transmitter

0802

8-0D

/H52

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.12

MAN Diesel

L23/30H

The pressure transmitter registers the actual pres-sure and marks the change to an electrical signal, which adjusts the pressure.

91.45 - ES0S-G

509-05.03Edition 01H

Working CardPage 2 (2)

Adjustment:

1) The pressure transmitter shall not be ad just-ed, but the alarm limit must be set on the alarm plant. Kindly see the instruction book for the alarm plant.

Set points, see page 500.30.

Test:

2) It is possible to make a functional test of the pressure transmitter. This is carried out according to the following procedure:

3) Shut off system pressure with the valve pos. 3.

4) Remove the screw pos. 2.

5) Mount the testing apparatus on the trial fl ange pos. 1. and pump on a pressure within the working area of the transmitter.

If the alarm plant has an instrument unit, the pres-sure can be read on this. Other wise the test can be carried out by watching if the alarm plant gives any alarm, when the alarm limit which is stated on page 500.30 is exceeded (if the alarm plant is adjusted).

6) The screw pos. 2 is mounted, and the valve pos. 3. is opened after the test is fi nished.

Fig 1.

1. Trial fl ange. 2. Drain screw. 3. Valve.

Adjustment and Test of Analogous Pressure Transmitter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Adjustment and test of analogous temperature transmitter, (PT 100 sensor).

Starting position:

Functional test and adjustment of safetyalarm and monitoring equipment, 509-01.00

Related procedure:

Mampower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

509-05.04Edition 01H

96.26 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note

Hand tools:

Special testing devices.

Replacement and wearing parts:

Plate no Item no Qty/

Working CardPage 1 (2)

Adjustment and Test of Analogous Temperature Transmitter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

96.26 - ES0S-G

509-05.04Edition 01H

Working CardPage 2 (2)

Otherwise the test can be carried out by watching if the alarm plant gives any alarm, when the alarm limit which is stated on page 500.30 is exceeded (if the alarm plant is adjusted).

5) The sensor is mounted again.

The PT 100 sensor consists of a resistance wire which changes resistance depending on the tem-pe ra ture.

Look and design varify depending on the place of measurement and manufacture.

Adjustment:

1) The PT 100 sensor cannot be adjusted, but the alarm limit must be set on the alarm plant.

Set point, see page 500.30.

Test:

2) The functional trial of the PT 100 sensor can be carried out according to the following procedure.

3) Take out the sensor of the pocket.

4) Test the sensor by diving the sensor in the water. Compare the signal from the sensor with the water temperature.

If the alarm plant has an instrument unit, the tem pe-ra ture can be read on this.

Fig 1.

Adjustment and Test ofAnalogous Temperature Transmitter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions

Stopped engine Shut off starting air Shut off cooling water Shut off fuel oil Shut off cooling oil Stopped lub. oil circul.

Description

Adjustment of lambda controller.

Starting position

Related procedure

Manpower

Working time : 1 hourCapacity : 1 man

Data

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

509-10.00Edition 13H

L23/30H

Lambda ControllerWorking CardPage 1 (3)

03.13 - ES0

Special tools

Plate no Item no Note

Hand tools

Adjustable spanner 10"-12"

Replacement and wearing parts

Plate no Item no Qty /

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Working CardPage 2 (3)

L23/30H

03.13 - ES0

Lambda Controller509-10.00

Edition 13H

2) Turn the lever (fi g 2) of the governor a few times to full load with an adjustable spanner (spring between governor and fuel rack full com-pressed). Check that the fuel index is 17 at the fuel pump.

3) In case of large deviation from index 17 ad-justment is done by turning the regulating arm (4), fi g 3. Finally adjustment is done at the adjustment screw (3), fi g 3.

4) Adjustment completed.

Adjustment of the Stop Screw

5) Remove pipe for charge air pressure.

6) Supply air pressure until the piston rod reaches its upper position.

7) Turn the lever (fi g 2) of the governor to full load with an adjustable spanner. Adjust the stop screw (fi g 2) to 110 % load (stationary 100%) according to the test bed, plus 1.5 index.

Fig 3 Lambda Controller

Min

1 m

m fr

ee s

pace

acro

ss p

ick-

up

1

23

1. Band steel2. Pick-up3. Regulating arm

Adjustment of the Lambda Controller

All adjustments are made when the engine is in standstill position.

1) Check that the free space between the pick-up and the band steel on the regulating arm is min. 1 mm, see fi g 1.

Fig 2 Adjustment of the stop screw

Fig 1 Check of free space

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

509-10.00Edition 13H

L23/30H

Lambda ControllerWorking CardPage 3 (3)

03.13 - ES0

Use the index arm on the fuel injection pump nearest to the lambda controller as the control for the index.

8) Adjustment completed.

Adjustment of Start Index, only if mounted

After adjustment of the lambda index the start index must be adjusted.

Force the piston by the screw on the back, see fi g 4. Check that the index is 18 mm. Adjustment is made on the self-locking nut on the back of the lambda controller, see fi g 4.

Fig 4 Adjustment of start index

Note : In case of start failure due to wear of the fuel pump, the start index must be raised to a higher level by turning the self-locking nut anticlockwise.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Governor and Governor DrivePlatePage 1 (2)

06.44 - ES0

50901-21H

212+

224

248

236

033

045

057

069

070

082

094

141

153

165

177

261

273

285

297

320

307

189

190

200

332

For governor,see specialinstruction book

403439

393

415

427

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.44 - ES0

Plug screw

Gasket

Nut

Stud

O-ring

Castle nut

Split pin

Shim (set 0,1 -0,3 - 0,5 - 1,0 mm)

Disc

Ball bearing

Bevel gear wheel

Key

Castle nut

Split pin

Housing

Stud

Pin

Plug

Plug

Axle journal

Bush

Bevel gear wheel

Gear wheel

Wear disc

Key

Synchronizing motor

Governor, Europa(720/750 rpm)

Designation BenævnelseBenævnelseDesignation

Governor and Governor Drive PlatePage 2 (2)

L23/30H

Item No.

Qty.

Qty.

Item No.

415

427

439

4/E

1/E

1/E

Screw

Shutdown solenoid

Governor, Europa(900 rpm)

+ Item No. 212 require an individual match-ing (by shims) before mounting, contact, MAN B&W, Holeby

Skrue

Shutdown spole

Regulator, Europa(900 rpm)

+ Item nr. 212 kræver en individual tilpasning (med shims) før monte-ring, kontakt MAN B&W, Holeby.

50901-21H

Propskrue

Pakning

Møtrik

Tap

O-ring

Kronemøtrik

Split

Mellemlæg (sæt 0,1 -0,3 - 0,5 - 1,0 mm)

Skive

Kugleleje

Konisk tandhjul

Feder

Kronemøtrik

Split

Hus

Tap

Stift

Prop

Prop

Akseltap

Bøsning

Konisk tandhjul

Tandhjul

Slidskive

Feder

Synkromiseringsmotor

Regulator, Europa(720/750 rpm)

1/E

1/E

4/E

2/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

2/E

2/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

033

045

057

069

070

082

094

141

153

165

177

189

190

200

212+

224

236

248

261

273

285

297

307

320

332

393

403

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Governor and Governor DrivePlatePage 1 (2)

06.32 - ES0

50901-22H

212+

224

248

236

033

045

057

069

070

082

094

021

116439

104

128

141

153

165

177

261

273

285

297

320

307

189

190

200

332

For governor,see specialinstruction book

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.32 - ES0

Synchronnizingmotor

Plug screw

Gasket

Nut

Stud

O-ring

Castle nut

Split pin

Shut downsolenoid

Governor720/750 rpm

Screw

Shim (set 0,1 -0,3 - 0,5 - 1,0 mm)

Disc

Ball bearing

Bevel gear wheel

Key

Castle nut

Split pin

Housing

Stud

Pin

Plug

Plug

Axle journal

Bush

Bevel gear wheel

Gear wheel

Designation BenævnelseBenævnelseDesignation

Governor and Governor Drive PlatePage 2 (2)

L23/30H

Item No.

Qty.

Qty.

Item No.

320

332

439

1/E

1/E

1/E

Wear disc

Key

Governor900 rpm

+ Item No. 212 require an individual match-ing (by shims) before mounting, contact, MAN B&W, Holeby

Slidskive

Feder

Regulator900 rpm

+ Item nr. 212 kræver en individual tilpasning (med shims) før monte-ring, kontakt MAN B&W, Holeby.

50901-22H

Synchroniserings-motor

Propskrue

Pakning

Møtrik

Tap

O-ring

Kronemøtrik

Split

Shut-downspole

Regulator720/750 rpm

Skrue

Mellemlæg (sæt 0,1 -0,3 - 0,5 - 1,0 mm)

Skive

Kugleleje

Konisk tandhjul

Feder

Kronemøtrik

Split

Hus

Tap

Stift

Prop

Prop

Akseltap

Bøsning

Konisk tandhjul

Tandhjul

1/E

1/E

1/E

4/E

2/E

1/E

1/E

1/E

1/E

1/E

4/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

2/E

2/E

1/E

1/E

1/E

1/E

1/E

1/E

021

033

045

057

069

070

082

094

104

116

128

141

153

165

177

189

190

200

212+

224

236

248

261

273

285

297

307

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Governor and Governor DrivePlatePage 1 (2)

06.45 - ES0

50901-23H

212+

224

248

236

033

045

057

069

070

082

094

116

128

141

153

165

177

261

273

285

297

320

307

189

190

200

332

For actuator,see specialinstruction book

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.45 - ES0

Plug screw

Gasket

Nut

Stud

O-ring

Castle nut

Split pin

Actuator

Screw

Shim (set 0,1 -0,3 - 0,5 - 1,0 mm)

Disc

Ball bearing

Bevel gear wheel

Key

Castle nut

Split pin

Housing

Stud

Pin

Plug

Plug

Axle journal

Bush

Bevel gear wheel

Gear wheel

Designation BenævnelseBenævnelseDesignation

Governor and Governor Drive PlatePage 2 (2)

L23/30H

Item No.

Qty.

Qty.

Item No.

50901-23H

Propskrue

Pakning

Møtrik

Tap

O-ring

Kronemøtrik

Split Aktuator

Skrue

Mellemlæg (sæt 0,1 -0,3 - 0,5 - 1,0 mm)

Skive

Kugleleje

Konisk tandhjul

Feder

Kronemøtrik

Split

Hus

Tap

Stift

Prop

Prop

Akseltap

Bøsning

Konisk tandhjul

Tandhjul

1/E

1/E

4/E

2/E

1/E

1/E

1/E

1/E

4/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

2/E

2/E

1/E

1/E

1/E

1/E

1/E

1/E

033

045

057

069

070

082

094

116

128

141

153

165

177

189

190

200

212+

224

236

248

261

273

285

297

307

When ordering spare parts, see also page 600.50.

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

Ved bestilling af reservedele, se også side 600.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

Wear disc

Key

+ Item No. 212 require an individual match-ing (by shims) before mounting, contact, MAN Diesel A/S.

Slidskive

Feder

+ Item nr. 212 kræver en individual tilpasning (med shims) før mon-tering, kontakt MAN Diesel A/S.

1/E

1/E

320

332

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Regulating Device 50902-06HPlatePage 1 (2)

06.45 - ES0

015

027

039

040

064

Governor Plate 50901

052

088111

123135

147159

160172

184196

206218

231088

052

064

243

255267027279280292302

Lambda controllersee plate 50910

314745757769

542

554

566

530

578

326

363

351

375

338

387399

422409

434

458483

410

446

471495

040

076

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Skrue

Låseblik

Regulatorarm

Split

Selvlåsende møtrik

Skrue for kuglehoved

Fjederbelastet træk-stang, komplet

Trækstangshoved

Split

Trækstangsende

Cylindrisk stift

Fjederhus

Pinolskrue

Fjeder

Cylindrisk stift

Styrering

Styrering

Trækstang

Møtrik

Låseblik

Arm

Fjederstift

Skrue

Styrestift

Skrue

Leje

Bøsning

Reguleringsaksel,5 cyl. motor

06.45 - ES0

Screw

Locking plate

Governor arm

Split pin

Self locking nut

Screw for ball head

Spring loaded pull rod, complete

Pull rod head

Split pin

Pull rod end

Cylindrical pin

Spring housing

Pointed screw

Spring

Cylindrical pin

Guide ring

Guide ring

Pull rod

Nut

Locking plate

Arm

Spring pin

Screw

Guide pin

Screw

Bearing

Bushing

Regulating shaft,5 cyl. engine

Designation BenævnelseBenævnelseDesignation

Regulating Device PlatePage 2 (2)50902-06H

L23/30H

015

027

039

040

052

064

076

088

111

123

135

147

159

160

172

184

196

206

218

231

243

255

267

279

280

292

302

314

1/R

2/R

1/R

2/R

2/R

2/R

1/R

2/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/E

Item No.

Qty.

Qty.

Item No.

Stopring

Skrue

Lænkeled

Split

Stift

Stift

Fjederarm

Fjeder

Fjederstift

Armholder

Skrue

Bøsning

Lejeblik

Fjederstift

Skrue

Skrue

Skrue

Skive

Møtrik

Konsol

Reguleringsaksel,6 cyl. motor

Reguleringsaksel,7 cyl. motor

Reguleringsaksel,8 cyl. motor

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare part kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./R = Qty./Regulating device

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/R = Antal/Reguleringsmekanisme

1/E

1/E

1/C

1/C

1/C

1/C

1/C

1/C

3/C

1/C

1/C

1/C

1/C

2/C

2/C

2/E

2/E

2/E

2/E

1/E

1/E

1/E

1/E

338

351

363

375

387

399

409

410

422

434

446

458

471

483

495

530

542

554

566

578

745

757

769

Stop ring

Screw

Linkage

Split pin

Pin

Pin

Spring arm

Spring

Spring pin

Armholder

Screw Bushing

Bearing bracket

Spring pin

Screw

Screw

Screw

Washer

Nut

Bracket

Regulating shaft,6 cyl. engine

Regulating shaft,7 cyl. engine

Regulating shaft,8 cyl. engine

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Regulating Device 50902-07HPlatePage 1 (2)

06.45 - ES0

015

027

039

040

064

Governor Plate 50901

052

088111

123135

147159

160172

184196

206218

231088

052

064

243

255267027279280292302

Lambda controllersee plate 50910

314745757769

542

554

566

530

578

326

363

351

375

338

387399

422409

434

458483

410

446

471495

040

076

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Skrue

Låseblik

Regulatorarm

Split

Selvlåsende møtrik

Skrue for kuglehoved

Fjederbelastet træk-stang, komplet

Trækstangshoved

Split

Trækstangsende

Cylindrisk stift

Fjederhus

Pinolskrue

Fjeder

Cylindrisk stift

Styrering

Styrering

Trækstang

Møtrik

Låseblik

Arm

Fjederstift

Skrue

Styrestift

Skrue

Leje

Bøsning

Reguleringsaksel,5 cyl. motor

06.45 - ES0

Screw

Locking plate

Governor arm

Split pin

Self locking nut

Screw for ball head

Spring loaded pull rod, complete

Pull rod head

Split pin

Pull rod end

Cylindrical pin

Spring housing

Pointed screw

Spring

Cylindrical pin

Guide ring

Guide ring

Pull rod

Nut

Locking plate

Arm

Spring pin

Screw

Guide pin

Screw

Bearing

Bushing

Regulating shaft,5 cyl. engine

Designation BenævnelseBenævnelseDesignation

Regulating Device PlatePage 2 (2)50902-07H

L23/30H

015

027

039

040

052

064

076

088

111

123

135

147

159

160

172

184

196

206

218

231

243

255

267

279

280

292

302

314

1/R

2/R

1/R

2/R

2/R

2/R

1/R

2/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/R

1/E

Item No.

Qty.

Qty.

Item No.

Stopring

Skrue

Lænkeled

Split

Stift

Stift

Fjederarm

Fjeder

Fjederstift

Armholder

Skrue

Bøsning

Lejeblik

Fjederstift

Skrue

Skrue

Skrue

Skive

Møtrik

Konsol

Reguleringsaksel,6 cyl. motor

Reguleringsaksel,7 cyl. motor

Reguleringsaksel,8 cyl. motor

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare part kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./R = Qty./Regulating device

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/R = Antal/Reguleringsmekanisme

1/E

1/E

1/C

1/C

1/C

1/C

1/C

1/C

3/C

1/C

1/C

1/C

1/C

2/C

2/C

2/E

2/E

2/E

2/E

1/E

1/E

1/E

1/E

338

351

363

375

387

399

409

410

422

434

446

458

471

483

495

530

542

554

566

578

745

757

769

Stop ring

Screw

Linkage

Split pin

Pin

Pin

Spring arm

Spring

Spring pin

Armholder

Screw Bushing

Bearing bracket

Spring pin

Screw

Screw

Screw

Washer

Nut

Bracket

Regulating shaft,6 cyl. engine

Regulating shaft,7 cyl. engine

Regulating shaft,8 cyl. engine

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Overspeed Device 50903-02HPlatePage 1 (2)

06.45 - ES0

010022034046058071083105117129130142

225

154

333

345 369

357370382394

453

465

477

489512

490

416441428

286298

500

191178

095

237

249250

262274

404

166, 524

201213

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.45 - ES0

Socket

Button

Spring pin

Spring

Screw

Screw

Cover

Spindle

Spring pin

Cylindrical pin

Lever

Screw

Flyweight housing

Adjusting screw

Spring720/750 rpm

Circlip

Flyweight

Key

Ball bearing

Housing

Cover

Washer

Screw

Pin

Lever

Nut

Gasket

Spindle

Designation BenævnelseBenævnelseDesignation

Overspeed Device PlatePage 2 (2)50903-02H

L23/30H

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

345

357

369

370

382

394

404

416

428

441

453

465

477

489

490

500

512

524

1/E

1/E

1/E

1/E

1/E

1/E

2/E

2/E

1/E

1/E

1/E

1/E

4/E

1/E

1/E

1/E

1/E

1/E

Spring

Button

Nipple

Spindle

Spring (left)

Spindle

Washer

Screw

Ball bearing

Elastic coupling

Spring (right)

Valve attachment

Screw

Pneumatic valve

Silencer

Overspeed device,complete

Spare parts kit foritem 489

Spring900 rpm

Fjeder

Knap

Nippel

Spindel

Fjeder (venstre)

Spindel

Skive

Skrue

Kugleleje

Elastisk kobling

Fjeder (højre)

Ventilholder

Skrue

Pneumatisk ventil

Lyddæmper

Overspeed anordning,komplet

Reservedelskit foritem 489

Fjeder900 rpm

010

022

034

046

058

071

083

095

105

117

129

130

142

154

166

178

191

201

213

225

237

249

250

262

274

286

298

333

1/E

1/E

1/E

1/E

4/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

4/E

4/E

1/E

1/E

1/E

1/E

1/E

Muffe

Knap

Fjederstift

Fjeder

Skrue

Skrue

Dæksel

Spindel

Fjederstift

Cylindrisk stift

Arm

Skrue

Hus for svingvægt

Justeringsskrue

Fjeder720/750 rpm

Sikringsring

Svingvægt

Not

Kugleleje

Hus

Dæksel

Skive

Skrue

Stift

Arm

Møtrik

Pakning

Spindel

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Instrument PanelPlatePage 1 (2) 50905-07H

L23/30H

96.29 - ES0S-G

PI 01 LT fresh water, inlet to air cooler

PI 10 HT fresh water, inlet engine

PI 21/22 Lubricating oil, inlet/outlet to fi lter

PI 23 Lub. oil, inlet to turbocharger

PI 31 Charge air, outlet from cooler

PI 40 Fuel oil, inlet to engine

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Instrument Panel50905-07H

Designation BenævnelseBenævnelse

1/E

1/E

4/E

8/E

8/E

2/E

3/E

1/E

6/E

1/E

1/E

1/E

1/E

2/E

2/E

2/E

2/E

6/E

2/E

1/E

2/E

1/E

Housing forinstrument panel

Bracket forinstrument panel

Rubber clutch

Nut

Spring lock

Pressure gauge0-3 bar(PI 31 and PI 23)

Pressure gauge0-6 bar(PI 01, PI 10, PI 21-22)

Pressure gauge0-10 bar (PI 40)

Needle valve

3-way valve forPI 21-22

Washer

Pipe

Angle union

Straight union

Pressure gauge hose 140 mm

Pressure gauge hose 195 mm

Pressure gauge hose 340 mm

Packing ring

Reduction

Damper (fuel oil)

Coupling formanometer

Damper(charging air)

143

155

167

179

180

192

202

214

226

238

251

263

275

287

299

309

310

322

334

346

358

371

Hus forinstrumentpanel

Konsol forinstrument-panel

Gummikobling

Møtrik

Fjederskive

Manometer0-3 bar(PI 31 og PI 23)

Manometer0-3 bar(PI 01, PI 10, PI 21-22)

Manometer0-10 bar (PI 40)

Nåleventil

3-vejsventil forPI 21-22

Skive

Rør

Vinkelforskruning

Ligeforskruning

Manometer slange195 mm

Manometer slange 140 mm

Manometer slange 300 mm

Pakningsring

Reduktion

Dæmper (fuel oil)

Kobling formanometer

Dæmper(ladeluft)

704

716

728

741

753

765

417

4/E

4/E

2/E

2/E

8/E

1/E

1/E

Screw

Serrated lock washer

Screw

Serrated lock washer

Screw

Side plate

Instrument panel,complete

Skrue

Stjernefjederskive

Skrue

Stjernefjederskive

Skrue

Sideplade

Instrument panel,komplet

Item No Qty. Designation Qty.

Item No

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 600.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

PlatePage 2 (2)

96.29 - ES0S-G

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

98.35 - ES0S-L

L23/30H

Instrument Panel 50905-11HPlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Qty.

Qty.

Instrument PanelPlate

Page 2 (2)

L23/30H

50905-11H

1/E

1/E

4/E

8/E

8/E

2/E

3/E

1/E

6/E

1/E

1/E

1/E

1/E

2/E

2/E

2/E

2/E

6/E

2/E

1/E

2/E

1/E

4/E

Housing forinstrument panel

Bracket for instrument panel , L23/30H

Rubber clutch

Nut

Spring locks

Pressure gauge 0-3 bar (PI 31 and PI 23)

Pressure gauge 0-6 bar, PI 01, PI 10, PI 21-22

Pressure gauge 0-10 bar (PI 40)

Needle valve

3-way valve forPI 21-22

Washer

Steel pipe

Screwed connection

Union

Pressure gauge hose 140 mm

Pressure gauge hose 195 mm

Pressure gauge hose 340 mm

Gasket

Reduction adapter

Damper (fuel oil)

Coupling for mano-meter

Damper(charging air)

Screw

143

155

167

179

180

192

202

214

226

238

251

263

275

287

299

309

310

322

334

346

358

371

383

Hus forinstrument panel

Konsol for instrument panel, L23/30H

Gummikobling

Møtrik

Fjedrende skive

Manometer 0-3 bar(PI 31 og PI 23)

Manometer 0-3 bar,PI 01, PI 10, PI 21-22

Manometer 0-10 bar(PI 40)

Nåleventil

3-vejsventil forPI 21-22

Skive

Stålrør

Forskruning

Forskruning

Manometer slange140 mm

Manometer slange 195 mm

Manometer slange 340 mm

Pakning

Reduktionsforskruning

Dæmper (fuel oil)

Kobling for manometer

Dæmper(ladeluft)

Skrue

4/E

1/E

Lock washer

Instrument panel, complete, L23/30H

Låseskive

Instrument panel,komplet, L23/30H

98.35 - ES0S-L

395

417

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PI 01 LT fresh water, inlet to air cooler

PI 10 HT fresh water, inlet engine

PI 21/22 Lubricating oil, inlet/outlet to fi lter

PI 23 Lub. oil, inlet to turbocharger

PI 31 Charge air, outlet from cooler

PI 40 Fuel oil, inlet to engine

PI 50 Nozz. cool. oil, inlet to fuel valves

Instrument PanelPlatePage 1 (2) 50905-12H

L23/30H

00.21 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Instrument Panel50905-12H

Designation BenævnelseBenævnelse

1/E

1/E

4/E

8/E

8/E

2/E

4/E

1/E

7/E

1/E

1/E

1/E

1/E

2/E

2/E

2/E

2/E

1/E

7/E

2/E

1/E

2/E

Housing forinstrument panel

Bracket forinstrument panel

Rubber clutch

Nut

Spring lock

Pressure gauge0-3 bar(PI 31 and PI 23)

Pressure gauge0-6 bar(PI 01, PI 10, PI 50,PI 21-22)

Pressure gauge0-10 bar (PI 40)

Needle valve

3-way valve forPI 21-22

Washer

Pipe

Angle union

Straight union

Pressure gauge hose 195 mm

Pressure gauge hose 140 mm

Pressure gauge hose 300 mm

Pressure gauge hose 340 mm

Packing ring

Reduction

Damper (fuel oil)

Coupling for mano-meter

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22

Hus forinstrument panel

Konsol forinstrument panel

Gummikobling

Møtrik

Fjederskive

Manometer0-3 bar(PI 31 og PI 23)

Manometer0-3 bar(PI 01, PI 10, PI 50,PI 21-22)

Manometer0-10 bar (PI 40)

Nåleventil

3-vejsventil forPI 21-22

Skive

Rør

Vinkelforskruning

Ligeforskruning

Manometer slange195 mm

Manometer slange 140 mm

Manometer slange 300 mm

Manometer slange 340 mm

Pakningsring

Reduktion

Dæmper (fuel oil)

Kobling formanometer

23

43

44

45

46

47

48

49

1/E

4/E

4/E

2/E

2/E

8/E

1/E

1/E

Damper (charging air)

Screw

Serrated lock washer

Screw

Serrated lock washer

Screw

Side plate

Instrument panel,complete

Dæmper (ladeluft)

Skrue

Stjernefjederskive

Skrue

Stjernefjederskive

Skrue

Sideplade

Instrument panel,komplet

Item No Qty. Designation Qty.

Item No

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

L23/30H

PlatePage 2 (2)

00.21 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.45 - ES0

50907-17H

L23/30H

Fig. and Description Range Code Item No.L

0-8 bar

6-18 bar

20-60°C

50-100°C

70-120°C

0.2-2.5 bar

PSL 22PAL 10PAL 22

PAL 70

TAL 10

TAH 12TSH 12TAH 22TSH 22

PDAH 21-22

PDAH 43-40

012

024

061073

085097107

119120132

144

Pressostate

2 m5 m

2 m5 m8 m

2 m5 m8 m

Thermostate

L

Difference Pressostate

Instruments

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

07.45 - ES0

PlatePage 2 (2)50907-17H

156

168

181

203

239

240

048

Fig. and Description Range Code Item No.L

0-4 bar

0-6 bar

0-10 bar

0-16 bar

PT 31

PT 10

PT 22

PT 40

PT 70

Pressure Transmitter

Needle Valve

Needle Valve with 3/8" pipe thread

Needle valve with 1/2" pipe thread

1-10 bar PAL 40

Instruments

Pressostate

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

04.11 - ES0

Thermometer 50907-09H

L23/30H

PlatePage 1 (3)

Fig.Scale Length

CodeItemNo.°F °C L1L

40-240

40-240

40-600

40-400

40-220

0-120

0-120

0-300

0-200

0-120

110

110

150

110

110

100

63

100

40

100

TI 01

TI 02

TI 31

TI 22

TI 20

TI 30

TI 40

TI 51

TI 03

TI 10

TI 11

252

264

276

288

311

L

L1

L

L1

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Thermometer50907-09H PlatePage 2 (3)

L23/30H

04.11 - ES0

100

65

Fig.Scale Length

CodeItemNo.°F °C L1L

100-1300

100-1300

50-650

50-650

115

115

215

215

TI 60

TI 61

323

335

347

359

Pocket

Pocket

L

L1

L1

° C ° F

° C° F

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 3 (3)

04.11 - ES0

Thermometer 50907-09H

L23/30H

Fig.Scale Length

CodeItemNo.°F °C L1L

120-1200

Thermo-meter

FeelerNiCr-Ni

Pocket

120-1200

120-1200

FeelerNiCr-Ni

Thermo-meter

Pocket

50-650

50-650

50-650

140

165

190

215

100

115

115

200

TI 61

TI 62

TI 60

TI 60

360

372

384

396

406

418

431

443

455

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Fig. RangeLength

CodeItemnoL mm

Working temp.-25°C - 70°C

0 - 1 kHz 55

SE 90

SE 89

SE 90-3

018

031

043

Pick-up

PlatePage 1 (1)

07.48 - ES0

50908-02H

L23/30H

Pick-up

101

75

2.7

19

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lambda ControllerPlatePage 1 (2) 50910-02H

97.14 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

97.14 - ES0S

Designation BenævnelseBenævnelseDesignation

Lambda Controller PlatePage 2 (2)50910-02H

L23/30H

Item No.

Qty.

Qty.

Item No.

Regulating arm,complete

Pick-up,incl. sleeve

Lambda cylinder,complete

Reguleringsarm,komplet

Pick-up, incl. afstandsring

Lambdacylinder,komplet

1/E

1/E

1/E

019

020

032

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.11 - ES0

L23/30H

Prelubricating Oil Alarm (LAL 25) 50919-01HPlatePage 1 (2)

Switch point

018

031

055

043

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

1/E

1/E

1/E

1/E

Plug screw

Packing ring

Loctite 577

Level switch

Propskrue

Pakningsring

Loctite 577

Niveauafbryder

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

L23/30H

07.11 - ES0

Prelubricating Oil Alarm (LAL 25)50919-01H PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

Level Switch in Oil Sump (LAL/LAH 28) 50920-13HPlatePage 1 (2)

L23/30H

501

513

525 579

981 430

491

442

580

549

549

777

789

789

501

454

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

PlatePage 2 (2)50920-13H

Designation BenævnelseBenævnelseDesignation

Qty.

Qty.

430

442

454

491

501

513

525

549

579

580

777

789

968

981

4/E

1/E

1/E

2/E

4/E

1/E

1/E

2/E

1/E

2/E

1/E

/I

1/E

1/E

Nut

Pipe for levelswitch

Box for levelalarm

Red. adaptor

Screw

Plate

Gasket

Level switch

Pipe for levelswitch

Red. adaptor

Dipstick, complete

Loctite 577

Level switch,complete

O-ring

Møtrik

Rør for niveau-alarm

Box for level alarm

Red. adapter

Skrue

Plade

Pakning

Niveaualarm

Rør for niveau-alarm

Red. adaptor

Pejlestok, komplet

Loctite 577

Level switch,komplet

O-ring

Level Switch in Oil Sump (LAL/LAH 28)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/MotorQty./I = Antal/Individuel

L23/30H

Item No.

Item No.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

Level Switch in Oil Sump (LAL 28) 50920-14HPlatePage 1 (2)

L23/30H

501

513

525

430

491

442

580

549

777

789

501

454

478

466

981

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

PlatePage 2 (2)50920-14H

Designation BenævnelseBenævnelseDesignation

Qty.

Qty.

430

442

454

466

478

491

501

513

525

549

580

777

789

968

981

2/E

1/E

1/E

1/E

1/E

1/E

4/E

1/E

1/E

1/E

1/E

1/E

/I

1/E

1/E

Nut

Pipe for levelswitch

Box for levelalarm

Plug screw

Packing ring

Red. adaptor

Screw

Plate

Gasket

Level switch

Red. adaptor

Dipstick, complete

Loctite 577

Level switch,complete

O-ring

Møtrik

Rør for niveau-alarm

Box for level alarm

Propskrue

Pakningsring

Red. adapter

Skrue

Plade

Pakning

Niveaualarm

Red. adaptor

Pejlestok, komplet

Loctite 577

Level switch,komplet

O-ring

Level Switch in Oil Sump (LAL 28)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/MotorQty./I = Antal/Individuel

L23/30H

Item No.

Item No.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

Level Switch in Oil Sump (Dipstick only) 50920-15HPlatePage 1 (2)

L23/30H

501

513

525

478

466

478

466777

501

454

981

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

PlatePage 2 (2)50920-15H

Designation BenævnelseBenævnelseDesignation

Qty.

Qty.

454

466

478

501

513

525

777

968

981

1/E

2/E

2/E

4/E

1/E

1/E

1/E

1/E

1/E

Box for levelalarm

Plug screw

Packing ring

Screw

Plate

Gasket

Dipstick, complete

Level switch,complete

O-ring

Box for level alarm

Propskrue

Pakningsring

Skrue

Plade

Pakning

Pejlestok, komplet

Level switch,komplet

O-ring

Level Switch in Oil Sump (Dipstick only)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/MotorQty./I = Antal/Individuel

L23/30H

Item No.

Item No.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

096

072

059035 023

047

060

084

106

07.18 - ES0

L23/30H

Fuel Oil Leakage Alarm (LAH 42) 50925-08HPlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.18 - ES0

Designation BenævnelseBenævnelseDesignation

Fuel Oil Leakage Alarm (LAH 42) PlatePage 2 (2)50925-08H

L23/30H

Item No.

Qty.

Qty.

Item No.

023

035

047

059

060

072

084

096

106

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

2/E

Plug screw

Packing ring

Level switch

Plug screw

Packing ring

Fuel oil leakage alarm, complete (DIN)

Fuel oil leakage alarm, complete (JIS)

Instruction plate

Screw

Propskrue

Tætningsring

Niveaukontakt

Propskrue

Tætningsring

Brændolie lækage-alarm, komplet (DIN)

Brændolie lækage-alarm, komplet (JIS)

Instruktionsplade

Skrue

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

MAN Diesel

07.45 - ES0

Local Starting Box - No 1 50935-11H

L23/30H

PlatePage 1 (2)

MAN Diesel

Local Starting Box - No 1 PlatePage 2 (2)50935-11H

L23/30H

017

029

Item No. Benævnelse

Panel

Startboks

Designation

Panel

Starting box

Qty.

1/E

1/E

Item No. DesignationQty. Benævnelse

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit. Qty./E = Qty./Enigne.

07.45 - ES0

MAN Diesel

07.45 - ES0

Local Starting Box - No 2 50935-12H

L23/30H

PlatePage 1 (2)

MAN Diesel

Local Starting Box - No 2 PlatePage 2 (2)50935-12H

L23/30H

017

029

Item No. Benævnelse

Panel

Startboks

Designation

Panel

Starting box

Qty.

1/E

1/E

Item No. DesignationQty. Benævnelse

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit. Qty./E = Qty./Enigne.

07.45 - ES0

MAN Diesel

07.45 - ES0

Local Starting Box - No 2 (incl. high lub. oil temp.) 50935-13H

L23/30H

PlatePage 1 (2)

MAN Diesel

Local Starting Box - No 2 (incl. high lub. oil temp.) PlatePage 2 (2)50935-13H

L23/30H

017

029

Item No. Benævnelse

Panel

Startboks

Designation

Panel

Starting box

Qty.

1/E

1/E

Item No. DesignationQty. Benævnelse

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit. Qty./E = Qty./Enigne.

07.45 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.45 - ES0

Engine Control Box 50936-13H

L23/30H

243513

14

23212422

1920

1718

15119

1612107

85

63

41

2

-F3.

0.1

-F3.

0

GR

OU

ND

2425

2427

2429

2431

2433

2437

2439

2441

2443

2445

2447

2449

2451

2453

2455

2457

2459

2461

2463

2465

2467

2469

2471

2473

2475

2477

2479

2481

2483

2485

2487

2489

2491

2493

2495

2497

2499

OK

OU

TP

UT

ANALOG

OK

INP

UT

ANALOGRelay

AC

/DC

OU

T

0

1

2

3

4

6

7

55

7

6

4

3

2

1

0

AC

/DC

OU

T

Relay0

1

2

3

4

6

7

5 9

11

10

8 12

14

15

13

8

10

11

95

7

6

4

3

2

1

0

-k3.2 -k7.0 -k8.0 -k9.0 -k9.6

DC INPUTS

DC/RELAY OUT

44434241

131211

-k9.2

536

585

345345

333

644

274

561

095

573

656

404

394

548142

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Engine Control Box PlatePage 2 (2)50936-13H

L23/30H

095

142

274

333

345

394

404

536

548

561

573

585

644

656

668

Item no Benævnelse

Sikkerhedssystem,Base unit

Jordklemme

Endestop

Analogoutputmodul

Digitaloutputmodul

Sikringsklemme

Endeplade

Panel

Klemme, dobbelt

Endeplade

Processor unit (CPU)

Endestykke

Analoginputmodul

Konverter

Kabel

Designation

Safety system,Base unit

Terminal, earth

End stop

Analogoutput module

Digitaloutput module

Fuse terminal

End plate

Panel

Terminal double

End plate

Processor unit (CPU)

End cap

Analoginput module

Converter

Cable

Qty

1/E

1/E

3/E

1/E

2/E

2/E

1/E

1/E

50/E

1/E

1/E

1/E

1/E

1/E

1/E

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

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

07.45 - ES0

Item no BenævnelseDesignationQty

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.45 - ES0

Terminal Box 50936-20H

L23/30H

(

)4P

1S

SH

81

SA

H 8

1U

X 9

5

F1/

1F

1/2

3K9

3K3

3K2

4K2

5K6

4K3

4K5

4K6

X:2

X:1

4K7

5K4

5K9

4K4

536490500

477489

453465

274656

597632703

607619620

225

394416

681693

274644668

250

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Terminal Box PlatePage 2 (2)50936-20H

L23/30H

225

250

274

394

416

453

465

477

489

490

500

536

597

607

619

620

632

644

656

668

681

693

703

Item no Benævnelse

Ledningskanal

Ledningskanal

Endestop

Sikringsklemme

Sikring 2A

Kabelunion M16

Møtrik M16

Kabelunion M20

Møtrik M20

Kabelunion M25

Møtrik M25

Panel

Speed converter,motor 720 omdr

Timer

Hjælperelæ

Sokkel

Speed converter,motor 750 omdr

Klemme

Klemme

Diode klemme

Kabelunion M32

Møtrik M32

Speed converter,motor 900 omdr

Designation

Conduit

Conduit

End stop

Fuse terminal

Fuse 2A

Cable union M16

Nut M16

Cable union M20

Nut M20

Cable union M25

Nut M25

Panel

Speed converter,engine 720 rpm

Timer

Aux. relay

Socket

Speed converter,engine 750 rpm

Terminal

Terminal

Diode terminal

Cable union M32

Nut M32

Speed converter,engine 900 rpm

Qty

1/E

1/E

4/E

2/E

2/E

2/E

2/E

2/E

2/E

2/E

2/E

1/E

1/E

1/E

11/E

11/E

1/E

12/E

54/E

2/E

3/E

3/E

1/E

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

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

07.45 - ES0

Item no BenævnelseDesignationQty

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

98.13 - EO0

APM Motor Control 50948-01

General

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

APM Motor Control PlatePage 2 (2)50948-01

General

016

Item No Benævnelse

APM motor control

Designation

APM motor control

Qty

1/E

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

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

98.13 - EO0

Item No BenævnelseDesignationQty

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.37 - ES0

Converter 50956-01

General

ADAM

DAT

A +

DAT

A -

TX

+

TX

-

RX

+

RX

-

(R)

+V

s

(B)

GN

D 1

0(RS 485)(RS 422)

ADAM-4520RS-232 TO RS-422/RS-485CONVERTER

(RS-232)021

033

045

0802

8-0D

/H52

50/9

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.12

MAN Diesel

Converter PlatePage 2 (2)50956-01

General

021

033

045

Item no Benævnelse

Converter

Kabel, længde 1.8 m

Kabel, længde 10 m

Designation

Coverter

Cable, length 1.8 m

Cable, length 10 m

Qty

1/E

1/E

1/E

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

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

07.37 - ES0

Item no BenævnelseDesignationQty

Crankshaft

510/610

MAN Diesel

DescriptionPage 1 (1) Crankshaft and Main Bearings 510.01

Edition 01H

Crankshaft

The crankshaft, which is a one-piece forging with ground main bearing and crankpin journals, is sus-pended in inderslung bearings. The main bearings are equipped with insertion-type shells, which are coated with a wearing surface. To attain a suitable bearing pressure the crankshaft is provided with counterweights, which are attached to the crank shaft by means of two screws.

At the fl ywheel end the crankshaft is fi tted with a gear wheel which through an intermediate wheel drives the camshaft. Also fi tted here is the fl ywheel and a coupling fl ange for connection of a reduction gear or an alternator. At the opposite end there is a claw-type coupling for the lub. oil pump or a fl exible gear wheel connection for lub. oil and water pumps.

96.03 - ES0U

L23/30H

Vibration Damper

In special cases a vibration damper is mounted on the crankshaft to limit torsional vibrations. The damper consists essentially of a heavy fl ywheel totally en-closed in a light casing. A small clearance is allowed between the casing and the fl ywheel, and this space is fi lled with a highly viscous fl uid. The casing is rigidly connected to the front end of the engine crankshaft and the only connection between the crankshaft and the damper fl ywheel is through the fl uid. Under conditions of no vibration, the casing and damper fl ywheel tend to rotate as one unit, since the force required to shear the viscous fi lm is consi-derable. As the torsional vibration amplitudes increase, the casing follows the movement of the crankshaft but the fl ywheel tends to rotate uniformly by virtue of its inertia, and relative motion occurs between the fl ywheel and the casing. The viscous fl uid fi lm there-fore undergoes a shearing action, and vibration energy is absorbed and appears as heat.

0802

8-0D

/H52

50/9

4.08

.12

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Checking of main bearings alignment (autolog).

Starting position:

Turning gear in engagement. (If mounted).Cover for crankshaft has been removed from frame.All indicator valves open.

Related procedure:

Manpower:

Working time : 1 1/2 hoursCapacity : 2 men

Data:

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

510-01.00Edition 04H

00.27 - ES0

Special tools:

Plate no. Item no. Note

52010 011 52010 059 52010 358

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty /

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 1 (7)

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

00.27 - ES0

510-01.00Edition 04H

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 2 (7)

Alignment of Main Bearings.

The lower main bearing shells should be posi tion ed so that they keep the main bearing journals of the crankshaft centered in a straight (ashore horizon-tal) line. Deviations from this centre line cause the crankshaft to bend and increase the load on some main bearings.

If two adjacent main bearings are placed too low, the crankshaft centre line will in this place be lowered to form an arc, causing the intermediate crank throw to bend in such a way that it "closes" when turned into bottom position and "opens" in top position.

As the magnitude of such axial lengthening and shor ten ing during the turning of the throw increases in proportion to the difference in the height of the bearing, it is measured as a check on the alignment and condition of the bearing.

As the crankshafts of medium speed engines are very stiff, any great deviations in the alignment will result in clearance at the bottom shell of the bearings.

The cause of incorrect main bearing position may be wear of the bearings or misalignmnet of the engine.

Effecting The Defl ection Measurement.

The defl ection measurement is effected by placing a springloaded dial gauge in the centre punch marks provided for this purpose, see fi g. 1.

"Closing" of the throw in top dead centre is regarded as negative, (compression of the gauge).

In the example, page 3, the defl ection reading is therefore negative.

Fig. 1 Placing of dial gauge

Not for measuring (autolog)

Existing centre punch marks for measuring (autolog)

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510-01.00Edition 04H

00.27 - ES0

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 3 (7)

L23/30H

As during the turning of the throw, the gauge and the connecting rod will meet near the bottom position of the throw, the measurement for the bottom position is to be replaced by the average of the two near by positions on either side.

The dial gauge is set to zero, when the crank throw is in the near-bottom (x in fi g. 8) and during the turning the throw is stopped in the position ho ri zon-tal-top-horizontal-near bottom (P-T-S-Y in fi g. 8) for reading of the gauge.

Checking The Defl ection Measurement.

The reading is entered in the table page 6, see example in fi g. 2 - 6.

As "bottom" reading is used the mean value of the two "near bottom" readings X and Y, fi g. 3.

The total defl ection ("opening-closing") of the throw during the turning from bottom to top position is entered in fi g. 4.

These fi gures are due to vertical misalignment of the main bearings.

Similarly, horizontal misalignment procedures the fi gures in the table fi g. 5.

Besides misalignment of the bearings, the readings can be infl uenced by ovality or eccentricity of the journals.

Engines Equipped with Turning Gear.

When taking these defl ection readings for the three aftmost cylinders, the turning gear should at each stoppage be turned a little backwards to ease off the tangential pressure on the teeth of the turning wheel as this pressure may otherwise falsify the readings.

0802

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MAN Diesel

Bottom (0,5 x Y) = B 1 -0.5 0 -0.5 0 1

Defl ection of crankshaft in 1/100 mm. (0.01 mm).

Cyl. No.Crank position 1 2 3 4 5 6 Bottom start X 0 0 0 0 0 0

Left side P 2 0 2 0 -1 2

Top T 3 -2 4 5 -2 3

Right side S 3 -2 2 0 0 1

Bottom stop Y 2 -1 0 1 0 2

Defl ection from vertical misalignment

top - bottom or T - B = V 2 -1.5 4 4.5 -2 2

Defl ection from hori-zontal misalignment

Right side - left sideor P - S = H -1 2 0 0 -1 1

Check on T + B = C 4 -2.5 4 5.5 -2 4gauge readings P + S = D 5 -2 4 0 -1 3

T

S

Y X

P

Front end view. Start in position X. Turn anti clockwise

"Closing" of the crankthrow is considered negative.

Fig. 4.

Fig. 2. Fig. 5.

Fig. 3.

Fig. 6.

C and D should be nearly the same, reading for cylinder 4 to be repeated.

Fig. 8.Fig. 7.

L23/30H

00.27 - ES0

510-01.00Edition 04H

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 4 (7)

0802

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MAN Diesel

Measurement of Crank Throw Defl ections by Means of Dial Indicator (Autolog)

Crank throw defl ection = Difference in dial indicator readings in two diametrically opposite crank throw positions, i.e. two positions dis- placed 180°.

Vertical defl ection = Difference in top-bottom readings.

Horizontal defl ection = Difference in side-side readings.

Vertical of Horizontal Defl ections of Crank Throws

Unless otherwise stated the values refer to cold engine.

For new or realigned aggregate Aim for + or - 3/100 mm Acceptable + or - 5/100 mm

For aggregate in service realignmentis recommended if defl ections exceed + or - 9/100 mm

Vertical Defl ection of Crank Throw at Flywheel

Unless otherwise stated the values refer to cold engine.

Rigid coupling between Flexible coupling between diesel engine and driven machine diesel engine and driven machine

For new or realigned For new or realignedaggregate 0 to + 3/100 mm aggregate Aim for - 9/100 mm Acceptable - 11/100 mm

For aggregate in service realignment is For aggregate in servicerecommended if defl ection measured realignment recommendableon warm engine exceeds - 9/100 mm if defl ection exceeds - 16/100 mm

510-01.00Edition 04H

00.27 - ES0

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 5 (7)

L23/30H

0802

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MAN Diesel

Process/Proces I.D. no.

Plant/Anlæg Page of/Side af Engine Type/Motortype Engineer/Operatør Date/Dato

Instruction/Instruktion

Top

Left side

1/100 mm

Right side

Cyl. no 1 2 3

Left side

Right side

Cyl. no 1 2 3

Cyl. no 1 2 3

Left side

Right side

Remarks/Bemærkninger

Bottom end/Bund slut

Bottom start/Bund start

L23/30H

00.27 - ES0

510-01.00Edition 04H

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 6 (7)

0802

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MAN Diesel

Defl ection fromvertical misalign-ment.Top - bottomor T - B = V

Check on gaugereadings. T + B = C

P + S = D

Defl ection fromhorizontal mis- alignment.Left side - Right side or P - S = H

Cyl. no. 1 2 3 4 5 6 7 8 9

Bottom X 0 0 0 0 0 0 0 0 0

Left side P

Top T

Right side S

Bottom Y

Component/Komponent Type I.D. no.

Process/Proces Page of/Side af

Test place/ Test bed/prøvehal Cold/KoldCondition On board/Om bord Warm/VarmTeststed/ Tilstand Plant/Maskinhal

Engine no.:Motornr.:

Bottom (0.5xY)=B

510-01.00Edition 04H

00.27 - ES0

Checking of Main Bearings Alignment (Defl ection)(Hydraulic Tightened Connecting Rod)

Working CardPage 7 (7)

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Checking of main bearings alignment (autolog).

Starting position:

Turning gear in engagement. (If mounted).Cover for crankshaft has been removed from frame.All indicator valves open.

Related procedure:

Manpower:

Working time : 1 1/2 hoursCapacity : 2 men

Data:

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

510-01.00Edition 05H

01.46 - ES0

Special tools:

Plate no. Item no. Note

52010 011 52010 059

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty /

Checking of Main Bearings Alignment (Autolog)Working Card

Page 1 (6)

L23/30H

0802

8-0D

/H52

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MAN Diesel

01.46 - ES0

510-01.00Edition 05H

Alignment of Main Bearings.

The lower main bearing shells should be posi tion ed so that they keep the main bearing journals of the crankshaft centered in a straight (ashore horizon-tal) line. Deviations from this centre line cause the crankshaft to bend and increase the load on some main bearings.

If two adjacent main bearings are placed too low, the crankshaft centre line will in this place be lowered to form an arc, causing the intermediate crank throw to bend in such a way that it "closes" when turned into bottom position and "opens" in top position.

As the magnitude of such axial lengthening and shor ten ing during the turning of the throw increases in proportion to the difference in the height of the bearing, it is measured as a check on the alignment and condition of the bearing.

As the crankshafts of medium speed engines are very stiff, any great deviations in the alignment will result in clearance at the bottom shell of the bearings.

The cause of incorrect main bearing position may be wear of the bearings or misalignmnet of the engine.

Effecting The Defl ection Measurement.

The defl ection measurement is effected by placing a springloaded dial gauge in the centre punch marks provided for this purpose, see fi g. 1.

"Closing" of the throw in top dead centre is regarded as negative, (compression of the gauge).

In the example, page 3, the defl ection reading is therefore negative.

As during the turning of the throw, the gauge and the connecting rod will meet near the bottom position of the throw, the measurement for the bottom position is to be replaced by the average of the two near by positions on either side.

The dial gauge is set to zero, when the crank throw is in the near-bottom (x in fi g. 8) and during the turning the throw is stopped in the position ho ri zon-tal-top-horizontal-near bottom (P-T-S-Y in fi g. 8) for reading of the gauge.

Fig 1. Placing of dial gauge.

Checking The Defl ection Measurement.

The reading is entered in the table page 6, see example in fi g. 2 - 6.

As "bottom" reading is used the mean value of the two "near bottom" readings X and Y, fi g. 3.

The total defl ection ("opening-closing") of the throw during the turning from bottom to top position is entered in fi g. 4.

These fi gures are due to vertical misalignment of the main bearings.

Similarly, horizontal misalignment procedures the fi gures in the table fi g. 5.

Besides misalignment of the bearings, the readings can be infl uenced by ovality or eccentricity of the journals.

Engines Equipped with Turning Gear.

When taking these defl ection readings for the three aftmost cylinders, the turning gear should at each stoppage be turned a little backwards to ease off the tangential pressure on the teeth of the turning wheel as this pressure may otherwise falsify the readings.

Checking of Main Bearings Alignment (Autolog) Working CardPage 2 (6)

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Bottom (0,5 x Y) = B 1 -0.5 0 0.5 0 1

Defl ection of crankshaft in 1/100 mm. (0.01 mm).

Cyl. No.Crank position 1 2 3 4 5 6 Bottom start X 0 0 0 0 0 0

Left side P 2 0 2 0 -1 2

Top T 3 -2 4 5 -2 3

Right side S 3 -2 2 0 0 1

Bottom stop Y 2 -1 0 1 0 2

Defl ection from vertical misalignment

top - bottom or T - B = V 2 -1.5 4 4.5 -2 2

Defl ection from hori-zontal misalignment

Left side - right sideor P - S = H -1 2 0 0 -1 1

Check on T + B = C 4 -2.5 4 5.5 -2 4gauge readings P + S = D 5 -2 4 0 -1 3

T

S

Y X

P

Front end view. Start in position X. Turn anti clockwise

"Closing" of the crankthrow is considered negative.

510-01.00Edition 05H

01.46 - ES0

Fig 4.

Fig 2. Fig 5.

Fig 3.

Fig 6.

C and D should be nearly the same, reading for crank throw 4 to be repeated.

Fig 8.Fig 7.

Working CardPage 3 (6) Checking of Main Bearings Alignment (Autolog)

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510-01.00Edition 05H

Measurement of crank throw defl ections by means of dial indicator (Autolog)

Crank throw defl ection = Difference in dial indicator readings in two diametrically opposite crank throw positions, i.e. two positions dis- placed 180°.

Vertical defl ection = Difference in top-bottom readings.

Horizontal defl ection = Difference in side-side readings.

Vertical and horizontal defl ections of crank throws

Unless otherwise stated the values refer to cold engine.

For new or realigned aggregate Aim for + or - 3/100 mm Acceptable + or - 5/100 mm

For aggregate in service realignmentis recommended if defl ections exceed + or - 8/100 mm

Vertical defl ection of crank throw at fl ywheel

Unless otherwise stated the values refer to cold engine.

Rigid coupling between Flexible coupling between diesel engine and driven machine diesel engine and driven machine

For new or realigned For new or realignedaggregate 0 to + 3/100 mm aggregate Aim for - 8/100 mm Acceptable - 10/100 mm

For aggregate in service realignment is For aggregate in servicerecommended if defl ection measured realignment is recommendedon warm engine exceeds - 8/100 mm if defl ection exceeds - 14/100 mm

Working CardPage 4 (6)Checking of Main Bearings Alignment (Autolog)

L23/30H

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Process/Proces I.D. no.

Plant/Anlæg Page of/Side af Engine Type/Motortype Engineer/Operatør Date/Dato

Instruction/Instruktion

Top

Left side

1/100 mm

Right side

Cyl. no 1 2 3

Left side

Right side

Cyl. no 1 2 3

Cyl. no 1 2 3

Left side

Right side

Remarks/Bemærkninger

Working CardPage 5 (6)

510-01.00Edition 05H

01.46 - ES0

Bottom end/Bund slut

Bottom start/Bund start

Checking of Main Bearings Alignment (Autolog)

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Defl ection fromvertical misalign-ment.Top - bottomor T - B = V

Check on gaugereadings. T + B = C

P + S = D

Defl ection fromhorizontal mis- alignment.Left side - Right side or P - S = H

Cyl. no. 1 2 3 4 5 6 7 8 9

Bottom X 0 0 0 0 0 0 0 0 0

Left side P

Top T

Right side S

Bottom Y

510-01.00Edition 05H

Component/Komponent Type I.D. no.

Process/Proces Page of/Side af

Test place/ Test bed/prøvehal Cold/KoldCondition On board/Om bord Warm/VarmTeststed/ Tilstand Plant/Maskinhal

Engine no.:Motornr.:

Bottom (0.5xY)=B

L23/30H

Checking of Main Bearings Alignment (Autolog) Working CardPage 6 (6)

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Safety precautions:

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

Description:

Dismantling, inspection and/or replacement and mounting of main bearing shells.

Starting position:

Related procedure:

Inspection of guide bearing shell, 510-01.10Criteria for replacement of bearings, 506-01.16

Manpower:

Working time : 2 hoursCapacity : 2 men

Data:

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

510-01.05Edition 01H

96.30 - ES0S-G

L23/30H

Special tools:

Plate no Item no Note

52010 106 2 pieces 52010 202 52010 011 52010 155 2 pieces 52021 405 Hydraulic tools 52021 501 2 pieces 52021 513 52021 202

Hand tools:

Allen key, 12 mm.Socket spanner, 36 mm.Lead hammer.Silastene.Copaslip.

Replacement and wearing parts:

Plate no Item no Qty/

Inspection of Main Bearing ShellsWorking CardPage 1 (3)

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Make Ready for Dismantling of the Main Bear-ing

1) Dismount crankcase covers in front and oppo-site the bearing concerned.

2) Turn the engine until the crank is in a con ve ni-ent position for carrying out the work.

3) Dismount the bracing screw (side screw).

4) Mount the hydraulic tools and loosen the main bearing stud nuts. For operation of the hydraulic tools, see working card 520-01.05.

96.30 - ES0S-G

510-01.05Edition 01H Inspection of Main Bearing Shells Working Card

Page 2 (3)

Fig 1. Mounting of Hydraulic Tools.

5) Dismount the hydraulic tools and slacken the nuts somewhat.

Dismantling of the Main Bearing Cap

6) Fit the eye screws, diagonally, in the threaded holes in the main bearing cap, see fi g 2.

Pass the wire supplied through the eye screw and at-tach it as shown, so as to keep the bearing cap in place when the main bearing stud nuts are removed.

7) Work the main bearing cap loose from the engine frame with a lead hammer or similar.

8) Lift the main bearing cap a little and unscrew the bearing stud nut.

9) Fit guide tubes on the threads of the bearing studs and lower the bearing cap to make it rest on the collar of the guide tubes.

Dismantling of the Main Bearing Shells

10) Remove the locking piece from the bearing cap and take out the bearing shell.

11) Fit the tool for upper main bearing, for dis-mant-ling of upper main bearing shell, in the lubricating hole in the crankshaft and turn out the upper bearing shell by turning the crankshaft, see fi g 3.

Fig 2. Mounting of Wire Straps.

Tool for upper main bearing

Fig 3. Mounting of tool for upper main bearing.

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510.01-05Edition 01H

96.30 - ES0S-G

L23/30H

16) Lubricate the end of the bearing shells with molycote pasta or similar.

17) Insert the lower bearing shell in the bearing cap and mount the locking piece.

Lubricate the bearing shell and journal with clean lubricating oil.

Mounting of the Main Bearing Cap

18) Raise the bearing cap into position, dismount the guide tubes, coat the bearing studs with mo ly co te pasta or similar and fi t the bearing stud nuts.

Make sure that the bearing cap and bearing shell are in their correct position.

19) Dismantle the wire straps.

20) Mount the hydraulic tools, see working card 520-01.05, and tighten the nuts as prescribed on page 500-40.

21) Coat the back side of the bracing screws' (side screws') hexagonal head with a thin coat of silastene or similar.

22) Mount the screws and tighten with a torque spanner as indicated on page 500.40.

Inspection of Main Bearing ShellsWorking CardPage 3 (3)

Cleaning

12) Clean all machined surfaces, on frame, bearing cap, stud, nuts and bearing shells.

Inspection of Main Bearing Shells

13) Inspect the main bearing shells according to working card 506-01.16.

Note: The bearing is marked according to size and when replaced it must be by a new bearing of the same size.

Mounting of the Main Bearing Shells

14) Push the upper bearing shell as far into po si tion as possible. 15) Fit the tool for upper main bearing in the lub-ricating hole in the crankshaft and turn in the upper bearing shell by turning the crankshaft.

Make sure that the shell enters its correct position then remove the tool for upper main bearing.

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Safety precautions:

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

Description:

Dismantling, inspection and/or replacement and mounting of guide bearing shells and thrust washer.

Starting position:

Related procedure:

Inspection of main bearing shells. 510-01.05Criteria for replacement of bearingshells. 506-01.16

Manpower:

Working time : 2 hoursCapacity : 2 men

Data:

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

510-01.10Edition 01H

96.20 - ES0S

L23/30H

Special tools:

Plate no Item no Note

52006 273 80 - 360 Nm 52010 106 2 pieces 52010 202 52010 011 52010 155 2 pieces 52021 405 Hydraulic tools 52021 501 2 pieces 52021 513 52021 202

Hand tools:

Allen key, 12 mm.Socket spanner, 36 mm.Lead hammer.Silastene.Copaslip.

Replacement and wearing parts:

Plate no Item no Qty/

Inspection of Guide Bearing ShellsWorking CardPage 1 (3)

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L23/30H

96.20 - ES0S

510-01.10Edition 01H

Working CardPage 2 (3)

Fig 2. Mounting of Wire Straps.

Make Ready for Dismantling of the Guide Bea-ring

1) Dismount the crankcase covers opposite the bearing concerned.

2) Turn the engine until the crank is in a convenient position for carrying out the work.

3) Dismount the bracing screw (side screw).

4) Mount the hydraulic tools, see fi g 1, and loosen the guide bearing stud nuts. For operation of the hydraulic tools, see working card 520-01.05.

Fig 1. Mounting of Hydraulic Tools.

5) Dismount the hydraulic tools and slacken the nuts somewhat.

Dismantling of the Guide Bearing Cap

6) Fit the eye screws, diagonally, in the threaded holes in the guide bearing cap, see fi g 2.

Pass the wire supplied through the eye screw and attach it as shown, so as to keep the bearing cap in place when the guide bearing stud nuts are removed.

7) Work the guide bearing cap loose from the engine frame with a lead hammer or similar.

8) Lift the guide bearing cap a little and unscrew the bearing stud nut.

Inspection of Guide Bearing Shells

9) Fit guide tubes on the threads of the bearing studs and lower the bearing cap to make it rest on the collar of the guide tubes.

Dismantling of the Guide Bearing Shells

10) Remove the locking piece from the bearing cap and take out the bearing shell.

The thrust washer of the guide bearing is partially countersunk into the engine frame and attached by means of four screwed-on clamps which are visible after lowering the bearing cap, see fi g 3.

Thrust washer

Fig 3. Guide Bearing with Thrust Washer.

11) Unscrew the clamps and push out the thrust washers.

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96.20 - ES0S

Inspection of Guide Bearing ShellsWorking Card

Page 3 (3)510-01.10

Edition 01H

L23/30H

Fig 5. Mounting of Upper Shell in Guide Bearing.

Guide for mounting of upper shell.

Fig 4. Dismounting of Upper Shell.

12) The upper bearing shell is dismounted by means of special tool see fi g 4.

Cleaning of Components

13) Clean all machined surfaces, on frame, bearing cap, stud, nuts and bearing shells.

Inspection of Guide Bearing Shells

14) Inspect the guide bearing shells according to working card 506-01.16.

Mounting of the Guide Bearing Shells

The bearing shells of the guide bearing, which are identical to those of the main bearings, are narrower than the bore for the guide bearing and it is therefore essential that the shells are positioned perfectly cor-rect in the bore.

For this purpose a guide tool is supplied for positio-ning on the engine frame when the upper bearing shell is to be fi tted, see fi g 5.

15) Push the bearing shell into correct position through this guide tool, by using tool item 202, if necessary use a plastic hammer.

16) Fit the thrust washers and clamps.

Note: Clearance in guide bearing axially, see page 500.35.

17) Lubricate the end of the bearing shells with molycote pasta or similar.

18) Insert the lower bearing shell in the bearing cap, and mount the locking piece.

Mounting of Guide Bearing Cap

Lubricate the bearing shell and journal with clean lubricating oil.

19) Raise the bearing cap into position, dismount the guide tubes, coat the bearing stud with molycote pasta or similar and fi t the bearing stud nuts.

Make sure that the thrust washers, bearing shell and bearing cap are in their correct position.

20) Dismantle the wire straps.

21) Mount the hydraulic tools, see working card 520-01.05, and tighten the nuts as prescribed on page 500-40.

22) Coat the back side of the bracing screws' (side screws') hexagonal head with a thin coat of silastene or similar.

23) Mount the screws and tighten with a torque spanner as indicated on page 500.40.

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MAN Diesel

Safety precautions:

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

Description:

Taking a silicone oil sample

Starting position:

Related procedure:

Manpower:

Working time : 2-4 hoursCapacity : 1 man

Data:

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

510-04.00Edition 01H

96.03 - ES0S-G

L23/30H

Vibration DamperWorking CardPage 1 (3)

Special tools:

Plate no Item no Note

Hand tools:

Ring and open end spanner, 19 mm.

Replacement and wearing parts:

Plate no Item no Qty /

See plate 51004

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510-04.00Edition 01H Vibration Damper Working Card

Page 2 (3)

A. Blank fl ange or cooling water pump. B. Front end cover. C. Damper. D. Gearwheel (if mounted) E. Main bearing (Frame) F. Crankshaft.

Fig 1. Mounting of Vibration Damper.

The vibration damper is equipped with extraction plugs which provide the opportunity of testing the viscosity of the silicone oil inside the damper without having to dismantle it.

Corresponding to the condition of the silicone oil an approximate assessment of the damper effi ciency is possible.

A silicone oil sample should be extracted as follows by means of a special tube that can be required from MAN B&W Holeby, see plate 51004.

1) After the engine is stopped let damper cool down to nearly 40°C.

2) For access to the damper remove the blank fl ange (A) on the front end cover (B) see fi g 1.

In some cases it is necessary to dismount the lub. oil pump or the cooling water pump, for access to the damper.

3) Rotate the engine in order to bring the extraction plugs (6) of the damper in optimal position, see fi g 2 A .

F

E

B

D

C

A

5

3

1110

Fig 2. Vibration Damper

4) Prepare the sample container (10) by removing one of its caps (11), see fi g 2 C.

C

5

6

7

B

6

6

A

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L23/30H

Working CardPage 3 (3) Vibration Damper

5) Unscrew and remove one of the extraction plugs (6) and replace it with the sample container (10).

If meeting the inertia ring (3) unscrew the container one revolution.

6) Remove the second cap from the sample container and wait until silicone fl uid (5) begins to fl ow out from the free end. Depending on the silicone viscosity the process needs a certain amount of time. If possible it, can be speeded up by means of:

A Turning the damper until the sample contai-ner is underneath the crankshaft.

B Temporarily removing the second extraction plug too.

7) As soon as the silicone fl uid begins to fl ow, shut the sample container by the cap. Remove the container from the damper casing, wipe off the sea-ling jace round the extraction hole and screw in the plugs together with new sealing washers (7). Now close the second side of the container.

8) Tighten both extraction plugs with thumb and forefi nger then turn them further 45° (about 20 Nm). Seal both plugs by caulking their grooves.

9) Send the sample container to MAN B&W Holeby, att.: Service Department, together with the label fi lled in with:

- Name of ship. - Engine type. - Engine no. - Running hours. - Data for vibration damper.

10) For hours between taking new samples, see page 500.25.

The quantity of silicone oil removed it so small that up to 10 such samples can be taken without risk.

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L23/30H

Crankshaft 51001-04HPlatePage 1 (2)

98.34 - ES0S

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Kontravægt

Skrue forkontravægt

Propskrue

Propskrue

Skrue

Selvlåsende møtrik

Skive

Olieafslyngningsring

Cylindrisk stift

Krumtapaksel5 cyl. motor

Tandhjul (krumtap)

Krumtapaksel6 cyl. motor

Krumtapaksel7 cyl. motor

Krumtapaksel,8 cyl. motor

+ Item nr. 021 kræver en individuel tilpasning før montering, kontakt MAN Diesel

98.34 - ES0S

Counterweight

Screw forcounterweight

Plug screw

Plug screw

Screw

Self locking nut

Washer

Oil throw ring

Cylindrical pin

Crankshaft,5 cyl. engine

Gear wheel(crankshaft)

Crankshaft6 cyl. engine

Crankshaft7 cyl. engine

Crankshaft8 cyl. engine

+ Item No. 021 require an indi vidual match-ing before mounting contact MAN Diesel

Designation BenævnelseBenævnelseDesignation

Crankshaft PlatePage 2 (2)51001-04H

L23/30H

021+

069

070

082

094

104

116

128

153

165

177

189

190

200

2/C

2/W

1/C

1/E

10/E

10/E

10/E

1/E

1/W

1/E

1/E

1/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/W = Antal/KontravægtAntal/C = Antal/Cylinder

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./W = Qty./CounterweightQty./C = Qty./Cylinder

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L23/30H

Coupling for Central Driven Lub. Oil Pump 51002-01HPlatePage 1 (2)

06.43 - ES0

279

Crankshaft(Plate 51001)

027

038

015

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Koblingsfl ange

Låseplade

Skrue

Svingvægt5 cyl. motor

06.43 - ES0

Coupling fl ange

Locking plate

Screw

Flyweight5 cyl. engine

Designation BenævnelseBenævnelseDesignation

Coupling for Central Driven Lub. Oil Pump PlatePage 2 (2)51002-01H

L23/30H

015

027

038

279

1/E

3/E

6/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

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L23/30H

Resilient Gear Wheel 51002-02HPlatePage 1 (2)

06.41 - ES0

243

123

135

206

111

196

218

111

231

111

172

172

052

088

040

172

064

184

076

267

147

111

159

160

Crankshaft(Plate 51001)

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Afstandsstykke

Afstandsstykke

Fjeder

Fjederstyr

Glidesko

Møtrik

Akseltap

Skrue

Selvlåsende møtrik

Sætteskrue

Cylindrisk stift

Låseskive

Skrue

Tandhjul

Nav

Sideplade

Cylindrisk stift

Fjederende tandhjul,komplet

Bolt

06.41 - ES0

Distance piece

Distance piece

Spring

Spring guide

slide shoe

Nut

Axle journal

Screw

Self locking nut

Hexagon soc. screwwith cup point

Cylindrical pin

Locking washer

Screw

Gear wheel

Hub

Side plate

Cylindrical pin

Resilient gear wheel,complete

Bolt

Designation BenævnelseBenævnelseDesignation

Resilient Gear Wheel PlatePage 2 (2)51002-02H

L23/30H

040

052

064

076

088

111

123

135

147

159

160

172

184

196

206

218

231

243

267

3/E

3/E

6/E

6/E

6/E

12/E

1/E

2/E

4/E

2/E

2/E

18/E

6/E

1/E

1/E

1/E

4/E

1/E

2/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

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PlatePage 1 (2)

96.03 - ES0S

Flywheel with Flexible Coupling and Gear Rim 51003-01H

L23/30H

022

010

034

Crankshaft(Plate 51001)

117

105

083

071+

095

046+

058

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Flywheel with Flexible Coupling and Gear Rim PlatePage 2 (2)51003-01H

L23/30H

010

022

034

046+

058

071+

083

095

105

117

Item No. Benævnelse

Tandkrans

Skrue

Selvlåsende møtrik for item nr. 046

Pasbolt

Svinghjul

Pasbolt

Fleksibel kobling,komplet

Gummielement

Skrue

Selvlåsende møtrik for item nr. 071

+ Item nr. 046 and 071 kræver en individuel tilpasning, før monte-ring

Designation

Gear rim

Screw

Self locking nut, for item no. 046

Fitted bolt

Flywheel

Fitted bolt

Flexible coupling, complete

Rubber element

Screw

Self locking nut, for item no. 071

+ Item 046 and 071 require an individu-al matching, before mounting.

Qty.

1/E

14/E

12/E

12/E

1/E

12/E

1/E

24/E

2/E

12/E

Item No. DesignationQty. Benævnelse

96.03 - ES0S

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

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MAN Diesel

PlatePage 1 (2)

96.03 - ES0S

Flywheel with Gear Rim 51003-02H

L23/30H

022

010

034

Crankshaft(Plate 51001)

105

046+

058

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

010

022

034

046+

058

105

Item No. Benævnelse

Tandkrans

Skrue

Selvlåsende møtrik for item nr. 046

Pasbolt

Svinghjul

Skrue

+ Item nr. 046 kræver en individuel tilpasning før montering.

Designation

Gear rim

Screw

Self locking nut, for item no. 046

Fitted bolt

Flywheel

Screw

+ Item 046 require an individual matching before mounting.

Qty.

1/E

14/E

12/E

12/E

1/E

2/E

Item No. DesignationQty. Benævnelse

96.03 - ES0S

L23/30H

Flywheel with Gear Rim51003-02H PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

96.03 - ES0S

Flywheel with Gear Rim 51003-03H

L23/30H

022

010

034

Crankshaft(Plate 51001)

105

046+

058

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

010

022

034

046+

058

105

Item No. Benævnelse

Tandkrans

Skrue

Selvlåsende møtrik for item nr. 046

Pasbolt

Svinghjul

Skrue

+ Item nr. 046 kræver en individuel tilpasning før montering.

Designation

Gear rim

Screw

Self locking nut, for item no. 046

Fitted bolt

Flywheel

Screw

+ Item 046 require an individual matching before mounting.

Qty.

1/E

14/E

12/E

12/E

1/E

2/E

Item No. DesignationQty. Benævnelse

96.03 - ES0S

L23/30H

Flywheel with Gear Rim51003-03H PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.14 - ES0

Flywheel with Gear Rim 51003-22H

L23/30H

022

010

034

Crankshaft(Plate 51001)

105

046+

058

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

010

022

034

046+

058

105

Item No. Benævnelse

Tandkrans

Skrue

Selvlåsende møtrik for item nr. 046

Pasbolt

Svinghjul

Skrue

+ Item nr. 046 kræver en individuel tilpasning før montering.

Designation

Gear rim

Screw

Self locking nut, for item no. 046

Fitted bolt

Flywheel

Screw

+ Item 046 require an individual matching before mounting.

Qty.

1/E

14/E

12/E

12/E

1/E

2/E

Item No. DesignationQty. Benævnelse

07.14 - ES0

L23/30H

Flywheel with Gear Rim51003-22H PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

07.14 - ES0

Flywheel with Gear Rim 51003-23H

L23/30H

022

010

034

Crankshaft(Plate 51001)

105

046+

058

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

010

022

034

046+

058

105

Item No. Benævnelse

Tandkrans

Skrue

Selvlåsende møtrik for item nr. 046

Pasbolt

Svinghjul

Skrue

+ Item nr. 046 kræver en individuel tilpasning før montering.

Designation

Gear rim

Screw

Self locking nut, for item no. 046

Fitted bolt

Flywheel

Screw

+ Item 046 require an individual matching before mounting.

Qty.

1/E

14/E

12/E

12/E

1/E

2/E

Item No. DesignationQty. Benævnelse

07.14 - ES0

L23/30H

Flywheel with Gear Rim51003-23H PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

08.21 - ES0

Flywheel with Gear Rim 51003-24H

L23/30H

022

010

034

Crankshaft(Plate 51001)

105

046+

058

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Antal/Motor

010

022

034

046+

058

105

Item No. Benævnelse

Tandkrans

Skrue

Selvlåsende møtrik for item nr. 046

Pasbolt

Svinghjul

Skrue

+ Item nr. 046 kræver en individuel tilpasning før montering.

Designation

Gear rim

Screw

Self locking nut, for item no. 046

Fitted bolt

Flywheel

Screw

+ Item 046 require an individual matching before mounting.

Qty.

1/E

14/E

12/E

12/E

1/E

2/E

Item No. DesignationQty. Benævnelse

08.21 - ES0

L23/30H

Flywheel with Gear Rim51003-24H PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-01H

94.23 - ES0S

PlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

94.23 - ES0S

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-01H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-26H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-26H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-27H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-27H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-28H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-28H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-29H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-29H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-30H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-30H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-31H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-31H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-32H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-32H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-33H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-33H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-34H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-34H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-35H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-35H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-36H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-36H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-37H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-37H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Torsional Vibration Damper 51004-38H

07.14 - ES0

PlatePage 1 (2)

016

053

028*

041*

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Svingningsdæmpermed 25 mm monte-ringsfl ange

Tætningsskive

Prøveudtagings-beholder

Prøvesæt for sving-ningsdæmper

+ Se også arbejdskort 510-04.00

07.14 - ES0

Torsional vibration damper, with 25 mm mounting fl ange

Sealing washer

Sample container

Sampling kit for tor-sional vibration dam-per

+ See also working card 510-04.00

Designation BenævnelseBenævnelseDesignation

Torsional Vibration Damper PlatePage 2 (2)51004-38H

L23/30H

1/E

2/E

1/E

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

016

028*

041*

053+

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Tuning Wheel 51004-02HPlatePage 1 (2)

94.23 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Afstemningshjul med25 mm monterings-fl ange

94.23 - ES0S

Tuning wheel with,25 mm mountingfl ange

Designation BenævnelseBenævnelseDesignation

Tuning Wheel PlatePage 2 (2)51004-02H

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

065

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Tuning Wheel 51004-39HPlatePage 1 (2)

07.18 - ES0

065

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Afstemningshjul med25 mm monterings-fl ange

07.18 - ES0

Tuning wheel with,25 mm mountingfl ange

Designation BenævnelseBenævnelseDesignation

Tuning Wheel PlatePage 2 (2)51004-39H

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

065

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Tuning Wheel 51004-40HPlatePage 1 (2)

07.18 - ES0

065

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Afstemningshjul med25 mm monterings-fl ange

07.18 - ES0

Tuning wheel with,25 mm mountingfl ange

Designation BenævnelseBenævnelseDesignation

Tuning Wheel PlatePage 2 (2)51004-40H

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

065

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Tuning Wheel 51004-41HPlatePage 1 (2)

07.18 - ES0

065

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Afstemningshjul med25 mm monterings-fl ange

07.18 - ES0

Tuning wheel with,25 mm mountingfl ange

Designation BenævnelseBenævnelseDesignation

Tuning Wheel PlatePage 2 (2)51004-41H

1/E

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

065

L23/30H

Engine frame/Oil pan

511/611

MAN Diesel

DescriptionPage 1 (1) Engine Frame and Base Frame 511.01

Edition 01H

Frame

The engine frame is made of cast iron, and is at-tached to the top of the base frame by means of bolts. The cross girders of the frame are provided with bores for the main bearings in which the crank-shaft is underslung, i.e. it is carried by the main bearing caps.

The main bearing caps are attached by means of studs and nuts, which are loosened and tightened with the aid of hydraulic tools. After mounting, the main bearing caps are further secured by means of bracing screws, which are screwed horizontally into the sides of the caps and tightened against the sides of the engine frame. The main bearings are equip ped with replaceable shells which are fi tted without scraping.

The crankshaft guide bearing is located at the fl y-wheel end of the engine.

94.26 - ES0U

L23/30H

On the sides of the frame there are covers for acces to the camshaft, the charge air receiver and crank-case. Some of the covers are fi tted with relief valves which will act, should oil vapours in the crankcase be ignited, for instance in the event of a hot bearing.

The charge air cooler housing is a integrated part of the frame.

Base Frame

Engine and alternator (gear, pump) are mounted on a common base frame which is in welded design.

The base frame is used as lubricating oil reservoir "wet sump".

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Functional test of crankcase safety relief val-ves.

Starting position:

Related procedure:

Manpower:

Working time : 1/4 hourCapacity : 1 man

Data:

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

511-01.00Edition 10H

06.46 - ES0

L23/30H

Functional Test of Crankcase Safety Relief ValvesWorking CardPage 1 (2)

Special tools:

Plate no Item no Note.

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty/

51106 058 1/cyl. 51106 071 1/relief valve 51106 740 12/relief valve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

06.46 - ES0

511-01.00Edition 10H Functional Test of Crankcase Safety Relief Valves Working Card

Page 2 (2)

Functional Testing

Functional testing of the crankcase safety relief valves cannot be performed during operation of the engine, but it must be checked during overhauls that the valve fl ap is movable.

When Painting

When painting the engine, take care not to block up the safety relief valves with paint.

Check of Opening Pressure

To check the proper opening pressure, proceed as follows:

1) Remove the relief valve cover from the engi-ne.

2) Place the cover on the fl oor with the pressure area upwards.

3) Apply a weight at 5 kg on the pressure area.

The relief valve must open under this pres-sure.

4) Remount the relief valve cover of the engine.

If the safety relief valves are actuated, the engine must be stopped immediately, and it must not be restarted until the cause is detected and the fault is detected, see also description 503.04, Ignition in Crankcase.

Fig 1 Cover with relief valve

Cover

Reliefvalve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (2)

00.09 - ES0

Frame with Main Bearings 51101-09H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

00.09 - ES0

PlatePage 2 (2)

L23/30H

Frame with Main Bearings51101-09H

Designation BenævnelseBenævnelseDesignation

013

025

037

049

050

062

074

086

098

108+

121

133

145

157

169

170

182+

194

216

228

241

253

265

290

300+

312

1/E

5/E

1/C

4/C

4/C

4/C

1/E

1/E

2/E

1/C

1/B

1/B

1/B

1/C

2/B

2/B

2/B

6/B

2/E

1/B

2/B

2/E

4/E

4/E

1/E

/I

Item No.

Qty.

Qty.

Item No.

Frame

Bracing bolt

Wear ring

Nut for cylinderhead stud

Protective cap

Stud for cylinder head

Plug

Coupling

Plug

Main bearing cap

Screw

Securing piece

Spring pin

Main bearing shell 2/2

Main bearing stud

Nut for mainbearing stud

Distance piece

Screw

Cylindrical pin

Plug

Bracing bolt

Thrust washer

Locking piece

Screw

Guide bearing cap

Loctite 542

Stativ

Sideskrue

Slidring

Møtrik for cylinder-dækseltap

Beskyttelseshætte

Tap for cylinderdæk-sel

Prop

Kobling

Prop

Hovedlejedæksel

Skrue

Sikringstykke

Fjederstift

Hovedlejeskaller 2/2

Hovedlejetap

Møtrik forhovedlejetap

Afstandsstykke

Skrue

Cylindrisk stift

Prop

Sideskrue

Trykskive

Låsestykke

Skrue

Styrelejedæksel

Loctite 542

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./B = Qty./BearingQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/B = Antal/LejeAntal/I = Antal/Individuelt

Loctite 243

Molykote paste

Frame complete, incl. item 049, 062, 108, 133, 145, 169, 170, 182, 194, 216, 241, 290, 300, 324, 348, 361, plate 50701 item 048, 061, 073, 276, plate 50705 item 350, 362

+ Item No 108, 182, 300 require an individual matching beforemoun ting, contactMAN B&W, Holeby

Loctite 243

Molykote

Stativ komplet, inkl.item 037, 049, 062, 108, 133, 145, 169, 170, 182, 194, 216, 241, 290, 300, 324, 348, 361, plate 50701 item 048, 061, 073, 276, plate 50705 item 350, 362

+ Item nr. 108, 182, 300 kræver en individueltilpasning før mon-tering, kontakt MAN B&W,Holeby

324

336

397

/I

/I

1/E

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (2)

00.09 - ES0

Frame with Main Bearings 51101-10H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

00.09 - ES0

PlatePage 2 (2)

L23/30H

Frame with Main Bearings51101-10H

Designation BenævnelseBenævnelseDesignation

013

025

049

050

062

074

086

098

108+

121

133

145

157

169

170

216

228

241

253

265

290

300+

312

324

1/E

5/E

4/C

4/C

4/C

1/E

1/E

2/E

1/C

1/B

1/B

1/B

1/C

2/B

2/B

2/E

1/E

2/B

2/E

4/E

4/E

1/E

/I

/I

Item No.

Qty.

Qty.

Item No.

Frame

Bracing bolt

Nut for cylinderhead stud

Protective cap

Stud for cylinder head

Plug

Coupling

Plug

Main bearing cap

Screw

Securing piece

Spring pin

Main bearing shell 2/2

Main bearing stud

Nut for mainbearing stud

Cylindrical pin

Plug

Bracing bolt

Thrust washer

Locking piece

Screw

Guide bearing cap

Loctite 542

Loctite 243

Stativ

Sideskrue

Møtrik for cylinder-dækseltap

Beskyttelseshætte

Tap for cylinderdæk-sel

Prop

Kobling

Prop

Hovedlejedæksel

Skrue

Sikringstykke

Fjederstift

Hovedlejeskaller 2/2

Hovedlejetap

Møtrik forhovedlejetap

Cylindrisk stift

Prop

Sideskrue

Trykskive

Låsestykke

Skrue

Styrelejedæksel

Loctite 542

Loctite 243

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./B = Qty./BearingQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/B = Antal/LejeAntal/I = Antal/Individuelt

Molykote paste

Frame complete, incl. item 049, 062, 108, 133, 145, 169, 170, 216, 241, 290, 300, 324, 348, 361, plate 50701 item 048, 061, 073, 276, plate 50705 item 350, 362

+ Item No 108, 300 require an individual matching beforemoun ting, contactMAN B&W, Holeby

Molykote

Stativ komplet, inkl.item 049, 062, 108, 133, 145, 169, 170, 216, 241, 290, 300, 324, 348, 361, plate 50701 item 048, 061, 073, 276, plate 50705 item 350, 362

+ Item nr. 108, 300 kræ-ver en individueltilpasning før mon-tering, kontakt MAN B&W,Holeby

336

397

/I

1/E

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

06.50 - ES0

Mounting of Pumps 51102-05HPlatePage 1 (2)

164

140

451

211

247

235

223

Low temperature fresh water pump,see Plate 51610

For lubricating oil pump,see Plate 51501

127

103

152

259

152

260

093

176

188

High temperature fresh water pump,see Plate 51610

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.50 - ES0

L23/30H

Mounting of Pumps51102-05H

Designation BenævnelseBenævnelseDesignation

093

103

127

140

152

164

176

188

211

223

235

247

259

260

451

1/E

1/E

1/E

24/E

12/E

2/E

3/E

6/E

6/E

1/E

1/E

2/E

1/E

1/E

10/E

Item No.

Qty.

Qty.

Item No.

Guard end, fore

Cover

Gasket

Screw

Screw

Guide pin

Spray pipe

Locking plate

Screw

Plug screw

Sealing ring

Nut

Cover

Gasket

Screw

Endedæksel, for

Dæksel

Pakning

Skrue

Skrue

Styrestift

Sprøjterør

Låseplade

Skrue

Propskrue

Tætningsring

Møtrik

Dæksel

Pakning

Skrue

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (2)

06.50 - ES0

Front Cover for Lubricating Oil Pump 51102-10H

081

For lubricatingoil pump, seePlate 51501

247

164

451

140

020

019

032

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.50 - ES0

PlatePage 2 (2)

L23/30H

Front Cover for Lubricating Oil Pump51102-10H

Designation BenævnelseBenævnelseDesignation

019

020

032

081

140

164

247

451

1/E

1/E

6/E

1/E

24/E

2/E

2/E

10/E

Item No.

Qty.

Qty.

Item No.

Cover

Gasket

Screw

Guard end, fore

Screw

Guide pin

Nut

Screw

Dæksel

Pakning

Skrue

Endedæksel, for

Skrue

Styrestift

Møtrik

Skrue

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

06.50 - ES0

Mounting of Pumps 51102-11HPlatePage 1 (2)

115

152

127

164

140

211

247

103235

223

For fresh water pump,see Plate 51610

For lubricating oil pump,see Plate 51501

152

139

093

176

188

235

223

451

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.50 - ES0

L23/30H

Mounting of Pumps51102-11H

Designation BenævnelseBenævnelseDesignation

093

103

115

127

139

140

152

164

176

188

211

223

235

247

451

1/E

1/E

2/E

1/E

2/E

24/E

18/E

2/E

2/E

4/E

4/E

2/E

2/E

2/E

10/E

Item No.

Qty.

Qty.

Item No.

Guard end, fore

Cover

Cover

Gasket

Gasket

Screw

Screw

Guide pin

Spray pipe

Locking plate

Screw

Plug screw

Sealing ring

Nut

Screw

Endedæksel, for

Dæksel

Dæksel

Pakning

Pakning

Skrue

Skrue

Styrestift

Sprøjterør

Låseplade

Skrue

Propskrue

Tætningsring

Møtrik

Skrue

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

PlatePage 2 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (3)

07.09 - ES0

Covers on Frame 51106-17H

010058071083

130 FramePlate 51101142

129

490

370

154

166178

428788

465453441

477

489

394058416

129

308382

370369

249345333

321500

308298286

308

298286

274

262250249191

201

213

225

237

250357

404

Cover seeplate 51102

703693

715

071

5 cyl.

6 cyl.

7 cyl.

8 cyl.

When ordering cover forcrankshaft with relief valve,please see diagram with covers.

752764

740

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.09 - ES0

PlatePage 2 (3)

L23/30H

Covers on Frame51106-17H

010

058

071

083

129

130

142

154

166

178

191

201

213

225

237

249

250

262

274

286

6/D

2/C

12/D

6/D

8/C

2/E3/E3/E4/E

2/E3/E3/E4/E

58/E66/E80/E88/E

1/E

1/E

2/C

2/E

4/C

1/C

1/C

5/E

5/E

1/E

1/E

22/E26/E30/E34/E

Screw

O-ring

Washer

Self locking nut

Screw

Cover5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Gasket5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Screw5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Cover

Gasket

Stud

Stud

Screw

Cover for camshafthousing

O-ring

Screw

Washer

Guard end aft

Guard end aft

Spring pin5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Skrue

O-ring

Skive

Selvlåsende møtrik

Skrue

Dæksel5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Pakning5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Skrue5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Dæksel

Pakning

Tap

Tap

Skrue

Dæksel for kamaksel-hus

O-ring

Skrue

Skive

Skærm, agter

Skærm, agter

Fjederstift5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./D = Qty./Safety cover

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/D = Antal/sikkerhedsdæksel

298

308

321

333

345

357

369

370

382

394

404

416

428

441

453

465

477

489

22/E26/E30/E34/E

24/E28/E32/E36/E

4/E5/E6/E7/E

2/C

1/E

1/E

1/E

14/E

1/E

6/C

2/E

6/E8/E10/E11/E

4/E

2/E

2/E

2/E

6/C

6/C

Handle5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Washer5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Guard intermediate5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Stud

Guard end fore

Guard end fore

Guard

Screw

Guard end fore

Screwonly for 900 rpm

Screw

Cover forcrankcase5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Screw, 720/750 rpm

Tapered dowel

Washer

Nut

Nutonly for 720/750 rpm

Screwonly for 720/750 rpm

BenævnelseDesignationItemNo Qty. BenævnelseDesignation

ItemNo Qty.

Håndtag5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Skive5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Mellemskærm5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Tap

Skærm, for

Skærm, for

Skærm

Skrue

Skærm, for

Skruekun for 900 omdr.

Skrue

Dæksel forkrumtaphus5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Skrue, 720/750 rpm

Styrestift

Skive

Møtrik

Møtrikkun for 720/750 omdr.

Skruekun for 720/750 omdr.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./D = Qty./Safety cover

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/D = Antal/sikkerhedsdæksel

Dæksel med sikker-hed-sventil, komplet5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Mellemskærm, komplet inkl. item 191, 286, 298, 308, 321, 333

5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Silicone

Dæksel

Skrue

O-ring

Sikkerhedsventil,komplet5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Flange

Skrue, 900 rpm

L23/30H

PlatePage 3 (3)

07.09 - ES0

Covers on Frame 51106-17H

BenævnelseDesignationItemNo Qty. BenævnelseDesignation

ItemNo Qty.

490

500

693

703

715

740

752

764

788

4/E4/E4/E5/E

4/E5/E6/E7/E

/I

1/E

6/E

1/D

4/E4/E4/E5/E

1/D

4/E

Cover with safetyvalve, complete5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Guard intermediatecomplete, incl. item 191, 286, 298, 308, 321, 3335 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Packingsilicone paste

Cover

Screw

O-ring

Safety valve,complete5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Flange

Screw, 900 rpm

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (2)

07.09 - ES0

Covers on Frame 51106-30H

512

668

811

585

607

619

597

776

620

681

823

536

548

561

693

693

644

632

656

573

524

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.09 - ES0

PlatePage 2 (2)

L23/30H

Covers on Frame51106-30H

Designation BenævnelseBenævnelseDesignation

512

524

536

548

561

573

585

597

607

619

620

632

644

656

668

681

693

776

811

823

1/E

22/E

4/E

4/E

1/E

4/E

1/E

16/E

2/E

2/E

2/E

1/E

8/E

1/E

2/E

4/E

/I

2/E

2/E

4/E

Item No.

Qty.

Qty.

Item No.

Cover 2/2

Screw

Guide pin

Nut

Plug screw

Screw

Sealing ring 2/2

Screw

Guide pin

Nut

Cylindrical pin

Cover

Screw

Gasket

Screw, 720/750 rpm

Screw, 720/750 rpm

Packingsilicone paste

Screw

Screw, 900 rpm

Screw, 900 rpm

Dæksel 2/2

Skrue

Styrestift

Møtrik

Propskrue

Skrue

Tætningsring 2/2

Skrue

Styrestift

Møtrik

Cylindrisk stift

Dæksel

Skrue

Pakning

Skrue, 720/750 rpm

Skrue, 720/750 rpm

Silicone

Skrue

Skrue, 900 rpm

Skrue, 900 rpm

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/I = Antal/Individuelt

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

PlatePage 1 (3)

06.49 - ES0

Covers on Frame 51106-31H

FramePlate 51101

154

166178

428

465453441

477

489

394058416

129

308382

370369

249345

191201

213

225

237

250357

404

Coolerbox seeplate 51203

Cover seeplate 51102

703693

715

333

321500

308298286

308298286

274

262250249

010058071083

129

490

071

752764

740

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

06.49 - ES0

PlatePage 2 (3)

L23/30H

Covers on Frame51106-31H

Designation BenævnelseBenævnelseDesignation

010

058

071

083

129

154

166

178

191

201

213

225

237

249

250

262

274

286

298

308

6/D

2/C

12/D

6/D

8/C

28/E

2/E

2/E

2/C

2/E

4/C

1/C

1/C

5/E

5/E

1/E

1/E

22/E26/E30/E34/E

22/E26/E30/E34/E

24/E28/E32/E36/E

Item No.

Qty.

Qty.

Item No.

Coach bolt

O-ring

Washer

Self locking nut

Screw

Screw

Cover

Gasket

Stud

Stud

Screw

Cover for camshafthousing

O-ring

Screw

Washer

Guard end aft

Guard end aft

Spring pin5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Handle5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Washer5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Bræddebolt

O-ring

Skive

Selvlåsende møtrik

Skrue

Skrue

Dæksel

Pakning

Tap

Tap

Skrue

Dæksel for kamaksel-hus

O-ring

Skrue

Skive

Skærm, agter

Skærm, agter

Fjederstift5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Håndtag5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Skive5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./D = Qty./Safety cover

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/D = Antal/sikkerhedsdæksel

321

333

345

357

369

370

382

394

404

416

428

441

453

465

477

489

490

4/E5/E6/E7/E

2/C

1/E

1/E

1/E

6/E

1/E

6/C

2/E

6/E7/E9/E10/E

4/E

2/E

2/E

2/E

6/C

6/C

4/E5/E5/E6/E

Guard intermediate5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Stud

Guard end fore

Guard end fore

Guard

Screw

Guard end fore

Screwonly for 900 rpm

Screw

Cover forcrankcase5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Screw

Tapered dowel

Washer

Nut

Nutonly for 720/750 rpm

Screwonly for 720/750 rpm

Cover with safetyvalve, complete incl. item 010, 022, 034, 046, 071, 083, 095, 105, 1175 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Mellemskærm5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Tap

Skærm, for

Skærm, for

Skærm

Skrue

Skærm, for

Skruekun for 900 omdr.

Skrue

Dæksel forkrumtaphus5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Skrue

Styrestift

Skive

Møtrik

Møtrikkun for 720/750 omdr.

Skruekun for 720/750 omdr.

Dæksel med sikker-hedsventil, komplet inkl. item 010, 022, 034, 046, 071, 083, 095, 105, 1175 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

0802

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/H52

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.12

MAN Diesel

06.49 - ES0

PlatePage 3 (3)

L23/30H

Covers on Frame 51106-31H

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./D = Qty./Safety cover

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/CylinderAntal/D = Antal/sikkerhedsdæksel

500

693

703

715

740

752

764

4/E5/E6/E7/E

/I

1/E

6/E

1/D

4/E4/E4/E5/E

1/D

Guard intermediatecomplete, incl. item 191, 286, 298, 308, 321, 3335 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Packingsilicone paste

Cover

Screw

O-ring

Safety valve,complete5 cyl. engine6 cyl. engine7 cyl. engine8 cyl. engine

Flange

Mellemskærm, komplet inkl. item 191, 286, 298, 308, 321, 333

5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Silicone

Dæksel

Skrue

O-ring

Sikkerhedsventil,komplet5 cyl. motor6 cyl. motor7 cyl. motor8 cyl. motor

Flange

Turbocharger

512/612

MAN Diesel

DescriptionPage 1 (2) Turbocharger System 512.01

Edition 01H

95.26 - ES0S

L23/30H

Fig. 1. Diagram for Turbocharger System

Turbocharger System

The turbocharger system of the engine, which is a constant pressure system, consists of an exhaust gas receiver, a turbocharger, a charging air cooler and a charging air receiver, the latter being inte grated in the engine frame.

The turbine wheel of the turbocharger is driven by the engine exhaust gas, and the turbine wheel dri-ves the turbocharger compressor, which is moun-ted on the same shaft. The compressor sucks air from the engine room, through the air fi lters.

Turbocharger, see separate manual.

The turbocharger pumps the air through the char-ging air cooler to the charging air receiver. From the charging air receiver, the air fl ows to each cylinder, through the inlet valves.

The charging air cooler is a compact tube-type cooler with a large cooling surface. The cooling wa-ter is passed twice through the cooler, the end covers being designed with partitions which cause the cooling water to turn.

The cooling water tubes are fi xed to the tube plates by expansion.

From the exhaust valves, the exhaust is led through a water cooled intermediate piece to the exhaust gas receiver where the pulsatory pressure from the indi-vidual exhaust valves is equalized and passed to the turbocharger as a constant pressure, and further to the exhaust outlet and silencer arrangement.

The exhaust gas receiver is made of pipe sections, one for each cylinder, connected to each other, by means of compensators, to prevent excessive stress in the pipes due to heat expansion.

Water washing compressor side

P6 Drain from turbocharger, outlet

M1 Charge air, inletExhaust gas, outlet P2P8 Water washing, compressor side with quick coupling, inlet

Water washing, turbine side, inlet P7

Exhaust gas to TC

Charging air from TC

Lambda Cylinder

MAN Diesel

DescriptionPage 2 (2)Turbocharger System

95.26 - ES0S

L23/30H

512.01Edition 01H

In the cooled intermediate piece a thermometer for reading the exhaust gas temperature is fi tted and there is also possibility of fi tting a sensor for remote reading.

To avoid excessive thermal loss and to ensure a reasonably low surface temperature the exhaust gas receiver is insulated.

MAN Diesel

DescriptionPage 1 (1)

512.05Edition 01

Compressor

Fouling of the airways depends primarily on the pu-rity of the inlet air and thus, in turn, on the general maintenance condition of the machinery, i.e. mainly of the gas and oil tightness of the engines and on the fresh air ventilation system of the engine room.

Fouling of air fi lter, compressor or charging air cooler may be observed as changes in performance para-meters:

- Decreasing charging air pressure. - Decreasing turbocharger rotor speed. - Increasing exhaust gas temperature. - Severe fouling of airways may even result in

compressor surge.

Regular cleaning during operation by injection of water before the compressor wheel will reduce the fouling rate considerably, and consequently prolong the intervals between dismantling necessary for mechanical cleaning.

94.26 - ES0U-G

General

Cleaning the Turbocharger In ServiceWater Washing of Compressor

Chemical cleaning will not improve the cleaning process as this primarily is based on the mechanical effect from the impact of the water droplets.

Certain types of fl uid solvents can give formation of deposits on the compressor wheel, and should under no circumstances be used.

The intervals between cleaning by injection of water should be adjusted after assessing the degree and rate of fouling in the particular plant, i.e. based on observations and experience.

MAN Diesel

L23/30HV28/32S

DescriptionPage 1 (3)

Cleaning the Turbocharger in ServiceDry Cleaning - Turbine

512.10Edition 02H

Description

The tendency to fouling on the gas side of turbo-char gers depends on the combustion conditions, which are a result of the load and the maintenance con di tion of the engine as well as the quality of the fuel oil used.

Fouling of the gas ways will cause higher exhaust gas temperatures and higher wall temperatures of the combustion chamber components and will also lead to a higher fuel consumption rate.

Tests and practical experience have shown that ra di-al-fl ow turbines can be successfully cleaned by the dry cleaning method.

This cleaning method employs cleaning agents con-sisting of dry solid bodies in the form of granules. A certain amount of these granules, depending on the turbocharger size, is, by means of compressed air, blown into the exhaust gas line before the gas inlet casing of the turbocharger.

The injection of granules is done by means of wor-king air with a pressure of 5-7 bar.

On account of their hardness, particularly suited blasting agents such as nut-shells, broken or arti fi -ci ally shaped activated charcoal with a grain size of 1.0 mm to max. 1.5 mm should be used as cleaning a gents.

The solid bodies have a mechanical cleaning effect which removes any deposits on nozzle vanes and turbine blades.

Dry cleaning can be executed at full engine load and does not require any subsequent operating period of the engine in order to dry out the exhaust system.

Experience has shown that regular cleaning intervals are essential to successful cleaning, as excessive fouling is thus avoided. Cleaning every second day during operation is recommended.

The cleaning intervals can be shorter or longer based on operational experience.

97.08 - ES2

Fig 1 Arrangement of dry cleaning of turbocharger - Turbine

1 Closing valve 2 Container 3 Air valve 4 working air inlet 5 Exhaust pipe 6 Snap coupling

Cleaning System

The cleaning system consists of a cleaning agent container (2) with a capacity of approx. 0.5 liters and a removable cover. Furthermore the system con sists of an air valve (3), a closing valve (1) and two snap on connectors.

The position numbers (2) and (3) indicate the system's "blow-gun". Only one "blow-gun" is used for each en gine plant. The blow-gun is working according to the ejector principle with pressure air (working air) at 5-7 bar as driven medium. Injection time approx. 2 min. Air consumption approx. 5 Nm3/2 min.

MAN Diesel

L23/30HV28/32S

DescriptionPage 2 (3)

Cleaning the Turbocharger in ServiceDry Cleaning - Turbine

512.10Edition 02H

Dry cleaning of turbochargers

Suppliers of cleaning agents:

1. "Solf Blast Grit, Grade 14/25"

TURCO Products B.V. Verl. Blokkenweg 12, 617 AD EDE - Holland Tel.:08380 - 31380, Fax.: 08380 - 37069

2. Designation unknown

Neptunes Vinke B.V. Schuttevaerweg 24, 3044 BB Rotterdam Potbus 11032, 3004 E.A. Rotterdam, Holland Tel.: 010 - 4373166 Fax.: 4623466

3. "Grade 16/10"

FA. Poul Auer GmbH Strahltechnik D-6800 Mainheim 31, Germany

4. "Granulated Nut Shells"

Eisenwerke Würth GmbH + Co. 4107 Bad Friederichshall, Germany Tel.: 0 71 36-60 01

5. "Soft Blasting Grade 12/3a"

H.S. Hansen Eftf. Kattegatvej 2 2100 Copenhagen Ø, Denmark Tel.:(01) 29 97 00 Telex: 19038

6. "Crushed Nutshells"

Brigantine, Hong Kong

7. "Turbine Wash"

Ishikawajima-Harima Heavy Industries Co. Ishiko Bldg., 2-9-7 Yassu, Chuo-Ku Tokyo 104, Japan Tel.: 03-2 77-42 91

97.08 - ES2

MAN Diesel

DescriptionPage 3 (3)

L23/30HV28/32S

Cleaning the Turbocharger in ServiceDry Cleaning - Turbine

512.10Edition 02H

97.08 - ES2

8. "A-C Cleaner" (Activated Coal)

Mitsui Kozan Co. Ltd. (Fuel Dept.) Yamaguchi Bldg., 2-1-1 Nihonbashi Muromachi, Chuo-Ku Tokyo 103, Japan

9. "OMT-701"

Marix KK Kimura Bldg., 6-2-1 Shinbashi Minato-Ku, Tokyo 105, Japan Tel.: 03-4 36-63 71, Telex: 242-7232 MAIX J

10. "OMT-701"

OMT Incorporated 4F, Kiji Bldg., 2-8 Hatchobori, 4-chome, Chuo-Ku, Tokyo 104, Japan Tel.: 03-5 53-50 77, Telex: 252-2747 OMTINC J

11. "Marine Grid No. 14" (Walnut)

Hikawa Marine Kaigan-Dori 1-1-1, Kobe 650, Japan Tel.: 0 78-3 21-66 56

12. "Marine Grid No. 14"

Mashin Shokai Irie-Dori, 3-1-13, Hyogo-Ku Kobe 652, Japan Tel.: 0 78-6 51-15 81

13. Granulate

MAN B&W Diesel A/S Stamholmen 161 DK-2650 Hvidovre Tel.: +45 31 492501 Fax.: +45 31 494397 Telex: 31197 manbw dk

The list is for guidance only and must not be considered complete. We undertake no responsibility that might be caused by these or other products.

MAN Diesel

DescriptionPage 1 (1)

512.15Edition 01H

Description

The tendency to fouling on the gas side of turbo-chargers depends on the combustion conditions, which are a result of the load on and the maintenance condition of the engine as well as the quality of the fuel oil used.

Fouling of the gas ways will cause higher exhaust gas temperatures and higher surface temperatures of the combustion chamber components and will also lead to a lower performance.

Tests and practical experience have shown that radial-fl ow turbines can be successfully cleaned by injection water into the inlet pipe of the turbine. The cleaning effect is based on the water solubility of the deposits and on the mechanical action of the im pinging water droplets and the water fl ow rate.

The necessary water fl ow is dependent on the gas fl ow and the gas temperature. Enough water must be injected per time unit so that, not the entire fl ow will evaporate, but about 0.25 l/min. will fl ow off through the drainage opening in the gas outlet. Thus ensuring that suffi cient water has been injected.

Service experience has shown that the above men-tioned water fl ow gives the optimal cleaning effect. If the water fl ow is reduced the cleaning effect will be reduced or disappear. If the recommended water fl ow is ex ceed, there is a certain risk of a accumulation of water in the turbine casing, which can result in damage on the turbocharger.

The best cleaning effect is obtained by cleaning at low engine load approx. 20% MCR. Cleaning at low load will also reduce temperature shocks.

Experience has shown, that washing at regular inter-vals is essential to successful cleaning, as excessive fouling is thus avoided. Washing at inter vals of 100 hours is therefore recommended. De pending on the fuel quality these intervals can be shorter or longer. However, the turbine must be washed at the latest when the exhaust gas tempe rature upstream of the turbine has risen about 20° C above the normal temperature.

96.39 - ES0

L23/30HV28/32S

Cleaning the Turbocharger in ServiceWater Washing - Turbine Side

Heavily contami nated turbines, which where not cleaned periodically from the very beginning or after an overhaul, cannot be cleaned by this method.

If vibration in the turbocharger occur after water-wa-shing has been carried out, the washing should be repeated. If unbalance still exists, this is pre sumably due to heavy fouling, and the engine must be stop-ped and the turbocharger dismantled and manually cleaned.

The washing water should be taken from the fresh water system and not from the fresh cooling water system or salt water system. No cleaning agents and solvents need to be added to the water.

To avoid corrosion during standstill, the engine must, upon completing of water washing run for at least 1 hour before stop so that all parts are dry.

Water Washing System

The water washing system consists of a pipe system equipped with a regulating valve, a manoeuvring valve, a 3-way cock and a drain pipe with a drain valve from the gas outlet, see illustration on working card 512-15.00.

The water for washing the turbine, is supplied from the external fresh water system through a fl exible hose with couplings. The fl exible hose must be disconnected after water washing.

By activating the manoeuvring valve and the regu-lating valve, water is led through the 3-way cock to the exhaust pipe intermediate fl ange, equipped with a channel to lead the water to the gas inlet of the turbocharger.

The water which is not evaporated, is led out through the drain pipe in the gas outlet.

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Safety precautions:

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

Description:

Overhaul of charging air cooler.

Starting position:

Related procedure:

Manpower:

Working time : 3-4 hoursCapacity : 2 men

Data:

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

512-01.00Edition 01H

96.20 - ES0S

L23/30H

Overhaul of Charging Air CoolerWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Ring and open end spanner, 13 mm.Ring and open end spanner, 19 mm.Ring and open end spanner, 24 mm.Allen key, 10 mm.Wire rope.Tackle.

Replacement and wearing parts:

Plate no Item no Qty/

51201 113 6/cooler 51201 029 1/cooler 51201 066 1/cooler 61203 035 1/cooler

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L23/30H

96.20 - ES0S

512-01.00Edition 01H Overhaul of Charging Air Cooler Working Card

Page 2 (2)

The charging air cooler is normally cleaned and overhauled at the intervals indicated in the "Planned Maintenance Program", or if observations prove that the cooler does not work satisfactory, see section 502.

Overhaul of Charging Air Cooler.

1) Close the cooling water inlet and outlet valves and disconnect the pipes.

2) Remove the screw (1), fi g 1, which secure the end cover of the cooler element to the cooler hous-ing, and pull the cooler element half-way out.

Place a wire rope round the cooler element and at-tach a tackle hook, after which the elements are lifted and pulled out of the cooler housing and landed on a couple of wooden planks on the fl oor.

4) Clean the cooler element of the water and air sides.

After using cleaning agents the manufacting re com-mendation must be followed.

The greatest care must be exercised when dis mant-ling cleaning and mounting the cooler element, as the thin fi ns of the tubes cannot stand impacts and pressure.

If nevertheless, the metal is bended, it should be carefully straightened, as bent fi ns will increase the pressure drop across the cooler considerably.

Should one ore more cooler tubes become leaky it/they must immediately be made tight, either by expending the tube ends into the tube plates or by blanking of the tube(s) concerned with plugs.

It is important that the charging air cooler is not leaky as any sea water that leaks in will be carried along with the air to the cylinders where the salt contained in the water will damage valves, piston rings, and cylinder liners.

5) Also clean end cover and coat it on the inside with an anti-corrosion blocks agent. Inspect the anti-corrosion (6) and renew if ne ces sa ry.

Note: That paint or similar must not be applied to these blocks.

6) Fouling and deposite in the pipes can be remo-ved by using a hand or machine operated circular steel brush. The pipe inner diameter is 13 mm.

7) When mounting the air cooler, renew all gas-kets.

Out of Service Periods.

At longer periods out of service the air cooler is drained if the coolant is sea water followed by fl ushing with fresh water and left with drain and venting cocks open.

At fresh water coolant systems recommendations for the entire system is followed.

3) Remove screws (2) and end cover (3) reversal chamber (4) and side plates (5).

Fig 1.

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Safety precautions

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

Description

Water washing of compressor side.Turbocharger cleaning with engine in service.

Starting position

Related procedure

Manpower

Working time : 1/4 hourCapacity : 1 man

Data

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

512-05.00Edition 01

02.20 - ES0S-G

General

Special tools

Plate no Item no Note

Hand tools

Replacement and wearing parts

Plate no Item no Qty /

See the special instructions for turbocharger.

Working CardPage 1 (3) Water Washing of Compressor Side

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General

02.20 - ES0S-G

512-05.00Edition 01

Working CardPage 2 (3)

Before Cleaning

The cleaning process is only to be carried out when the engine is at operating temperature (see Opera-ting Data 500.30) and when it is loaded as close as possible to full load (see Main Data 500.00).

See also "Cleaning the Turbocharger in Service, Water Washing of Compressor", 512.05.

Cleaning Procedure

1) Run the engine with as high a load as pos-sible.

2) Discharge the excesspressure in the container by drawing out the spindle in the safety valve (see fi g. 1) before loosening the top cover.

The spindle returns automatically by means of a built-in spring.

Water Washing of Compressor Side

Fig 1 Fig 2

3) Fill the container with 2 litres fresh water (see the scale on the container).

Warning: Do not use sea water or cooling water.

4) Mount the top cover on the container.

5) Blow air into the container by means of a blow gun, until an operation pressure of 3 bar is reached (see fi g 2).

The safety valve will open at a pressure of 4 bar.

Excesspressure will discharge through the safety valve.

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512-05.00Edition 01

02.20 - ES0S-G

General

Working CardPage 3 (3) Water Washing of Compressor Side

5 Hand valve with handle6 Container7 Charge air line

1 Injection tube2 Pipe3 Snap coupling4 Plug-in coupling

6) Connect the plug-in coupling of the lance to the snap coupling on the pipe (see fi g 3).

7) Depress the handle on the hand valve until the water is completely injected into the compressor (approx. 30 seconds).

The water will enter the compressor in atomized condition, impinge the vanes of the compressor wheel with high velocity and thus wash off the dirt deposited.

8) Release the plug-in coupling and vent the container by drawing the spindle out of the safety valve.

After Cleaning

9) Run the engine for minimum 10 minutes at un al ter ed high load.

10) Compare the measurements of the operating data (see fi g 4) before and after the cleaning proce-dure (see Operating Data 500.30).

IF

the comparison indicates success of the washing procedure

the comparison indicates lack of the wa-shing procedure

severe dirt is being deposited in the com-pressor

THEN

the water washing of the compressor side is fi nished

carry out the washing procedure from step 1 with 10 minutes interval from the initial washing

dismantling of the compressor com ponents for manual cleaning is neces sary (see spe-cial turbocharger manual in section 512).

Fig 3

Fig 4

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MAN Diesel

Safety precautions:

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

Description:

Water washing of compressor side.Turbocharger cleaning with engine in service.

Starting position:

Related procedure:

Manpower:

Working time : 1/4 hourCapacity : 1 man

Data:

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

512-05.05Edition 01H

91.45 - ES0S

5, 6L23/30H

Working CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand injector.

Hand tools:

Ring and open end spanner, 17 mm.

Replacement and wearing parts:

Plate no Item no Qty/

See the special instructions for turbocharger.

Water Washing of Compressor SideTurbocharger Type NR15/R

0802

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.12

MAN Diesel

5, 6L23/30H

91.45 - ES0S

512-05.05Edition 01H

Working CardPage 2 (2)

Cleaning Procedure.

The cleaning process is only to be carried out, when the engine is at operating temperature and when it is loaded as close as possible to full load.

The engine must not be shut off immediately after cleaning but should be allowed to operate con ti nu ous-ly for some time to ensure drying out of the charge air system.

Sequence of Operations.

1) Run the engine with as high a load as pos-sible.

2) Unscrew the plug, see fi g 1, together with the seal ring from air fi lter silencer.

3) Fill the hand injector with clean fresh water and insert it through the screw plug opening.

4) Inject the complete content of the hand injector within a period of 4 - 10 sec.

5) Run the engine for about 10 minutes at un al-ter ed high load.

6) Make comparative measurements of the ope-rating data. This comparison will indicate the success or lack of same of the washing procedure.

If necessary, carry out the washing once more.

7) Screw in the plug together with the seal ring to the air fi lter silencer.

Water Washing of Compressor sideTurbocharger Type NR15/R

Compressor cleaning by inspection of water with a hand injector is suffi cient if a normal degree of fouling is present.

In case of serve dirt being deposited in the com pres-sor, dismantling of the compressor, is necessary.

Components for mechanical and manual cleaning are necessary.

For manual cleaning of compressor, see special instruction.

For water washing of compressor side, see also description for water washing.

Seal ringScrew plug

Hand injector

Fig 1.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Water washing of compressor side.Turbocharger cleaning with engine in service.

Starting position:

Related procedure:

Manpower:

Working time : 1/4 hourCapacity : 1 man

Data:

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

512-05.05Edition 02H

91.45 - ES0S

7, 8L23/30H

Special tools:

Plate no Item no Note

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty /

See the special instructions for turbocharger.

Working CardPage 1 (2)

Water Washing of Compressor SideTurbocharger Type NR20/R

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

7, 8L23/30H

91.45 - ES0S

512-05.05Edition 02H

Working CardPage 2 (2)

Cleaning Procedure.

The cleaning process is only to be carried out, when the engine is at operating temperature and when it is loaded as close as possible to full load.

The engine must not be shut off immediately after cleaning but should be allowed to operate con ti nu ous-ly for some time to ensure drying out of the charge air system.

Sequence of Operations.

1) Run the engine with as high a load as pos-sible.

2) Remove the fi lling plug (6), see fi g 1 on the dosage container (5) and fi ll the container with water. Screw on the fi lling plug.

3) Activate the push buttom of the manoeuvring valve (3) for approx. 20 sec.

Air from the compressor outlet casing will now be supplied via the pipe connection (2) to the dosage container, and will force the water through the hose (7) to the injection tube (8).

The water will enter the compressor in atomized condition, impinge the vanes of the compressor wheel with high velocity and thus wash of the dirt deposited.

4) Run the engine for about 10 minutes at un al-ter ed high load.

5) Make comparative measurement of the ope ra-ting data.

This comparison will indicate the success or lack of same of the washing procedure.

If necessary, carry out the washing once more, but with 10 minutes interval from the initial washing.

Compressor cleaning by injection of water is suf fi ci ent if a normal degree of fouling is present.

In case of severe dirt being deposited in the com pres-sor, dismantling of the compressor components for manual cleaning is necessary.

For manual cleaning of compressor side , see spe-ci al instruction.

For water washing of compressor side, see also description for water washing.

8

6

7

3 15

4 2

1 Charge air line 2 Pipe

3 Manoeuvring valve 4 Hose or pipe

5 Dosage container 6 Filling plug

7 Hose or pipe 8 Injection tube

Fig 1. Arrangement for water washing.

Water Washing of Compressor SideTurbocharger Type NR20/R

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Water washing of turbine side, cleaning with engine in service.

Starting position:

Related procedure:

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

512-15.00Edition 01H

91.04 - ES0S

L23/30H

Water Washing of Turbine SideWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Replacement and wearing parts:

Plate no. Item no. Qty. /

See the special instruction for turbocharger.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

91.04 - ES0S

512-15.00Edition 01H Water Washing of Turbine Side Working Card

Page 2 (2)

Cleaning Procedure.

1) Adjust the engine load to approx. 20 % and let the engine stabilize for 10 min.

2) Open the drain cock at the turbocharger outlet and check for free passage, see fi g 1.

3-way cock

Plate with clean-ing instruction

Manoeuvering valve

Regulating valve

Cleaning water inlet

Fig 1. Arrangement for water washing.

Drain cock

3) Turn the 3-way cock to position 2 "Open", see fi g. 2 and check for free passage. If ok turn to the water wash position 3 "Wash".

4) Connect the water supply to the water wash system.

5) Activate the manoeuvring valve, see fi g 1.

Then open the regulating valve and adjust the water fl ow until the drain fl ow is approx. 0,25 l/min.

6) Continue the water washing 5 - 10 min. or until the drain water is free of particles.

7) Release the manoeuvring valve and dis con nect the water supply.

Turn the 3-way cock to position 1, "Closed" and check that the water drain fl ow has stopped.

8) Continue at this load at least 5 min. before increasing the load to the normal condition.

9) After the water washing, the engine should run for at least 1 hour before stop.

Note: The regulating valve has to be opened slowly.

The manoeuvring valve must not be locked in open position.

The water injection time mentioned in item 6 must be not exceeded.

For water washing of turbine side, see also de scrip-tion for water washing.

Fig 2. 3-way cock.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Charging Air Cooler - Freshwater

97.06 - ES0S

51201-02HPlatePage 1 (2)

5L23/30H-720/750 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

97.06 - ES0S

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

017

029

030

042

054

066

078

091

101

113

125

137

149

150

162

174

186

198

208

221

233

245

257

282

304

1/K

1/K

2/K

1/K

1/K

4/K

4/K

1/K

4/K

8/K

1/K

1/K

1/K

29/K

1/K

3/K

3/K

5/K

1/K

4/K

1/K

1/K

1/K

22/K

1/E

Crossmember

Crossmember

Pipe

Cooler block

Gasket end cover

Plug screw

Cu-washer

End cover

Nut

Screw

Top plate

Gasket reversingcover

Reversing cover

Screw

Crossmember

Screw

Cu-washer

Screw

Bottom plate

Screw

O-ring

Plug

Gasket

Screw

Charging air cooler, complete, incl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 162, 174, 186, 198, 208, 221, 233 and 245

Travers

Travers

Rør

Kølerblok

Pakning endedæksel

Propskrue

Cu-skive

Endedæksel

Møtrik

Skrue

Topplade

Pakning vendekam-mer

Vendekammer

Skrue

Travers

Skrue

Cu-skive

Skrue

Bundplade

Skrue

O-ring

Prop

Pakning

Skrue

Ladeluftkøler, komplet, inkl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 162, 174, 186, 198, 208, 221, 233 og 245

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./K = Cooler

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Køler

Charging Air Cooler - Freshwater51201-02H PlatePage 2 (2)

5L23/30H-720/750 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Charging Air Cooler - Freshwater

97.06 - ES0S

51201-03HPlatePage 1 (2)

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

97.06 - ES0S

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

017

029

030

042

054

066

078

091

101

113

125

137

149

150

162

174

186

198

208

221

233

245

257

282

304

1/K

1/K

2/K

1/K

1/K

4/K

4/K

1/K

4/K

8/K

1/K

1/K

1/K

29/K

1/K

3/K

3/K

5/K

1/K

4/K

1/K

1/K

1/K

22/K

1/E

Crossmember

Crossmember

Pipe

Cooler block

Gasket end cover

Plug screw

Cu-washer

End cover

Nut

Screw

Top plate

Gasket reversingcover

Reversing cover

Screw

Crossmember

Screw

Cu-washer

Screw

Bottom plate

Screw

O-ring

Plug

Gasket

Screw

Charging air cooler, complete, incl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 162, 174, 186, 198, 208, 221, 233 and 245

Travers

Travers

Rør

Kølerblok

Pakning endedæksel

Propskrue

Cu-skive

Endedæksel

Møtrik

Skrue

Topplade

Pakning vendekam-mer

Vendekammer

Skrue

Travers

Skrue

Cu-skive

Skrue

Bundplade

Skrue

O-ring

Prop

Pakning

Skrue

Ladeluftkøler, komplet, inkl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 162, 174, 186, 198, 208, 221, 233 og 245

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./K = Cooler

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Køler

Charging Air Cooler - Freshwater51201-03H PlatePage 2 (2)

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Charging Air Cooler - Freshwater

97.06 - ES0S

51201-04HPlatePage 1 (2)

5L23/30H-720/750 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

97.06 - ES0S

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

017

029

030

042

054

066

078

091

101

113

125

137

149

150

174

186

198

208

221

233

257

269

270

282

294

304

1/K

1/K

2/K

1/K

1/K

4/K

4/K

1/K

4/K

8/K

1/K

1/K

1/K

29/K

3/K

3/K

5/K

1/K

8/K

1/K

1/K

1/K

1/K

22/K

1/K

1/E

Crossmember

Crossmember

Pipe

Cooler block

Gasket end cover

Plug screw

Cu-washer

End cover

Nut

Screw

Top plate

Gasketreversing cover

Reversing cover

Screw

Screw

Cu-washer

Screw

Bottom plate

Screw

O-ring

Gasket

Ring

Drain pipe for WMC

Screw

Water mist catcher

Charging air cooler, complete, incl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 174, 186, 198, 208, 221, 233, 269, 270 and 294

Travers

Travers

Rør

Kølerblok

Pakning endedæksel

Propskrue

Cu-skive

Endedæksel

Møtrik

Skrue

Topplade

Pakningvendekammer

Vendekammer

Skrue

Skrue

Cu-skive

Skrue

Bundplade

Skrue

O-ring

Pakning

Ring

Drænrør for WMC

Skrue

Vandudskiller

Ladeluftkøler, komplet, inkl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 174, 186, 198, 208, 221, 233, 269, 270 og 294

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./K = Cooler

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Køler

Charging Air Cooler - Freshwater51201-04H PlatePage 2 (2)

5L23/30H-720/750 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Charging Air Cooler - Freshwater

97.06 - ES0S

51201-05HPlatePage 1 (2)

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

97.06 - ES0S

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

017

029

030

042

054

066

078

091

101

113

125

137

149

150

174

186

198

208

221

233

257

269

270

282

294

304

1/K

1/K

2/K

1/K

1/K

4/K

4/K

1/K

4/K

8/K

1/K

1/K

1/K

29/K

3/K

3/K

5/K

1/K

8/K

1/K

1/K

1/K

1/K

22/K

1/K

1/E

Crossmember

Crossmember

Pipe

Cooler block

Gasket end cover

Plug screw

Cu-washer

End cover

Nut

Screw

Top plate

Gasketreversing cover

Reversing cover

Screw

Screw

Cu-washer

Screw

Bottom plate

Screw

O-ring

Gasket

Ring

Drain pipe for WMC

Screw

Water mist catcher

Charging air cooler, complete, incl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 174, 186, 198, 208, 221, 233, 269, 270 and 294

Travers

Travers

Rør

Kølerblok

Pakning endedæksel

Propskrue

Cu-skive

Endedæksel

Møtrik

Skrue

Toplade

Pakningvendekammer

Vendekammer

Skrue

Skrue

Cu-skive

Skrue

Bundplade

Skrue

O-ring

Pakning

Ring

Drænrør for WMC

Skrue

Vandudskiller

Ladeluftkøler, komplet, inkl. item 017, 029, 030, 042, 054, 066, 078, 091, 101, 113, 125, 137, 149, 150, 174, 186, 198, 208, 221, 233, 269, 270 og 294

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./K = Cooler

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Køler

Charging Air Cooler - Freshwater51201-05H PlatePage 2 (2)

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Exhaust Pipe Arrangement 51202-01HPlatePage 1 (2)

98.34 - ES0S

132

132

097

073 061 085

276

107

288156

168144156

132

239012-181

240

264252264

215

227193

024

036

203

024

5L23/30H6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

98.34 - ES0S

Exhaust Pipe Arrangement PlatePage 2 (2)51202-01H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./Cylinder

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/cylinder

Designation BenævnelseBenævnelseDesignation

Item no.

Qty.

Qty.

Item no.

012

024

036

061

073

085

097

107

132

144

156

168

181

193

203

215

227

239

240

252

264

276

288

1/C

2/C

4/C

1/E

1/E

4/E5/E

1/E

1/E

3/E

8/E

16/E

8/E

1/C

3/C

3/C

1/C

1/C

1/C

4/C

1/C

2/C

4/E5/E

8/E

Intermediate piece,complete, incl. item181, 193, 203, 215 and 227

Gasket

Screw

Exhaust pipe forcyl. 1

Flange

Compensator5 cyl. engine6 cyl. engine

Compensator

End cover, aft

Gasket

Screw

Nut

Screw

Intermediate piece

Plug screw

Gasket

Plug screw

Sealing ring

Screw

Screw

Cooling waternipple

O-ring

Exhaust pipe5 cyl. engine6 cyl. engine

Screw

Mellemstykke, kom-plet, inkl. item 181, 193, 203, 215 og 227

Pakning

Skrue

Udstødsrør forcyl. 1

Flange

Kompensator5 cyl. motor6 cyl. motor

Kompensator

Endeplade, bag

Pakning

Skrue

Møtrik

Skrue

Mellemstykke

Propskrue

Pakning

Propskrue

Tætningsring

Skrue

Skrue

Kølevandsnippel

O-ring

Udstødsrør5 cyl. motor6 cyl. motor

Skrue

5L23/30H6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Exhaust Pipe Arrangement 51202-02HPlatePage 1 (2)

98.34 - ES0S

239012-181

240

264252264

215

227193

024

036

203

024

168144156

168

132

073

097

132085061

276

107

132

7-8L23/30H-720/750 RPM6-7-8L23/30H-900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

98.34 - ES0S

Exhaust Pipe Arrangement PlatePage 2 (2)51202-02H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./Cylinder

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/C = Antal/cylinder

012

024

036

061

073

085

097

107

132

144

156

168

181

193

203

215

227

239

240

252

264

276

1/C

2/C

4/C

1/E

1/E

5/E6/E7/E

1/E

1/E

3/E

8/E

8/E

16/E

1/C

3/C

3/C

1/C

1/C

1/C

4/C

1/C

2/C

5/E6/E7/E

Intermediate piece,complete, incl. item181, 193, 203, 215 and 227

Gasket

Screw

Exhaust pipe forcyl. 1

Exhaust pipe

Compensator6 cyl. engine7 cyl. engine8 cyl. engine

Compensator

End cover, aft

Gasket

Screw

Nut

Screw

Intermediate piece

Plug screw

Gasket

Plug screw

Sealing ring

Screw

Screw

Cooling waternipple

O-ring

Exhaust pipe6 cyl. engine7 cyl. engine8 cyl. engine

Mellemstykke, kom-plet, inkl. item 181, 193, 203, 215 og 227

Pakning

Skrue

Udstødsrør forcyl. 1

Udstødsrør

Kompensator6 cyl. motor7 cyl. motor8 cyl. motor

Kompensator

Endeplade, bag

Pakning

Skrue

Møtrik

Skrue

Mellemstykke

Propskrue

Pakning

Propskrue

Tætningsring

Skrue

Skrue

Kølevandsnippel

O-ring

Udstødsrør6 cyl. motor7 cyl. motor8 cyl. motor

Designation BenævnelseBenævnelseDesignation

Item no.

Qty.

Qty.

Item no.

7-8L23/30H-720/750 RPM6-7-8L23/30H-900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Turbocharging Arrangement 51203-09HPlatePage 1 (2)

03.18 - ES0S

5L23/30H-720/750 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

03.18 - ES0S

Turbocharging Arrangement PlatePage 2 (2)51203-09H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/E = Antal/CylinderAntal/I = Antal/Individuelt

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

092

102

114

126

138

151

209

210

222

234

246

283

295

305

317

378

391

401

413

425

437

1/E

12/E

1/E

6/E

6/E

6/E

1/E

14/E

1/E

18/E

1/E

1/E

1/C

1/C

4/C

1/C

1/E

2/E

2/E

2/E

2/E

/I

4/E

8/E

2/E

2/E

4/E

Gas outlet

Screw

Bracket fortubocharger

Screw

Spring lock

Screw

Gasket

Screw

Shield

Screw

Cooler box forcharge air

Compensator

Inlet pipe

Gasket

Screw

Sealing ring

Gasket

Plug screw

Packing ring

Plug screw

Packing ring

Packingsilicone paste

Nut

Screw

Support

Support

Screw

Gasudløb

Skrue

Konsol forturbolader

Skrue

Låseskive

Skrue

Pakning

Skrue

Skærm

Skrue

Kølerboks for ladeluft

Kompensator

Indstrømningsrør

Pakning

Skrue

Tætningsring

Pakning

Propskrue

Pakningsring

Propskrue

Pakningsring

Silicone

Møtrik

Skrue

Holder

Holder

Skrue

5L23/30H-720/750 RPM6L23/30H-720/750 RPM

Pakning

Skrue

Diffuser

Kompensator

Gasket

Screw

Diffusor

Compensator

2/E

8/E

1/E

1/E

449

450

462

508

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Turbocharging Arrangement 51203-10HPlatePage 1 (2)

01.30 - ES0S

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.30 - ES0S

Turbocharging Arrangement PlatePage 2 (2)51203-10H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/E = Antal/CylinderAntal/I = Antal/Individuelt

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

092

102

114

126

138

151

209

210

222

234

246

258

271

283

295

305

317

329

330

342

354

1/E

16/E

1/E

5/E

5/E

6/E

1/E

14/E

1/E

18/E

1/E

1/E

1/C

1/C

4/C

1/C

1/E

16/E

1/E

2/E

2/E

2/E

2/E

1/E

1/E

1/E

16/E

Gas outlet

Screw

Bracket fortubocharger

Screw

Spring lock

Screw

Gasket

Screw

Shield

Screw

Cooler box forcharge air

Compensator

Inlet pipe

Gasket

Screw

Sealing ring

Gasket

Nut

Plug screw

Plug screw

Packing ring

Plug screw

Packing ring

Plug screw

Packing ring

Packing ring

Nut

Gasudløb

Skrue

Konsol forturbolader

Skrue

Låseskive

Skrue

Pakning

Skrue

Skærm

Skrue

Kølerboks for ladeluft

Kompensator

Indstrømningsrør

Pakning

Skrue

Tætningsring

Pakning

Møtrik

Propskrue

Propskrue

Pakningsring

Propskrue

Pakningsring

Propskrue

Pakningsring

Pakningsring

Møtrik

366

378

391

401

413

425

437

449

450

462

474

486

498

508

521

533

16/E

/I

4/E

8/E

2/E

2/E

4/E

1/E

4/E

1/E

8/E

8/E

2/E

1/E

8/E

1/E

Screw

Packingsilicone paste

Nut

Screw

Support

Support

Screw

Gasket

Screw

Diffusor

Screw

Nut

Gasket

Compensator

Screw

Flange

Skrue

Silicone

Møtrik

Skrue

Holder

Holder

Skrue

Pakning

Skrue

Diffuser

Skrue

Møtrik

Pakning

Kompensator

Skrue

Flange

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Turbocharging Arrangement 51203-11HPlatePage 1 (2)

01.30 - ES0S

5L23/30H-720/750/900 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.30 - ES0S

Turbocharging Arrangement PlatePage 2 (2)51203-11H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/E = Antal/CylinderAntal/I = Antal/Individuelt

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

092

102

114

126

138

151

209

210

222

234

246

283

295

305

317

378

391

401

413

425

437

1/E

12/E

1/E

6/E

6/E

6/E

1/E

14/E

1/E

18/E

1/E

1/E

1/C

1/C

4/C

1/C

1/E

2/E

2/E

1/E

1/E

/I

4/E

8/E

2/E

2/E

4/E

Gas outlet

Screw

Bracket fortubocharger

Screw

Spring lock

Screw

Gasket

Screw

Shield

Screw

Inlet bend

Compensator

Inlet pipe

Gasket

Screw

Sealing ring

Gasket

Plug screw

Packing ring

Plug screw

Packing ring

Packingsilicone paste

Nut

Screw

Support

Support

Screw

Gasudløb

Skrue

Konsol forturbolader

Skrue

Låseskive

Skrue

Pakning

Skrue

Skærm

Skrue

Indstrømningsbøjning

Kompensator

Indstrømningsrør

Pakning

Skrue

Tætningsring

Pakning

Propskrue

Pakningsring

Propskrue

Pakningsring

Silicone

Møtrik

Skrue

Holder

Holder

Skrue

449

450

462

508

2/E

8/E

1/E

1/E

Gasket

Screw

Diffusor

Compensator

Pakning

Skrue

Diffuser

Kompensator

5L23/30H-720/750/900 RPM6L23/30H-720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Turbocharging Arrangement 51203-12HPlatePage 1 (2)

01.30 - ES0S

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.30 - ES0S

Turbocharging Arrangement PlatePage 2 (2)51203-12H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./C = Qty./CylinderQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/E = Antal/CylinderAntal/I = Antal/Individuelt

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

092

102

114

126

138

151

209

210

222

234

246

258

271

283

295

305

317

329

330

342

354

366

1/E

16/E

1/E

5/E

5/E

6/E

1/E

14/E

1/E

18/E

1/E

1/E

1/C

1/C

4/C

1/C

1/E

16/E

1/E

2/E

2/E

1/E

1/E

1/E

1/E

1/E

16/E

16/E

Gas outlet

Screw

Bracket fortubocharger

Screw

Spring lock

Screw

Gasket

Screw

Shield

Screw

Inlet bend

Compensator

Inlet pipe

Gasket

Screw

Sealing ring

Gasket

Nut

Plug screw

Plug screw

Packing ring

Plug screw

Packing ring

Plug screw

Packing ring

Packing ring

Nut

Screw

Gasudløb

Skrue

Konsol forturbolader

Skrue

Låseskive

Skrue

Pakning

Skrue

Skærm

Skrue

Indstrømningsbøjning

Kompensator

Indstrømningsrør

Pakning

Skrue

Tætningsring

Pakning

Møtrik

Propskrue

Propskrue

Pakningsring

Propskrue

Pakningsring

Propskrue

Pakningsring

Pakningsring

Møtrik

Skrue

378

391

401

413

425

437

449

450

462

474

486

498

508

521

533

/I

4/E

8/E

2/E

2/E

4/E

1/E

4/E

1/E

8/E

8/E

2/E

1/E

8/E

1/E

Packingsilicone paste

Nut

Screw

Support

Support

Screw

Gasket

Screw

Diffusor

Screw

Nut

Gasket

Compensator

Screw

Flange

Silicone

Møtrik

Skrue

Holder

Holder

Skrue

Pakning

Skrue

Diffuser

Skrue

Møtrik

Pakning

Kompensator

Skrue

Flange

6L23/30H-900 RPM7-8L23/30H-720/750/900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

General

Water Washing of Compressor Side

94.01 - ES0S-G

51205-01PlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Top cover with non-return valve

O-ring for top cover

O-ring for non-return valve

Valve seat

Spring for non-return valve

Cap screw for non-return valve

Top cover with non-return valve complete, incl. item 019-020-032-044-056 and 068

Safety valve

O-ring

Finger nut

Cap

Gasket for the cap

Cable binder

Strap

Eye for strap

Strap complete, incl. item 140-152 and 164

Container

Flexible pipe

Handle with fl exible pipe and cap screw

Filter insert

Gasket for handle

Hand valve

Gasket for hand val-ve

Lance

Designation BenævnelseBenævnelseDesignation

019*

020*

032*

044*

056*

068*

081

093

103

115

127

139

140*

152*

164*

176

188

211

223

235

247

259

260

272*

Item No.

Qty.

Item No. Qty.

94.01 - ES0S-G

51205-01 PlatePage 2 (2)Water Washing of Compressor Side

General

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

2/E

2/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

Straight male stud coupling

Plug in coupling

Lance complete, incl. item 272-284 and 296

Container complete, as shown on plate

284*

296*

306

318

Topdæksel med kon-traventil

O-ring for topdæksel

O-ring for kontraventil

Ventilsæde

Fjeder for kontraventil

Omløber til kontraven-til

Topdæksel med kontra-ventil komplet, inkl. item 019-020-032-044-056and 068

Sikkerhedsventil

O-ring

Fingermøtrik

Top

Pakning for top

Kabelbinder

Gjord

Øje for gjord

Gjord komplet, inkl. item 140-152 and 164

Beholder

Fleksibel slange

Håndtag med fl eksibel slange og omløber

Filterinsats

Pakning til håndtag

Håndventil

Pakning til håndventil

Lanse

Ligeforskruning

Kobling

Lanse komplet, inkl. item 272-284 and 296

Beholder komplet, som vist på plate

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2) Steam Trap

L23/30HV28/32S

97.07 - ES0S

51208-01H

052

064

076

040

039

027

015

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

015

027

039

040

052

064

076

Vandudlader,komplet

Pakning

Klemme

Hus, bund

Hus, top

Svømmer

Ventil

Steam Trap

97.07 - ES0S

L23/30HV28/32S

PlatePage 2 (2)51208-01H

Steam trap,complete

Packing

Clip

House, bottom

House, top

Swimmer

Valve

1/E

1/E

1/E

1/E

1/E

1/E

1/E

When ordering spare parts, see also page 600.50.

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

Ved bestilling af reservedele, se også side 600.50.

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

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2) Blowgun for Dry Cleaning of Turbocharger

01.12 - ES0

51210-01

016 112 028 041 028053

065 077

089

100

136

148

L23/30H, L21/31, L27/38, V28/32S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

016

028

041

053

065

077

089

100

112

136

148

Snapkobling

Nippel

T-stykke

Kugleventil

Snapkobling

Snapkobling

Pakningsring

beholder, komplet

Muffe

Rensepistol, complete

Granulat

Blowgun for Dry Cleaning of Turbocharger

01.12 - ES0

PlatePage 2 (2)51210-01

Snap coupling

Nipple

Tee

Ball valve

Snap coupling

Snap coupling

Packing ring

Container, complete

Socket

Blowgun, complete

Granulate

1/E

2/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

/I

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./MotorQty./I = Qty./Individuelt

L23/30H, L21/31, L27/38, V28/32S

Compressed air system

513/613

MAN Diesel

DescriptionPage 1 (2) Compressed Air System 513.01

Edition 05H

L23/30H

00.11 - ES0

Fig 1 Diagram for compressed air system.

Control System

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

For remote activation, the starting spool is connected so that every starting signal to the starting spool goes through the safe start function, which is connected to the converter for engine RPM.

Further, the system is equipped with an emergency starting valve which makes it possible to activate the air starter manually in case of a power failure.

General

The compressed air system on the engine contains a starting system, starting control system and safety system. Further, the system supplies air to the jet system.

The compressed air is supplied from the starting air receivers (30 bar) through a reduction station, where from compressed air at 7-9 bar is supplied to the engine.

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

Starting System

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

MAN Diesel

Safety System

As standard the engine is equipped with a pneu ma-ti cal ly/mechanically overspeed device, which starts to operate if the maximum permissible RPM is ex-ceeded. This device is fi tted to the end cover of the engine driven lubricating pump and is driven from the pump through a resilient coupling.

Compressed Air System

L23/30H

00.11 - ES0

DescriptionPage 2 (2)

When the maximum permissible RPM is exceeded, the overspeed device will activate a pneumatically controlled lambda controller, which will bring the fuel index to zero and stop the engine.

Emergency Starting Valve

The emergency starting valve is activated by means of a screw-driver or similar as illustrated in fi g 2.

Pneumatic Start Sequence

When the starting valve is opened, air will be sup plied to the drive shaft housing of the air starter.

The air supply will - by activating a piston - bring the drive pinion into engagement with the gear rim on the engine fl y wheel.

When the pinion is fully engaged, the pilot air will fl ow to, and open the main starting valve, whereby air will be led to the air starter, which will start to turn the engine.

When the RPM exceeds approx. 140, at which fi ring has taken place, the starting valve is closed whereby the air starter is disengaged.

513.01Edition 05H

Emergencystart valve

⇓

Press down

Fig 2 Emergency start valve.

0802

8-0D

/H52

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4.08

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MAN Diesel

Safety precautions

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

Description

Cleaning and/or maintenance of air fi lter.

Starting position

Related procedure

Manpower

Working time : hoursCapacity : man

Data

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

513-01.21Edition 02

08.21 - ES0

General

Air FilterWorking CardPage 1 (2)

Special tools

Plate no Item no Note

Hand tools

Replacement and wearing parts

Plate no Item no Qty/

0802

8-0D

/H52

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4.08

.12

MAN Diesel

General

08.21 - ES0

513-01.21Edition 02 Air Filter Working Card

Page 2 (2)

Cleaning Air Filter

1) Depressurize unit.

2) Remove bowl and bowl guard assembly by turning counter-clockwise.

3) Inspect bowl for damage seals and replace, if nessesary. 4) If bowl becomes dirty clean it by wiping the bowl with a soft dry cloth or mild detergent.

5) Before returning to service, insure that all seals have been reinstalled or replaced.

6) Reinstall bowl and bowl guard assembly and rotate bowl guard clockwise to securely lock in place. Align arrow on bowl guard with arrow on fi lter body.

To replace fi lter element

7) Depressurize unit.

8) Remove bowl and bowl assembly by turning counter-clockwise.

9) Unscrew baffl e by turning counter-clockwise.

10) Remove fi lter element and discard.

11) Install new fi lter element and reassemble in reverse order.

12) Before returning to service, insure that all seals have been reinstalled or replaced.

13) Reinstall bowl and bowl guard assembly and rotate bowl guard clockwise to securely lock in place. Align arrow on bowl guard with arrow on fi lter body.

Fig 1 Air Filter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Disassembly, overhaul and assembly of the air starter.

Starting position:

All connections to the air starter have been re-moved, and air starter is removed.

Related procedure:

Manpower:

Working time : 4 hoursCapacity : 1 man

Data:

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

513-01.30Edition 01H

03.47 - ES0-G

L23/30H

Special tools:

Plate no Item no Note

52006 261 20 - 120 Nm.

Hand tools:

Allen key, 4 mm.Allen key (long), 8 mm.Screwdriver.Big screwdriver.Chisel.Retaining ring pliers.Plastic hammer.Lubricating oil.Copaslip or similar.Sleeve.Bearing puller.Impact WrenchBearing pressing tool.

Replacement and wearing parts:

Plate no Item no Qty/

See plate 51309.

Overhaul, Test and Inspection of Turbine StarterWorking CardPage 1 (9)

0802

8-0D

/H52

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4.08

.12

MAN Diesel

513-01.30Edition 01H

Working CardPage 2 (9)

General Information

1) Always mark adjacent parts on the housing exhaust cover (1), motor housing (8), intermediate gear case (13), gear case (28) and drive housing (40) so these members can be located in the same relative position when the starter is reassembled.

Note: Do not disassemble the starter any further than necessary to replace worn or damaged parts.Never reuse old seals or O-rings.Never wash the inertia drive in a solvent.

2) Do not remove any part which is a press fi t in or on a subassembly unless the removal of that part is necessary for replacement or repairs.

3) Always have a complete set of seals and O-rings on hand before starting any overhaul of the turbine starter.

4) When grasping a part in a vice, always use copper-covered vice jaws to protect the surface of the part and help prevent distortion. This is particularly true of threaded members.

Housing Exhaust Cover, Motor Assembly, and Motor Housing

1) If replacing the motor assembly (12), remove both housing plugs (10) and drain the oil from the gearing before beginning disassembly of the starter. Inspect the magnetic housing plugs (10) for metal particles. Very fi ne metal particles are normal. Re-move particles and reinstall plugs. Large particles or chips are an indication of a problem. Disassemble gear case (28) and inspect.

2) Using a screw driver, unscrew the exhaust cover (67) from the housing exhaust cover (1).

3) Using an 8 mm hex-head wrench, unscrew and remove the starter assembly cap screws (6) and washers (7), See fi g 1.

4) Pull the housing exhaust cover (1) from the motor housing (8). To dislodge the housing exhaust cover, rotate it until the ears clear the motor housing. Using a plastic hammer, tap the ears alternately until the housing cover can be removed from the motor housing.

Fig 1.

5) Remove the defl ector retaining screw (5), de-fl ector retaining spring (4) and the splash defl ector (3) from the housing exhaust cover (1), See fi g 2.

L23/30H

Overhaul, Test and Inspection of Turbine Starter

03.47 - ES0-G

Fig 2.

6) Tap the motor housing with a plastic hammer to dislodge it from the intermediate gear case (13).

7) Grasp the rear of the motor assembly (12) and pull it from the rear of the motor housing (8).If the motor assembly (12) is diffi cult to remove, lightly push the motor pinion which is on the front of the motor assembly toward the exhaust side of the motor housing in order to free the motor assembly.

0802

8-0D

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MAN Diesel

8) Tap the intermediate gear case (13) with a plastic hammer to dislodge it from the gear case (28).

9) Position the intermediate gear case (13) on a bench in a copperfaced vice so that the intermediate pinion (26) is secured in the jaws of the vise. Tighten the vice only enough to hold the intermediate pinion securely.

10) Loosen the intermediate pinion retaining screw (27) 1-1/2 turns only. Do not remove.

Warning: If the intermediate gear case is not sup-ported on a bench and if the intermediate pinion retaining screw is completely removed, the interme-diate gear case and compoments could fall causing injury.

11) Tap the intermediate pinion lightly to back the planet gear frame assembly out of the intermediate gear case.

12) Remove the intermediate gear case assembly from the vice and remove the intermediate pinion (26). Remove the rear gear case O-ring (14) and front gear case O-ring (15) from the intermediate gear case (13), See fi g 3.

513-01.30Edition 01H

03.47 - ES0-G

13) Remove the planet gear frame assembly from the intermediate gear case. Using a sleeve that con-tacts the outer race of the front gear frame bearing (17), press the planet gear frame shaft seal (16) and the front gear frame bearing (17) from the front end and out of the rear of the intermediate gear case.

14) Remove the rear gear frame bearing (24) from the planet gear frame (18), using a bearing puller and remove the gear shaft retaining washer (23), see fi g 4.Remove the planet gear shafts (22), planet gears (19), planet gear bearings (20) and bearing spac-ers (21).

15) Remove the front bearing spacer (25), using a bearing puller and the gear shaft retaining washer (23) from the front of the planet gear frame by press-ing on the front of the planet gear frame shaft.Remove the gear shaft retaining washer only if the washer or front bearing spacer is damaged.

Working CardPage 3 (9) Overhaul, Test and Inspection of Turbine Starter

L23/30H

Fig 3.

Fig 4.

Drive Housing

1) Grasp the drive pinion (63) in a copper-faced vice with the starter supported on the workbench.

0802

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MAN Diesel

513-01.30Edition 01H

Working CardPage 4 (9)

2) Remove the drive pinion retaining screw (61) which has a right-hand thread.

3) Remove the starter from the vice.

4) Remove the drive pinion washer (62) and the drive pinion (63).

5) Slide the pinion spring sleeve (64) and the pinion spring (65) off the drive shaft (57).

6) Unscrew the drive gear screw (34). Using an impact wrench with a 5/16" (8 mm) x 8" (203 mm) log hex inserted into the end of the drive shaft.

7) Unscrew and remove the drive housing cap screws (38) and lock washers (39).

8) Tap the drive housing (40) with a plastic ham-mer to help dislodge it from the gear case (28).

Warning: Failure to follow this procedure could result in injury to personnel.

9) Place the drive housing (40) in an arbor press, piston end up. Apply a load to the piston (54) using the arbor press to compress the piston return spring (59) before removing the bulkhead retainer (45). Do not use compressed air to load the piston.

10) Remove the bulkhead retainer (45). Using a screwdriver and the arbor press.

Caution: Make sure the tension of the spring pushes the bulkhead out of the drive housing before removing the drive housing from the arbor press.

11) Remove the bulkhead (46) from the piston (54).

12) Remove the outer bulkhead ring (47) and the inner bulkhead ring (48).

13) Slide the drive shaft (57) from the drive housing (40).

14) Pull the piston return spring (59) off the drive shaft.

Note: Do not remove the front drive shaft bearing (42) or the drive housing seal (43) unless replace-

ment is necessary and new parts are available. The bearing and/or the seal will always be damaged when removed from the drive housing.

15) Remove the piston ring (55) from the piston (54).

16) Press the clutch spring cup (50) down and remove the clutch spring cup retainer (49).

17) Remove the clutch spring cup and clutch spring (51).

18) Remove the two clutch jaws (52).

19) Remove the front drive gear bearing (30), drive gear cup (36), drive gear lock washer (35), drive gear screw ring (37) and drive gear screw (34).

20) Remove the large drive shaft bearing retainer (53) using a screwdriver.

21) Press the rear drive shaft bearing and drive shaft (57) out of the piston. If the rear drive shaft bearing needs to be replaced, proceed as follows:

a. Cut and remove the small drive shaft bear-ing retained in the drive shaft, using a small chisel.

b. Press the rear drive shaft bearing (58) off the drive shaft.

22) Place the gear case (28) on a workbench.

23) Remove the drive gear bearing retainer (32), using retaining ring pliers and working through the access holes in the gear web, See fi g 5.

24) Pull the drive gear (29) out of the gear case.

Note: Do not disassemble the drive gear and clutch parts of the turbine powered starters. If the drive shaft is defective, install a new or factory-rebuilt unit.

25) Remove the drive gear shaft bearing retainer (33), using retaining ring pliers.

26) Remove the rear drive gear bearing (31) from the drive gear.

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Working CardPage 5 (9)

5) Install the drive gear bearing retainer, using retaining ring pliers and working through the access holes in the gear web.

6) Lubricate the drive gear with approximately 240 ml of SHELL ALVANIA EPO grease.

7) Press the rear drive shaft bearing (58) onto the drive shaft.

8) Slide the small bearing retainer, convex side fi rst, onto the drive shaft. Press it into position in accordance with the instructions packaged with the new retainer.

9) Assemble the drive gear Schrew (34), drive gear lock washer (35), drive gear cup (36) and drive gear screw O-ring (37).

10) Grasp the drive shaft (57) in a vice, external splined end down. Place assembled drive shaft screw Unit into the drive shaft, screwhead down. Lubricate the inside diameter of the drive shaft with SHELL ALVANIA EPO grease.

11) Slide the drive gear bearing (30) into the drive shaft.

12) Lubricate with SHELL ALVANIA EPO grease and install the driving clutch jaw teeth facing up and driven clutch jaw teeth facing down into the drive shaft.

13) Insert the clutch spring (51) into the drive shaft.

14) Insert the clutch spring cup (50) into the drive shaft.

15) Press the inserted parts into the drive shaft, and install the clutch spring cup retainer (49).

Note: If it is necessary to replace the drive hous-ing (40) and drive components, make sure that the piston seal has been removed from the rear of the new piston (54).The piston seal must be removed to prevent pressure build-up which will cause move-ment of the planet gear frame shaft seal (16). If this conditions occurs, the piston cannot retract and the drive pinion (63) will remain in engagement with the fl ywheel, causing damage to the starter drive train

L23/30H

Overhaul, Test and Inspection of Turbine Starter

Fig 5.

Assembly of the Starter

1) Always press on the inner ring of a ball bearing when installing the bearing on a shaft.

2) Always press on the outer ring of a ball bearing when pressing the bearing in a bearing recess.

3) Whenever grasping a part in a vice, always use leather-covered, copper-covered vice jaws to protect the surface of the part and help prevent distortion. This is particularly true of threaded members.

4) Always clean every part, and wipe every part with a thin fi lm of oil before installation.

Gear Case

1) Place the drive gear bearing retainer over the rear end of the drive gear.

2) Press the rear drive gear bearing (31) onto the rear end of the drive gear, using an arbor press.

3) Seat the rear drive gear bearing into the gear case by tapping the opposite end of the drive gear, using a plastic hammer.

4) Install the drive gear shaft bearing retainer (33), using retaining ring pliers.

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and/or starter motor. To remove the piston seal, in-sert a screwdriver inside the lip of the seal and pry it loose from the piston.

16) Install the piston (54) onto the drive shaft until the rear drive shaft bearing seats into the piston.

17) Coil the large drive shaft bearing retainer (53) into the groove of the piston to retain the outer race of the drive shaft bearing, using a thin fl at blade screwdriver to assist in this operation.

18) Lubricate the piston O-ring (55) and install it in the groove of the piston.

19) Position the drive housing in an arbor press, pinion-end down and install the drive housing seal (43) into the drive housing. Using a pressing sleeve of the proper size, press the seal into the drive housing so that the lip of the seal faces away from the drive pinion.

20) Press the bearing into the drive housing until it seats, using a sleeve that contacts the outer race of the front drive shaft bearing (42). Drop the piston return spring seat (60) on top of front drive shaft bearing.

21) Slide the piston return spring (59) onto the drive shaft and snap it into the front of the piston so that it is against the large drive shaft bearing retainer (53).

22) Lubricate and insert the assembled drive shaft into the drive housing.

23) Lubricate and install the outer bulkhead O-ring (47) and the Inner bulkhead O-ring (48) on the bulkhead (46).

24) Slide the bulkhead onto the piston.

25) With the drive housing in the arbor press, press down on the rear face of the piston.

Note: Feel the underside of the drive housing to make sure the drive shaft passes through the bearing.

26) Install the bulkhead retainer (45), using a screwdriver.

Warning: Make sure the bulkhead retainer is properly seated in the motor housing groove before easing off the arbor press. Failure to do so will allow improperly retained parts to separate when removed from the arbor press resulting in injury to personnel.

27) Remove the drive housing from the arbor press.

28) Lubricate and install the drive housing O-ring (41) in the groove of the drive housing.

29) Position the assembled gear case on a work-bench. The as-sembled unit must be upright to accept the drive housing.Carefully position the assembled drive housing (40) onto the gear case so as not to damage the piston seal. Align the punch marks of the gear case and drive housing.

30) Install the drive housing cap screw lock wash-ers (39) and the drive housing cap screws (38) and tighten to 28 Nm torque.

31) Tighten the drive gear screw (34) 77.3 Nm torque, using an impact wrench with a 8 mm x 203 mm long hex inserted into the end of drive shaft.

32) Grease and slide the pinion spring (65) and the pinion spring sleeve (64) over the pinion end of the drive shaft.

33) Grease the pinion end of the drive shaft and install the drive pinion (63).

34) Grasp the drive pinion in a copper-covered vice with the starter supported on a workbench.

35) Place the drive pinion washer (62) onto drive pinion retaining screw (61).

Note: The thread on the drive pinion retaining screw is right-hand thread.

36) Install the drive pinion retaining screw into the end of the drive shaft and tighten it to 108.5 Nm torque.

513-01.30Edition 01H

L23/30H

Overhaul, Test and Inspection of Turbine Starter Working CardPage 6 (9)

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Working CardPage 7 (9)

Intermediate Gear Case, Motor Housing, Motor Assembly and Housing Exhaust Cover

1) Press the front gear frame bearing (17) into the rear of the intermediate gear case (13), using a bearing pressing tool of the proper size.

2) Press the planet gear frame shaft seal (16) into the rear of the intermediate gear case over the front gear frame bearing, using a sleeve which contacts the outer ring of the seal.

Note: Make sure the fl at side of the seal is installed against the bearing.

3) Install the rear gear case O-ring (14) in the groove at the rear of the intermediated gear case and the front gear case O-ring (15) in the groove at the front of the intermediate gear case. Coat both O-rings.

4) Install one gear shaft retaining washer (23) on the front of the planet gear frame (18). Press the front bearing spacer (25) on the front shaft of the planet gear frame to hold the gear shaft retaining washer snugly in position.

Note: Coat the front bearing spacer with gear Lube before installing it. Be careful not to gouge or scratch the front bearing spacer during installation as this could result in leakage between the planet gear frame and gear case.

5) Place planet gear frame on a bench, shaft side down. Place the planet gear bearing (20) inside of planet gear (19). Place bearing spacers (21) on top and bottom of bearing and gear. Slide the components into the slots in the side of the planet gear frame. Align holes in spacers and bearing with holes in planet gear frame and insert planet gear shaft (22), integral keyed end down, through the spacers and bearing so that the larger portion of the keyed end of the shaft contacts the planet gear shaft retain-ing washer (23). Repeat the procedure for the two remaining planet gears and components.

Note: Do not move or turn over the planet gear frame until step 6 and 7 have been completed. Movement of the planet gear frame assembly could dislodge assembled components, making it necessary to repeat step 5.

6) Install the other planet gear shaft retaining washer over the shaft at the rear of the planet gear.

7) Press the rear gear frame bearing (24) on the shaft at the rear of the planet gear frame, using the proper size bearing inserting tool.

8) Slide the planet gear frame assembly, coupling end fi rst, into the rear of the intermediate gear case (13), making sure that the planet gears mesh with the ring gear. Use care so as to not damage the seal.

9) Install the intermediate pinion (26), making sure that the notches at the rear of the pinion align with the notches and tangs in the shaft of the planet gear frame.

10) Clean the threads of the intermediate pinion retaining screw (27) and apply 2-3 drops of Perm-abond HM 118 to the threads approximately 3 mm from the end of the screw. Install screw and tighten enough to hold assembly together.

11) For fi nal tightening, position the intermediate gear case so the intermediate pinion is secured in the jaws of the copperfaced vice. Tighten the inter-mediate pinion retaining screw to 122 Nm torque.

12) Remove the intermediate gear case from the vice and set it on a bench.

Note: The intermediate gear case will work in only one orientation.

Align the punch marks on the intermediate gear case and gear case and tap the intermediate gear case with a plastic hammer until it seats in the rear of the gear case. Make sure the intermediate pinion meshes with the drive gear.

Coat the O-rings on the motor assembly and the inside of the cylinder before installing the motor assembly.

13) Install the motor assembly through the rear of the motor housing with the geared end of the rotor toward the front.

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Overhaul, Test and Inspection of Turbine Starter Working CardPage 8 (9)

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Fig 6. Turbine Starter.

Note: Turn the intermediate pinion so that the gear on the rotor meshes with the planet gears. Make sure that the rear of the motor assembly is installed fl ush with the rear of the cylinder.

14) Align the punch marks on the motor housing with the punch marks on the intermediate gear case and tap the motor housing with a plastic hammer until it seats on the rear of the intermediate gear case.

15) Install the splash defl ector (3), defl ector retain-ing spring (4) and defl ector retaining screw (5) in the rear of the housing exhaust cover.

Note: Coat the threads of the defl ector retaining screw with Ingersoll-Rand SMB-441 sealant.

16) Coat the exhaust cover seal (2) and install it in the groove on the housing exhaust cover.

17) Align the punch marks on the housing exhaust cover with the punch marks on the motor housing

and tap the housing exhaust cover with a plastic hammer until it seats.

18) Install the housing exhaust cover on the rear of the motor housing using the starter assembly cap screws (6) and cap screw washers (7). Use an 8 mm hex-head wrench to tighten each a little at a time to a fi nal torque of 61 to 68 Nm increments.

19) Mount the exhaust cover (68) on the housing exhaust cover (1).

Note: Use Intersoll-Rand SMB-441 pipe sealant on all plugs.

20) Install the bottom housing plug (10) and the housing plug inlet boss (11). Put the starter on its side with the side plug hole upward. Add 175 ml automatic transmission fl uid fulfi lling DEXRON II D specifi cation, e.g. SHELL DONAX TA, through the side plug hole.

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Caution: Do not overfi ll.Install the side housing plug (10) and tighten all plugs to 6.8 to 13.6 Nm torque.Test and Inspection Procedure

1) Clutch Ratcheting: Turn the drive shaft pinion (63) by hand in the direction of the starter rotation. The clutch should rachet smoothly with a slight click-ing action.

2) Motor and Gearing Freeness: Turn the drive shaft pinion (63) opposite the direction of the starter rotation. The drive shaft pinion should turn by hand.

Note: Inadvertent application of air pressure to the “OUT” port will result in drive malfunction (pinion will fail to retract). If this condition occurs, loosen the drive housing cap screws (38) to vent gear case (28). Also, loosen housing plugs (10) and (11) to vent motor.

3) Pinion Engagement: Apply 50 psig (3.4 bar/345 kPa) pressure to the engagement “IN” port. drive shaft pinion (63) should move outward and air should escape from the “OUT” port.

Plug the “OUT” port and apply 150 psig (10.3 bar/1034 kPa) pressure to the “IN” port. Check and make sure that no air is escaping.

Measure the dimension from the face of the drive shaft pinion (63) to the face of the mounting fl ange. It should be 69.0 +2.0 mm).

Working CardPage 9 (9) Overhaul, Test and Inspection of Turbine Starter 513-01.30

Edition 01H

03.47 - ES0-G

L23/30H

Remove the pressure from the “IN” port. Measure the distance form the face of the drive shaft pinion to the the face of the mounting fl ange. It should be 45.0 +2.0 mm.

4) Motor Action: Secure starter in a vise and ap-ply 90 psig (6.2 bar/620 kPa) pressure using a 3/8" (9 mm) supply line to the inlet of the motor. starter should run smoothly.

5) Motor Seals: Plug the exhaust and slowly apply 20 psig (1.38 bar/138 kPa) pressure to the inlet of the motor. Immerse the starter for 30 seconds in o non-fl ammable, bubble-producing liquid. If the starter is properly sealed, no bobbles will appear.

6) Gear Case Seals: Plug the exhaust and slowly apply 20 psig (1.38 bar/138 kPa) pressure to the inlet of the motor. Immerse the starter for 30 seconds in o non-fl ammable, bubble-producing liquid.

There should be no leakage in the housing joints in the gear case area or in the shaft seal in the intermediate gear system. If the starter is properly sealed, no bubbles will appear.

7) Confi rm Drive Rotation: Apply low pressure to the motor and observe rotation. Drive pinion (63) must rotate in the direction stamped on the nameplate. Chamfer on pinion teeth should be on the trailing edge of the gear tooth.

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Safety precautions:

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

Description:

Lubricating, disassembly and reassembly of main starting valve in starting system.

Starting position:

Related procedure:

Manpower:

Working time : 1 hourCapacity : 1 man

Data:

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

513-01.40Edition 01H

94.22 - ES0S-G

L23/30H

Main Starting ValveWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Soft hammer.Locking ring plier.Allen key, 1/4".

Replacement and wearing parts:

Plate no Item no Qty/

51310 104 1/eng

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Main Starting Valve Working CardPage 2 (2)

A Plug screw B Pilot air C Starting air outlet D Starting air inlet

1 Valve housing 2 Piston 3 End plug 4 Piston o-ring 5 O-ring retainer 6 Piston o-ring 7 Bumper 8 Spring 9 Retaining ring 10 O-ring 11 O-ring

3

1

2

B

D

11

7

910

C

4

8

A

5

6

Fig 1. Main starting valve.

94.22 - ES0S-G

513-01.40Edition 01H

Warning:

Do not attempt any maintenance on the main start-ing valve before the start ing air system has been bled off.

Important:

The main starting valve should be periodically lub ri-cat ed as follows:

1) Blend off the air pressure.

2) Remove the plug screw (A), see fi g 1 and squirt about 30 g of 10 w oil into the valve through the plug opening.

3) Reinstall the plug.

Disassembly:

4) Clamp the main starting valve, in a vice with the locking ring (9) end up.

5) Carefully remove the locking ring (9). The end plug (3) should spring out. If it does not, tap the valve housing (1) lightly with a soft hammer until it does.

6) Remove the end plug (3), spring (8) and piston (2) assembly.

7) Remove and discard all used O-rings, O-rings retainer (5), bumper (7) and spring (8).

8) Wash all other parts in a clean, nonfl ammable solvent.

Reassembly:

9) Using O-ring lubricant, lubricate and install the new piston O-ring (4) and the new upper piston O-ring (6) on the piston (2).

Note: The upper piston O-ring (6) is slightly larger in diameter than the end plug O-ring (11).

10) Turn the piston over and insert the new bum ber (7).

11) Using O-ring lubricant, lubricate and install the new end plug seal O-ring (10) and the new end plug O-ring (11) on the end plug (3).

12) Lubricate the lower small bore of the valve housing (1) with O-ring lubricant.

13) Insert the piston assembly into the valve hou-sing. Push on the piston until the piston O-ring seats against the bevelied face.

14) Install the new O-ring retainer (5) with the large opening over the piston O-ring.

15) Place the new piston spring (8) on the pi-ston.

16) Place the end plug assembly on the piston spring.

17) Using a press to hold down the end plug as-sembly, install the end plug locking ring (9).

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Safety precautions:

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

Description:

Check of compressed oil piping system.

Starting position:

Compressed air connected to the engine.

Related procedure:

Manpower:

Working time : ½ hourCapacity : 1 man

Data:

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

513-01.90Edition 01H

94.21 - ES0U-G

L23/30H

Check of Compressed Air Piping SystemWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Screwdriver.

Replacement and wearing parts:

Plate no Item no Qty /

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513-01.90Edition 01H Check of Compressed Air Piping System Working Card

Page 2 (2)

With air connected.

1) Examine the piping system for leaks.

2) Retighten all bolts and nuts in the piping system.

3) Drain the system for condensed water. - This should be based on observations.

4) Check fl exible connections for leaks and dama-ges.

5) Check manometers.

With air disconnected and stopped engine.

6) Move all valves and cocks in the piping system. Lubricate valve spindles with graphite or similar.

7) Connect the air supply and make a function test of the emergency valve. See description 513.01.

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PlatePage 1 (3)

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Turbine Starter 51309-01H

L23/30H

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Turbine Starter PlatePage 2 (3)51309-01H

014

026

038

051

063

075

087

099

109

110

122

134

146

158

171

183

195

205

217

229

230

242

Hus for udstøds-dæk-sel

Tætningsring for ud-stødsdæksel

Stænk defl ektor

Returfjeder for de-fl ektor

Spændeskive for defl ektor

Dækselskrue for mon-tage af starter

Skive for dækselskrue

Motorhus

Prop til motorhus

Tilgangsknast for prop til motorhus

Motor samling

O-ringstætning for cylinder

O-ringstætning for motorhus

Mellem gearkasse

Bagerste gearkasse o-ring

Forreste gearkasse o-ring

Tætningsring for pla-netgearakselstel

Afstandsring

Forreste gearstelleje

Planetgearstel

Planetgear

Nålevalse for planet-gear

Housing exhaust cover

Exhaust cover seal

Splash defl ector

Defl ector return spring

Defl ector retaining screw

Starter assembly cap screw

Cap screw washer

Motor housing

Housing plug

Housing plug inlet boss

Motor assembly

Cylinder o-ring seal.

Housing o-ring seal.

Intermediate gear case

Rear gear case o-ring

Front gear case o-ring

Planet gear frame shaft seal.

Spacer ring

Front gear frame bearing

Planet gear frame

Planet gear

Planet gear needle roller

1/S

1/S

1/S

1/S

1/S

4/S

4/S

1/S

1/S

1/S

1/S

2/S

2/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

96.26 - ES0S-G

L23/30H

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

Bearing spacer

Planet gear shaft

Gear shaft retainer washer

Rear gear frame bearing

Front bearing spacer

Intermediate pinion

Intermediate pinion retaining screw

Gear case

Drive gear

Front drive gear bearing

Rear drive gear bearing

Drive gear bearing retainer

Drive gear shaft bearing retainer

Drive gear screw

Drive gear lock washer

Drive gear cup

Drive gear screw o-ring

Drive housing cap screw

Drive housing cap screw lock washer

Drive housing kit

Drive housing o-ring

Front shaft bearing

Drive housing seal.

254

266

278

291

301

313

325

337

349

350

362

374

386

398

408

421

433

445

457

469

470

482

494

1/S

1/S

2/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

8/S

8/S

1/S

1/S

1/S

1/S

Ligemellemstykke

Planetgearaksel

Spænderingsskive for gearaksel

Bagerste gearstelleje

Forreste gearstelleje

Mellemtandhjul

Spændeskrue for mel-lemtandhjul

Gearkasse

Drivgear

Forreste drivgearleje

Bagerste drivgearleje

Spændskrue for driv-gearleje

Spændskrue for driv-gearakselleje

Drivgearskrue

Skive for drivgear

Dæksel for drivgear

O-ring for drivgearskrue

Dækselskrue for driv-gear

Skive for dækselskrue til drivgearhus

Drivgearhus

O-ring for drivgearhus

Forreste akselleje

Tætningsring for driv-gearhus

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit. Qty.//E = Qty./EngineQty./S = Qty./Turbine Starter

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./MotorQty./S = Qty./Turbinestarter

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Turbine Starter

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

1/S

1/S

1/S

1//S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

1/S

3/S

1/S

1/E

504

516

528

541

553

565

577

589

590

600

612

624

636

648

661

673

685

697

781

707

719

720

732

744

756

Drive housing vent plug

Bulkhead retainer

Bulkhead kit

Outer bulkhead o-ring

Inner bulkhead o-ring

Clutch spring cup retainer

Clutch spring cup

Clutch spring

Clutch jaw kit

Large drive shaft bearing retainer

Piston kit

Piston o-ring

Drive shaft kit

Rear drive shaft bearing

Piston return spring

Seat

Drive pinion retain-ing screw

Drive pinion washer

Drive pinion

Pinion spring sleeve

Pinion spring

Inlet fl ange kit

Cover

Self drilling screws

Turbine starter, complete

Afl uftningsprop for drivgearhus

Skotholder

Skotsæt

Ydre skot o-ring

Indre skot o-ring

Fjedertallerken holder

Fjedertallerken

Koblingsfjeder

Koblingssæt

Stor lejespændering for drivaksel

Stempelsæt

Stempel o-ring

Drivakselsæt

Bagerste drivakselleje

Stempel returfjeder

Sædering

Tandhjulsspænde-skrue

Tandhjulsskive

Tandhjul

Tandhjulsbøsning

Tandhjulsfjeder

Tilgangsfl angesæt

Dæksel

Selvborende skruer

Turbinestarter, komplet

96.26 - ES0S-G

51309-01H

L23/30H

PlatePage 3 (3)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit. Qty./E = Qty./MotorQty./S = Qty./Turbine Starter

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./MotorQty./S = Qty./Turbinestarter

Spare parts kit, incl. item 026, 134, 146, 171, 183, 195, 205, 217, 254, 278, 291, 301, 470, 516, 541, 553, 624, 685 and 697

Reservedelssæt inkl. item 026, 134, 146, 171, 183, 195, 205, 217, 254, 278, 291, 301, 470, 516, 541, 553, 624, 685 og 697

768

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L23/30H

Main Starting Valve 51310-01H

045*

021*

033*069*

070*

94.22 - ES0S-G

082*

057*

094

PlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Main Starting Valve PlatePage 2 (2)51310-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

021*

033*

045*

057*

069*

070*

082*

094

104

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/E

1/V

O-ring

O-ring retainer

O-ring

Bumper

Spring

O-ring

O-ring

Main starting valve,complete

Spare part kitItem No. 021, 033, 045, 057, 069, 070 and 082.

O-ring

O-ring holder

O-ring

Stødfanger

Fjeder

O-ring

O-ring

Hovedstartventil,komplet

ReservedelssætItem nr. 021, 033, 045, 057, 069, 070 and 082.

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./V = Qty./Valve

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/V = Antal/Ventil

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Muffl er 51312-01HPlatePage 1 (2)

010

94.22 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Muffl er PlatePage 2 (2)51312-01H

L23/30H

ItemNo.

Qty.

Qty

Item No.

010 1/S Muffl er Dæmper

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./S = Qty./Starting air motor

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/S = Antal/Startemotor

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Emergency Starting Valve 51313-01HPlatePage 1 (2)

94.22 - ES0S-G

016

089*

090*

041*

065*

100*

077*

028*

100*

053*

136

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Emergency Starting Valve PlatePage 2 (2)51313-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

016

028*

041*

053*

065*

077*

089*

090*

100*

112

124

136

1/E

1/V

1/V

4/V

1/V

1/V

1/V

1/V

2/V

1/V

1/V

1/V

Emergency startingvalve, complete

Piston

Washer

Screw

Nut

Spring

Gasket

Gasket

Gasket

Repair kit, incl. item 053, 089, 090 and 100

Repair kit, incl. item 028, 041, 065, 077 and 112

Silencer

Nødstarteventil,komplet

Stempel

Skive

Skrue

Møtrik

Fjeder

Pakning

Pakning

Pakning

Reservedelssæt, inkl.item 053, 089, 090 og 100

Reservedelssæt, inkl.item 028, 041, 065, 077 og 112

Lyddæmper

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./V = Qty./Valve

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/V = Antal/Ventil

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Starting Valve 51314-01HPlatePage 1 (2)

011

084*

035*

047*

072*

023*

059*

060

94.22 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Starting Valve PlatePage 2 (2)51314-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

011

023*

035*

047*

059*

060

072*

084*

096*

106

Starting valve,complete

Armature, complete

Spring

Gasket

Guide pipe, complete

Solenoid

Gasket

Nut

Repair kit, incl. item 023, 035, 047, 072 and 084

Repair kit, incl. item 059 and 096

Starteventil,komplet

Anker, komplet

Fjeder

Pakning

Styrerør, komplet

Spole

Pakning

Møtrik

Reservedelssæt, inkl. item 023, 035, 047, 072 og 084

Reservedelssæt, inkl. item 059 og 096

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./V = Qty./Valve

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/V = Antal/Ventil

1/E

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L21/31, L23/30H, L27/38

Main Stop Valve 51315-03PlatePage 1 (2)

00.41 - EO0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

00.41 - EO0

Designation BenævnelseBenævnelseDesignation

Main Stop Valve PlatePage 2 (2)51315-03

Item No.

Qty.

Qty.

Item No.

042

066

078

1/E

1/V

1/V

Stop valve,complete

Gasket

Gasket

Stopventil,komplet

Pakning

Pakning

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/V = Antal/Ventil

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./V = Qty./Valve

L21/31, L23/30H, L27/38

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Air Strainer 51316-01HPlatePage 1 (2)

94.22 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.20 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Air Strainer PlatePage 2 (2)51316-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

012

024

036

048

061

073

085

097

107

1/F

1/F

1/F

4/F

4/F

1/E

1/F

1/F

1/F

Housing

Cover

Filter

Stud

Nut

Air strainer,complete

Gasket

Plug screw

Gasket

Hus

Dæksel

Filter indsats

Tap

Møtrik

Filter, komplet

Pakning

Propskrue

Pakning

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor.Antal/F = Antal/Filter.

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./F = Qty./Filter.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Safety Valve 51319-01HPlatePage 1 (2)

94.22 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Safety Valve PlatePage 2 (2)51319-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

019

020

032

044

1/E

1/E

1/E

3/E

Safety valve,(10 bar)

Safety valve,(15 bar)

Protective device

Screw

Sikkerhedsventil,(10 bar)

Sikkerhedsventil,(15 bar)

Beskyttelseshætte

Skrue

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor.

When ordering spare parts, see also page 500.50.

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

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

ON-OFF Valve for Jet System 51320-01HPlatePage 1 (2)

94.22 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S-G

Designation BenævnelseBenævnelseDesignation

ON-OFF Valve for Jet System PlatePage 2 (2)51320-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

014

026

038

051

063

075

087

1/V

1/V

1/E

1/E

1/E

1/E

1/E

Coil

Housing

Valve, complete ¾" connecting branch

Valve, complete 1"Connecting branch

Valve, complete 1 ¼"Connecting branch

Valve, complete 1 ½"Connecting branch

Valve, complete 2"Connecting branch

Spole

Hus

Ventil, komplet ¾" tilslutningsstuds

Ventil, komplet 1"Tilslutningsstuds

Ventil, komplet 1 ¼"Tilslutningsstuds

Ventil, komplet 1 ½"Tilslutningsstuds

Ventil, komplet 2"Tilslutningsstuds

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor.Antal/V = Antal/Ventil.

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./V = Qty./Valve.

MAN Diesel

General

Air Filter 51321-03PlatePage 1 (2)

08.21 - ES0

190

MAN Diesel

08.21 - ES0

Designation BenævnelseBenævnelseDesignation

Air Filter PlatePage 2 (2)51321-03

General

Item No.

Qty.

Qty.

Item No.

190

200

1/E

1/F

Filter complete

Repair kit (fi lter and O-ring)

Filter komplet

Reparationssæt(fi lter og O-ring)

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/Motor.

When ordering spare parts, see also page 500.50.

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

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L16/24L23/30H

Pressure Reduction Valve 51322-02HPlatePage 1 (2)

99.03 - ES0-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

99.03 - ES0-G

Designation BenævnelseBenævnelseDesignation

Pressure Reduction Valve PlatePage 2 (2)51322-02H

L16/24L23/30H

Item no

Qty.

Qty.

Item no

015

027

039*

040

052*

064*

076*

088*

111

123*

135*

147*

159*

160

172

184*

196

206

218

231

243

255

267

1/V

10/V

2/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

1/V

2/V

2/V

1/V

1/E

1/E

1/V

2/V

1/V

1/E

Cover

Screw

Filter

Tube incl. o-ring

O-ring

Diaphragh

O-ring

O-ring

Valve, complete

O-ring

Valve spring

O-ring

O-ring

Bottom plug, incl.o-ring

Pipe plug

O-ring

Repair kit, incl. item039, 052, 064, 076, 088, 123, 135, 147, 159, and 184

Reduction valve,complete

Pilot valve, complete

Repair kit for item 218

Screw

Manometer0-25 bar - PI 70

Pressure reductionvalve, complete

Dæksel

Skrue

Filter

Rør, inkl. o-ring

O-ring

Membran

O-ring

O-ring

Ventil, komplet

O-ring

Ventilfjeder

O-ring

O-ring

Bundprop, inkl.o-ring

Rørprop

O-ring

Reparationssæt, inkl. item 039, 052, 064, 076, 088, 123, 135, 147, 159, and 184

Reduktionsventil,komplet

Styreventil, komplet

Reparationssæt foritem 218

Skrue

Manometer0-25 bar - PI 70

Trykreduktionsventil,komplet

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/V = Antal/Ventil

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty/E = Qty/EngineQty/V = Qty/Valve

Fuel oil system

514/614

MAN Diesel

DescriptionPage 1 (3)

L23/30H

Internal Fuel Oil System

94.26 - ES0S

514.01Edition 01H

Fuel leakage alarm

Leak fromfuel valve

Flywheel end

Drainfrom cyl. head

Fuel oil feedpump

Leak fromfuel pump

Fuel oil pump

Fuel oil return

Fuel oil inlet

High pressurepipe

Cyl. 1

Fuel oil fi lter

Waste tray

A2Fuel oil, outlet

A3Waste oil,

inlet

A1Fuel oil, inlet

The safety fi lter is a duplex fi lter of the split type with a fi lter fi neness of 50 my. The fi lter is equipped with a common three-way cock for manual change of both the inlet and outlet side.

During normal operation both fi lters should be in operation. Single operation only to be used when dismantling one of the fi lters for manual cleaning or inspection.

The feed pump (if part of the delivery,) which is of the gear wheel type, is equipped with a spring-loaded adjustable by-pass valve.

The outlet pressure of the feed pump can be ad justed by means of an adjusting screw in the by-pass valve assembly.

Fig. 1. Diagram for Fuel Oil System

General

The internal built-on fuel oil system consists of the following parts:

- the fuel oil feed system - the high-pressure injection equipment, comprising fuel oil injection pumps, fuel oil

injection valve and fuel oil high pressure pipe

- the waste oil system

Internal Fuel Oil Feed System

The fuel oil is led to the injection pumps through a safety fi lter by means of the engine driven feed pump (if part of the delivery).

MAN Diesel

For cir cu la tion of fuel during stand-still of the engine, a by-pass line is mounted with a non-return valve parallel to the feed pump.

Fuel Injection Equipment

Each cylinder unit has its own set of injection equip-ment, comprising injection pump, high-pressure pipe and injection valve.

The injection equipment and the distribution supply pipes are housed in a fully enclosed compartment thus minimizing heat losses from the preheated fuel.

This arrangement reduces external surface tem pe ra-tures and the risk of fi re caused by fuel leakage.

Fuel Oil Injection Pump

The fuel oil injection pump is installed on the roller guide housing directly above the camshaft, and it is activated by the cam on the camshaft through roller guides fi tted in the roller guide housing.

The injection amount of the pump is regulated by transversal displacement of a toothed rack in the side of the pump housing.

By means of a gear ring, the pump plunger with the two helical millings, the cutting-off edges, is turned.

Hereby the length of the pump stroke is reckoned from when the plunger closes the inlet holes until the cutting-off edges again uncover the holes.

The release of high pressure through the cutting-off edges presses the oil with great force against the wall of the pump housing. At the spot, two exchangeable plug screws are moun ted.

The amount of fuel injected into each cylinder unit is adjusted by means of the governor.

It main tains the engine speed at the preset value by a con tinuous positioning of the fuel pump racks, via a common regulating shaft and spring-loaded link ages for each pump.

L23/30H

Internal Fuel Oil System DescriptionPage 2 (3)

94.26 - ES0S

The injection valve is for "deep" building-in to the centre of the cylinder head.

Fuel Oil Injection Valve

The fuel oil injection valve consists of a nozzle holder and a nozzle connected by a union nut. The nozzle holder includes a threaded pipe stub for mounting the high-pressure pipe. It is led through a boring in the cylinder head, together with an adjusting screw, a spring and spring spindle for the initial tensioning of the nozzle needle.

The initial tension of the spring, which determines the opening pressure of the nozz le, can be adjusted by means of the centrally-mounted adjusting screw.

On the upper most thick part of the holder, there are three sealing O-rings.

Between the two lowest O-rings, the leak oil from the nozzle needle is led out into the space between the high-pressure pipe and the protection tube.

The nozzle and needle are lapped together as a pair, and cannot be replaced individually. The noz-zle is controlled by two pins attached to the bottom of the holder.

The joint surface between the nozzle and holder is machine-lapped to make it oil-tight.

The fuel injector is mounted in the cylinder head by means of the integral fl ange in the holder and two studs with distance pieces and nuts.

A bore in the cylinder head vents the space below the bottom rubber sealing ring on the injection valve, thus preventing any pressure build-up due to gas leakage, but also unveiling any mal func tion of the bottom rubber sealing ring for leak oil.

514.01Edition 01H

MAN Diesel

DescriptionPage 3 (3)

L23/30H

Internal Fuel Oil System 514.01Edition 01H

Fuel Oil High Pressure Pipe

The connection between injection pump and fuel injector is a shielded high pressure pipe. The high pressure pipe is equipped with connection tapers matching to simiular taper facings on the threaded connectors on the injection pump and the fuel in-jector.

Waste Oil System

Waste leak oil from the compartment, fuel valve and engine feed pump is led to a fuel leakage alarm unit.

The alarm unit consists of a box with a fl oat switch for level monitoring. In case of a larger leakage than normal leakage, the fl oat switch will initiate alarm. The supply fuel oil to the engine is led through the unit in order to keep this heated up, thereby ensur-ing free drainage passage even for high-viscous waste/leak oil.

94.26 - ES0S

0802

8-0D

/H52

50/9

4.08

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MAN Diesel

Safety precautions:

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

Description:

Dismounting, inspection/overhaul and mounting of fuel injection pump. Inspection of fuel injection pipe.

Starting position:

Cover in front of fuel injection pump has been removed.

Related procedure:

Inspection of roller guide for fuel injection pump, 508-01.05

Manpower:

Working time : 4 hoursCapacity : 1 Man

Data:

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

Working CardPage 1 (4) Fuel Injection Pump and Fuel Injection Pipe 514-01.05

Edition 12H

08.03 - ES0S

L23/30H

Special tools:

Plate No. Item No. Note

52014 01352014 02552014 20452014 25352006 261 20-120 Nm52006 273 80-360 Nm

Hand tools:

Ring and open end spanner 13 mmRing and open end spanner 14 mmRing and open end spanner 17 mmRing and open end spanner 19 mmAllen key 8 mm, 10 mmPlier for lock ring. Tools for cleaning.Clean kerosene or gas oil.Clean lubricating oil.Anti seize product (Copaslip, Molykote GN Plusor similar).

Spare and wearing parts:

Plate No. Item No. Qty./

51401 189 1/pump51401 190 1/pump51401 236 1/pump51401 248 1/pump

0802

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MAN Diesel

Dismounting of fuel injection pump

1. Dismount the fuel injection pipe pos. 1 fi g 1 and the fuel inlet pipe pos 2.

2. Separate the spring loaded lever from the regulating rod on the fuel injection pump.

Fuel Injection Pump and Fuel Injection Pipe Working CardPage 2 (4)

514-01.05Edition 12H

08.03 - ES0S

L23/30H

Fig 1 View from Control Side

3. Remove the pipe for lub.oil and drain.

4. Remove the screws in the bottom fl ange (4 pieces) and take the fuel injection pump away.

Separation of fuel injection pump.

5. If necessary, clean the exterior of the injection pump.

6. Mount the injection pump in the clamping bracket PYO-W020 (see plate 52014 item 037), on the test pump.

7. Press the thrust cap (N) fi g. 2 downwards and remove the securing ring (P). Remove the thrust cap (N) with lower spring plate (O) and plunger (M). Be sure not to damage the plunger.

8. Take out the plunger spring (L), upper spring plate (K) and pinion (J). If necessary remove the lock ring (R) and guide pin (I) and dismount the regulating rod (H) as well as the cap screw in the opposite end of the regulating rod (H).

2. O-ring inside dia. 37 mm x 3

3. O-ring inside dia. 41 mm x 3

5. O-ring inside dia. 34 mm x 3

6. O-ring inside dia. 31 mm x 3

Fig 2 Cross Section of Fuel Injection Pump

1 2

A

B

C

D, F

2

35IR

K

L

NOP

EM

G

6

JH

9. Unscrew the four screws (A) and remove the connecting piece (B). Take out the valve spring (D) and the non-return valve (F).

10. Loosen and remove the four screws (C) and take out the barrel (E).

11. Remove all the O-rings from the injection pump.

0802

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MAN Diesel

Working CardPage 3 (4) Fuel Injection Pump and Fuel Injection Pipe 514-01.05

Edition 12H

L23/30H

12. All parts must be cleaned, using kerosene or gas oil and a hand brush (not a steel brush).Blow through the holes for sealing oil in the pump houses and the barrel (E).

Inspection of fuel injection pump:

13. Insert plunger (M) and non-return valve (F) into the barrel (E) after wetting with clean gas oil. Plunger and non-return valve must slide into the barrel by their own weight.

14. The axial clearance between lower spring plate and plunger foot must not exceed 0.25 mm. The clearance between lower spring plate and plunger foot is 0.05 to 0.1 mm when new. See fi g 3.

Assembling of fuel injection pump:

17. When assembling the injection pump, proceed in the reverse order to disassembling. Pay attention to the following:

A. At initial tightening up of new parts the following (C) for barrel (E).Tighten screws to 55-65 Nm.

B. Renew all sealing rings. For placing of the rings, see fi g 2.

C. Coat all the threads with an anti seize pro-duct.

D. Wipe dry with paper plane sealing surface on barrel (E) and connecting piece (B).

E. Before inserting the pinion (J), the easy mo-tion of the plunger (M) in the barrel (E) must be checked.

08.03 - ES0S

Fig 3 Clearance between Lower Spring Plate and Plunger

Lower spring

Plate (O)

Max

. 0.2

5 m

m

Spring (L)

Plunger (M)

Marking on

regulating rod

Tooth with chamfer

Marking on pinion

Fig 4 Mounting of Regulating Rod Mechanism

F. When assembling the pinion (J), ascertain that the tooth (recognizable by the chamfer) will enter the space of the regulating rod (H) marked by two sings, see fi g 4.

15. Check the cavitation plugs (G) for wear and renew if necessary.

16. Barrel (E), plunger (M) and non-return valve (F) are manufactured to very close tolerances. Any attempt to refi nish these parts causes altera-tions of the tolerances and must therefore NOT be carried out.If during the visual inspection of the parts, heavy abrasion symptoms or damage can be observed, the part in question must be replaced.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Fuel Injection Pump and Fuel Injection Pipe

L23/30H

Working CardPage 4 (4)

514-01.05Edition 12H

08.03 - ES0S

G. The marking on the guide cam of the plunger (M), must be in line with the marking in the slots of the pinion (J). (Not shown on fi g 4).

18. After assembling, the easy motion of the re-gulating rod (H), must be checked and the plunger (M) must be moved from the no-load stop to full-load stop.

Mounting of fuel injection pump:

19. Before mounting the fuel injection pump, clean the roller guide spring and washer for spring in the roller guide housing.

20. Reconnect the regulating rod (H) to the spring loaded lever and all the pipes to the fuel pump.

Fuel injection pipe:

By normal working conditions the fuel injection pipe require very little maintenance except replacement of O-rings and gasket in connection with the normal overhaul of fuel injection equipment.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Dismounting, overhaul, pressure testing and mounting of fuel injection valve.

Starting position:

Top cover on the cylinder head and front cover on the fuel injection pump has been dismounted.Fuel injection pipe dismounted 514-01.05

Related procedure:

Manpower:

Working time : 2 hoursCapacity : 1 man

Data:

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

514-01.10Edition 02H

95.50 - ES0S

L23/30H

Fuel Injection ValveWorking CardPage 1 (4)

Special tools:

Plate no Item no Note

52006 261 20-120 NM 52014 013 52014 108 52014 204 52014 300 Extra tools 52014 361 52014 407

Hand tools:

Ring and open end spanner 12 mmRing and open end spanner 24 mmSocket spanner 24 mmSocket spanner 30 mmTools for cleaning.Clean kerosene or gas oil.Antiseizure product.(Copaslip, Molykote GN Plus or similar).

Replacement and wearing parts:

Plate no Item no Qty/

51402 116 3/valve

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514-01.10Edition 02H

Working CardPage 2 (4)

The fuel injection valve is the single component that has the greatest infl uence on the diesel engine con-dition. Various forms of operation and quality of fuel oil affect the overhaul intervals. In some cases it may be necessary to shorten the prescribed intervals.

Dismounting and cleaning:

1. Dismount the fuel injection valve from the cy-linder head by means of the special tool as shown in fi g. 1.

Fig 1 Dismounting of fuel injection valve from cylinder head.

2. Mount the fuel injection valve into the clamping bracket VTO-W020 (see plate 52014, item 025) on the pressure testing pump, and loosen the lock nut (B) fi g 2.Unstress the nozzle spring by turning the adjusting screw (D).

Fuel Injection Valve

L23/30H

3. Clean the lower part of the nozzle (J) from carbonized oil deposits before dismantling the nozzle nut (H). Remove the nozzle nut (H) and the nozzle (J).

Fig 2 Fuel injection valve.

Attention!Do not damage the lapped surface.

4. The nozzle spring (F) and the spring spindle (G), are to be taken out by loosening the adjusting screw (D), completely.

5. All parts must be cleaned with kerosene or gas oil and a hard brush (not a steel brush).

6. Clean the nozzle holes of charred coke by means of the supplied special drill (see plate 52014-01H item 108) with holder.

7. Clean the cooling chamber and the cooling ducts in the nozzle guide and injector body by placing these in a cleaning liquid and then blow through the parts with dry working air.

D

B

E

C

F

G

H

J

B. Lock nut

C. Sealing ring

D. Adjusting screw

E. Sealing ring

F. Nozzle spring

G. Spring spindle

H. Nozzle nut

J. Nozzle

95.50 - ES0S

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514-01.10Edition 02H

L23/30H

Fuel Injection ValveWorking CardPage 3 (4)

Inspection of the parts:

8. Nozzles are matched by lapping and are the-refore only interchangeable as units. Insert nozzle needle with gas oil in the needle guide. It must be controlled whether the nozzle needle slides down by its dead weight on its seat.

9. If the holes are oval worn, which is checked with of a magnifying glass, the nozzle must be scrap-ped.

10. The best way, however, to check if the holes are worn out is to control the fl ow rate of the nozzle which, in general, only can be made at the manu-facturer's works on a special test stand.

11. Every effort to refi nish will result in alterations of these values and malfunction of the nozzle. If heavy abrasion symptoms, respectively damages are observed at the visual inspection of the parts, the parts in question must be replaced.

Reassembling:

12. When all parts have been overhauled, found in good order and carefully cleaned, assemble the fuel injection valve again.

13. When assembling the injection valve, proceed in the opposite order compared to the disassembly. Pay attention to the following:

A. Lubricate the threads on the adjusting screw (D) with lub. oil, and the threads of the nozzle holder for the nozzle nut. The shoulder of the nozzle which is in contact with the nozzle nut, must be lubricated with an antiseizure product.

B. The sealing plane surface of body and nozzle must be wiped dry with paper.

C. Renew the sealing rings (C) and (E).

D. Tighten torque for nozzle nut (see page 500.40.)

Pressure testing of fuel injection valve:

14. The most effective checking of the fuel valves is obtained through pressure testing, preferably carried out after each overhaul and also in case of irregularities in operation. The pressure testing is carried out in the following way by means of the pressure testing apparatus supplied.

15. Mount the fuel injection valve in the bracket VTO-W020 (see plate 52014 item no. 25) again. The bracket to be in such a position that the nozzle of the injector is pointing downwards.

16. For test of the injection pressure and ato-mizing mount the test pipe VTO-W021 (see plate 52014 item 049), increase pressure by means of the lever on the test pump, and adjust the opening pressure to 320 bar, by the adjusting screw (D), see fi g 2, then tighten lock nut (B) and check opening pressure again.Do not expect chattering, but make sure that the nozzle spray from all holes in the same angle. The nozzle might chatter if the lever is worked very fast, actually by hitting it.Do not expect a nozzle tip with more than 1000 running hours to perform like a new nozzle in the test pump.Then increase the pressure to 300 bar and keep the pressure by working the lever slowly downwards. When the pressure is kept at 300 bar, there should be no more than one drip from the nozzle tip for approx. 3-5 sec.

WARNING: Keep out of the fuel jets as they will penetrate the skin. Fuel which has penetrated the skin can cause painful infl ammations (blood poisoning).

95.50 - ES0S

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L23/30H

95.50 - ES0S

514-01.10Edition 02H

Working CardPage 4 (4)

Mounting of the fuel injection valve in cylinder head:

Fuel Injection Valve

19. Mount the high pressure pipe before tightening the nuts then it is easier to fi t the threads.

20. Put on the distance pieces, fi t the nuts and tighten up with a torque spanner (for torque moment, see page 500.40).

Fig 3 Grinding tools for seat and liner for fuel injection valve.

17. Before mounting the fuel valve, clean and inspect the valve sleeve in the cylinder head. If ne-cessary, grind the seating face with the grinding tool (see fi g 3).

18. Coat the O-rings and the lower part of the valve with an antiseizure product, place the valve in the cylinder head and press it down to the seat.

Fig 4 Grinding tools for fuel injection valve (extra tools).

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Safety precautions:

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

Description:

Disassembly, cleaning and assembly of fuel oil split fi lter.

Starting position:

Related procedure:

Manpower:

Working time : 1/2 hourCapacity : 1 man

Data:

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

514-01.15Edition 01H

91.08 - ES0S-G

L23/30H

Fuel Oil Split FilterWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Ring and open end spanner, 13 mm.Ring and open end spanner, 17 mm.Kerosene, gas oil or similar.

Replacement and wearing parts:

Plate no Item no Qty. /

0802

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MAN Diesel

L23/30H

91.08 - ES0S-G

514-01.15Edition 01H Fuel Oil Split Filter Working Card

Page 2 (2)

1) During normal operation both fi lters should be in operation, single operation only to be used when dismantling one of the fi lters for manual cleaning or inspection.

2) Normally the fi lters are cleaned during ope ra-tion by turning the handle, (1) see fi g 1, on the fi lter housing top a couple of turns. (clockwise).

Simultaneously with turning of the handle, the drain cock, (2) in bottom of the fi lter housing should be opened in order to drain of the dirt being scraped of the fi lter element, (3).

1

2

3

5

Fig 1 Fuel oil split fi lter

3) Position of three way cock, see fi g 2.

4 5

Both fi lters in operation.

Right FilterThis position is only for clea ning of the left fi lter, not for con ti nu-ous operating.

Left FilterThis position is only for clea ning of the right fi lter, not for con ti nu-ous operating.

Fig 2. Fuel oil split fi lter (top view).

Note: Shut-off fuel oil, before dismantling fi lter e le-ment.

4) If no drainage occurs when the drain cock is opened, the fi lter housing should be dismantled for manual cleaning. Remove the nuts (5), and take out the fi lter element (3).

5) Clean the fi lter element in kerosene gas oil or similar and blow it dry with working air.

6) Mount the fi lter element again.

7) The fi lter element itself should never be dis-mant led, but has to be replaced if damage or mal function is experienced.

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Safety precautions

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

Description

Check of fuel oil piping system.

Starting position

Engine is running.

Related procedure

Manpower

Working time : ½ hourCapacity : 1 man

Data

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

514-01.90Edition 01H

92.04 - ES0S-G

L23/30HV28/32S

Check of Fuel Oil Piping SystemWorking CardPage 1 (2)

Special tools

Plate no Item no Note

Hand tools

Replacement and wearing parts

Plate no Item no Qty /

0802

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MAN Diesel

L23/30HV28/32S

92.04 - ES0S-G

514-01.90Edition 01H Check of Fuel Oil Piping System Working Card

Page 2 (2)

Fuel Oil System

1) Dismount the covers to the injection pumps. Blow-through drain pipes.

2) Examine the piping system for leaks.

3) Retighten all bolts and nuts in the piping sy-stem.

Venting pipe

Fig 1. Cross section of cylinder head

4) Move all valves and cocks in the piping sy-stem.

Lubricate valve spindles with graphite or si-milar.

5) Check fl exible connections for leaks and da-mages.

6) Check the condition of the lower O-ring for the fuel injecting valves by means of the venting pipe.

For fuel oil condition, see section 504.

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Safety precautions:

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

Description:

Adjustment of the maximum combustion pressure for the cylinders one by one and for all cylinders in total.

Starting position:

Camshaft mounted and adjusted in relation to the crankshaft (lead), 507-01.20Intermediate wheel mounted.

Related procedure:

Manpower:

Working time : 2-5 hoursCapacity : 1 man

Data:

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

514-05.01Edition 01H

91.45 - ES0S-G

L23/30H

Adjustment of The Maximum Combustion PressureWorking CardPage 1 (3)

Special tools:

Plate no Item no Note

52006 261 20 - 120 Nm. 52010 011 52008 058

Hand tools:

Ring and open end spanner, 19 mm.Socket spanner, 19 mm.Depth gauge.Plastic hammer.

Replacement and wearing parts:

Plate no Item no Qty /

50801 124 1 set/cyl

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MAN Diesel

L23/30H

91.45 - ES0S-G

514-05.01Edition 01H Adjustment of The Maximum Combustion Pressure Working Card

Page 2 (3)

Fig 2

Action Results

Total height Distance Injection Max. combustion on roller guide "x" timing pressure

increased Reduced Advanced increased

Reduced increased Delayed Reduced

↑

↓

↑

↓

↓

↑

↑

↓

If fuel oil valve, piston, inlet and exhaust valves as well as turbocharger and charge air cooler are working correct and the compression pressure Pcomp is normal the maximum combustion pressure will indicate the injection timing for the fuel oil pump.

If Pmax is too low it indicates that the injection timing is delayed.

If Pmax is too high it indicates that the injection timing is advanced.

The injection timing can be altered by inserting or removing shims under the thrust piece on the roller guide, thus changing the measure “X”, see fi g 1.

Measure "x"

Total height

Fig 1

21

3

4

1

2

3

4

5

23

4

1 Extractor 2 Thrust piece

3 Shims 4 Roller guide

5 Soft hammer

Fig 3

Thinner and/or fewer shims (increase of the distance “X”) results in a delayed injection timing and a lower Pmax.

Thicker and/or more shims (reduction of the distance “X”) results in an advanced injection timing and a higher Pmax.

If the distance “X” is to be changed the trigger (1) is used for dismantling of the thrust piece (2), where-after the thickness and/or the number of shims (3) can be changed.

By changing “X” with 0.10 mm the maximum combu-stion pressure is changed with - see page 500.35.

After replacement of shims the thrust piece is re-mounted in the roller guide (4) with a soft hammer (5).

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Fig. 4

514-05.01Edition 01H

91.45 - ES0S-G

L23/30H

Adjustment of The Maximum Combustion PressureWorking CardPage 3 (3)

When changing “X” it must be ensured that the di-stance between the upper edge of the roller guide housing and the thrust piece on the roller guide is not exceeded, when the roller is resting on the circular part of the fuel cam, see page 500.35.

In all cases “X” must be checked and adjusted, if necessary, when fuel oil pump, roller guide, roller guide housing and/or camshaft section have been replaced/dismantled.

Note: If several fuel oil pumps, roller guides, rol-ler guide housings and/or camshaft sections are dismantled at the same time it is advisable to num-ber the parts in order to facilitate remounting and adjustment.

If the maximum combustion pressure differs from the test bed records after adjustment of each individual pump the camshafts placement can be changed, as the camshafts gear wheels are provided with oblonged holes so that they can be turned in relation to the hub.

The gear wheel is provided with an engraved scale, see fi g 4, and the hub of the cam shaft is provided with a mark.

When the screws, which fasten the gear wheel, are loosened the gear wheel is turned (by turning the crankshaft) in relation to the camshaft. By reading the angle in which the gear wheel is displaced in relation to the camshaft the altered Pmax can be calculated. A line on the scale corresponds to: see page 500.35.

If the crankshaft is turned in the engines normal direction of rotation the maximum combustion pres-sure P-max. is reduced.

If the crankshaft is turned against the engines normal direction of rotation the maximum combustion pres-

0802

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Safety precautions:

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

Description:

Disassembly, overhaul and assembly of fuel oil feed pump.Adjustment of fuel oil pressure.

Starting position:

All pipe connections to the feed pump have been disconnected, and the feed pump is removed from the engine.

Related procedure:

Man power:

Working time : 4 HoursCapacity : 1 man

Data:

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

514-10.00Edition 01H

96.26 - ES0S

L23/30H

Fuel Oil Feed PumpWorking CardPage 1 (3)

Special tools:

Plate no. Item no. Note.

Hand tools:

Allen key, 8 mm, 10 mm, 22 mm.Ring and open end spanner, 17 mm.Ring and open end spanner, 46 mm.Big screwdriver.Adjustable spanner.Puller.Hard brush.Gas oil.

Replacement and wearing parts:

Plate no. Item no. Qty. /

51410 049 1/pump 51410 050 4/pump 51410 108 1/pump 51410 265 1/pump

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L23/30H

514-10.00Edition 01H Fuel Oil Feed Pump Working Card

Page 2 (3)

Disassembly.

1) Remove the coupling part (14), see fi g. 1, by means of a puller.

2) Remove screws (12) and dismount the cover (11) with locking ring, sealing ring, o-ring and rotating packing (9).

3) After removal of the screws (4) (6 pcs.) the cover (3) is dismantled and the gear wheels (5 and 7) are pulled out.

4) Dismounting of the spring loaded adjustable by-pass valve.

Remove the cap nut (21), nut (20), spring housing (19), spring (18) and the cylinder (23). If the piston (17) cannot be pulled out from the same side the plug screw (15) can be removed and the piston can be pressed from this side with a screw driver or the like.

Overhaul:

5) Clean all the parts with gas oil and a hard brush.

Warning: Never use a steel brush.

The parts are blown clean with working air.

6) If the bearing bush are to be removed the existing bearing bush is plugged out, the bores are cleaned and new bearing bush is mounted, see fi g. 2.

Before the gear wheels can be mounted the bearing bush must be adjusted with a reamer or a bearing scraper, so that the gear wheel can run easily when the pump is assembled.

7) Renew the sealing ring in cover (11).

8) Inspect all other parts for wear and damage, and renew, if necessary.

Assembly:

9) Mount the gear wheel (5 and 7), coat the sea-ling lip with silastene or similar and mount the cover (3).

10) Mount the rotating packing (9) and the cover (11) with sealing ring, o-ring, locking ring and coupling (14).

11) Mount the spring loaded by-pass valve, nut (20), gasket (16), cap nut (21) and plug screw (15).

12) Mount the feed pump on the engine and con-nect all the pipes.

Adjusting of Fuel Oil Pressure.

13) The outlet pressure of the feed pump, can be adjusted by means of an adjusting screw in the by-pass valve.

Remove the cap nut (21) and loosen the nut (20).

By turning the spring housing clockwise the pres-sure is raised and reverse the pressure is lowered by turning the spring housing (19) anti-clockwise. When the correct pressure is reached, see page 500.30, the spring housing (19) is locked with nut (20) and fi nally the gasket (16) and cap nut (21) are mounted.

96.26 - ES0S

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514-10.00Edition 01H

96.26 - ES0S

L23/30H

Fuel Oil Feed PumpWorking CardPage 3 (3)

Fig. 2. Mounting of bearing bush.

Fig. 1. Fuel oil feed pump.

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03.36 - ES0

Fuel Injection Pump 51401-10HPlatePage 1 (2)

L23/30H

0802

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MAN Diesel

03.36 - ES0

Fuel Injection Pump51401-10H

Designation BenævnelseBenævnelseDesignation

021

033

045

057

069

070

082

094

104

116

128

141

153

165

177

189

190

200

212

224

236

248

261

273

285

297

307

Item No.

Qty.

Qty.

Item No.

Pump housing

Screw

Packing ring

Fuel injection pump,complete

Plunger and barrelincl. non-return valve

Joint washer

Washer

Screw

Circlip

Regulating rod

Guide pin

Upper spring plate

Spring

Lower spring plate

Thrust cap

O-ring

O-ring

Circlip

Spring

Connecting piece

O-ring

O-ring

Pointer

Nut

Screw

Cap screw

Securing ring

Pumpehus

Skrue

Pakningsring

Fuel indsprøjtnings-pumpe, komplet

Stempel og cylinderinkl. kontraventil

Pakning

Skive

Skrue

Låsering

Reguleringsstang

Styretap

Øverste fjederplade

Fjeder

Nederste fjederplade

Trykhætte

O-ring

O-ring

Låsering

Fjeder

Forbindelsesstykke

O-ring

O-ring

Viser

Møtrik

Skrue

Hætteskrue

Beskyttelsesring

PlatePage 2 (2)

Gear rim

Screw

Packing ring

Screw

+ Are not included in fuel injection pump, complete

Tandkrans

Skrue

Pakningsring

Skrue

+ Indgår ikke i fuel ind-sprøjtningspumpe,komplet

L23/30H

319

344+

356+

368

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./P = Qty./PumpQty./C = Qty./Cylinder

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/P = Antal/PumpeAntal/C = Antal/Cylinder

1/P

2/P

2/P

1/C

1/P

1/P

2/P

4/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

4/P

1/P

1/P

1/P

1/P

1/P

2/P

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MAN Diesel

L23/30H

Fuel Injection Valve 51402-16HPlatePage 1 (2)

153

165

021*

116

033*

045

057

141

189

104

189

094

177

082

069

07.20 - ES0

* When ordering, please state IMO-17.02

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Designation BenævnelseBenævnelseDesignation

Fuel Injection Valve PlatePage 2 (2)51402-16H

L23/30H

Item No.

Qty.

Qty.

Item No.

021

033

045

057

069

082

094

104

116

141

153

165

177

189

1/V

1/V

2/V

1/V

1/V

1/V

1/V

1/V

3/V

1/V

1/V

1/V

1/C

2/V

Injector housing, plea-se state IMO-17.02

Nozzle, complete, please state IMO-17.02

Dowel pin

Screw cap

Thrust spindle

Spring

Adjusting screw

Nut

O-ring

Cap nut

Bolt

Washer

Fuel injection valve,complete

Washer

Ventilhus, venligst oplys IMO-17.02

Forstøver, komplet, ven-ligst oplys IMO-17.02

Styrestift

Omløber

Trykspindel

Fjeder

Justeringsskrue

Møtrik

O-ring

Hættemøtrik

Bolt

Skive

Brændselsventii,komplet

Skive

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./V = Qty./ValveQty./C = Qty./Cylinder.

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./V = Qty./VentilQty./C = Qty./Cylinder.

07.20 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Fuel Injection Valve 51402-17HPlatePage 1 (2)

153

165

021*

116

033*

045

057

141

189

104

189

094

177

082

069

07.20 - ES0

* When ordering, please state IMO-17.06

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Fuel Injection Valve PlatePage 2 (2)51402-17H

L23/30H

Item No.

Qty.

Qty.

Item No.

021

033

045

057

069

082

094

104

116

141

153

165

177

189

1/V

1/V

2/V

1/V

1/V

1/V

1/V

1/V

3/V

1/V

1/V

1/V

1/C

2/V

Injector housing, plea-se state IMO-17.06

Nozzle, complete, please state IMO-17.06

Dowel pin

Screw cap

Thrust spindle

Spring

Adjusting screw

Nut

O-ring

Cap nut

Bolt

Washer

Fuel injection valve,complete

Washer

Ventilhus, venligst oplys IMO-17.06

Forstøver, komplet, ven-ligst oplys IMO-17.06

Styrestift

Omløber

Trykspindel

Fjeder

Justeringsskrue

Møtrik

O-ring

Hættemøtrik

Bolt

Skive

Brændselsventii,komplet

Skive

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./V = Qty./ValveQty./C = Qty./Cylinder.

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./V = Qty./VentilQty./C = Qty./Cylinder.

07.20 - ES0

0802

8-0D

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4.08

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MAN Diesel

Designation BenævnelseBenævnelseDesignation

Fuel Injection Valve - NICO PlatePage 2 (2)51402-03H

L23/30H

Item No.

Qty.

Qty.

Item No.

190

200

221

224

236

248

261

273

285

297

307

319

320

325

1/V

1/V

1/V

3/V

2/V

1/V

1/V

3/V

1/V

1/V

1/V

1/V

1/V

1/V

Plug screw

Gasket

Injector body

O-ring

Dowel pin

Atomizer, complete

Nozzle nut

Cap nut

Nut

Adjusting screw

O-ring

Spring

Spindle

Fuel Injection Valve, Complete

Propskrue

Pakning

Brændstofsventil

O-ring

Styrestift

Forstøver, komplet

Forstøver

Hættemøtrik

Møtrik

Justeringsskrue

O-ring

Fjeder

Spindel

Brændstofsventil, komplet

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./V = Qty./ValveQty./C = Qty./Cylinder.

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./V = Qty./VentilQty./C = Qty./Cylinder.

00.13 - EO0

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MAN Diesel

190

200

221*

224

236

248*

261

273

285

297

307

319

320

325

L23/30H

Fuel Injection Valve - NICO 51402-18HPlatePage 1 (2)

07.20 - EO0

* When ordering, please state IMO-17.03

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/H52

50/9

4.08

.12

MAN Diesel

190

200

221*

224

236

248*

261

273

285

297

307

319

320

325

L23/30H

Fuel Injection Valve - NICO 51402-19HPlatePage 1 (2)

07.20 - EO0

* When ordering, please state IMO-17.05

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Fuel Injection Valve - NICO PlatePage 2 (2)51402-19H

L23/30H

Item No.

Qty.

Qty.

Item No.

190

200

221

224

236

248

261

273

285

297

307

319

320

325

1/V

1/V

1/V

3/V

2/V

1/V

1/V

3/V

1/V

1/V

1/V

1/V

1/V

1/V

Plug screw

Gasket

Injector body, please state IMO-17.05

O-ring

Dowel pin

Atomizer, complete, please state IMO-17.05

Nozzle nut

Cap nut

Nut

Adjusting screw

O-ring

Spring

Spindle

Fuel Injection Valve, Complete

Propskrue

Pakning

Brændstofsventil, ven-ligst oplys IMO-17.05

O-ring

Styrestift

Forstøver, komplet, ven-ligst oplys IMO-17.05

Forstøver

Hættemøtrik

Møtrik

Justeringsskrue

O-ring

Fjeder

Spindel

Brændstofsventil, komplet

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./V = Qty./ValveQty./C = Qty./Cylinder.

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./V = Qty./VentilQty./C = Qty./Cylinder.

07.20 - EO0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Fuel Oil Filter Duplex 51403-03H Plate

Page 1 (2)

02.08 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

02.08 - ES0

Designation BenævnelseBenævnelseDesignation

Fuel Oil Filter Duplex PlatePage 2 (2)51403-03H

L23/30H

Item No.

Qty.

Qty.

Item No.

015

027

052

064

076

088

111

123

135

147

159

160

172

184

196

206

218

231

1/E

2/F

8/F

2/F

1/F

2/F

2/F

2/F

1/F

1/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

2/F

Fuel oil fi lter duplex,complete

Filter element,complete

Nut

O-ring

O-ring

Plug screw

Gasket

Drain cock,complete

Gasket

Fixing screw

Disc

Gasket

Counter nut

Sealing screw

Handle

Split pin

Washer

Nut

Brændselsoliespalte-fi lter, komplet

Filterelement, komplet

Møtrik

O-ring

O-ring

Propskrue

Pakning

Aftapningshane,komplet

Pakning

Fastspændingsskrue

Skive

Pakning

Omløbsmøtrik

Tætningsskrue

Håndtag

Split

Skive

Møtrik

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./Engine.Qty./F = Qty./Filter.

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./Engine.Qty./F = Qty./Filter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Fuel Injection Pipe 51404-01HPlatePage 1 (2)

94.22 - ES0S

178010

130

130

237

250

262

142

166

154

178

262

142

154

166

095

213

201

225

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.22 - ES0S

Fuel Injection Pipe PlatePage 2 (2)51404-01H

L23/30H

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

010

095

130

142

154

166

178

201

213

225

237

250

262

1/C

1/C

2/C

2/C

4/C

2/C

2/C

2/C

2/C

1/C

1/C

1/C

4/C

Fuel injection pipe, complete

Sleeve

O-ring

Flange

Screw

Sealing ring

O-ring

Sleeve in 2/2

Wire lock ring

Nut

Screwed socket

Nut

Locking washer

Højtryksrør,komplet

Styrebøsning

O-ring

Flange

Skrue

Tætningsring

O-ring

Bøsning 2-delt

Wire låsering

Møtrik

Gevindmuffe

Møtrik

Låseskive

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

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

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Fuel Oil Feed Pump 51410-01HPlatePage 1 (2)

96.20 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

96.20 - ES0S

Designation BenævnelseBenævnelseDesignation

Fuel Oil Feed Pump PlatePage 2 (2)51410-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

013

025

037

049

050

062

074

086

098

108

121

145

157

169

170

182

194

204

216

228

241

253

265

277

289

290

300

312

1/P

1/P

1/P

1/P

4/P

1/P

1/P

2/P

2/P

1/P

6/P

1/P

3/P

2/P

1/P

1/P

1/P

1/P

1/P

1/P

3/P

6/P

1/P

1/P

4/P

1/E

1/P

1/P

Housing

Cover

Gear wheel

Gear wheel

Bush

Key

Coupling, complete

Cap nut

Gasket

Rotating sealing

Screw

Plug screw

Gasket

Cylindrical pin

Cap nut

Nut

Spring housing

Plunger

Spring

Flange

Screw

Screw

Sealing ring

Cover

Screw

Pump, complete

Circlip

Cylinder

Hus

Dæksel

Tandhjul

Tandhjul

Foring

Feder

Kobling, komplet

Kapselmøtrik

Pakning

Roterende pakning

Skrue

Propskrue

Pakning

Cylindrisk stift

Kapselmøtrik

Møtrik

Fjederhus

Stempel

Fjeder

Flange

Skrue

Skrue

Tætningsring

Dæksel

Skrue

Pumpe, komplet

Sikringsring

Cylinder

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./P = Qty./Pumpe.Qty./E = Qty./Motor

When ordering spare parts, see also page 500.50.

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

MAN Diesel

PlatePage 1 (2)

07.17

Pipes on Cylinder Section 51430-01H

5L23/30H

MAN Diesel

Pipes on Cylinder Section PlatePage 2 (2)51430-01H

012

024

036

048

061

073

085

097

107

119

120

132

144

156

168

181

193

203

215

227

239

Br. oliefordelingsrør

Stikrørcylindersektion

Ligeforskruning

Br. oliereturrør

Stikrørcylindersektion

Vinkel-forskruning

Br. oliereturrør

Smøreolierør

Stikrørcylindersektion

Ligeforskruning

Ligeforskruning

Propskrue

Pakningsring

Smøreolie-fordelingsrør

Stikrørcylindersektion

Ligeforskruning

Spærreolie-fordelingsrør

Stikrørsmøreolie

Ligeforskruning

Rør forbr. olie pumpedræn

Banjo forskruning

Fuel oildistributor pipe

Branch pipecylinder section

Straight malestud coupling

Fuel oil returnpipe

Branch pipecylinder section

Screwed connection

Fuel oilreturn pipe

Lub. oil pipe

Branch pipecylinder section

Straight malestud coupling

Straight malestud coupling

Plug screwwith SRG

Packing ring

Lub. oildistribution pipe

Branch pipecylinder section

Straight malestud coupling

Sealing oildistribution pipe

Branch pipelub. oil

Straight malestud coupling

Pipe from fuelpump drain

Banjo coupling

1/E

1/C

1/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

2/C

2/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

07.17

5L23/30H

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

* = Only available as part of a spare parts kit. Qty./E = Engine Qty./C = Qty./Cylinder

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = MotorAntal/C = Antal/Cylinder

Holder

Låsefjeder

Møtrik

Beslag

Rørholder

Rørholder

Rørholder

Skrue

Skrue

Skrue

Skrue

Forskruning

Forskruning

Forskruning

Forskruning

Forskruning

Rørholder

Beslag, komplet

Clamp

Spring lock

Nut

Bracket

Pipe clamp

Pipe clamp

Pipe clamp

Hexagon screw

Hexagon screw

Hexagon screw

Hexagon screw

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Pipe clamp

Bracket, complete

240

252

264

276

288

311

323

335

347

359

360

372

384

396

406

418

431

443

1/C

2/C

2/C

1/C

1/C

2/C

1/C

1/C

2/C

2/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

MAN Diesel

PlatePage 1 (2)

07.17

Pipes on Cylinder Section 51430-15H

6L23/30H

MAN Diesel

Pipes on Cylinder Section PlatePage 2 (2)51430-15H

012

024

036

048

061

073

085

097

107

119

120

132

144

156

168

181

193

203

215

227

239

Br. oliefordelingsrør

Stikrørcylindersektion

Ligeforskruning

Br. oliereturrør

Stikrørcylindersektion

Vinkel-forskruning

Br. oliereturrør

Smøreolierør

Stikrørcylindersektion

Ligeforskruning

Ligeforskruning

Propskrue

Pakningsring

Smøreolie-fordelingsrør

Stikrørcylindersektion

Ligeforskruning

Spærreolie-fordelingsrør

Stikrørsmøreolie

Ligeforskruning

Rør forbr. olie pumpedræn

Banjo forskruning

Fuel oildistributor pipe

Branch pipecylinder section

Straight malestud coupling

Fuel oil returnpipe

Branch pipecylinder section

Screwed connection

Fuel oilreturn pipe

Lub. oil pipe

Branch pipecylinder section

Straight malestud coupling

Straight malestud coupling

Plug screwwith SRG

Packing ring

Lub. oildistribution pipe

Branch pipecylinder section

Straight malestud coupling

Sealing oildistribution pipe

Branch pipelub. oil

Straight malestud coupling

Pipe from fuelpump drain

Banjo coupling

1/E

1/C

1/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

2/C

2/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

07.17

6L23/30H

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

* = Only available as part of a spare parts kit. Qty./E = Engine Qty./C = Qty./Cylinder

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = MotorAntal/C = Antal/Cylinder

Holder

Låsefjeder

Møtrik

Beslag

Rørholder

Rørholder

Rørholder

Skrue

Skrue

Skrue

Skrue

Forskruning

Forskruning

Forskruning

Forskruning

Forskruning

Rørholder

Beslag, komplet

Clamp

Spring lock

Nut

Bracket

Pipe clamp

Pipe clamp

Pipe clamp

Hexagon screw

Hexagon screw

Hexagon screw

Hexagon screw

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Pipe clamp

Bracket, complete

240

252

264

276

288

311

323

335

347

359

360

372

384

396

406

418

431

443

1/C

2/C

2/C

1/C

1/C

2/C

1/C

1/C

2/C

2/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

MAN Diesel

PlatePage 1 (2)

07.17

Pipes on Cylinder Section 51430-16H

7L23/30H

MAN Diesel

Pipes on Cylinder Section PlatePage 2 (2)51430-16H

012

024

036

048

061

073

085

097

107

119

120

132

144

156

168

181

193

203

215

227

239

Br. oliefordelingsrør

Stikrørcylindersektion

Ligeforskruning

Br. oliereturrør

Stikrørcylindersektion

Vinkel-forskruning

Br. oliereturrør

Smøreolierør

Stikrørcylindersektion

Ligeforskruning

Ligeforskruning

Propskrue

Pakningsring

Smøreolie-fordelingsrør

Stikrørcylindersektion

Ligeforskruning

Spærreolie-fordelingsrør

Stikrørsmøreolie

Ligeforskruning

Rør forbr. olie pumpedræn

Banjo forskruning

Fuel oildistributor pipe

Branch pipecylinder section

Straight malestud coupling

Fuel oil returnpipe

Branch pipecylinder section

Screwed connection

Fuel oilreturn pipe

Lub. oil pipe

Branch pipecylinder section

Straight malestud coupling

Straight malestud coupling

Plug screwwith SRG

Packing ring

Lub. oildistribution pipe

Branch pipecylinder section

Straight malestud coupling

Sealing oildistribution pipe

Branch pipelub. oil

Straight malestud coupling

Pipe from fuelpump drain

Banjo coupling

1/E

1/C

1/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

2/C

2/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

07.17

7L23/30H

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

* = Only available as part of a spare parts kit. Qty./E = Engine Qty./C = Qty./Cylinder

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = MotorAntal/C = Antal/Cylinder

Holder

Låsefjeder

Møtrik

Beslag

Rørholder

Rørholder

Rørholder

Skrue

Skrue

Skrue

Skrue

Forskruning

Forskruning

Forskruning

Forskruning

Forskruning

Rørholder

Beslag, komplet

Clamp

Spring lock

Nut

Bracket

Pipe clamp

Pipe clamp

Pipe clamp

Hexagon screw

Hexagon screw

Hexagon screw

Hexagon screw

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Pipe clamp

Bracket, complete

240

252

264

276

288

311

323

335

347

359

360

372

384

396

406

418

431

443

1/C

2/C

2/C

1/C

1/C

2/C

1/C

1/C

2/C

2/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

MAN Diesel

PlatePage 1 (2)

07.17

Pipes on Cylinder Section 51430-17H

8L23/30H

MAN Diesel

Pipes on Cylinder Section PlatePage 2 (2)51430-17H

012

024

036

048

061

073

085

097

107

119

120

132

144

156

168

181

193

203

215

227

239

Br. oliefordelingsrør

Stikrørcylindersektion

Ligeforskruning

Br. oliereturrør

Stikrørcylindersektion

Vinkel-forskruning

Br. oliereturrør

Smøreolierør

Stikrørcylindersektion

Ligeforskruning

Ligeforskruning

Propskrue

Pakningsring

Smøreolie-fordelingsrør

Stikrørcylindersektion

Ligeforskruning

Spærreolie-fordelingsrør

Stikrørsmøreolie

Ligeforskruning

Rør forbr. olie pumpedræn

Banjo forskruning

Fuel oildistributor pipe

Branch pipecylinder section

Straight malestud coupling

Fuel oil returnpipe

Branch pipecylinder section

Screwed connection

Fuel oilreturn pipe

Lub. oil pipe

Branch pipecylinder section

Straight malestud coupling

Straight malestud coupling

Plug screwwith SRG

Packing ring

Lub. oildistribution pipe

Branch pipecylinder section

Straight malestud coupling

Sealing oildistribution pipe

Branch pipelub. oil

Straight malestud coupling

Pipe from fuelpump drain

Banjo coupling

1/E

1/C

1/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

2/C

2/C

1/E

1/C

1/C

1/E

1/C

1/C

1/C

1/C

07.17

8L23/30H

BenævnelseDesignationQty.Item No.

Item No. Qty. Designation Benævnelse

* = Only available as part of a spare parts kit. Qty./E = Engine Qty./C = Qty./Cylinder

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = MotorAntal/C = Antal/Cylinder

Holder

Låsefjeder

Møtrik

Beslag

Rørholder

Rørholder

Rørholder

Skrue

Skrue

Skrue

Skrue

Forskruning

Forskruning

Forskruning

Forskruning

Forskruning

Rørholder

Beslag, komplet

Clamp

Spring lock

Nut

Bracket

Pipe clamp

Pipe clamp

Pipe clamp

Hexagon screw

Hexagon screw

Hexagon screw

Hexagon screw

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Screwed connection

Pipe clamp

Bracket, complete

240

252

264

276

288

311

323

335

347

359

360

372

384

396

406

418

431

443

1/C

2/C

2/C

1/C

1/C

2/C

1/C

1/C

2/C

2/C

2/C

1/C

1/C

1/C

1/C

1/C

1/C

1/C

Lubricating oil system

515/615

MAN Diesel

DescriptionPage 1 (5) Internal Lubricating Oil System

L23/30H

07.47 - ES0

Fig 1 Diagram for internal lubricating oil system.

Flange connections are as standard according to DIN 2501

Pipe description for connection at the engine

DN25

DN25

DN65

DN65

DN20

DN50

DN50

DN25

Lubricating oil from separator

Lubricating oil to separator

Lubricating oil from separate fi lter

Lubricating oil to separate fi lter

Back-fl ush from full-fl ow fi lter

Oil vapour discharge*

Lubricating oil overfl ow

Lubricating oil supply

C3

C4

C7

C8

C9

C13

C15

C16

* For external pipe connection, please see section for crankcase ventilation.

General

As standard the lubricating oil system is based on wet sump lubrication.

All moving parts of the engine are lubricated with oil circulating under pressure in a closed built-on system.

The lubricating oil is furthermore used for the purpose of cooling the pistons.

The standard engine is equipped with built-on:

– Engine driven lubricating oil pump – Lubricating oil cooler – Lubricating oil thermostatic valve – Duplex full-fl ow depth fi lter – Pre-lubricating oil pump

Governordrive

Drain fromoil vapourdischarge

C13

LAL28

LAH28

TE29

TE29

TE29

TE29

TE29

PI21-22

PDAH21-22

PDT21-22

PT22

TE22

PAL22

TAH22

PSL22

LAL25

TI22

TE20

TI20

PI23

TAH20

Standard

Optionals

Cyl. 1

C3C16 C15

Lub. oil cooler

Filter

Hand wing pump

El. Driven pre-lub. oil pump

Prelub.oil inlet

TC

Centri-fugalfilter

Topiston

To pumpdrive

To main bearing

Engine drivenlub. oil pump

C4 C9

Boring incamshaft

Forced oil

To rocker arms

Tocamshaftdrive

Separate full flow filter

A

B

A When full flow filter

B 1 piece for 5-6 cyl. engines, 2 pcs. for 7-8 cyl. engines

C8C7

515.01Edition 11H

MAN Diesel

07.47 - ES0

DescriptionPage 2 (5)Internal Lubricating Oil System

L23/30H

Oil Quantities

The approximate quantities of oil necessary for a new engine, before starting up are given in the table, see "B 12 01 1 / 504.06 Lubricating Oil in Base Frame" (max. litre H3)

If there are connected external, full-fl ow fi lters etc., the quantity of oil in the external piping must also be taken into account.

Max. velocity recommendations for external lub ri ca-ting oil pipes:

– Pump suction side 1.0 - 1.5 m/s – Pump discharge side 1.5 - 2.0 m/s

Lubricating Oil Consumption

The lubricating oil consumption is 0.6 - 1.0 g/kWh, see "Specifi c Lubricating Oil Consumption - SLOC, B 12 15 0 / 504.07"

It should, however, be observed that during the run-ning in period the lubricating oil consumption may exceed the values stated.

Quality of Oil

Only HD lubricating oil (Detergent Lubricating Oil) should be used, characteristic stated in "Lubricating Oil Specifi cation B 12 15 0 / 504.01".

System Flow

The lubricating oil pump draws oil from the oil sump and presses the oil through the cooler and fi lter to the main lubricating oil pipe, from where the oil is distri buted to the individual lubricating points. From the lubricating points the oil returns by gravity to the oil sump.

The main groups of components to be lubricated are:

1 – Turbocharger

2 – Main bearings, big-end bearing etc.

3 – Camshaft drive

4 – Governor drive

5 – Rocker arms

6 – Camshaft

1) For priming and during operation, the tur bo char-ger is connected to the lubricating oil circuit of the engine, the oil serves for bearing lubrication and also for dissipation of heat.

The inlet line to the turbocharger is equipped with an orifi ce in order to adjust the oil fl ow and a non-return valve to prevent draining during stand-still.

The non-return valve has back-pressure func-tion requiring a pressure slightly above the prim-ing pres sure to open in normal fl ow direction. In this way overfl ooding of the turbocharger is prevented during stand-still periods, where the pre-lubricating pump is running.

2) Lubricating oil for the main bearings is sup-plied through holes drilled in the engine frame. From the main bearings it passes through bores in the crankshaft to the connecting rod big-end bea rings.

The connecting rods have bored channels for supply of oil from the big-end bearings to the small-end bearings, which has an inner circum-ferential groove, and a pocket for distribution of oil in the bush itself and for supply of oil to the pin bosses and the piston cooling through holes and channels in the piston pin.

From the front main bearings channels are bored in the crankshaft for lubricating of the pump drive.

3) The lubricating oil pipes, for the camshaft drive gear wheels, are equipped with nozzles which are adjusted to apply the oil at the points where the gear wheels are in mesh.

4) The lubricating oil pipe, and the gear wheels for the governor drive are adjusted to apply the oil at the points where the gear wheels are in mesh.

515.01Edition 11H

MAN Diesel

07.47 - ES0

Internal Lubricating Oil System

L23/30H

DescriptionPage 3 (5)

5) The lubricating oil to the rocker arms is led through pipes to each cylinder head. It con-tinuous through bores in the cylinder head and rocker arm to the movable parts to be lubricated at rocker arms and valve bridge. Further, lubricating oil is led to the movable parts in need of lubrication.

6) Through a bore in the frame lubricating oil is led to the fi rst camshaft bearing and through bores in the camshaft from where it is distributed to the other camshaft bearings.

Lubricating Oil Pump

The lubricating oil pump, which is of the gear wheel type, is mounted on the front end of the engine and is driven by means of the crankshaft through a cou-pling. The oil pressure is controlled by an ad just able spring- loaded relief valve built-on the oil pump.

Thermostatic Valve

The thermostatic valve is designed as a T-piece with the inlet in the cover (A) under which the thermostatic elements are located.

The outlet to the engine (by-passing cooler) is marked (B) and outlet to the cooler is marked (C). In the warming up period, the oil is by-passing the cooler. When the oil from the engine reaches the normal temperature see "Operation data & set points 500.30" a controlled amount af oil passes through the cooler.

The thermostatic elements must be replaced if the temperature during normal operation deviates es-sential from the one stated in the test report.

The valve cannot be set or adjusted, and it requires no maintenance.

Built-on Full-fl ow Depth Filter

The lubricating oil fi lter is a double fi lter which is generally used with only one fi lter chamber being in operation, the other fi lter chamber being stand-by.

If the fi lter chamber in operation needs to be servi-ced, the operation can be switched to the other fi lter chamber without any interruption in lubricating oil supply to the engine.

Servicing is generally restricted to replacing of the paper cartridges, cleaning of the radial mesh insert and inspection of sealings, the latter to be replaced if damages observed.

Each fi lter chamber is equipped with 1 or 2 replaceable paper cartridges of fi neness 10-15 microns.

In the centre of each fi lter chamber a fi lter basket (central element) is situated. This fi lter basket is acting as a safety fi lter, having a fi neness of about 60 microns.

During operation an increased pressure drop across the fi lter will be observed as dirt particles will deposit on the fi ltration surfaces of the paper cartridges and thus increase the fl ow resistance through the fi lter.

If the pressure drop across the fi lter exceeds 2.0 bar, a release valve will open and by-pass the 10-15 microns fi lter element, and the engine will run with only the 60 microns safety fi lter.

To ensure safe fi ltering of the lubricating oil, none of the by-pass valves must open during normal service and the elements should be replaced at a pressure drop across the fi lter of 1.5 bar.

515.01Edition 11H

C B

A

Fig 2 Thermostatic Valve

MAN Diesel

DescriptionPage 4 (5)Internal Lubricating Oil System

07.47 - ES0

L23/30H

Servicing is essential the exchange of the paper cartridges.

When exchanging cartridges, it is advisable to release any old oil remaining in the fi lter housing by means of the drain plug provided for this purpose, and to wipe out the housing with a cloth.

The fi lter chambers can be serviced successively du-ring operation or when the engine is at standstill.

It is essential to follow the instructions in work card 515-01.10 closely when replacing fi lter cartridges.

Filter cartridges must under no circumstances be cleaned and used again.

Pre-lubricating

As standard the engine is equipped with an electric-driven pre-lubricating pump mounted parallel to the main pump. The pump must be arranged for automatic operation, ensuring stand-still of the pre-lubricating pump when the engine is running, and running dur-ing engine stand-still in stand-by position.

Running period of the pre-lubricating pump is prefer-ably to be continuous. If intermittent running is requi-red for energy saving purpose, the timing equipment should be set for shortest possible intervals, say 2 minutes of running, 10 minures of stand-still, etc. Further, it is recommended that the pre-lubricating pump is connected to the emergency switch board thus securing that the engine is not started without pre-lubrication.

Draining of the Oil Sump

It is recommended to use the separator suction pipe for draining of the lubricating oil sump.

Crankcase Ventilation

The crankcase ventilation is not to be directly con-nected with any other piping system. It is preferable that the crankcase ventilation pipe from each engine is led independently to the open air. The outlet is to be fi tted with corrosion resistant fl ame screen separately for each engine.

However, if a manifold arrangements is used, its arrangements are to be as follows:

1) The vent pipe from each engine is to run indepently to the manifold, and be fi tted with corrosion resistant fl ame screen within the manifold.

2) The manifold is to be located as high as practi-cable so as to allow substantial length of piping separating the crankcase.

3) The manifold is to be vented to the open air, such that the vent outlet is fi tted with corrosion resistant fl ame screen, and the clear open area of the vent outlet is not less than the aggregate area of the individual crankcase vent pipes entering the manifold.

4) The manifold is to be provided with drainage arrangement.

The ventilation pipe should be designed to eliminate the risk of water condensation in the pipe fl owing back into the engine and should end in the open air:

– The connection between engine (C13) and the ventilation pipe must be fl exible.

– The ventilation pipe should be continuously inclined (min. 5 degrees).

– A continuous drain has to be installed near the engine. The drain must not be lead back to the engine.

– Dimension of the fl exible connection DN50. – Dimension of the ventilation pipe after the fl ex-

ible connection min. DN65.

Optionals

Besides the standard components, the following optionals can be built-on:

– Level switch for low/high level in oil sump (LAL/LAH 28) – Centrifugal by-pass fi lter (standard for stationary engines) – Hand wing pump Pressure differential transmitting – PDT 21-22 Lubricating oil inlet across fi lter

515.01Edition 11H

MAN Diesel

Temperature alarm high – TAH 20 Lubricating oil inlet before cooler

Pressure transmitting – PT 22 Lubricating oil inlet after cooler

Temperature element – TE 20 Lubricating oil inlet before cooler

Temperature element – TE 22 Lubricating oil inlet after cooler

Temperature element – TE 29 Lubricating oil inlet main bearings

Branches for:

– External fi ne fi lter – External full/fl ow fi lter

Branches for separator is standard.

07.47 - ES0

Internal Lubricating Oil System

L23/30H

DescriptionPage 5 (5)

515.01Edition 11H

MAN Diesel

DescriptionPage 1 (1) Lubricating Oil Cooler 515.06

Edition 01H

96.26 - ES0U-G

L23/30H

Principle of the Plate Heat Exchanger

The built-on lubricating oil cooler is a plate heat exchanger.

The plate heat exchanger consist of a number of cold pressed plates which are compressed between a frame plate (head) and the pressure plate (follow) by means of tie bolts.

The plates are made with special corrugations, which ensures turbolent fl ow and high heat transfer coffi cients.

Plates

After clamping of the plate pack, the plates - which are fi tted gaskets - ensure an effective seal between fl uids and atmosphere. In addition, intermixing of the fl uids is eliminated by a double gasket seal around the inlet ports.

Every second plate is turned through 180°. This means that the double gasket seal occurs around every second inlet to the channels between the plates.

The plate pack now forms a series of parallel fl ow channels in which the fl uids fl ow in a counter cur-rent regime.

MAN Diesel

DescriptionPage 1 (1) Centrifugal By-Pass Filter 515.15

Edition 01H

96.03 - ES0S-G

L23/30HV28/32S

C

B

D

E

F

A

D Cleaning chamber E Strainer F Drive chamber

A Cut-off valve B Top C Rotor

Fig 1. Diagram showing Principle of Operation.

Description

The centrifugal fi lter is a by-pass fi lter mounted directly at the engine base frame. The centrifugal fi lter is a supplement to the main fi lter.

During service, a part of the lubricating oil supplied from the engine driven lubricating oil pump enters the centrifugal fi lter and returns to the oil sump in the base frame.

The centrifugal fi lter relies on the centrifugal force and can therefore remove high density, sub-micron particles.

Principle of Operation

Oil enters the base of the fi lter and depresses the cut-off valve (A) which has a pre-set pressure valve. The cut-off valve is fi tted to ensure that at low pres-sure and fl ow conditions the entire oil pump output is supplied to the engine working parts. Having depressed the cut-off valve the oil travels up the centre of the spindle. Through holes at the top (B) and enters the rotor (C) at the maximum height above the stand tube. The oil completely fi lls the cleaning chamber (D) and travels through the strainer (E) into the drive chamber (F), leaving under pres sure via diametrically opposed tangential nozzles in the bottom of the rotor.

The reaction of the oil leaving the nozzles provides the driving force causing the rotor to spin about the spindle at high speed. The oil leaving the nozzles is then allowed to drain back to the sump, by gravity at atmospheric pressure.

The centrifugal force fi eld within the spinning rotor forces the contaminants to travel to the inner wall of the rotor, where they form a dense rubber-like slud ge which is easily removed.

For proper fi ltration, it is important that the rotor is always correctly balanced.

An out-of-balance condition can occur as a result of an uneven built-up of sludge or as a result of ex-cessive bearing or spindle wear.

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Safety precautions:

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

Description:

Disassembly, overhaul and assembly of lubrica-ting oil pump, engine driven.Adjusment of lub. oil pressure.

Starting position:

All pipe connections to the lub. oil pump have been disconnected, and the lub. oil pump is re-moved from the engine.

Related procedure:

Manpower:

Working time : 6-8 hoursCapacity : 1 man

Data:

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

515-01.00Edition 01H

96.26 - ES0S-G

L23/30H

Lubricating Oil Pump, Engine DrivenWorking CardPage 1 (3)

Special tools:

Plate no Item no Note

52005 273 80 - 360 Nm.

Hand tools:

Ring and open end spanner, 19 mm.Ring and open end spanner, 10 mm.Ring and open end spanner, 46 mm.(Socket spanner, 46 mm).Allen key, 8 mm, 4 mm.Plier for locking ring.Soft hammer.Big screw driver.Adjustable spanner.Puller.Silastene or similar.Hard brush.

Replacement and wearing parts:

Plate no Item no Qty/

51501 234 1/pump 51501 055 5/pump 51501 151 1/pump

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515-01.00Edition 01H Lubricating Oil Pump, Engine Driven Working Card

Page 2 (3)

Disassembly:

1) Remove the coupling part or gear wheel (1), see fi g. 2, by means of a puller or a soft hammer.

2) Remove screws (2) and dismount the cover (3).

3) Dismount the locking ring (4), screws (5) and remove the cover (6) with the overspeed device.

4) Remove the gear wheel (7 and 8).

5) Dismounting of the spring loaded adjustable by-pass valve.

Remove the cap nut (9), nut (10), spring housing (11), spring (12) and the cylinder (13). If the piston (14) cannot be pulled out from the same side, the plug screw (15) can be removed and the piston can be pressed out from this side with a screw driver or the like.

Fig. 1.

Overhaul.

6) Clean all the parts with gas oil and a hard brush, (never use a steel brush). The parts are blown clean with working air.

7) If the bearing bush is to be removed the existing bearing bush is plugged out by means of a mandrel, the bores are cleaned and new bearing bush is mounted, see fi g. 1.

Before the gear wheels (7 and 8) can be mounted the bearing bush must be adjusted with a reamer or a bearing scraper, so that the gear wheel can run easily when the pump is assembled.

8) Inspect all other parts for wear and damage, and renew, if necessary.

Fig. 2.

Assembly:

9) Mount the gear wheel (7 and 8).

Coat the sealing lip with silastene or similar and mount the cover (6) with gear wheel and locking ring (4).

10) Mount the cover (3) with gasket.

11) Mount the gear wheel or coupling part (1).

For tightening the nut for gear wheel, see page 500.40.

12) Mount the spring loaded by-pass valve, nut (10) with gasket, cap nut (9) and plug screw (15).

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Adjusting of Lub. Oil Pressure.

13) The outlet pressure of the lub. oil pump, can be adjusted by means of a adjusting screw in the by-pass valve.

Remove the cap nut (9) and loosen the nut (10).

515-01.00Edition 01H

96.26 - ES0S-G

L23/30H

Lubricating Oil Pump, Engine DrivenWorking CardPage 3 (3)

By turning the spring housing clockwise the pressure is raised and reverse the pressure is low er ed by turning the spring housing (11) anti-clock wise. When the correct pressure is reached , see page 500.30, the spring housing (11) is locked with nut (10) and fi nally the gasket and cap nut (9) are mounted.

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Safety precautions

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

Description

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

Starting position

Related procedure:

Man power:

Working time : 2-3 HoursCapacity : 1 man

Data:

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

515-01.05Edition 08

02.39 - ES0

General

Prelubricating PumpWorking CardPage 1 (3)

Special tools

Plate No Item No Note.

Hand tools

Bench vice.Spanner.Torque spanner.Plier for lock ring.Soft hammer.

Replacement and wearing parts:

Plate No Item No Qty./

See plate 51504.

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General

02.39 - ES0

515-01.05Edition 08 Prelubricating Pump Working Card

Page 2 (3)

Overhauls

Overhauls for the purpose of avoiding functional trouble are not normally necessary for the prelubri-cating pumps, when properly used, there is very little wear on the pump gear shaft.

Spare Parts

Before any overhaul is done, please note the fol-lowing:

If a pump gets unusable by wear, it must be repla-ced. Installation of spare parts cannot bring it back to normal condition.

It pays to keep extra pumps in stock or to have repairs (overhauls) carried out at our repair shop.

The shaft seal needs only to be replaced in case of leakage or after dismounting of drive shaft. The marks from the seal do not necessarily mean that the sealing is defective, but there is a risk of leakage after replacement of sealing.

We advise not to change the bearing bushes. In connectin with damages on the bearings it is normal that also the shafts and the parts in the gear box will be damaged.

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

Replacement of mechanical seal

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

2) Remove the pump from the engine base frame.

3) Separate the pump and the el-motor.

4) Remove the coupling part and key (109), see fi g. 1, from the driving gear shaft (051).

5) Tighten the pump to the fl ange. Pressure control valve (038) upwards.

6) Loosen screws (075) and take off the pressure control valve (038).

Fig 1. Prelubricating Pump

109 099 122 014 051 026 075038

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7) Take off the gear box (026), if necessary use a soft hammer for separation.

8) Remove the gear wheels from the cover (014). Dismounting is only possible by disturbing the rotor shaft seal and by breaking the bearing bush.

9) Remove the security ring (099) and take off the rotary shaft seal (122).

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

11) Gear box (026). Dismounting is only possible by damaging the shaft bush. Press out the shaft bushes.

12) Pressure control valve (038). The pressure control valve can be dismounted also without dismounting the pump.

515-01.05Edition 08

02.39 - ES0

General

Prelubricating PumpWorking CardPage 3 (3)

Mounting

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

Especially the sealing faces must be clean.

Tightening of screw pos. (075):

R25 10 Nm R35 50 Nm

In connection with the bearing bush, attention must be paid to the placement of the butt joint and the mounting depth.

The new shaft seal cannot be pressed into the pro-tection cover before exact mounting of the pump.

O-ring must be changed.

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Safety precautions:

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

Description:

Replacement of paper fi lter element(s).Cleaning of safety fi lter and fi lter housing.

Starting position:

Related procedure:

Manpower:

Working time : 2 hoursCapacity : 1 man

Data:

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

515-01.10Edition 01H

91.45 - ES0S-G

L23/30H

Lubricating Oil FilterWorking CardPage 1 (3)

Special tools:

Plate no Item no Note

Hand tools:

Ring and open end spanner, 22 mm.Ring and open end spanner, 24 mm.Ring and open end spanner, 27 mm.Adjustable spanner.

Replacement and wearing parts:

Plate no Item no Qty. /

51502 013 See plate 51502 51502 290 1/Filter.

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L23/30H

91.45 - ES0S-G

515-01.10Edition 01H Lubricating Oil Filter Working Card

Page 2 (3)

The lubricating oil fi lter is dimensioned so that each of the two fi lter parts has suffi cent capacity to treat the amount of lubricating oil delivered by the pump.

The three-way valve positioned is determining whether the left hand or the right hand fi lter chamber is in operation, and also gives the possibility of having both fi lter chambers in operation simultaneously.

The three-way valve is marked with fl ow directions and the fi gure indicates the operation modes ac cor-ding to valve positions.

4) Filter housing cap is dismantled.

5) Remove the inner safety element. Clean the element with detergent. Check that it is intact.

6) Remove the outer element(s). Filter element is of disposable type. It change always to new original fi lter.

7) Clean the fi lter housing and the cap. Be careful of not to let the oil from the dirty side to go into the clean oil channel in the middle of bottom.

5 6 5

1 2 88

4

6

7

3

1 Left hand fi lter camber 2 Right hand fi lter chamber 3 Inlet 4 Outlet 5 Vent screw 6 Three-way valve/ switch valve 7 Fill-up valve 8 Drain plug

Three-way valve positions

Left hand fi lter cam-ber in operation.

Right hand fi lter camber in opera-

tion.

Both fi lter camber in operation.

Fig 1. Three-way valve positions.

Service Procedure.

1) Turn the three-way valve, see fi g 2, into the position setting the stand-by fi lter chamber in ope-ra tion and the fi lter chamber requiring service out of operation.

2) Open the vent screw (5) on the top of the fi lter to get the pressure out of the fi lter half.

3) Open the drain plug (8) under the fi lter housing and drain off oil.

Fig 2.

8) Check the seal on the bottom of the fi lter hou-sing and in the cap. Change if needed.

9) Assemble the fi lter in opposite order.

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515-01.10Edition 01H

91.45 - ES0S-G

L23/30H

Lubricating Oil FilterWorking CardPage 3 (3)

10) Let the air valve be open and fi ll the fi lter hou-sing with oil by means of the slow fi ll-up valve (7) in position FILL, see fi g 3. This valve is inside the three-way valve and by using it, the fi lling can be made so slowly that the pressure on the other part of the fi lter does not drop too much.

11) Close the vent screw (5) after the housing is fi lled up with oil.

12) Open the three-way valve (6) and close the fi ll-up valve (7) by turning it to position CLOSED, see fi g. 3.

13) The fi lter just serviced is now ready to be set in operation.

Inspect for oil leakages in order to ascertain all sealings to be tight.

Check that pressure drop across fi lter is correct.

Clean the other side of the fi lter correspondingly.

Fill-up valve positions

Operation Changing over

Switch in normal operation position

Switch in fi ll position

Fig 3. Fill-up valve position.

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Safety precautions:

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

Description:

Inspection of thermostatic valve and replacement of elements.

Starting position:

Lubricating oil drained from engine (if neces-sary).

Related procedure:

Manpower:

Working time : 2 hoursCapacity : 1 Man

Data:

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

515-01.20Edition 01H

92.05 - ES0S-G

L23/30H

Lubricating Oil, Thermostatic ValveWorking CardPage 1 (2)

Special tools:

Plate No Item No Note

Hand tools:

Ring and open end spanner 24 mmCopaslipTools and cleaning preparation for cleaning.

Replacement and wearing parts:

Plate No Item No Qty/

51503 020 2/engine 51503 044 2 /engine 51503 093 3/engine

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L23/30H

92.05 - ES0S-G

515-01.20Edition 01H Lubricating Oil, Thermostatic Valve Working Card

Page 2 (2)

The thermostatic valve cannot be adjusted and un-der normal working conditions maintenance is not required. However, in some cases it is necessary to replace the elements in the thermostatic valve.

Replacement of elements:

1) Remove nuts (1) and washers (2), 4 or 6 pcs. See fi g 1.

2) Disconnect upper and lower part of the hou-sing.

3) Remove the assembled elements (3) and the elements O-ring sealing.

4) Remove the gaskets between the upper and lower part of the housing.

5) The upper and lower part of the housing are thoroughly cleaned inside and on the gasket sur-faces.

6) The sealing rings (4) for the elements in the housing are replaced and lubricated with a thin layer of copaslip.

7) Remount the assembled elements in the hou-sing by wriggling these somewhat over side.

8) Upper and lower part of the housing are as-sembled with a new gasket (5), the nuts (1) are mounted and tightened "cross-wise".

Note:

After inspection or replacement of the elements the lub. oil temperature is checked to ensure that the elements are working correctly.

2

1

3

5

4

1. Nut

2. Washer

3. Element

4. O-rings sealing

5. Gasket

Fig 1 Thermostatic valve

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Safety precautions:

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

Description:

Check and examination of the lubricating oil piping system.

Starting position:

Engine running.

Related procedure:

Manpower:

Working time : ½ hourCapacity : 1 man

Data:

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

515-01.90Edition 01H

92.04 - ES0U-G

L23/30H

Check of Lubricating Oil Piping SystemWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty /

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L23/30H

92.04 - ES0U-G

515-01.90Edition 01H Check of Lubricating Oil Piping System Working Card

Page 2 (2)

Checks to be carried out.

1) Examine the piping system for leaks.

2) Retighten all bolts and nuts in the piping system.

3) Move all valves and cocks in the piping system. Lubricate valve spindles with graphite or similar.

4) Blow-through drain pipes.

5) Check fl exible connections for leaks and dama-ges.

6) Check manometers and thermometers for pos-sible damages. For lubricating oil condition, see section 504.

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L23/30H

96.39 - ES0S

Working CardPage 1 (4)

515-06.00Edition 02HLubricating Oil Cooler

Safety precautions:

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

Description:

Separation, cleaning and assembling.Replacement of plates and gaskets.

Starting position:

Cooling water and lub. oil have been drained from cooler/engine. All pipes are disconnected.

Related procedure:

Manpower:

Working time : 4 hoursCapacity : 1 man

Data:

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

Special tools:

Plate No Item No Note

Hand tools:

Ring and open end spanner 10 mmRing and open end spanner 55 mmRing and open end spanner 30 mmAdjustable spanner

Replacement and wearing parts:

Plate No Item No Qty./

51506 111/279 4/cooler

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L23/30H

96.39 - ES0S

Working CardPage 2 (4)

515-06.00Edition 02H

Manual Cleaning

Clean the plates with a soft brush and a suitable detergent. In case of dense coating of scale or organic materials, the plates must be put in a bath of detergent.

Note: Never use a steel brush, metal scraper or the like.

A high-pressure cleaner can be used with care, how-ever, never with sand or other abrasives added.

Detergents

A detergent is suitable, if it will remove any coating on the plates without causing any damage to plates and gaskets.

Note: It is of great importance that decomposition of the protective fi lm on the stainless steel does not take place - the fi lm preserves the corrosion resistancy of the steel.

Do not use chlorine-containing agents such as hydrochloricacid (HCI)!

Oil and fats are removed by using a water emulsify-ing oil solvent, e.g. BP-system cleaner.

Organic and greasy coatings are removed by using sodium hydroxide (NaOH):

- max. concentration 1.5% (1.5% concentration corresponds to 3.75

l 30% NaOH per 100 l water). - max. temperature 85o C. Stone and lime/calcareous deposits are removed by using nitric acid (HNO3):

- max. concentration 1.5% (1.5% concentration corresponds to 1.75 l

62% HNO3 per 100 l water). - max. temperature 65o C.

Note: The nitric acid has an important constructive ef-fect on the protective fi lm of stainless steel.

Lubricating Oil Cooler

Introduction

Cleaning of the cooler has to take place, when the pressure drop on the oil and water side is larger than allowable and/or if the oil cannot be suffi ciently cooled.

Separation

Cooling and Pressure Relief

Before opening the plate heat exchanger, it has to be cooled down to below 40o C and be without pressure!

The cooling must not exceed 10o C per minute.The pressure drop must not exceed 10 bar per minute.

Note: If these norms are exceeded, the guarantee will cease to be valid.

Separation of Edge-clamped Frame

Upon completion of the procedure “Cooling and Pressure Relief”, separate the frame by retaining two or four diagonally placed bolts.

Note: Take care that the pressure plate does not tilt!

Loosen the bolts uniformly and diagonally (max. 10 mm at a time), then push the pressure plate towards the end support. When the pressure plate is not tight anymore, the plates can be removed.

Note: When using plate heat exchangers on board ships, the pressure plate have to be secured in order to avoid danger due to the movements of the ship.

Cleaning

The capacity and corrosion resistance of the plate heat exchangers depend on the purity of the plates. Any coating on the plates can be removed manu-ally.

0802

8-0D

/H52

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MAN Diesel

L23/30H

Lubricating Oil Cooler

96.39 - ES0S

Working CardPage 3 (4)

515-06.00Edition 02H

Replacement of Glued Gaskets

On Plate 51506 are stated gasket and glue quan-tity.

Please use a degreasing agent on the new gas-kets.

The fi rst plate after the end cover and the connector grid must have gaskets in all grooves. The gaskets are to be cut according to the existing gaskets.

Loosen the glued gaskets by heating the plate in water at 100o C. Clean the plates and remove the coatings, if any.

Cleaning of New Gaskets and Plates

New gaskets and gasket grooves of the plates are cleaned with a cloth moistened with degreasing agent. The glue surfaces must be absolutely clean - without fi nger prints etc.

Please use our cleaning fl uid, which is according to suppliers recommendations.

Alternatively, please use:

- Trichloroethylene - Chlorothene VG - Acetone - Methyl ethyl ketone - Ethylacetat

It is important that all degreasing agent has evapo-rated, before the glue is applied. This will normally take approx. 15 min. at 20o C.

Clean the new gaskets on the glue surfaces with fi ne-grain sandpaper instead of the degreasing agent supplied.

Control of Cleaning Fluid Concentrations

Sodium hydroxide (NaOH) solution is tritrated with 0.1 n hydro-chloric acid (HCI) with methyl orange or methyl red as indicator.

Nitric acid (HNO3) solution is titrated with 0.1 n sodium hydroxide (NaOH) with phenolphtalin as indicator.

The concentration of the cleaning fl uid in % can be calculated from the titration result by means of the following formula:

Concentration = b x n x m % a x 10

a : ml cleaning fl uid taken out for titrationb : ml titration fl uid used as covern : the molecular concentration of titration fl uidm : The molecular weight of the cleaning fl uid (NaOH) molecular weight 40, HNO3 molecular

weight 63)

Replacement of Plates and Gaskets

Marking

The plates are marked with material codes and refer-ence numbers at each end, plus codes for non-glue gaskets, if any, and stamped with the letter V and H at either end (Fig 1).

Looking towards the gasket side, the plate is des-ignated as a left plate, when the letter V is turning upwards - and a right plate when the letter H is turn-ing upwards. Inlets and outlets of the V-plates are taking place through the corner holes Nos 1 and 4. Inlets and outlets of the H-plates are taking place through the corner holes Nos 2 and 3.

Replacement of Plates

Before mounting a spare plate in the plate stack, please make su-re that the spare plate is identical with the defective plate.

Note: The same corner holes must be open and the letters V and H must be placed correctly.

0802

8-0D

/H52

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MAN Diesel

96.39 - ES0S

Lubricating Oil Cooler Working CardPage 4 (4)

515-06.00Edition 02H

L23/30H

Assembling

If the plates have been dismounted, they have to be correctly assembled according to the plate item numbers.

The fi xed cover has number 1 and the serial numbers for the subsequent plates and intermediate frames, if any, have the numbers 2, 3, 4, 5 etc.

The serial number are stamped in the right top corner of the plates. Further, please note that the gasket side must face the fi xed cover.

Gluing

Pliobond 25, which is a nitrile rubber glue on solvent basis (25% solids). The glue is applied with a brush in a thin layer on the backs of the gaskets and the gaskets are to dry in a clean place free of dust.

Apply a thin layer of glue on the gasket grooves of the plates and press the gaskets down into the gasket grooves.

The insertion of gaskets starts at both ends of the plate - and continues with the straight sections along the edges.

The gluing process is most easily effected by placing the gaskets and the plates on a table. After having pressed the gaskets into the grooves of a plate, it is stacked.

The plates with the gaskets are now mounted in the frame which is lightly clamped. In case of use of rubber grooves, they are assembled to the mini-mum measure stated on the engine sign plus 0.2 mm per plate.

Heat up the plate heat exchanger to 90-100o C by means of water or steam.

Please note:

- The temperature must be kept for 1½-2 hours. - The liquid pressure must be kept as low as possible.

If there is no possibility of heating the plate heat exchanger, it must be placed in a spot as warm as possible with dismounted connections.

The drying time will at 20o C be approx. 48 hours. At for instance 40o C, the drying time is reduced to approx. 24 hours.

A487G

4211H

6120

15

1 2

Fig. 1.

Fastening

Fasten the plate heat exchanger until the movable cover touches the duct spacers.

Material Code

Serial number(please state when ordering single plates)

HorV

Four last digits are the ref.

number of plate

Four last digits are the ref. number of the plate. (only on plates for non-glue gasket)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Cleaning procedure, cleaning intervals.Maintenance intervals and procedures.

Starting position:

Isolate the fi lter for lub. oil inlet

Related procedure:

Manpower:

Working time : 1 hourCapacity : 1 man

Data:

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

515-15.00Edition 01H

96.03 - ES0S

L23/30H

Centrifugal Bypass FilterWorking CardPage 1 (3)

Special tools:

Plate no Item no Note

Hand tools:

Big adjustable spanner.Tools for cleaning.

Replacement and wearing parts:

Plate no Item no Qty/

51515 398 1/Filter 51515 408 1/Filter 51515 421 1/Filter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

96.03 - ES0S

515-15.00Edition 01H Centrifugal Bypass Filter Working Card

Page 2 (3 )

Cleaning Procedure, see Plate 51515

1) Isolate the fi lter by closing the valve for lubri-cating oil inlet to the fi lter.

2) Slacken cover clamp ring (266). Unscrew cover fi xing nut and lift off cover.

3) Lift off rotor assembly having allowed oil to drain from nozzles. The rotor should be removed and replaced on the spindle with extreme care in order to ensure that the bearings are not damaged.

4) Unscrew rotor cover nut (026) and separate cover (038) from body.

Note: Failure to do so could cause an out-of-balance condition which will accelerate bearing and spindle wear.

7) Clean nozzle with brass wire. Examine top and bottom bearings in tube assembly. If damaged or worn - replace tube assembly complete. Examine O-ring (063) and renew if damaged.

8) Reassemble rotor complete and tighten top nut.

9) Examine spindle journals. If damaged or worn - replace with body assembly complete.

10) Reassemble fi lter complete checking that rotor revolves freely. Then replace fi lter body cover. Tighten cover nut and secure safety clamp. The clamp ring should be securely fi tted at all times and the fi lter should not be run without the clamp ring fi tted.

11) Open for lubricating oil.

12) With fi lter running check all joints for leakage. Check for excessive vibration.

Maintenance - Bearings and Spindle

All rotors are correctly balanced before leaving the factory. An out-of-balance condition can occur as a result of an uneven build up of sludge in the rotor or as a result of excessive bearing or spindle wear.

Dependent on the conditions, wear will eventually take place on the spindle and bearings and these should be replaced with factory fi tted assemblies only.

Fig 1 Centrifugal Bypass Filter

026

038

266

075

5) Remove stand tube (075) and clean.

6) Remove sludge from inside the rotor by means of a spatula and wipe clean. Ensure that all rotor components are throughly cleaned and free from deposits of dirt before reassembling the rotor.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Centrifugal Bypass Filter

96.03 - ES0S

L23/30H

515-15.00Edition 01H

Working CardPage 3 (3 )

To Check Bearing Clearances

This is most easily done by applying a dial gauge to the outside of the rotor opposite each bearing in turn and measuring the total play thus:

1) Apply dial gauge and measure play. 2) Turn rotor 90° and repeat measurement.

3) Re-apply dial gauge at 90° to previous position and repeat.

4) Turn rotor 90° and repeat.

The highest reading is the play in the bearing.

The maximum clearances when new are 0,08 mm at top and 0,06 mm at bottom bearing. If the clearance exceeds 0,25 mm top or 0,2 mm bottom then check the sizes of the individual components and replace as necessary.

Spindle top journal diameter 14,98 mm Min.Spindle bottom journal diameter 21,63 mm Min.Top bearing bore diameter 15,06 mm Max.Bottom bearing bore diameter 21,69 mm Max.

The spindle and body assembly and the rotor bearing tube assembly are factory assembled items and should only be replaced with complete assemblies.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) 51501-01HPlatePage 1 (2)

94.22 - ES0S

13

163234

175

234187 210

199

330

209

366

258

138

126

114

092126

151

295354

317

018

079

067

234

222

329

305

271

055

031

043

246

055

283

342080102

5-6-7L23/30H 720/750 RPML23/30H-900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) PlatePage 2 (2)51501-01H

94.22 - ES0S

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

187

199

209

210

222

234

246

258

271

283

295

305

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

Pump housing

Shaft with gearwheel, long

Shaft with gearwheel, short

Bush

Coupling

Dog

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Adjusting screw

Spring

Piston

Cylinder

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Pumpehus

Aksel med tand-hjul, lang

Aksel med tand-hjul, kort

Bøsning

Kobling

Medbringer

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Justerskrue

Fjeder

Stempel

Cylinder

Propskrue

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Styrestift

6/P

2/P

1/E

1/P

1/P

1/P

317

329

330

342

354

366

Screw

Nut

Lub. oil pump,complete

End cover

Cover

Key

Skrue

Møtrik

Smøreoliepumpe,komplet

Endedæksel

Dæksel

Feder

5-6-7L23/30H 720/750 RPML23/30H-900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) 51501-02HPlatePage 1 (2)

94.22 - ES0S

13

163234

175

234187 210

199

330

209

366

258

138

126

114

092126

151

295354

317

018

079

067

234

222

329

305

271

055

031

043

246

055

283

342080102

8L23/30H720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Central driven) PlatePage 2 (2)51501-02H

94.22 - ES0S

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

8L23/30H720/750 RPM

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

187

199

209

210

222

234

246

258

271

283

295

305

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

Pump housing

Shaft with gearwheel, long

Shaft with gearwheel, short

Bush

Coupling

Dog

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Adjusting screw

Spring

Piston

Cylinder

Plug screw

Gasket

Cylindical pin

Pin

Key

Screw

Screw

Guide pin

Pumpehus

Aksel med tand-hjul, lang

Aksel med tand-hjul, kort

Bøsning

Kobling

Medbringer

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Justerskrue

Fjeder

Stempel

Cylinder

Propskrue

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Styrestift

6/P

2/P

1/E

1/P

1/P

1/P

317

329

330

342

354

366

Screw

Nut

Lub. oil pump,complete

End cover

Cover

Key

Skrue

Møtrik

Smøreoliepumpe,komplet

Endedæksel

Dæksel

Feder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) 51501-10HPlatePage 1 (2)

07.01 - ES0

5-6L23/30H-720/750 RPM6-7-8L23/30H-900 RPM

6L23/30H-900 RPM (High Capacity)

079

067

271317

018

234

222

305055

329

043

031

330

366

055

246283

342080102

258138126114126092

151354295

401

175234

234

163

391

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) PlatePage 2 (2)51501-10H

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

5-6L23/30H-720/750 RPM6-7-8L23/30H-900 RPM

6L23/30H-900 RPM (High Capacity)

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

222

234

246

258

271

283

295

305

317

329

330

342

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

6/P

2/P

1/E

1/P

Pump housing

Shaft with gearwheel, long

Shaft with gearwheel, short

Bush

Gear wheel

Nut

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Screw

Nut

Lub. oil pump,complete

End cover

Pumpehus

Aksel med tand-hjul, lang

Aksel med tand-hjul, kort

Bøsning

Tandhjul

Møtrik

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Cylinder

Styrestift

Skrue

Møtrik

Smøreoliepumpe,komplet

Endedæksel

1/P

1/P

1/P

1/P

354

366

391

401

Cover

Key

Gasket

Piston, complete

Dæksel

Feder

Pakning

Trykregulerings-stemple, komplet

07.01 - ES0

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) 51501-11HPlatePage 1 (2)

07.01 - ES0

7-8L23/30H-720/750 RPM5-6L23/30H-720/750 RPM (High Capacity)

7-8L23/30H-900 RPM (High Capacity)

079

067

271317

018

234

222

305055

329

043

031

330

366

055

246283

342080102

258138126114126092

151354295

401

175234

234

163

391

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) PlatePage 2 (2)51501-11H

07.01 - ES0

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

7-8L23/30H-720/750 RPM5-6L23/30H-720/750 RPM (High Capacity)

7-8L23/30H-900 RPM (High Capacity)

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

222

234

246

258

271

283

295

305

317

329

330

342

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

6/P

2/P

1/E

1/P

Pump housing

Shaft with gearwheel, long

Shaft with gearwheel, short

Bush

Gear wheel

Nut

Cog wheel

Cog wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Screw

Nut

Lub. oil pump,complete

End cover

Pumpehus

Aksel med tand-hjul, lang

Aksel med tand-hjul, kort

Bøsning

Tandhjul

Møtrik

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Cylinder

Styrestift

Skrue

Møtrik

Smøreoliepumpe,komplet

Endedæksel

1/P

1/P

1/P

1/P

354

366

391

401

Cover

Key

Gasket

Piston, complete

Dæksel

Feder

Pakning

Trykregulerings- stempel, komplet

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lubricating Oil Pump (Gear driven) 51501-22HPlatePage 1 (2)

07.01 - ES0

7-8L23/30H-720/750 RPM (High Capacity)

079

067

271317

018

234

222

055

391

043

031

330

366

055

246283

342080102

258138126114126092

151354295

401

175234

234

163

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

High Capacity Lubricating Oil Pump (Gear driven) PlatePage 2 (2)51501-22H

07.01 - ES0

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

7-8L23/30H-720/750 RPM (High Capacity)

Designation BenævnelseBenævnelseDesignation

Item

No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

222

234

246

258

271

283

295

305

317

329

330

342

1/P

1/P

1/P

5/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

1/P

1/P

1/P

1/P

3/P

2/P

1/P

1/P

10/P

6/P

2/P

6/P

2/P

1/E

1/P

Pump housing

Shaft with gearwheel, long

Shaft with gearwheel, short

Bush

Gear wheel

Nut

Conical wheel

Conical wheel

Circlip

Circlip

Ball bearing

Socket

Gasket

Cap nut

Nut

Plug screw

Gasket

Cylindrical pin

Pin

Key

Screw

Screw

Guide pin

Screw

Nut

Lub. oil pump,complete

End cover

Pumpehus

Aksel med tand-hjul, lang

Aksel med tand-hjul, kort

Bøsning

Tandhjul

Møtrik

Konisk tandhjul

Konisk tandhjul

Sikringsring

Sikringsring

Kugleleje

Muffe

Pakning

Hættemøtrik

Møtrik

Propskrue

Pakning

Cylindrisk stift

Stift

Feder

Skrue

Skrue

Styrestift

Skrue

Møtrik

Smøreoliepumpe,komplet

Endedæksel

1/P

1/P

1/P

1/P

354

366

391

401

Cover

Key

Gasket

Piston, complete

Dæksel

Feder

Pakning

Trykregulerings-stempel, komplet

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Filter (Type A) 51502-07H

02.16 - ES0-G

PlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

02.16 - ES0-G

Lubricating Oil Filter (Type A) PlatePage 2 (2)51502-07H

L23/30H

Item No.

Item No. Designation BenævnelseBenævnelseDesignation

Qty.

Qty.

013

025

037+

049

050+

062

074

086+

108

121

133

145

157

169

170

182

194

204

216

228

241

277

289

290

2/F

2/F

1/F

2/F

2/F

1/F

2/F

2/F

2/F

1/F

4/F

12/F

12/F

4/F

12/F

4/F

12/F

12/F

5/F

6/F

2/F

2/F

2/F

1/F

Paper element

Safety element

Valve housing, incl.item 074 and 216

Housing, incl. O-ring

Cap, complete, incl. item 133, 348, 361, 373 and 407

Spindle, incl. item 121, 312 and 444

Thrust ring

By-pass code, incl. item 324, 336, 385, 432 and 493

Vent screw, incl. item 228 and 241

Fill-up valve

Sealing ring

Stud

Screw

Screw

Nut

Washer

Washer

Washer

Pin

Pin

Gasket

Opening guard, incl. vent screw

Drain plug

Seal kit, not shown on the front side of the plate

Papirelement

Sikkerhedselement

Ventilhus, inkl.item 074 og 216

Hus, inkl. O-ring

Dæksel , komplet, inkl. item 133, 348, 361, 373 og 407

Spindel, inkl. item 121, 312 og 444

Trykring

By-passventil, inkl. item 324, 336, 385, 432 og 493

Luftskrue, inkl. item 228 og 241

Opfyldningsventil

Tætningsring

Støttetap

Skrue

Skrue

Møtrik

Skive

Skive

Skive

Tap

Tap

Pakning

Åbningsbeskyttelses-skærm, inkl. luftskrue

Drænskrue

Pakningssæt, ikke vist på forsiden af platen

Lub. oil fi lter,complete

Smøreoliefilter, kom-plet

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./F = Qty./Filter

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/F = Antal/Filter

300 1/E

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30HV28/32S

Lubricating Oil Filter (Suppl. for Plate 51502-06H/07H) 51502-02HPlatePage 1 (2)

02.16 - ES0-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

02.16 - ES0-G

Designation BenævnelseBenævnelseDesignation

Lubricating Oil Filter (Suppl. for Plate 51502-06H/07H) PlatePage 2 (2)51502-02H

L23/30HV28/32S

Item No.

Qty.

Qty.

Item No.

312

324

336

348

361

373

385

397

407

419

420

432

444

456

468

481

493

1/F

2/F

2/F

2/F

2/F

2/F

2/F

8/F

2/F

2/F

6/F

2/F

2/F

2/F

2/F

4/F

2/F

Cap

By-pass valve seat

By-pass valve spool

Flange

Flange

Screw

By-pass valve spring

Seal

Spring

Spring

Pin

Gasket

O-ring

O-ring

O-ring

O-ring

O-ring

Dæksel

By-passventilsæde

By-passvnetilspindel

Flange

Flange

Skrue

By-passventilfjeder

Tætningsring

Fjeder

Fjeder

Stift

Pakning

O-ring

O-ring

O-ring

O-ring

O-ring

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./F = Qty./Filter

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/F = Antal/Filter

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Thermostatic Valve 51503-01HPlatePage 1 (2)

94.23 - ES0S-L

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S-L

Designation BenævnelseBenævnelseDesignation

Lubricating Oil Thermostatic Valve PlatePage 2 (2)51503-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

019

020

032

044

056

068

081

093

103

115

4/T

2/T

2/T

2/T

2/T

4/T

16/T

3/T

12/T

1/E

Screw

O-ring

Thermostaticelement

O-ring

Sleeve

Washer

Nut

Gasket

Screw

Thermostaticvalve, complete

Skrue

O-ring

Følerelement

O-ring

Bøsning

Skive

Møtrik

Pakning

Skrue

Termostatventil,komplet

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/T = Antal/Termostatsventil

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./T = Qty./Thermostatic valve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

General

Prelubricating Pump with El-Motor 51504-02HPlatePage 1 (2)

94.23 - ES0S-L

0802

8-0D

/H52

50/9

4.08

.12

94.23 - ES0S-L

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

254

266

278

291

301

313

325

337

349

350

362

374

386

398

408

421

433

445

457

469

470

482

494

504

516

528

1/P

1/P

1/P

1/P

1/P

4/P

2/P

1/P

1/P

2/P

1/P

1/E

1/P

1/P

1/P

1/P

1/P

1/P

2/P

2/P

2/P

1/P

1/E

1/E

1/E

1/E

Driving cover

Gear casing

End cover, complete, incl. item 386, 398, 408, 421, 433, 445, 457, 469 and 470

Driving gear shaft

Gear shaft

Screw

Parallel pin

Retaining ring

Parallel key

O-ring

Rotary shaft seal

Pumpe, completewithout El-motor

End cover

Piston

Spindle

Dome nut

Spring

Pipe nut

Screwed plug

Sealing ring

Sealing ring

Coupling, complete

El-motor, complete

Pre.lub oil pump,complete with el-motor

Ball bearing, rear

Ball bearing, front

Medbringerdæksel

Gearhus

Endedæksel, komplet inkl. item 386, 398, 408, 421, 433, 445, 457, 469 og 470

Drivende gearaksel

Gearaksel

Skrue

Styrestift

Sikringsring

Not

O-ring

Roterende akseltæt-ning

Pumpe, komplet uden el-motor

Endedæksel

Stempel

Spindel

Lukkemøtrik

Fjeder

Rørmøtrik

Propskrue

Tætningsring

Tætningsring

Kobling, komplet

El-motor, komplet

Forsmørepumpe,komplet med el-motor

Kugleleje, bagside

Kugleleje, forside

General

51504-02H Prelubricating Pump with El-Motor PlatePage 2 (2)

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

MAN Diesel

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

General

Prelubricating Pump with El-Motor 51504-08HPlatePage 1 (2)

02.39 - ES0

099 014 063 051 026 134122 087 110 075038109

217

229

183

195

146

158

242

254

230

230205

171

266

0802

8-0D

/H52

50/9

4.08

.12

02.39 - ES0

Designation BenævnelseBenævnelseDesignation

Prelubricating Pump with El-Motor PlatePage 2 (2)51504-08H

General

Item No.

Qty.

Qty.

Item No.

014

026

038

051

063

075

087

099

109

110

122

134

146

158

171

183

195

205

217

229

230

242

254

266

1/P

1/P

1/P

1/P

1/P

4/P

2/P

1/P

1/P

2/P

1/P

1/E

1/P

1/P

1/P

1/P

1/P

1/P

2/P

2/P

2/P

1/P

1/E

1/E

Driving cover

Gear casing

End cover, complete, incl. item 21 to 29

Driving gear shaft

Gear shaft

Screw

Parallel pin

Retaining ring

Parallel key

O-ring

Rotary shaft seal

Pump, completewithout El-motor

End cover

Piston

Spindle

Dome nut

Spring

Pipe nut

Screwed plug

Sealing ring

Sealing ring

Coupling, complete

El-motor, complete

Pre.lub. oil pump,complete with el-motor

Medbringerdæksel

Gearhus

Endedæksel, komplet inkl. item 21 til 29

Drivende gearaksel

Gearaksel

Skrue

Styrestift

Sikringsring

Not

O-ring

Roterende akseltæt-ning

Pumpe, komplet uden el-motor

Endedæksel

Stempel

Spindel

Lukkemøtrik

Fjeder

Rørmøtrik

Propskrue

Tætningsring

Tætningsring

Kobling, komplet

El-motor, komplet

Forsmørepumpe,komplet med el-motor

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

MAN Diesel

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Cooler 51506-01HPlatePage 1 (2)

07.06 - ES0S-G

027039

015016017

040

B

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

052

064065066

076077078079080081082088111123

147159

160

135

351

172173174175176177178

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.06 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Lubricating Oil Cooler PlatePage 2 (2)51506-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

015

016

017

027

039

040

052

064

065

066

076

077

078

079

080

4/K

4/K

4/K

4/K

4/K

1/K

/I

2/K

2/K

2/K

4/K

4/K

4/K

4/K

4/K

Hexagon screw5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Hexagon screw7 cyl. engine(900 rpm)

Hexagon screw8 cyl. engine(900 rpm)

Washer

Washer

Pressure plate

Gasket

Guide bar5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Guide bar7 cyl. engine(900 rpm)

Guide bar8 cyl. engine(900 rpm)

Distance piece5 cyl. engine(720/750 rpm)

Distance piece6 cyl. engine(720/750 rpm)

Distance piece7 cyl. engine(720/750 rpm)

Distance piece8 cyl. engine(720/750 rpm)

Distance piece6 cyl. engine(900 rpm)

Bolt5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Bolt7 cyl. motor(900 rpm)

Bolt8 cyl. motor (900 rpm)

Skive

Skive

Trykplade

Pakning

Styrepind5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Styrepind7 cyl. motor(900 rpm)

Styrepind8 cyl. motor (900 rpm)

Afstandsstykke5 cyl. motor(720/750 rpm)

Afstandsstykke6 cyl. motor(720/750 rpm)

Afstandsstykke7 cyl. motor(720/750 rpm)

Afstandsstykke8 cyl. motor(720/750 rpm)

Afstandsstykke6 cyl. motor(900 rpm)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel

Afstandsstykke7 cyl. motor(900 rpm)

Afstandsstykke8 cyl. motor(900 rpm)

Stativplade

Pakning

Skrue

Lim

Styrepind(for demontering)

Skrue

Smøreoliekøler,komplet

Plader5 cyl. motor(720/750 rpm)

Plates6 cyl. motor(720/750 rpm)

Plates7 cyl. motor(720/750 rpm)

Plates8 cyl. motor(720/750 rpm)

Plates6 cyl. motor(900 rpm)

Plates7 cyl. motor(900 rpm)

Plates8 cyl. motor(900 rpm)

Rensevæske

Distance piece7 cyl. engine(900 rpm)

Distance piece8 cyl. engine(900 rpm)

Frame plate

Gasket

Screw

Glue

Guide bar(for dismantling)

Screw

Lubricating oil cooler,complete

Plates5 cyl. engine(720/750 rpm)

Plates6 cyl. engine(720/750 rpm)

Plates7 cyl. engine(720/750 rpm)

Plates8 cyl. engine(720/750 rpm)

Plates6 cyl. engine(900 rpm)

Plates7 cyl. engine(900 rpm)

Plates8 cyl. engine(900 rpm)

Cleaning fl uid

4/K

4/K

1/K

4/K

2/K

1/K

2/K

32/K

1/E

/I

/I

/I

/I

/I

/I

/I

081

082

088

111

123

135

147

159

160

172

173

174

175

176

177

178

351

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Combined Lubricating Oil Cooler 51506-02HPlatePage 1 (2)

96.26 - ES0S-G

196

206

184218 321

A

B

C

Gasket, model A,mounting betweenframe plate andPlate No 2.

Gasket, model B,mounting betweenthe rest of the plates.

Gasket, model C,mounting betweenplate No 26 andNo 27.

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

All the gaskets are delivered as model C.Gasket A and B must be unreeved frommodel C.

321

321

243

255

267

279

280

302314

326

338

292

363

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

96.26 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Combined Lubricating Oil Cooler PlatePage 2 (2)51506-02H

L23/30H

Item No.

Qty.

Qty.

Item No.

184

196

206

218

321

243

255

267

279

280

292

302

314

326

338

363

4/K

4/K

4/K

1/K

/I

2/K

4/K

1/K

4/K

2/K

1/K

2/K

32/K

1/E

/I

/I

Hexagon screw

Washer

Washer

Pressure plate

GasketAll the Gaskets are de-livered as model C.Gasket A and B must be unreeved from mo-del C.

Guide bar

Distance piece

Frame plate

Gasket

Screw

Glue

Guide bar(for dismantling)

Screw

Lubricating oil cooler,complete

Plates

Cleaning fl uid

Bolt

Skive

Skive

Trykplade

PakningAlle pakningerne leve-res som model C.Pakning A og B skal skæres ud fra model C.

Styrepind

Afstandsstykke

Stativplade

Pakning

Skrue

Lim

Styrepind(for demontering)

Skrue

Smøreoliekøler,komplet

Plader

Rensevæske

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Cooler 51506-11HPlatePage 1 (2)

07.06 - ES0S-G

027039

015016017

040

B

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

052

064065066

076077078079080081082

088111123

147159

160

172173174175176177178

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.06 - ES0S-G

Designation BenævnelseBenævnelseDesignation

Lubricating Oil Cooler PlatePage 2 (2)51506-11H

L23/30H

Item No.

Qty.

Qty.

Item No.

015

016

017

027

039

040

052

064

065

066

076

077

078

079

080

4/K

4/K

4/K

4/K

4/K

1/K

/I

2/K

2/K

2/K

4/K

4/K

4/K

4/K

4/K

Hexagon screw5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Hexagon screw7 cyl. engine(900 rpm)

Hexagon screw8 cyl. engine(900 rpm)

Washer

Washer

Pressure plate

Gasket

Guide bar5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Guide bar7 cyl. engine(900 rpm)

Guide bar8 cyl. engine(900 rpm)

Distance piece5 cyl. engine(720/750 rpm)

Distance piece6 cyl. engine(720/750 rpm)

Distance piece7 cyl. engine(720/750 rpm)

Distance piece8 cyl. engine(720/750 rpm)

Distance piece6 cyl. engine(900 rpm)

Bolt5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Bolt7 cyl. motor(900 rpm)

Bolt8 cyl. motor (900 rpm)

Skive

Skive

Trykplade

Pakning

Styrepind5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Styrepind7 cyl. motor(900 rpm)

Styrepind8 cyl. motor (900 rpm)

Afstandsstykke5 cyl. motor(720/750 rpm)

Afstandsstykke6 cyl. motor(720/750 rpm)

Afstandsstykke7 cyl. motor(720/750 rpm)

Afstandsstykke8 cyl. motor(720/750 rpm)

Afstandsstykke6 cyl. motor(900 rpm)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel

Afstandsstykke7 cyl. motor(900 rpm)

Afstandsstykke8 cyl. motor(900 rpm)

Stativplade

Pakning

Skrue

Styrepind(for demontering)

Smøreoliekøler,komplet

Plader5 cyl. motor(720/750 rpm)

Plates6 cyl. motor(720/750 rpm)

Plates7 cyl. motor(720/750 rpm)

Plates8 cyl. motor(720/750 rpm)

Plates6 cyl. motor(900 rpm)

Plates7 cyl. motor(900 rpm)

Plates8 cyl. motor(900 rpm)

Distance piece7 cyl. engine(900 rpm)

Distance piece8 cyl. engine(900 rpm)

Frame plate

Gasket

Screw

Guide bar(for dismantling)

Lubricating oil cooler,complete

Plates5 cyl. engine(720/750 rpm)

Plates6 cyl. engine(720/750 rpm)

Plates7 cyl. engine(720/750 rpm)

Plates8 cyl. engine(720/750 rpm)

Plates6 cyl. engine(900 rpm)

Plates7 cyl. engine(900 rpm)

Plates8 cyl. engine(900 rpm)

4/K

4/K

1/K

4/K

2/K

2/K

1/E

/I

/I

/I

/I

/I

/I

/I

081

082

088

111

123

147

160

172

173

174

175

176

177

178

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Lubricating Oil Cooler 51506-12HPlatePage 1 (2)

07.08 - ES0

027039

015

040

B

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

052

064065066

076077078079080081082088111123

147159

160

135

351

172173174175176177178

399411

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0

Designation BenævnelseBenævnelseDesignation

Lubricating Oil Cooler PlatePage 2 (2)51506-12H

L23/30H

Item No.

Qty.

Qty.

Item No.

015

027

039

040

052

064

065

066

076

077

078

079

080

081

082

4/K

4/K

4/K

1/K

/I

2/K

2/K

2/K

4/K

4/K

4/K

4/K

4/K

4/K

4/K

Hexagon screw5-6-7-8 cyl. engine(720/750 rpm) and6-7-8 cyl. engine (900 rpm)

Washer

Washer

Pressure plate

Gasket

Guide bar5-6-7-8 cyl. engine(720/750 rpm) and6 cyl. engine (900 rpm)

Guide bar7 cyl. engine(900 rpm)

Guide bar8 cyl. engine(900 rpm)

Distance piece5 cyl. engine(720/750 rpm)

Distance piece6 cyl. engine(720/750 rpm)

Distance piece7 cyl. engine(720/750 rpm)

Distance piece8 cyl. engine(720/750 rpm)

Distance piece6 cyl. engine(900 rpm)

Distance piece7 cyl. engine(900 rpm)

Distance piece8 cyl. engine(900 rpm)

Bolt5-6-7-8 cyl. motor(720/750 rpm) og6-7-8 cyl. motor (900 rpm)

Skive

Skive

Trykplade

Pakning

Styrepind5-6-7-8 cyl. motor(720/750 rpm) og6 cyl. motor (900 rpm)

Styrepind7 cyl. motor(900 rpm)

Styrepind8 cyl. motor (900 rpm)

Afstandsstykke5 cyl. motor(720/750 rpm)

Afstandsstykke6 cyl. motor(720/750 rpm)

Afstandsstykke7 cyl. motor(720/750 rpm)

Afstandsstykke8 cyl. motor(720/750 rpm)

Afstandsstykke6 cyl. motor(900 rpm)

Afstandsstykke7 cyl. motor(900 rpm)

Afstandsstykke8 cyl. motor(900 rpm)

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel

Stativplade

Pakning

Skrue

Lim

Styrepind(for demontering)

Skrue

Smøreoliekøler,komplet

Plader5 cyl. motor(720/750 rpm)

Plates6 cyl. motor(720/750 rpm)

Plates7 cyl. motor(720/750 rpm)

Plates8 cyl. motor(720/750 rpm)

Plates6 cyl. motor(900 rpm)

Plates7 cyl. motor(900 rpm)

Plates8 cyl. motor(900 rpm)

Rensevæske

Gummipakning

Gummipakning

Frame plate

Gasket

Screw

Glue

Guide bar(for dismantling)

Screw

Lubricating oil cooler,complete

Plates5 cyl. engine(720/750 rpm)

Plates6 cyl. engine(720/750 rpm)

Plates7 cyl. engine(720/750 rpm)

Plates8 cyl. engine(720/750 rpm)

Plates6 cyl. engine(900 rpm)

Plates7 cyl. engine(900 rpm)

Plates8 cyl. engine(900 rpm)

Cleaning fl uid

Rubber linning

Rubber linning

1/K

4/K

2/K

1/K

2/K

32/K

1/E

/I

/I

/I

/I

/I

/I

/I

/I

2/K

2/K

088

111

123

135

147

159

160

172

173

174

175

176

177

178

351

399

411

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Combined Lubricating Oil Cooler 51506-13HPlatePage 1 (2)

07.08 - ES0

196

206

184

218

321

A

B

C

Gasket, model A,mounting betweenframe plate andPlate No 2.

Gasket, model B,mounting betweenthe rest of the plates.

Gasket, model C,mounting betweenplate No 26 andNo 27.

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

All the gaskets are delivered as model C.Gasket A and B must be unreeved from model C.

321

321

243244245

255256257258259260261

267

279

280

302314

326

338339340341342343344

292

363

375

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0

Designation BenævnelseBenævnelseDesignation

Combined Lubricating Oil Cooler PlatePage 2 (2)51506-13H

L23/30H

Item No.

Qty.

Qty.

Item No.

184

196

206

218

321

243

244

245

255

256

257

258

259

260

261

267

279

280

292

302

314

4/K

4/K

4/K

1/K

/I

2/K

2/K

2/K

4/K

4/K

4/K

4/K

4/K

4/K

4/K

1/K

4/K

2/K

1/K

2/K

32/K

Hexagon screw

Washer

Washer

Pressure plate

GasketAll the Gaskets are de-livered as model C.Gasket A and B must be unreeved from mo-del C.

Guide bar,720/750 rpm

Guide bar, 6-7 cyl.900 rpm

Guide bar, 8 cyl.900 rpm

Distance piece,720/750 rpm, 5 cyl.

Distance piece,720/750 rpm, 6 cyl.

Distance piece,720/750 rpm, 7 cyl.

Distance piece,720/750 rpm, 8 cyl.

Distance piece,900 rpm, 6 cyl.

Distance piece,900 rpm, 7 cyl.

Distance piece,900 rpm, 8 cyl.

Frame plate

Gasket

Screw

Glue

Guide bar(for dismantling)

Screw

Bolt

Skive

Skive

Trykplade

PakningAlle pakningerne leve-res som model C.Pakning A og B skal skæres ud fra model C.

Styrepind,720/750 rpm

Styrepind, 6-7 cyl900 rpm

Styrepind, 8 cyl900 rpm

Afstandsstykke,720/750 rpm, 5 cyl.

Afstandsstykke,720/750 rpm, 6 cyl.

Afstandsstykke,720/750 rpm, 7 cyl.

Afstandsstykke,720/750 rpm, 8 cyl.

Afstandsstykke,900 rpm, 6 cyl.

Afstandsstykke,900 rpm, 7 cyl.

Afstandsstykke,900 rpm, 8 cyl.

Stativplade

Pakning

Skrue

Lim

Styrepind(for demontering)

Skrue

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual

326

338

339

340

341

342

343

344

363

375

1/E

/I

/i

/I

/I

/I

/I

/I

/I

3/K

Lubricating oil cooler,complete

Plates, 720/750 rpm5 cyl. engine

Plates, 720/750 rpm6 cyl. engine

Plates, 720/750 rpm7 cyl. engine

Plates, 720/750 rpm8 cyl. engine

Plates, 900 rpm6 cyl. engine

Plates, 900 rpm7 cyl. engine

Plates, 900 rpm8 cyl. engine

Cleaning fl uid

Rubber linning

Smøreoliekøler,komplet

Plader, 720/750 rpm5 cyl. motor

Plader, 720/750 rpm6 cyl. motor

Plader, 720/750 rpm7 cyl. motor

Plader, 720/750 rpm8 cyl. motor

Plader, 900 rpm6 cyl. motor

Plader, 900 rpm7 cyl. motor

Plader, 900 rpm8 cyl. motor

Rensevæske

Gummipakning

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Combined Lubricating Oil Cooler 51506-14HPlatePage 1 (2)

07.08 - ES0

196

206

184

218

321

A

B

C

Gasket, model A,mounting betweenframe plate andPlate No 2.

Gasket, model B,mounting betweenthe rest of the plates.

Gasket, model C,mounting betweenplate No 26 andNo 27.

Note: When orderingplates, please statethe serial numbers ofthe plates. The serialnumbers of the platescan be found in thetop right-hand cornerof the plates. (SeeWorking Card 515-06.00)

Husk: Ved bestillingaf plader angivesserienummeret påpladen. Serienum-meret er stemplet itoppen af pladen tilhøjre. (Se arbejdskort515-06.00)

All the gaskets are delivered as model C.Gasket A and B must be unreeved from model C.

321

321

243244

255256257258259260261

267

279

280

302314

326

338339340341342343344

292

363

375387

399411

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0

Designation BenævnelseBenævnelseDesignation

Combined Lubricating Oil Cooler PlatePage 2 (2)51506-14H

L23/30H

Item No.

Qty.

Qty.

Item No.

184

196

206

218

243

244

255

256

257

258

259

260

261

267

279

280

292

302

314

321

326

4/K

4/K

4/K

1/K

2/K

2/K

4/K

4/K

4/K

4/K

4/K

4/K

4/K

1/K

4/K

2/K

1/K

2/K

32/K

/I

1/E

Hexagon screw

Washer

Washer

Pressure plate

Guide bar,720/750 rpm6 cyl., 900 rpm

Guide bar, 7-8 cyl.900 rpm

Distance piece,720/750 rpm, 5 cyl.

Distance piece,720/750 rpm, 6 cyl.

Distance piece,720/750 rpm, 7 cyl.

Distance piece,720/750 rpm, 8 cyl.

Distance piece,900 rpm, 6 cyl.

Distance piece,900 rpm, 7 cyl.

Distance piece,900 rpm, 8 cyl.

Frame plate

Gasket

Screw

Glue

Guide bar(for dismantling)

Screw

GasketAll the Gaskets are de-livered as model C.Gasket A and B must be unreeved from mo-del C.

Lubricating oil cooler,complete

Bolt

Skive

Skive

Trykplade

Styrepind,720/750 rpm6 cyl., 900 rpm

Styrepind, 7-8 cyl900 rpm

Afstandsstykke,720/750 rpm, 5 cyl.

Afstandsstykke,720/750 rpm, 6 cyl.

Afstandsstykke,720/750 rpm, 7 cyl.

Afstandsstykke,720/750 rpm, 8 cyl.

Afstandsstykke,900 rpm, 6 cyl.

Afstandsstykke,900 rpm, 7 cyl.

Afstandsstykke,900 rpm, 8 cyl.

Stativplade

Pakning

Skrue

Lim

Styrepind(for demontering)

Skrue

PakningAlle pakningerne leve-res som model C.Pakning A og B skal skæres ud fra model C.

Smøreoliekøler,komplet

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/K = Antal/KølerAntal/I = Antal/Individuel

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./K = Qty./CoolerQty./I = Qty./Individual

338

339

340

341

342

343

344

363

375

387

399

411

/I

/i

/I

/I

/I

/I

/I

/I

2/K

2/K

2/K

2/K

Plates, 720/750 rpm5 cyl. engine

Plates, 720/750 rpm6 cyl. engine

Plates, 720/750 rpm7 cyl. engine

Plates, 720/750 rpm8 cyl. engine

Plates, 900 rpm6 cyl. engine

Plates, 900 rpm7 cyl. engine

Plates, 900 rpm8 cyl. engine

Cleaning fl uid

Rubber linning

Rubber linning

Rubber linning

Rubber linning

Plader, 720/750 rpm5 cyl. motor

Plader, 720/750 rpm6 cyl. motor

Plader, 720/750 rpm7 cyl. motor

Plader, 720/750 rpm8 cyl. motor

Plader, 900 rpm6 cyl. motor

Plader, 900 rpm7 cyl. motor

Plader, 900 rpm8 cyl. motor

Rensevæske

Gummipakning

Gummipakning

Gummipakning

Gummipakning

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S

L23/30H

Centrifugal By-Pass Filter 51515-01HPlatePage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S

Centrifugal By-Pass Filter PlatePage 2 (2)51515-01H

L23/30H

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./F = Qty./Filter

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/F = Antal/Filter

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

2/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

1/F

Rotor, complete incl. item 026, 038, 063, 075, 109, 110, 171, 195 and 205

Cover nut

Rotor cover

Body

O-ring

Stand tube

Pin

Paper insert

Rotor body

Nozzle

Plug (cut off valve)

Spring (cut off valve)

Gasket (cutoff valve)

Shuttle (cutoff valve)

Bearing, completeincl. item 195 and 205

Circlip

Pin

Gasket

O-ring

Spindle

Body, complete incl. item 051, 122, 134, 146, 158, 229, 230 and 242

Cover clamp ring

Cover fi xing nut

Rotor, komplet inkl. item 026, 038, 063, 075, 109, 110, 171, 195 og 205

Dækselmøtrik

Rotordæksel

Sokkel

O-ring

Standrør

Stift

Papirindsats

Rotorsokkel

Dyse

Prop (modtryksventil)

Feder (modtryksventil)

Pakning (modtryks-ventil)

Ventilkegle (modtryks-ventil)

Lejemontering, komplet inkl. item 195 og 205

Låsering

Stift

Pakning

O-ring

Spindel

Sokkel, komplet inkl. item 051, 122, 134, 146, 158, 229, 230 og 242

Dækselspændering

Dækselmøtrik

014

026

038

051

063

075

087

099

109

110

122

134

146

158

171

195

205

229

230

242

254

266

278

291

301

313

325

337

349

350

362

374

386

398

408

421

1/F

1/F

1/F

1/F

1/E2/E

4/F

4/F

1/F

4/F

1/F

1/F

1/F

1/F

O-ring

Circlip

Cover

Body cover, complete incl. item 087, 266, 278, 291, 301 and 313

Centrifugal by-passfi lter, complete5-6 cyl.7-8 cyl.

Nut

Screw

Bracket for mounting

Screw

Gasket

Spare parts kit, incl.item 087, 278, 291 and 301

Spare parts kit, incl.item 122, 134, 146 and 158

Spare parts kit, incl. item 063, 146, 229, 230 and 291

O-ring

Låsering

Dæksel

Dæksel, komplet inkl. item 087, 266, 278, 291, 301 and 313

Centrifugal by-passfi lter, komplet5-6 cyl.7-8 cyl.

Møtrik

Skrue

Konsol for montering

Skrue

Pakning

Reservedelssæt, inkl.item 087, 278, 291 og 301

Reservedelssæt, inkl.item 122, 134, 146 og 158

Reservedelssæt, inkl. item 063, 146, 229, 230 og 291

0802

8-0E

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2)

94.20 - ES0S-G

Hand Wing Pump 51525-01H

L23/30H

019

0802

8-0E

/H52

50/9

4.08

.12

MAN Diesel

Hand Wing Pump PlatePage 2 (2)51525-01H

L23/30H

019

Item No. Benævnelse

Håndvingepumpe, komplet

Designation

Hand wing pump, complete

Qty.

1/E

Item No. DesignationQty. Benævnelse

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

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

94.20 - ES0S-G

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0

Lubricating Oil Separator 51530-04HPlatePage 1 (2)

L23/30H

053

041

065

077

089090

100

112

124

136

148

161

219

220

185

173

207

232

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.08 - ES0

Designation BenævnelseBenævnelseDesignation

Lubricating Oil Separator PlatePage 2 (2)51530-04H

L23/30H

Item No.

Qty.

Qty.

Item No.

041

053

065

077

089

090

100

112

124

136

148

161

173

185

207

219

220

232

1/F

1/F

4/F

8/F

1/F

1/F

1/F

1/F

4/F

1/F

1/F

4/F

1/F

1/F

1/F

4/F

1/E

1/F

Breather withfl ange

Gasket

Screw

Screw

Cover

Gasket

Insert for oilseparator

Housing foroil separator

Screw

Gasket

Bend

Nut

Oil trap

Union

Union

Screw

Oil separator, com-plete, incl item 077, 089, 090, 100, and 112

Gasket

Ånderør medfl ange

Pakning

Skrue

Skrue

Dæksel

Pakning

Indsats forolieudskiller

Hus forolieudskiller

Skrue

Pakning

Bøjning

Møtrik

Olielås

Forskruning

Forskruning

Skrue

Olieseparator, kompletinkl. item 077, 089, 090, 100 og 112

Pakning

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./F = Qty./Filter

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/F = Antal/Filter

Cooling water system

516/616

MAN Diesel

DescriptionPage 1 (1)

516.01Edition 01H

96.03 - ES0U-G

L23/30HV28/32S

Description

The cooling water system consists of two separate systems. The low temperature (LT) and the high temperature (HT) circuits.

Low Temperature Circuit

The low temperature circuit is used for cooling of the charge air and the lubricating oil, and the alternator if the latter is water cooled.

High Temperature Circuit

The high temperature circuit is used for cooling of the cylinder units.

Cooling water is led through a distributing pipe to the bottom of the cooling water space between the liner and the frame of each cylinder unit. The water is led out through bores in the top of the frame via the cooling water guide jacket to the bore.

Cooling Water System

MAN Diesel

Thermostatic Valve

The thermostatic valve in the high temperature cir-cuit is mainly located imediately after the outlet of the engine, but alternatively in the external cooling system near the fresh water cooler.

The cooling water enters through the cover (A) under which the thermostatic elements are located.

The number of elements depends on the size of the valve.

The outlet to the suction side of the pump is marked (B) and outlet to the cooler is marked (C).

In the warming-up period the cooling water is by-passing the cooler. When the outlet water from the cylinder heads reaches the normal temperature (75-85° C) a controlled amount of water passes through the cooler.

The thermostatic elements must be replaced if the cooling water temperature during normal operation deviates essentially from the one stated in the test report.

DescriptionPage 1 (1) Cooling Water Thermostatic Valve

L23/30HV28/32S

94.26 - ES0S-G

516.04Edition 01H

The thermostatic valve cannot be set or adjusted, and requires no maintenance.

In some plants a corresponding thermostatic valve is installed in the low temperature circuit. The ther-mostatic elements of this valve have an other tem-perature range.

C B

A

Fig. 1 Thermostatic Valve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions

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

Description

Check of cooling water system.

Starting position

Engine is running

Related procedure

Manpower

Working time : ½ hourCapacity : 1 man

Data

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

516-01.90Edition 04H

05.41 - ES0

L23/30H

Check of Cooling Water SystemWorking CardPage 1 (2)

Special tools

Plate no Item no Note

Hand tools

Replacement and wearing parts

Plate no Item no Qty/

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

05.41 - ES0

516-01.90Edition 04H Check of Cooling Water System Working Card

Page 2 (2)

Checks to be carried out

1) Examine the piping system for leaks.

2) Retighten all bolts and nuts in the piping system.

3) Move all valves and cocks in the piping system. Lubricate valve spindles with graphite or similar.

4) Check fl exible connections for leaks.

5) Check manometers and thermometers for pos-sible damages.

For check of the fresh water condition, see section 504.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions:

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

Description:

Inspection of thermostatic valve and replacement of elements.

Starting position:

Cooling water drained from engine (if neces-sary).

Related procedure:

Manpower:

Working time : 2 hoursCapacity : 1 Man

Data:

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

516-04.00Edition 01H

94.29 - ES0S-G

L23/30H

Cooling Water, Thermostatic ValveWorking CardPage 1 (2)

Special tools:

Plate No Item No Note

Hand tools:

Ring and open end spanner 24 mmCopaslipTools and cleaning preparation for cleaning.

Replacement and wearing parts:

Plate No Item No Qty/

51604 031 1/engine 51604 055 2 or 4/engine 51604 092 3/engine

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

94.29 - ES0S-G

516-04.00Edition 01H Cooling Water, Thermostatic Valve Working Card

Page 2 (2)

Replacement of elements:

1) Remove nuts (1) and washers (2), 4 or 6 pcs. See fi g. 1.

2) Disconnect upper and lower part of the hou-sing.

3) Remove the assembled elements (3) and the elements O-ring sealing.

4) Remove the gaskets between the upper and lower part of the housing.

5) The upper and lower part of the housing are thoroughly cleaned inside and on the gasket sur-faces.

6) The sealing rings (4) for the elements in the housing are replaced and lubricated with a thin layer of copaslip.

7) Remount the assembled elements in the hou-sing by wriggling these somewhat over side.

8) Upper and lower part of the housing are as-sembled with a new gasket (5), the nuts (1) are mounted and tightened "cross-wise".

Note:

After inspection or replacement of the elements the cooling water temperature is checked to ensure that the elements are working correctly.

The thermostatic valve cannot be adjusted and un-der normal working conditions maintenance is not required. However, in some cases it is necessary to replace the elements in the thermostatic valve.

2

1

3

5

4

1. Nut

2. Washer

3. Element

4. O-rings sealing

5. Gasket

Fig. 1 Thermostatic valve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

Cooling Water Thermostatic Valve 51604-01HPlatePage 1 (2)

94.23 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

94.23 - ES0S

Designation BenævnelseBenævnelseDesignation

Cooling Water Thermostatic Valve PlatePage 2 (2)51604-01H

L23/30H

Item No.

Qty.

Qty.

Item No.

018

031

043

055

067

079

080

092

102

114

4/T

2/T

2/T

2/T

2/T

4/T

16/T

3/T

12/T

1/E

Screw

O-ring

Thermostaticelement

O-ring

Sleeve

Washer

Nut

Gasket

Screw

Thermostaticvalve, complete

Skrue

O-ring

Følerelement

O-ring

Bøsning

Skive

Møtrik

Pakning

Skrue

Termostatventil,komplet

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/T = Antal/Termostatsventil

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit.Qty./E = Qty./EngineQty./T = Qty./Thermostatic valve

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

High Temperature Fresh Water Pump 51610-01HPlatePage 1 (2)

01.36 - ES0S

L23/30H720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.36 - ES0S

High Temperature Fresh Water Pump PlatePage 2 (2)51610-01H

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

When ordering spare parts, see also page 500.50.

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

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

130

142

154

166

178

191

201

213

225

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

1/P

2/P

2/P

1/P

8/P

1/E

1/E

4/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Locking washer

Self locking nut

Plug screw

Gasket

Ball valve

Screw

Fresh water pump,complete

Gasket

Screw

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul

Selvlåsende møtrik

Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder

Låseskive

Selvlåsende møtrik

Propskrue

Pakning

Kugleventil

Skrue

Ferskvandspumpe,komplet

Pakning

Skrue

L23/30H720/750 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

High Temperature Fresh Water Pump 51610-02HPlatePage 1 (2)

178

010

046

071

129

154-166

201

117

083 191 095 022 034 105 058 130

129 142

L23/30H900 RPM

93.05 - ES0S

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

93.05 - ES0S

High Temperature Fresh Water Pump PlatePage 2 (2)51610-02H

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

130

142

154

166

178

191

201

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

1/P

2/P

3/P

1/P

8/P

1/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Locking washer

Self locking nut

Plug screw

Gasket

Ball valve

Screw

Fresh water pump,complete

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul

Selvlåsende møtrik

Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder

Låseskive

Selvlåsende møtrik

Propskrue

Pakning

Kugleventil

Skrue

Ferskvandspumpe,komplet

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

When ordering spare parts, see also page 500.50.

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

L23/30H900 RPM

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Low Temperature Fresh Water Pump 51610-05HPlatePage 1 (2)

01.36 - ES0S

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.36 - ES0S

Low Temperature Fresh Water Pump PlatePage 2 (2)51610-05H

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

When ordering spare parts, see also page 500.50.

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

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

142

154

166

178

191

201

213

225

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

3/P

3/P

1/P

8/P

1/E

1/E

8/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Self locking nut

Plug screw

Gasket

Ball valve

Screw

Fresh water pump,complete

Gasket

Screw

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul

Selvlåsende møtrik

Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder

Selvlåsende møtrik

Propskrue

Pakning

Kugleventil

Skrue

Ferskvandspumpe,komplet

Pakning

Skrue

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Low Temperature Fresh Water Pump 51610-13HPlatePage 1 (2)

07.06 - ES0

L23/30H

178

010

046

071

129

154-166

201 117

213 191 095 022 034 105 058

129 142

083 225

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

07.06 - ES0

Low Temperature Fresh Water Pump PlatePage 2 (2)51610-13H

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

When ordering spare parts, see also page 500.50.

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

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

010

022

034

046

058

071

083

095

105

117

129

142

154

166

178

191

201

213

225

1/P

1/P

1/P

1/P

1/P

1/P

1/P

1/P

2/P

1/P

2/P

1/P

3/P

3/P

1/P

8/P

1/E

1/E

8/E

Pump housing

Bearing housing

Shaft

Impeller

Gear wheel

Self locking nut

Rotating sealing

Sealing ring

Ball bearing

Retaining ring

Key

Self locking nut

Plug screw

Gasket

Ball valve

Screw

Fresh water pump,complete

Gasket

Screw

Pumpehus

Lejehus

Aksel

Løbehjul

Tandhjul

Selvlåsende møtrik

Roterende pakdåse

Tætningsring

Kugleleje

Sikringsring

Feder

Selvlåsende møtrik

Propskrue

Pakning

Kugleventil

Skrue

Ferskvandspumpe,komplet

Pakning

Skrue

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Pipes on Cylinder HeadPlatePage 1 (2)

94.25 - ES0S

51625-01H

L23/30H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Pipes on Cylinder Head PlatePage 2 (2)51625-01H

L23/30H

012

024

036

048

061

073

085

097

107

119

120

132

144

Item No. Benævnelse

H.T. samlerør,5 cyl.

H.T. samlerør,6 cyl.

H.T. samlerør,7 cyl.

H.T. samlerør,8 cyl.

Pakning, oval

Skrue

Termometerstykke

Pakning, oval

Skrue

Skrue

Møtrik

Pakning, oval

Termometer

Designation

H.T. collecting pipe,5 cyl.

H.T. collecting pipe,6 cyl.

H.T. collecting pipe,7 cyl.

H.T. collecting pipe,8 cyl.

Packing, oval

Screw

Thermometer piece

Packing, oval

Screw

Screw

Nut

Packing, oval

Thermometer

Qty.

1/E

1/E

1/E

1/E

1/C

2/C

1/C

1/C

2/C

2/C

2/C

1/C

1/C

Item No. DesignationQty. Benævnelse

94.25 - ES0S

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Qty./E = Qty./MotorQty./C = Qty./Cylinder

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit. Qty./E = Qty./EngineQty./E = Qty./Cylinder

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

PlatePage 1 (2) Preheater - Fresh Water

L23/30HV28/32S

07.46 - ES0

51635-04H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Designation BenævnelseBenævnelseDesignation

Item No.

Qty.

Qty.

Item No.

353

365*

377*

389*

390*

400*

412*

424*

436*

Rør for forvarmer

Forvarmer5 L23/30H,stationær

Forvarmer6, 7 L23/30H,stationær

Forvarmer8 L23/30H,stationær

Forvarmer5 L23/30H,marine

Forvarme6, 7 L23/30H,marine

Forvarmer8 L23/30H,marine

Forvarmer12 V28/32S

Forvarmer16, 18 V28/32S

* Ved ordre oplyses spænding (V) og ef-fekt (W)

Preheater - Fresh Water

07.46 - ES0

L23/30HV28/32S

PlatePage 2 (2)51635-04H

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

1/E

Pipe for preheater

Preheater5 L23/30H,stationary

Preheater6, 7 L23/30H,stationary

Preheater8 L23/30H,stationary

Preheater5 L23/30H,marine

Preheater6, 7 L23/30H,marine

Preheater8 L23/30H,marine

Preheater12 V28/32S

Preheater16, 18 V28/32S

* At ordering please inform of voltage (V) and output (W)

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/E = Antal/MotorAntal/P = Antal/Pumpe

Specific plant information

519/619

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

The support of the individual conical mounting can be made in one of the following three ways:

1) The support between the bottom fl ange and the foundation of the conical mounting is made with a loose steel shim. This steel shim is ad-justed to an exact measurement (min. 40 mm) for each conical mounting.

Resilient Mounting of Generating Sets

On resilient mounted generating sets, the diesel engine and the generator are placed on a common rigid base frame mounted on the ship's/erection hall's foundation by means of resilient supports, type Conical.

All connections from the generating set to the ex ter nal systems should be equipped with fl exible con nec-tions, and pipes, gangway etc. must not be welded to the external part of the installation.

Resilient Support

A resilient mounting of the generating set is made with a number of conical mountings. The number and the distance between them depend on the size of the plant. These conical mountings are bolted to brackets on the base frame (see fi g 1).

The setting from unloaded to loaded condition is nor-mally between 5-11 mm for the conical mounting.

The exact setting can be found in the calculation of the conical mountings for the plant in question.

Resilient Mounting of Generating Sets

02.23 - ES1

Fig 2 Support of conicals.

L23/30H

Fig 1 Resilient mounting of generating sets.

519.03Edition 07H

DescriptionPage 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Resilient Mounting of Generating Sets DescriptionPage 2 (2)

02.23 - ES1

Adjustment of Engine and Generator on Base Frame

The resilient mounted generating set is normally delivered from the factory with engine and generator mounted on the common base frame. Eventhough engine and generator have been adjusted in the fac-tory with the generator rotor correctly placed in the stator, and the crankshaft bend of the engine (autolog) within the prescribed tolerances, it is re com men ded to make an autolog before starting up the plant.

L23/30H

2) The support can also be made by means of two steel shims, at the top a loose shim of at least 40 mm and below a shim of approx. 10 mm which are adjusted for each conical mounting and then welded to the foundation.

3) Finally, the support can be made by means of chockfast. It is recommended to use two steel shims, the top shim should be loose and have a minimum thickness of 40 mm, the bottom shim should be cast in chockfast with a thickness of at least 10 mm.

Irrespective of the method of support, it is re com men-ded to use a loose steel shim to facilitate a possible future replacement of the conical moun tings.

519.03Edition 07H

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Safety precautions

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

Description

Mounting and adjustment instruction for new GenSets, and adjustment instruction for existing plants.

Starting position

The foundation should be welded and milled off on shim surfaces.

Related procedure

Check of main beraings alignment(autolog) 510-01.00Replacement of conicals 5 1 9 -03.00

Man power

Working hours : 2 HoursCapacity : 2 Men

Data

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

Working cardPage 1 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 27H

03.50 - ES1

Special tools

Plate No Item No Note

Hand tools

Ring and open end spanner, 22 mmRing and open end spanner, 30 mmAllen key, 6 mmFeeler gauge, 1-2 mmMeasurement toolHydraulic jack (if necessary)

Spare and wearing parts

Plate No. Item No. Qty./

51903 013 1/conical mount. 51903 025 4/conical mount.

L23/30HL27/38

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30HL27/38

03.50 - ES1

Working cardPage 2 (4)Fitting Instructions for Resilient Mounting of GenSets519-03.00

Edition 27H

Mounting and Adjustment Instructions for New Generating Sets (Method 1)

Make Ready for Adjustment of Conical Ele-ments

If the conical elements have not been mounted by the factory, they must be mounted on the prepared brackets on the base frame. In case they have been mounted by the factory, please start with item number 2.

1) Fit the conical elements to the bracket on the base frame by means of four bolts screwed into the tapped holes on the top casting (5), see fi g 1.

2) Remove fi xing bolt (7), spring washer (8) and top lock ring (6) from the conical element, see fi g 1.

3) Position the four jacking bolts in the tapped holes (9) see fi g 1, in the base casting (1).

4) Position the jacking bolts with a through-going of minimum 40 mm, see fi g 2.

5) Lower the generating set until it rests completely on the foundation.

6) Check that all jacking bolts have full contact with the foundation.

7) Turn all the internal buffers (2), see fi g 1, to check that they can move freely.

If all internal buffers Then

Can move freely Let conical elements settle for 48 hours.

Cannot be moved Turn the four jacking bolts in the base casting clockwise or anticlock- wise to release the inter nal buffer.

Adjustment of Conical Elements after 48 Hours Settling

After the conical elements have been defl ected un-der static load for 48 hours, the laden height (H1) see fi g 2, should be measured and compared to the recommended laden height.

Fig 2 Conical mounting. Fig 1 Conical element

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

03.50 - ES1

L23/30HL27/38

Working cardPage 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 27H

8) Care must be taken, during levelling of the installation, to ensure that individual mountings are not overloaded. The variation in laden height should not exceed 2 mm and should ideally be less. The laden height can be measured between top and base casting at H, on two sides (see fi g 1).

Example:

Average =

If Then

Difference exceeds Level the conical ele-ment2 mm. by adjusting the jacking bolts - commencing with the conical element with the largest deviation.

Difference does not ex- The height of the steelceed 2 mm shim can be measured.

The difference between the two sides of a conical mounting should not be more than 0.6 mm.

Measuring of Steel Shim

9) Measure the steel shim on several points to obtain the highest possible accuracy during preparation.

Fabricating Steel Shim

10) Make sure that the minimum height of the steel shim is 40 mm to secure a future replacement of the conical element.

Drill the mounting holes in the steel shim according to the conical base casting dimensions.

Mounting of the Completed Steel Shim

11) Turn the internal buffer anticlockwise until it contacts the base casting to secure the laden height of each conical element.

12) Lift the generating set with crane or hydraulic jack.

13) Remove all the jacking bolts.

14) Position each completed steel shim.

15) Lower the generating set until it rests completely in itself.

16) Number each steel shim together with each conical element.

Adjustment of Internal Buffer

17) Turn the internal buffer clockwise (downwards) until it makes contact with the steel shim or foundation.

18) Turn the internal buffer anticlockwise (upwards) until it obtains contact with the base casting.

This must be four full turns.

19) Turn the internal buffer two full turns clockwise (downwards) and check with a feeler gauge between the base casting of the conical ele-ment and the steel shim that the internal buffer (2), see fi g 1, does not touch the steel shim or foundation.

20) Lock the internal buffer by remounting the top lock ring (6) and turn it to the nearest thread hole - then secure with fi xing bolt (7) and spring washer (8), see fi g 1.

Mounting of Conical Elements on the Foun-dation

21) Drill four mounting holes in the foundation for each conical element, either

a) Mark the positions of the mounting holes on the foundation through the conical element and the steel shim.

(Re)move the set completely so that the mark-ings can be reached by drilling with conventional tools.

H1 + H2 + H3 ----- HN

Number of conical elements

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

03.50 - ES1

L23/30HL27/38

Working cardPage 4 (4)Fitting Instructions for Resilient Mounting of GenSets519-03.00

Edition 27H

Place the set on its former position by aligning it with the drilled holes.

or

b) Drill the mounting holes in the foundation by means of the drilling pattern from the installa-tion drawing.

The drilling has to be done on beforehand and the set must be aligned with the foundation holes before the work starts to avoid further removal of the set.

22) Fix all the conical elements and the steel shims to the foundation with four bolts per conical.

Note! After completion of all works the buffer clear-ance must be checked, see points 17, 18, 19 and 20.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Working cardPage 1 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 28H

03.50 - ES1

Safety precautions

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

Description

Mounting and adjustment instruction for new GenSets, and adjustment instruction for existing plants.

Starting position

The foundation should be welded and milled off on shim surfaces.

Related procedure

Check of main beraings alignment(autolog) 510-01.00Replacement of conicals 5 1 9 -03.00

Man power

Working hours : 2 HoursCapacity : 2 Men

Data

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

Special tools

Plate No Item No Note

Hand tools

Ring and open end spanner, 22 mmRing and open end spanner, 30 mmAllen key, 6 mmFeeler gauge, 1-2 mmMeasurement toolHydraulic jack (if necessary)

Spare and wearing parts

Plate No. Item No. Qty./

51903 013 1/conical mount. 51903 025 4/conical mount.

L23/30HL27/38

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30HL27/38

03.50 - ES1

Working cardPage 2 (4)Fitting Instructions for Resilient Mounting of GenSets519-03.00

Edition 28H

Mounting and Adjustment Instructions for New Generating Sets (Method 2)

Make Ready for Adjustment of Conical Ele-ments

If the conical elements have not been mounted by the factory, they must be mounted on the prepared brackets on the base frame. In case they have been mounted by the factory, please start with item number 2.

1) Fit the conical elements to the bracket of the base frame by means of four bolts screwed into the tapped holes on the top casting (5), see fi g 1.

A supporting steel shim with a minimum height of 40 mm, to secure a future replacement of the conical element, complete with tapped holes for three jacking bolts and mounting holes drilled according to conical base casting dimensions, is required.

2) Remove fi xing bolt (7), spring washer (8) and top lock ring (6) from the conical element, see fi g 1.

3) Position the supporting steel shim as per fi g 2 and locate the conical element by means of dowel pins.

4) Position the three jacking bolts in the tapped holes in the supporting steel shim as per fi g 2.

Fig 2 Conical mounting.

5) Position the jacking bolts with a through-going of minimum 10 mm, see fi g 2.

6) Lower the generating set until it rests completely on the foundation.

7) Check that all jacking bolts have full contact with the foundation.

8) Turn the internal buffer (2), see fi g 1 to check that it can be moved freely.

If all internal buffers Then

Can move freely Let conical elements settle for 48 hours.

Cannot be moved Turn the three jacking freely bolts in the supporting steel shim clockwise, or anticlockwise to release the internal buffer.

Fig 1 Conical element

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

03.50 - ES1

L23/30HL27/38

Working cardPage 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 28H

Adjustment of Conical Elements after 48 Hours Settling

After the conical elements have been defl ected un-der static load for 48 hours, the laden height (H1) see fi g 2, should be measured and compared to the recommended laden height.

9) Care must be taken, during levelling of the installation, to ensure that individual mountings are not overloaded. The variation in laden height should not exceed 2 mm and should ideally be less. The laden height can be measured between top and base casting at H, on two sides (see fi g 1).

Example:

Average =

If Then

Difference exceeds Level the conical ele-ment2 mm. by adjusting the jacking bolts - commencing with the conical element with the largest deviation.

Difference does not ex- The height of the steel ceed 2 mm shim can be measured.

The difference between the two sides of a conical mounting should not be more than 0.6 mm.

Measuring of Steel Shim

10) Measure the steel shim on several points to obtain the highest possible accuracy during preparation.

Fabricating Steel Shim

11) Make sure that the minimum height of the steel shim is 10 mm.

Drill the mounting holes in the steel shim according to the mounting holes in the conical base casting and the mounting holes in the supporting steel shim.

Mounting of the Completed Steel Shim

12) Lift the generating set 1 mm totally be means of the three jacking bolts.

13) Position each completed steel shim.

14) Re-lower the generating set by means of the three jacking bolts until it rests completely in itself.

Adjustment of Internal Buffer

15) Turn the internal buffer clockwise (downwards) until it makes contact with the steel shim or foundation.

16) Turn the internal buffer anticlockwise (upwards) until it obtains contact with the base casting.

This must be four full turns.

17) Turn the internal buffer two full turns clockwise (downwards) and check with a feeler gauge between the base casting of the conical ele-ment and the steel shim that the internal buffer (2), see fi g 1, does not touch the steel shim or foundation.

18) Lock the internal buffer by remounting the top lock ring (6) and turn it to the nearest thread hole - then secure with fi xing bolt (7) and spring washer (8), see fi g 1.

Mounting of Conical Elements on the Foun-dation

19) Remove the dowel pins.

20) Drill four mounting holes in the foundation for each conical element, either

a) Mark the positions of the mounting holes on the foundation through the conical element and the steel shims.

H1 + H2 + H3 ----- HN

Number of conical elements

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

03.50 - ES1

L23/30HL27/38

Working cardPage 4 (4)Fitting Instructions for Resilient Mounting of GenSets519-03.00

Edition 28H

(Re)move the set completely so that the mark-ings can be reached by drilling with conventional tools.

Place the set on its former position by aligning it with the drilled holes.

or

b) Drill the mounting holes in the foundation by means of the drilling pattern from the installa-tion drawing.

The drilling has to be done on beforehand and the set must be aligned with the foundation holes before the work starts to avoid further removal of the set.

21) Fix all the conical elements and the supporting steel shims/steel shims to the foundation with four bolts per conical.

22) Weld the lowest steel shim of approx. 10 mm height to the foundation.

Note! After completion of all works, the buffer clear-ance must be checked, see points 15, 16, 17 and 18.

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Working cardPage 1 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 29H

03.50 - ES0

Safety precautions

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

Description

Mounting and adjustment instruction for new GenSets, and adjustment instruction for existing plants.

Starting position

The foundation should be welded and milled off on shim surfaces.

Related procedure

Check of main beraings alignment(autolog) 510-01.00Replacement of conicals 5 1 9 -03.00

Man power

Working hours : 2 HoursCapacity : 2 Men

Data

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

Special tools

Plate No Item No Note

Hand tools

Ring and open end spanner, 22 mmRing and open end spanner, 30 mmAllen key, 6 mmFeeler gauge, 1-2 mmMeasurement toolHydraulic jack (if necessary)

Spare and wearing parts

Plate No. Item No. Qty./

51903 013 1/conical mount. 51903 025 4/conical mount.

L23/30HL27/38

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Working cardPage 2 (4)Fitting Instructions for Resilient Mounting of GenSets519-03.00

Edition 29H

5) Position the jacking bolts with a through-going of minimum 10 mm plus permitted thickness, as specifi ed from the chockfast supplier, see fi g 2.

6) Lowed the generating set until it rests com-pletely on the foundation.

7) Check that all jacking bolts have full contact with the foundation.

8) Turn the internal buffer (2), see fi g 1, to check that it can be moved freely.

If all internal buffers Then

Can move freely Let conical elements settle for 48 hours.

Cannot be moved Turn the three jacking freely bolts in the supporting steel shim clockwise, or anticlockwise and slacken the four holddown bolts to release the internal buffer.

Mounting and Adjustment Instructions for New Generating Sets (Method 3)

Make Ready for Adjustment of Conical Ele-ments

If the conical elements have not been mounted by the factory, they must be mounted on the prepared brackets on the base frame. In case they have been mounted by the factory, please start with item number 2.

1) Fit the conical elements to the bracket of the base frame by means of four bolts screwed into the tapped holes on the top casting (5) see fi g 1.

A supporting steel shim with a minimum height of 40 mm, complete with tapped holes for three jacking bolts, four mounting holes and four tapped holes, drilled according to the conical base casting dimen-sion, is required see fi g 2.

2) Remove fi xing bolt (7), spring washer (8) and top lock ring (6) from the conical element, see fi g 1.

3) Position the supporting steel shim as per fi g 2 and locate the conical element by means of four hold-down bolts.

4) Position the three jacking bolts in the tapped holes in the supporting steel shim as per fi g 2.

Fig 2 Conical mounting.

Fig 1 Conical element

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Adjustment of Conical Element after 48 Hours Settling

After the conical elements have been defl ected un-der static load for 48 hours, the laden height (H1) see fi g 2, should be measured and compared to the recommended laden height.

9) Care must be taken, during levelling of the installation, to ensure that individual mountings are not overloaded. The variation in laden height should not exceed 2 mm and should ideally be less. The laden height can be measured between top and base casting at H, on two sides (see fi g 1).

Example:

Average =

If Then

Difference exceeds Level the conical ele-ment 2 mm. by adjusting the jacking bolts - commencing with the conical element with the largest deviation.

Difference does not ex- The height of the steel ceed 2 mm shim and the chockfast can be measured.

The difference between the two sides of a conical mounting should not be more than 0.6 mm.

Measuring of Steel Shim and Chockfast

10) The steel shim should be at least 10 mm high.

Check the minimum permitted thickness of chock-fast for the load and surface of this application with chockfast supplier.

03.50 - ES1

L23/30HL27/38

Working cardPage 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00

Edition 29H

Fabricating Steel Shim

Make sure that the minimum height of the steel shim is 10 mm. 11) Drill the mounting holes in the steel shim accord-

ing to the mounting holes in the conical base casting and in the supporting steel shim.

Adjustment of Internal Buffer

12) Turn the internal buffer clockwise (downwards) until it makes contact with the steel shim or foundation.

13) Turn the internal buffer anticlockwise (upwards) until it obtains contact with the base casting.

This must be four full turns.

14) Turn the internal buffer two full turns clockwise (downwards) and check with a feeler gauge between the base casting of the conical ele-ment and the steel shim that the internal buffer (2), see fi g 1, does not touch the steel shim or foundation.

15) Lock the internal buffer by remounting the top lock ring (6) and turn it to the nearest thread hole - then secure with fi xing bolt (7) and spring washer (8), see fi g 1.

Mounting of Conical Elements on the Foun-dation

16) Drill four mounting holes in the foundation for each conical element according to the sup-porting steel shim/steel shim, either

a) Mark the positions of the mounting holes on the foundation through the conical element and the shims.

(Re)move the set completely so that the mark-ings can be reached by drilling with conventional tools.

H1 + H2 + H3 ----- HN

Number of conical elements

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L23/30HL27/38

Working cardPage 4 (4)Fitting Instructions for Resilient Mounting of GenSets519-03.00

Edition 29H

Place the set on its former position by aligning it with the drilled holes.

or

b) Drill the mounting holes in the foundation by means of the drilling pattern.

The drilling has to be done on beforehand and the set must be aligned with the foundation holes before the work starts to avoid further removal of the set.

Make sure that the mounting bolts are isolated from the chockfast.

Note! After completion of all works, the buffer clear-ance must be checked, see points 12, 13, 14 and 15.

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Safety precautions:

Stopped engine Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circulation

Description:

Replacement of conicals.

Starting position:

Safety precautions.

Related procedure:

Fitting instructions for resilient mounting.

Manpower:

Working hours : xxx hoursCapacity : 2 men

Data:

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

Working cardPage 1 (2) Replacement of Conicals 519-03.05

Edition 01H

96.03 - EO0S-G

Special tools:

Plate No Item No Note

Hand tools:

Ring and open-end spanner, 22 mmRing and open-end spanner, 30 mmHydraulic jack

Spare and wearing parts:

Plate No Item No Qty/

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Replacement of Conicals

1. Loosen all conicals in one side.

2. Mount a jack under the base frame, see fi g 1.

Replacement of Conicals Working cardPage 2 (2)

519-03.05Edition 01H

96.03 - ES0S-G

L23/30H

3. Lift the GenSet until the steel shim can be removed. This will give enough space for removing damaged conical.

4. Mount the GenSet conical.

Note! Conicals should only be replaced in pairs, see fi g 2 and plate 51903.

5. Lower the GenSet again.

6. Repeat items 1-5 for the other side.

7. Adjust the conicals, see Working Card 519-03.00 "Fitting Instructions for Resilient Mounting of GenSet.

Fig 1 Removal of conicals

Fig 2 The conicals must be pairs

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Safety precautions

Stopped engine Shut-off starting air Shut-off cooling water Shut-off fuel oil Shut-off cooling oil Stopped lub. oil circulation

Description

Replacement of conicals.

Starting position

Safety precautions.

Related procedure

Fitting instructions for resilient mounting.

Manpower

Working hours : hoursCapacity : 2 men

Data

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

Working cardPage 1 (2) Replacement of Conicals 519-03.05

Edition 05H

08.17 - ES0

Special tools

Plate No Item No Note

Hand tools

Ring and open-end spanner, 22 mmRing and open-end spanner, 30 mmHydraulic jack

Spare and wearing parts

Plate No Item No Qty/

L23/30H

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Replacement of Conicals

1. Loosen all conicals in one side.

2. Mount a jack under the base frame, see fi g 1.

Replacement of Conicals Working cardPage 2 (2)

519-03.05Edition 05H

08.17 - ES0

L23/30H

3. Lift the GenSet until the steel shim can be removed. This will give enough space for removing damaged conical.

4. Mount the GenSet conical.

Note! Conicals should only be replaced in pairs, see fi g 2 and plate 51903.

5. Lower the GenSet again.

6. Repeat items 1-5 for the other side.

7. Adjust the conicals, see Working Card 519-03.00 "Fitting Instructions for Resilient Mounting of GenSet.

Fig 1 Removal of conicals

Fig 2 The conicals must be pairs

Steel shim

Foundation

Deck

Jack

One pair

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Safety precautions:

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

Description:

Control and adjustment of conicals.

Starting position:

Related procedure:

Check of crankshaft defl ection (autolog).

Manpower:

Working time : 2 hoursCapacity : 1 man

Data:

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

519-03.10Edition 01H

96.27 - EO0S-G

L23/30H

Maintenance of ConicalsWorking CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Ring and open-end spanner.Feeler gauge, 1-2 mm.Hexagon socket key 6 mm.

Replacement and wearing parts:

Plate no Item no Qty/

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2.2. Result of Clearance Check

If Then everything is OK check is completed

everything is not OK adjust conicals which do not comply with the clearance demands acc. to item 2.3. Recheck all conicals acc. to item 2.1.

everything is still not OK replace conical acc. to

Working Card 519-03.05

2.3. Adjustment of Conicals

a. Remove protective cap (No 10).

b. Remove fi xing bolt (No 9) and top locking ring (No 7). c. Turn buffer clockwise until it makes contact with the steel shim (No 1). d. Turn buffer anti-clockwise until it makes contact with the conical base casting (No 2). This must be done in four full rotations.

e. Turn buffer two full rotations clockwise. This will ensure full vertical movement for the buffer.

f. Check all conicals again.

g. Replace top locking ring, fi xing bolt and protec-tive cap etc.

Maintenance of Conicals

1. Visual Check

1.1 . What to Check

Check for oil deposits on the rubber element.Check for loose mounting bolts.Check for damage in the rubber element.

1.2. Result of Visual Check

If Then everything is OK continue to next conical

oil deposits on rubber clean rubber elementelement are observed

loose mounting bolts fasten mounting bolts

damage to conicals replace conical according to

is observed Working Card 519-03.05

2. Clearance Check

2.1 . What to Check

Check clearance on all conicals between steel shim and internal buffer through the slot in the base ca-sting of the conical (see fi g 1) with a feeler gauge of approx. 2 mm.

519-03.10Edition 01H

L23/30H

Working CardPage 2 (2)

96.27 - EO0S-G

Fig 1 Conical

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Safety precautions

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

Description

Control and adjustment of conicals.

Starting position

Related procedure

Check of crankshaft defl ection (autolog).

Manpower

Working time : 2 hoursCapacity : 1 man

Data

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

519-03.10Edition 05H

08.17 - ES0

L23/30H

Maintenance of ConicalsWorking CardPage 1 (3)

Special tools

Plate no Item no Note

Hand tools

Ring and open-end spannerFeeler gauge, 1-2 mmHexagon socket screw 12 mm

Replacement and wearing parts

Plate no Item no Qty/

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Periodical Inspection

Visual inspection

1) Inspect the rubber part visually for oil conta-mination, ozon cracking, swelling and mechanical damages.

2) Check if the installation is free to move on the mounts. No obstructions should be traceable between the mounts foundation and the suspended machinery.

Note! The rubber element should be replaced either when the rubber element is swollen due to conta-mination or cracks and tears in the surface. In case of replacement of the rubber element, attention is made to the identifi cation number and plate on the mount. When ordering spare parts allways mention the stamped numbers and type designation, to allow us to supply an identical product.

Defl ection Inspection

The resilient mounts are subjected to a constant load and present a defl ection determed by the amount of elastic deformation and permanent deformation in time (creep). This deformation is infl uenced be environmental conditions as temperature, static and dynamic load, etc. For this reason periodical inspections are necessary to be registered in the enclosed form (Annex 1), in order to evaluate the defl ection of the rubber element.

1) Check the dimensions TB1/2 in unloaded mount condition.

2) Check the dimensions TB1/2 in loaded mount condition, directly after loading the mounts.

3) Check the dimensions TB1/2 in loaded mount condition 7-10 days after installation of the mounts under the suspended machinery.

4) Check the dimensions TB1/2 in loaded mount condition after fi rst seatrial.

Maintenance of Conicals

Visual Check

Maintenance of the rubber element should be done in accordance with DIN 7716, to achieve the best possible lifetime of the rubber element.

Under normal working conditions and professional lay-out of the mounting system a lifetime expectancy of 8 to 12 years of the rubber element is realistic. The actual lifetime is infl uenced by (dynamic) load and environment.

The functional lifetime of the rubber element is de-termined by the vibration behaviour of the supported mass for which the ISO 10816-6 section 6A/B gives a good guidance.The maximum working defl ection due to nominal load, creep and thermal loads that the mount would accept is stated in the tables below for each individual type and compound. The mentioned values are to be measured at 20° C rubber temperature.

519-03.10Edition 05H

L23/30H

Working CardPage 2 (3)

08.17 - ES0

T90 45 51.5 ±0.75 mm 23.0 mm 28.5 mm

T90 50 51.5 ±0.75 mm 21.0 mm 30.5 mm

T90 55 51.5 ±0.75 mm 19.0 mm 32.5 mm

T90 60 51.5 ±0.75 mm 18.0 mm 33.5 mm

T90 65 51.5 ±0.75 mm 17.0 mm 34.5 mm

The environmental infl uences on the lifetime can be minimised by periodical visual inspection of the rub-ber part for oil contamination and damages. Any oil contamination should be cleaned with conventional mild household cleaning agents.Cleaning of the rubber element should be done in accordance with 7716, to achieve the best possible lifetime of the rubber element.

Under no circumstance the rubber element can be cleaned with solvent cleaning agents, if the direct environment of the rubber element is cleaned with these aggresive solvents, the rubber element must be cleaned afterwards with the above mentioned cleaning agent.

Rubbersurface temperature of the mounts must be within +70° C / -20° C.

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08.17 - ES0

L23/30H

Maintenance of ConicalsWorking CardPage 3 (3)

5) Check the dimensions TB1/2 in loaded con-dition periodically together with the clearance of the internal limiter. This should be integrated in the normal maintenance schedules of the suspended machinery. Re-adjustment of the clearance according to the installation instructions.

Note! The resilient mount has to be replaced if the values measured at TB1/2 are out of the limits as set in the maintenance instructions. In case of replace-ment of the rubber element, attention is made to the identifi cation number and plate on the mount. When ordering spare parts allways mention the stamped numbers and type designation, to allow us to supply an identical product.

Clearance Check

a) Now the central buffer clearance can be set. Fit the 12 mm hexagon socket screw to screw pos no (8) and turn it up (anticlockwise) until the greater torque, max. torque = 50 Nm, is felt. From the position the central buffer assembly must be turned down (clockwise) 2 revolutions. It is adviced to mark the position of screw pos no (8) relative to top casting pos no (2) prior to turning it down.

b) Check if the bolt ends pos no (6) do not protude from lock ring pos no (7), correct if necessary.

c) Fit lock ring pos no (7) to screw pos no (8) and turn it clockwise until it is in conntact with top casting pos no (2).

d) Correct the position of screw pos no (8) if necessary,

e) Tighten the bolts pos no (6) in 2 steps:

at fi rst handtight starting at a bolt, the next bolt to tighten is the direct opposite one, then the third bolts is found in clockwise direction from the last, repeating the same sequence until all bolts are handtight.

Then tighten the bolts in the same sequence with a torque prescribed in the below table.

f) Fit pos no (9) to the mount, we advice to use water resistant grease to the contact faces.

g) Insert the foundation bolts though the 4 holes in the base casting and foundation, use bolt material quality 8.8 or higher, tightening torques as per below table.

Note! The rubber element must not be painted, if painted is carried out on the supported machinery, the rubber element must be shielded from the paint.

Tightening torque

T90 M20-8.8, 400 Nm

Tightening torque

T90 M8-8.8, 24 Nm

4 1

3

5

2

8

7

69

1 Base casting 2 Top casting 3 Element 4 Central buffer 5 Rubber bushing

6 Cylinder head bolt 7 Lock ring 8 Hex. socket set screw 9 Cap

MAN Diesel

Item NoDesignationFigure Connection

96.03 - ES0S-G

A3

A7

A8

C3

C4

C9

C11

C12

C15

C16

F3

F5

F6

F7

F15

K1

K2

A1

A2

PlatePage 1 (2) Flexible External Connections 51902-01H

L23/30H

018

031

043

055

067

079

080

092

102

114

126

138

151

163

175

187

199

209

210

Waste oil, outlet

Nozzle cooling oil, inlet

Nozzle cooling oil, outlet

Lubricating oil from separator, inlet

Lubricating oil to separator, outlet

Back fl ush from full-fl ow fi lter, inlet

Lub. oil from by pass fi lter, inlet

Lub. oil to by pass fi lter, outlet

Lub. oil overfl ow

Lub. oil supply, inlet

Venting to expansion tank

HT fresh water from preheater, inlet

HT fresh water to preheater, outlet

Fresh water for fi lling/draining

Inlet from expansion tank

Compressed air, inlet

Control air, inlet

Fuel oil, inlet

Fuel oil, outlet

MAN Diesel

Item NoDesignationFigure Connection

Flexible External Connections51902-01H PlatePage 2 (2)

C13

C7

C8

F1

F2

G1

G2

G3

G4

222

234

246

258

271

283

295

305

317

Oil vapour discharge, outlet

Lubricating oil from full-fl ow fi lter, inlet

Lubricating oil to full-fl ow fi lter, outlet

HT fresh water, inlet

HT fresh water, outlet

LT fresh water/raw water,inlet

LT fresh water/raw water, outlet

Seawater, Inlet

Seawater, outlet

96.03 - ES0S-G

L23/30H

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96.03 - EO0S-G

L23/30H

51903-01H

Conical Element

Note! When ordering be aware that conical elements always should be replaced in pairs. State manufac-turing No of existing conical elements.

Bemærk! Ved bestilling af conicals elementer skalconicals elementer altid udskiftes parvis. Opgiv fabri-kationsnr. på eksisterende conicals elementer.

PlatePage 1 (2)

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L23/30H

96.03 - EO0S-G

51903-01H

PlatePage 2 (2)Conical Element

Item No Qty Designation Benævnelse

Screw

Washer

Conical element

Adjusting screw

Protecting cap

Fixing ring

013

025

037

049

050

062

4/M

4/M

1/M

4/M

1/M

1/M

Skrue

Skive

Konisk understøtning

Justerskrue

Beskyttelseskapsel

Fiksering ring

Item No Qty Designation Benævnelse

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/M = Antal/Conical montering.

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07.10 - EO0

General

51903-06H

Conical Element

Note! When ordering be aware that conical elements always should be replaced in pairs. State manufac-turing No of existing conical elements.

Bemærk! Ved bestilling af conicals elementer skal conicals elementer altid udskiftes parvis. Opgiv fabri-kationsnr. på eksisterende conicals elementer.

PlatePage 1 (2)

info@vulkan-dmr.itVULKAN-DMR

MANUF.DATE:

ID.NUMBER:

TYPE:

R

VULKAN

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General

07.10 - EO0

51903-06H

PlatePage 2 (2)Conical Element

Item No Qty Designation Benævnelse

Screw

Washer

Conical element

Adjusting screw

Protecting cap

Fixing ring

013

025

037

049

050

062

4/M

4/M

1/M

4/M

1/M

1/M

Skrue

Skive

Konisk understøtning

Justerskrue

Beskyttelseskapsel

Fiksering ring

Item No Qty Designation Benævnelse

When ordering spare parts, see also page 500.50.

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

Ved bestilling af reservedele, se også side 500.50.

* = Kun tilgængelig som en del af et reservedelssæt.Antal/M = Antal/Conical montering.

Tools

520/620

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DescriptionPage 1 (1)

520.01Edition 01H

96.03 - ES0

Introduction to Spare Part Plates for Tools

L23/30HV28/32S

However, some tools such as torque spanners, hy-draulic tools etc. may also have other applications. Information about the exact use of the tools appears from the relevant sections in the instruction book.

Note: The table on the spare part plates is marked with an S or an E. An S means that the tools are supplied when ordering Standard tools and an E means that the tools are supplied when ordering Extra tools, i.e. Tools for Reconditioning (extra tools are not standard delivery)

The contents of these spare part plates with tools are a summary of STANDARD TOOLS for normal maintenance and EXTRA TOOLS for reconditioning, which can be supplied by MAN B&W Diesel A/S, Holeby. Thus, the list comprises the total extent of tools available for this engine type.

For each specifi c plant the amount of tools delivered depends of the contractual specifi cations.

The tools listed are assembled in sections corres-ponding to the chapters of the instruction book.

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Safety precautions

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

Description

Safety hints and function of hydraulic tools.

Starting position

Application of hydraulic tools 520-01.06

Related procedure

Manpower

Working time : hoursCapacity : men

Data

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

520-01.05Edition 02

99.43 - ES0

General

Function of the Hydraulic ToolsWorking CardPage 1 (7)

Special tools

Plate no Item no Note

Hand tools

Replacement and wearing parts

Plate no Item no Qty/

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Function of the Bolt Tensioning Device

In order to achieve an optimal result with one or several devices, some rules have to be considered. We expressly point out that a conscientious handling of the device as well as the accessories is of high-est importance. To ignore these rules or separate hints means danger to life or danger of injuries! See Safety Hints.

Safety Hints

Beside regarding the general accident-prevention rules, the safe handling of the device and the hydraulic accessories demand especially the consideration of the following hints. When disregarding even single items, you can cause danger to life and/or danger of injuries!

1. When leakages occur during the pressuriza-tion, bleed pressure immediately and seal the leakage or replace defect parts.

2. In case of repair, use exclusively original spare parts. Inexpert substitution of damaged parts by non-original spare parts is prohibited.

3. All assembly parts are to be handled in corre-spondence to the working cards only. A change in the procedure or another operation of the device is not allowed.

4. Make sure that the components to be tensioned do not exceed the admissible strain.

5. In order to use the device, the thread has to be suffi ciently exceeding in order to avoid that the turn of a thread cracks, see item 4.

6. During the pressurization the people involved have to remain in an appropriate distance. Staying in direction towards the bolt axis is forbidden.

7. Tensioning pressures or tensioning forces are to be given or changed by authorized personnel only while considering the admissible compo-nent loads, see item 4.

8. The operation and handling of the device are to be carried out by expert staff only.

9. The given max. operation pressure is not to be exceeded in any case and is to be watched at the manometer of the pressure generator during the complete tensioning or loosening procedure. When having achieved the given pressure, stop the pressurization immedi-ately.

10. During the pressurization when tensioning or

loosening the bolt connection, always watch the admissible stroke of the device. Exceed-ing this stroke is connected with insuffi cient generating of tensioning force because the device is tensioned in itselve or the hydraulic pressure is bleeded automaticly.

11. On principle, when connecting high-pressure hoses it has to be taken care that the connec-tions are correct (see also separate hints).

12. The hydraulic hoses have to be installed in a way that they are not run over by vehicles or unnecessarily walked over by people. Never lay hoses across sharp objects (danger of cuts) and never bend or jam them in.

13. Never hold or transport the device by using the high-pressure hoses.

14. An incorrect working manometer that doesn´t show the right pressure leads to overstressing of the parts and to an incorrect bolt connec-tion. Apart from damaged parts an incorrect bolt connection can also cause conditions that are danger to life. Therefore take care that the manometer shows the right value or the tensioning force is checked in an other way (for example by using a master manometer). Tensioning forces can be checked for example by measuring the linear deformation. Damaged manometers have to be exchanged immedi-ately.

General

99.43 - ES0

520-01.05Edition 02 Function of the Hydraulic Tools Working Card

Page 2 (7)

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Working Hints

In order to achieve a bolt connection of high precision, it is vital to consider the following working hints:

- Prior to setting the device, clean all threads and remove possible damages in order to avoide a “freeze on”.

- The base plate for the device must be plain and free of dirt. Further check the square ness towards the bolt axis in order to avoid that the bolt has a bending stress during the pressuri-zation (tensioning).

- The stroke of the device may not at any point be exceeded.

- For transporting the device it is necessary to uncouple all high-pressure hoses.

- After each pressurization, bring the device back to zero, see also Piston Return Stroke.

Turnable Connection Unit

In order to simplify the connection of the hydraulic hose, a turnable connection unit is mounted on some devices.The turnable connection unit consists of the follow-ing components:

- bolt nipple - disc - seal - securing ring

Furthermore, an entry guide is available or contained in the scope of supply, see fi g.1.

Exchange of the Seals

Should leakages show up at the connection unit, it might be necessary to exchange the seals.For doing so, loosen the securing ring and take the disc off the bolt nipple. Having removed the seals, clean the components with fl uff-free cleaning material. You can also apply compressed air. Having checked the components for damages and oiled them slightly, apply new seals by help of the entry guide and reas-semble the turnable connection unit.

Hint: - For the cleaning, never use aggressive cleaning liquids.

- For oiling the parts, use exclusively hydraulic oil.

- For replacements, use exclusively new seals.

Coupling of the High-Pressure Hoses

- Only couple when the hydraulic system is in a pressureless condition.

- To produce a high-pressure connection, put one coupling and one nipple into each other while the coupling socket is pulled back. When letting the coupling socket go, there is a form fi t barring the connection.

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Function of the Hydraulic ToolsWorking Card

Page 3 (7)

Fig. 1. Turnable connection unit.

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- By drawing the hose with a manual force of about 100 N make sure that the connection is correctly barred.

- For decoupling the high-pressure hose in a pressureless condition, fi rst pull back the coupling socket and then take off the hose.

that the max. admissible stroke of the device is not exceeded. Beside that, it has to be ensured that the cylinder and the support sleeve remain centrically towards each other (consider centering shoulder).

Having made all hydraulic connections correctly, see fi g. 2, start the pressurization for the tensioning procedure. If the necessary pressure is achieved stop pressurization. The inducted force causes the bolt to extend or an edging of the components to be tensioned so that the main nut is lifted from the fl ange. Screw it back to the fl ange, see fi g. 3. Check by help of a feeler gauge leaf whether the main nut really fi ts tight to the fl ange. After that, bleed hydraulic pressure. Now the connection is tensioned.

Having brought the piston to its zero position, see fi g. 4, the hydraulic hoses can be decoupled. In order to prevent impurities, it is advisable to close coupling sockets and coupling nipples at once by protecting caps. The device can be unscrewed from the bolt.

● Always consider the safety and working hints!

Loosening Procedure

In order to loosen an existing bolt connection, screw the device onto the bolt. First put the support sleeve on the bolt and align it centrically to the bolt axis. When screwing on the device take care that the support sleeve at the cylinder is correctly centered (consider centering shoulder).

The piston of the device must be at its zero position. Having screwed the device down until the support sleeve or the support cylinder fi ts tight to the fl ange, turn back the device by at least the value (slit meas-ure) which the bolt and the components spring back elastically during the loosening procedure.

Hint: The adjusted slit measure may never exceed the admissible stroke of the device! Furthermore, take care that the window for the adjusting rod are well accessible.Having made all hydraulic connections correctly, see fi g. 2, start the pressurization.

General

99.43 - ES0

520-01.05Edition 02 Function of the Hydraulic Tools Working Card

Page 4 (7)

Hoses with fast-lock coupling sockets avoid, also when uncoupled, that oil runs out. When the hoses get heated, there can be an inside pressure in the uncoupled condition making a coupling impossible. By loosening one screw connection (see fi g. 2) the pressure can be bleeded

- To avoid a contamination use protecting caps for the sockets.

Tensioning Procedure

Prior to the tensioning procedure make sure that the components to be tensioned are correctly posi-tioned towards each other. Then screw the device onto the bolt.

First put the support sleeve on the bolt and align it centrically to the bolt axis. When screwing on the de-vice take care that the support sleeve at the cylinder is correctly centered (consider centering shoulder).

Screw the device until the support sleeve or the sup-port cylinder fi ts exactly to the fl ange. The piston of the device must be at its zero position. Furthermore, take care that the hydraulic connector and the window for the adjusting rod is well accessible. If necessary, turn back the device, but make sure

Fig. 2. Coupling of the high-pressure hoses.

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During the pressurization, a slight turn-back momen-tum is applied to the main nut with the adjusting rod. At the moment, when the main nut can be loosened, interrupt the pressurization. Should it not be possible to loosen the main nut when achieving the original tensioning pressure, interrupt the pressurization im-mediately. Find the cause with expert staff.

Having achieved the loosening pressure, turn back the main nut by the value that the bolt and the com-ponents spring back during the loosening procedure. The slit measure, however, must be lower than the slit measure adjusted at the device before, see also hint b.

The main nut may never be turned back until it fi ts to the piston or the cylinder since then the device can be tensioned in itself.

Having turned back the main nut, the pressure can be bled. The bolt connection is loosened. Before unscrewing the device, bring the piston back to its zero position, see fi g. 4. After that, the hydraulic hoses can be decoupled. In order to prevent impurities, it is advisable to close coupling sockets and coupling nipples at once by protecting caps. The device can be unscrewed from the bolt.

● Make sure that no operational forces (e.g. inner pressure) affect the components to be loosened since only part of the bolts take over these forces and thus the bolts, which are not yet loosened, might be overburdened.

● The pressure when the main nut can be loos-ened may never exceed the tensioning pressure by help of which the connection was tensioned! Should it not be possible to loosen the main nut when reaching the original tensioning pressure interrupt the pressurization immediately. Find the cause with expert staff.

● Always consider the safety and working hints!

Hint:

a) Should it be impossible to unscrew the device after the depressurization, it has been turned back by a too low measure prior to the pres-surization. Pressurize again until the original tensioning pressure is reached, turn the main nut and bleed the pressure again (tensioning procedure). Now you can turn back the device further. (Attention: consider the admissible stroke of the device!) Now repeat the loosening procedure explained above.

b) Should it be impossible to loosen the main nut after the depressurization, it has been turned back by a too low measure prior to the pres-surization. Pressurize again and turn the main nut further back. Bleed the pressure again.

Hint: Never screw the main nut back until it fi ts to the piston since the device can be tensioned in itself.

Adjustment and Turn Back of the Main Nut

During the pressurization of the device, the bolt is being extended by the tensioning force and the components are being edged. The result is that the main nut does no longer fi t to the fl ange.

Having achieved the necessary pressure, adjust the main nut - when tensioning - until it fi ts to the fl ange again before bleeding the pressure, see Tensioning Procedure. When loosening the bolts, turn back the main nut after the pressurization according to the bolt and component deformations, (see Loosening Procedure.

Hint: During the loosening procedure, never turn back the main nut until it fi ts to the piston or the cylinder since the main nut sticks after the depres-surization.

The main nut is equipped with several radial bores where the adjusting rod can be put in. The main nut is accessible through the window in the support sleeve.

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Function of the Hydraulic ToolsWorking CardPage 5 (7)

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General

99.43 - ES0

520-01.05Edition 02 Function of the Hydraulic Tools Working Card

Page 6 (7)

Piston Return Stroke

After each pressurization it must be ensured that the piston of the device is brought back to its zero position. On principle, it has to be considered that hydraulic oil is being displaced from the piston area. In order to enable the oil to fl ow back to the tank of the pressure generator, the corresponding hydraulic connections must be done.

The piston return stroke is done by a screw-down at the bolt itself before the device is taken off.

Hint: When using fast lock coupling elements, the oil’s running out and thus a piston return stroke in an uncoupled condition is impossible!

During the piston return stroke, considerable back-pressures can occur in the piston area of the device since quite large quantities of oil have to fl ow back through the small cross sections of the high-pres-sure connections.

In order not to unnecessarily increase the force for the piston return stroke turn the piston slowly. On principle the piston of the device has to be pushed back until it fi ts to the cylinder again.

Exchange of the Seals

Should leakages occur at the piston of the device, an exchange of the seals might be necessary.Drive out the piston by carefully beating with a hammer while using a plastic spacer in order to protect the device from unnecessary damages. After removing the hydraulic connector, you can also carefully lead compressed air into the piston area.

Attention: Sudden input of compressed air can lead to the piston’s uncontrolled outlet.After removal of the piston, the seals and the backup rings can be removed from the piston and the cyl-inder.

Carefully clean the components with fl uff-free mate-rial and check them for damages. If necessary, use compressed air for the cleaning, but never aggres-sive cleaning liquids. After that, slightly oil these components with hydraulic oil and assemble new backup rings as well as new seals to the piston and the cylinder according to the drawing.

Fig. 3 Adjustment and turn back of the main nut.

Fig. 4. Piston return stroke.

Fig. 5. Exchange of the seals.

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General

Function of the Hydraulic ToolsWorking CardPage 7 (7)

As shown in the picture, fi rst assemble the backup ring, then put the seal onto the backup ring. Piston and cylinder can now be assembled again by putting the components together. By slightly hammering on the piston (with plastic spacer), it can be driven in until it fi ts tightly to the cylinder (piston in its zero position). It is essential that the piston does not tilt during being driven in since this might damage the seals as well as the components. When assembling the piston it has to be taken care that the air can come out of the piston area.

Maintenance and Storage

Regular maintenance of the device is not necessary, but you should consider the following points:

a) Storage

After each operation, repair possible damages and clean the device in order for it to be ready for the next operation immediately. In order to avoid a cor-rosion it is advisable to oil the device and especially its thread. All coupling nipples, coupling sockets and also loosened screw connections are to be closed by protecting caps.

In addition, check the components of the device and its accessories for completion.Keep the device in the tool box also offering protec-tion from mechanical damages.The temperature must be between -20 C and +70 C in order to exclude a damage of the seals.

b) Start-up of the device

Prior to the device’s operation, repair possible dam-ages and clean the device.

Check the components of the device and its acces-sories for completion.

The operating manual has to be read by all users.

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Safety precautions

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

Description

Application of hydraulic tools for connecting rod.

Starting position

Function of hydraulic tools 520-01.05

Related procedure

Manpower

Working time : hoursCapacity : men

Data

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

520-01.06Edition 03H

00.20 - ES0

L23/30H

Application of Hydraulic Tools for Connecting RodWorking CardPage 1 (2)

Special tools

Plate no Item no Note

See page 2

Hand tools

Replacement and wearing parts

Plate no Item no Qty/

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520-01.06Edition 03H Application of Hydraulic Tools for Connecting Rod Working Card

Page 2 (2)

Fig 1 Connecting rod.

This working card gives the information for applica-tion of hydraulic tools, to be used in connection with working card 520-01.05.

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Safety precautions

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

Description

Application of hydraulic tools for cylinder head and main bearing.

Starting position

Function of hydraulic tools 520-01.05

Related procedure

Manpower

Working time : hoursCapacity : men

Data

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

520-01.06Edition 04H

00.20 - ES0

L23/30H

Application of Hydraulic Tools for Cylinder Head and Main Bearing

Working CardPage 1 (2)

Special tools

Plate no Item no Note

See page 2

Hand tools

Replacement and wearing parts

Plate no Item no Qty/

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L23/30H

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520-01.06Edition 04H

Application of Hydraulic Tools for Cylinder Head and Main Bearing

Working CardPage 2 (2)

Fig 1 Hydraulic tools.

This working card gives the information for applica-tion of hydraulic tools, to be used in connection with working card 520-01.05.

Please note:The numbers refer to the plate items in section 520.

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Safety precautions

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

Description

Application of hydraulic tools.

Starting position

Related procedure

Manpower

Working time : hoursCapacity : men

Data

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

520-01.07Edition 01

00.45 - ES0

General

Hand Lever PumpWorking CardPage 1 (4)

Special tools

Plate no Item no Note

52000 011

Hand tools

Replacement and wearing parts

Plate no Item no Qty/

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General

00.45 - ES0

520-01.07Edition 01 Hand Lever Pump Working Card

Page 2 (4)

Warning: The hand lever pump is not equipped with a pressure relief valve.Never use the pump without a mounted manometer. Always pay attention to the given pressure of the connected pressure consumers. Do never exceed this pressure or the max. pressure of the hand lever pump.

Important: Except for hydraulic oil, never use different liquids such as petrol, water, diesel oil, alcohol or brake liquid, since these can lead to damages or even to destruction of the pump and/or the parts connected with it. Choose a place of assembling and operation where the pump can always stand safe and fi rm on a horizontal plain. There should always be suffi cient space for operating the pump.Never handle the pump lever with oiled hands and never use hand lever extensions. Never expose the pump to great heat, fi re or extreme coldness, since this leads to damages or even destruction. Protect the pump from falling objects and avoid hard blows or pushes.

Attention - Danger to lifeCheck the manometer of the pump for the needed hydraulic pressure, given by an authorized person, not to be exceeded. Make sure that the pressure you want to generate is also admissible for all con-nection parts.

All pressure connections and connecting elements have to be clean and undamaged. High-pressure connections from the pump to the tools have to be established correctly prior to any pressurization. Disregard leads to danger to life. Please see working card 520-01.06.

Attention - Danger on injuriesLoads being lifted by the pump may never be held by the pump valves alone. Use additional non-return valves or safety relief valves and secure the load by suffi cient support against falling.

Initial Start-up and Venting

In general and venting

Please make sure that all parts of the pump, espe-cially the manometer and the pressure port, are in a perfect condition. Defect parts are to be exchanged against new ones immediately.

Turn the carrying handle with counter-clockwise rotation out of his fi xing. Then turn it into the hand lever of the pump against the stopping face.

Attention: If the carrying handle is not srewed-in into the hand lever, it can cause injuries while using the pump.

Open the oil fi ller cap and check the oil level. If nec-cessary, fi ll up the tank with hydraulic oil according to IS0 VG 32. Never overfi ll the tank. Close the oil fi ller cap.Open the tank breather with the square wrench (included in the scope of supply) by about one turn. Now loosen the breather screw at the pump on the left side on the pump housing with an allen key SW 2,5 by about one turn. Close the depressurization valve tightly. Seal the nipple on the pump with a hose and pump at the hand lever until oil fl ows out of the breather screw bladder-free. Only then are you al-lowed to close the breather screw. The pump is now vented and ready for operation.

After each operation and for the transport, close the tank breather in order to avoid the hydraulic oil’s running out.

Pressurization

- Open the tank breather with the square wrench approx. one turn.

Remark: The pump is only to be operated with open tank breather.

- Close the depressurization valve at the pump when turning clockwise by handoperation.

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General

Hand Lever PumpWorking CardPage 3 (4)

Remark: The depressurization valve is designed for manual operation. The use of any tools at the depressurization valve could cause damages of the valve or the valve seat.

- Pump at the hand lever until the wanted pres-sure is achieved. Check the pressurization at the manometer and take care of possible leakages.

Remark: The pump works with two stages. The change from the fi rst stage to the second stage happens automatical at a system pressure of about 30 bar.

Attention: The pump is not equipped with an internal pressure relief valve. The use of a manometer and the control of the system pressure during pressurization is indispensable.

Attention: Do not stand directly over the moving line of the pump lever. Under arising circumstances the lever can “hit back”. To avoid accidents stand sideways the pump.

Attention - High-pressure hydraulicOn principle, tihen leakages occur during the pressu-rization, immediately release the hydraulic pressure and seal the leakage or renew defect parts.

Depressurization

- Open the depressurization valve slowly by a turn to the left.

- Make sure that the hydraulic pressure at the manometer has been completely released. Consider the returning time of the hydraulic oil.

Adjustment of change-over pressure from stage 1 to stage 2

In exeptional case, it can be useful to adjust the change-over pressure from stage 1 to stage 2 (factory adjusted at approx. 30 bar).

Below of the pressure relief valve is an adjusting screw with inner hexagon (wrench size 10 mm). Turning out counter-clockwisely the adjusting screw minimizes the change-over pressure, turning in clockwise ma-ximizes the change-over pressure.

Attention: Inside of the adjusting screw is another grub screw with inner hexagon (wrench size 4 mm) to limit the stroke of the change-over piston inside ofthe pump block. It is absolutely necessary, to screw out the grub screw approx. 2 times before turning the adjusting screw!

The regulation of the adjusting screw follows gra-dually in approx. 10° - steps. After everv adjusting step the grub screw is to screw in until it fi ts closely and approx. a l/4 turn to loosen.

Check by carefully pumping if the change-over pres-sure wanted has been reached. If necessary, repeat the procedure as described above.

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Analysis and Correction of Malfunction

Correction of malfunctions

In case of malfunctions at the pump, the following points are to help you with the analysis of the problem and correcting it yourself.For this, uncouple or unscrew all consumer and high-pressure hoses from the pump.

Pressure Port

The pressure port of the pump is produced accor-ding to our customers’ wishes. In addition, there is a variety of possibilities to connect the pump with one or more pressure consumers.

Attention - Danger to lifePrior to the pump’ s start-up please make sure that, no matter which pressure port you chose, all con-nection elements are in a perfect condition. Convince yourself of the fact that these are correctly connected and suitable for the necessary pressure.

Attention - High-pressure hydraulicOn principle, when leakages occur during the pressu-rization, immediately release the hydraulic pressure and seal the leakane or renew defect parts.

Maintenance and Storage

The pump should be lubricated frequently at the movable parts. Protect it from contamination because dirt in the oil or in the pressure port can lead to the pump’ s failure. A dry storage avoids the steel parts’ getting rusty.The storage and transport of the pump should always be done in a horizontal position. Thus, you avoid a possibly necessary venting of the pump during its start-up.

For checking the oil level, please open the depres-surization valve and let the oil completely fl ow back into the tank. Open the oil fi ller cap and fi ll up hydraulic oil according to IS0 VG 32, if neccessary. Do not overcharge the tank. Close the oil fi llercap.

The use of the pump in a dirty area requires a regular oil change. Fill the pump with clean hydraulic oil and lubricate all moving parts (hinges) regulary.

Malfunction Correction

No pressurization 1. Check the oil level and, if necessary, fi ll it up as described in chapter maintenance and storage. 2. Close depressurization valve. 3. Visual inspection whether there are leakages. If so, seal them. 4. Vent the pump as described in chapter initial start-up and venting.

Insuffi cient pressurization 1. Check the oil level and, if necessary, fi ll it up, as described in chapter(prior to any corrections, mainteance and storage.open de-pressurization 2. Close depressurization valve.valve and release hydraulic 3. Visual inspection whether ther pressure completely) are leakages. If so, seal them. 4. Vent the pump as described in chapter initial start-up and venting.

Pressure drop 1. Visual inspection whether there are leakages. If so, (prior to any corrections, seal them.open de-pressurization 2. Close depressurization valve.valve and release hydraulic pressure completely).

If the problem cannot be solved, please contact MAN Diesel.

General

00.45 - ES0

520-01.07Edition 01 Hand Lever Pump Working Card

Page 4 (4)

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Safety precautions:

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

Description:

Maintenance of hydraulic tools and pressure testing of hoses.

Starting position:

Related procedure:

Man power:

Working time : 1/2 hourCapacity : 1 man

Data:

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

96.03 - ES0S-G

Working CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Allen key, 6 mm.Ring and open end spanner, 22 mm.Clean lub. oil.

Replacement and wearing parts:

Plate no Item no Qty/

52021 430 Hydraulic tool. 52021 442 Hydraulic tool. 52021 299 Hydraulic tool. 52021 309 Hydraulic tool.

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Working CardPage 2 (2)

1) The hydraulic jacks require no maintenance except replacement of defective sealing rings, each of which consists of an o-ring and a back-up ring fi tted in ring grooves in the piston and cylinder.

The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart by means of working air.

Fig 2.

Compression tool

Fig 1.

Work.air

Make sure that there are no marks or scratches on the sliding surfaces of the parts. The presence of metal particles will damage the sealing rings.

2) The sealing rings are to be fi tted with the o-rings nearest to the pressure chamber and with the back-up rings away from the pressure chamber.

Fit the sealing rings and lubricate with clean lub. oil. The piston and cylinder are pressed together by means of the tool supplied. See that the rings do not get stuck between the piston and cylinder.

Pressure Testing of Hoses

To avoid working accidents caused by emission of pressure oil from the hydraulic hoses, the hoses should be pressure tested at 1200 bar once a year.

Note: During the pressure testing the hoses must be covered carefully.

96.03 - ES0S-G

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520-01.10Edition 01H Maintenance of Hydraulic Tools

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Safety precautions:

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

Description:

Starting position:

Related procedure:

Manpower:

Working time : hourCapacity : man

Data:

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

Working CardPage 1 (2)

Special tools:

Plate no Item no Note

Hand tools:

Replacement and wearing parts:

Plate no Item no Qty/

Tightening with Torque Spanner520-01.15

Edition 01H

L23/30H

96.03 - ES0S-G

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Working CardPage 2 (2)

1) Before the nuts are screwed on, the threads and the contact faces should be greased with copaslip or similar, the tightening torques being based on a coeffi cient of fi ction in the threads.

2) The nuts should fi t easily on the thread, and it should be checked that they bear on the entire contact face.

3) In the case of new nuts and studs, tighten and loosen the nuts 2 or 3 times so that the thread may assume its difi nite shape, thus obviating the risk of loose nuts.

4) Nuts secured with a split pin are tightened to the stated torque and then to the next split-pin hole.

5) The following instructions apply to the use and maintenance of the torque spanner.

Torque Spanner

6) The handle of the torque spanner is provided with a scale indicating the torque at which the span-ner can be set.

7) For setting the spanner at the torque required, there is a ball on a small arm at the end of the handle.

8) When pulling the ball with the arm outwards, a small crank handle is formed.

A spring-loaded slide in the handle provided with a mark which, when turning the crank handle, can be set at the required torque on the scale.

The torque spanner functions are as follows:

9) The above-mentioned spring activates a pawl sy stem in the handle, and when using the spanner, this pawl system will be released when the pre-set torque has been reached, at which moment a small jerk is felt in the spanner and a small click is heard.

10) The torque spanner must not be used for torque higher than those stamped on it, and it must not be damaged by hammering on it or the like.

Scale for torque moment Key for adjusting

of torque moment

Fig 1. Torque spanner.

520-01.15Edition 01H Tightening with Torque Spanner

L23/30H

96.03 - ES0S-G

MAN Diesel

Safety precautions:

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

Description:

Tool combinations for tightening and checking connecting rod screws.

Starting position:

Related procedure:

Dismounting of piston and connecting rod 506-01.00Tightening and check of connecting rod screws 506-01.25On-situ inspection of connecting rod big-end bearing 506-01.30

Man power:

Working time : hoursCapacity : man

Data:

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

520-01.20Edition 01H

96.03 - ES0S

L23/30H

Working CardPage 1 (2)

Special tools:

Plate no. Item no. Note.

52006 273 80 - 360 Nm. 52006 320 52006 381 24 mm. 52006 415

Hand tools:

Replacement and wearing parts:

Plate no. Item no. Qty. /

Tool Combinations for Tighteningof Connecting Rod Screws

MAN Diesel

L23/30H

520-01.20Edition 01H

Working CardPage 2 (2)

The tightening procedure for connecting rod screws can be executed with the tools originally delivered with the GenSets.

The enclosed pages illustrate tool com bi na tions ap-plicable to tightening of connecting rod screws.

It is also acceptable to execute the turning of the screws through a 60° angle, by means of a pneu-ma tic impact spanner, with power and dimensions, if available.

Tool combinations for tightening of screws, see fi g. 1.

Tool Combinations for Tighteningof Connecting Rod Screws

Fig. 1. Tool combinations for tightening of screws.

3 2 1

1. Torque spanner, 80-360 Nm. 2. Ratchet, (only for tightening). 3. Socket, 24 mm.

The 24 mm socket to be used must be a socalled specially designed for socket use with mechanical or pneu ma tic impact tools.

Compared to sockets for manually operated span-ner, the power top has increased dimensions, see fi g. 2.

The connecting rod screws are situated very closely, leaving only minor space between collars and hex a-go nals of the screw heads.

Dependent of the manufactures, it can be necessary to adapt the power top to the limited space conditions around the screws.

In such case only the absolutely necessary ma chin-ing should be executed.

Special socket (power top)

Connecting rod screws

Connecting rod

Fig. 2. Special socket.

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Safety precautions

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

Description

Operation.Overhaul intervals.Dismantling, overhaul and assembly.

Starting position

Related procedure

Manpower

Working time : 1/2 hourCapacity : 1 man

Data

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

Special tools

Plate no Item no Note 52005 109 Max. press. indicator

Hand tools

Allen key, 3 and 6 mm.Copaslip or similar.

Replacement and wearing parts

Plate no Item no Qty/

See Plate 52005

Working CardPage 1 (2) Max Pressure Indicator

L23/30HV28/32S

520-01.25Edition 01H

96.03 - ES0

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8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30HV28/32S

Operation

1) Open the indicator valve and blow through shortly.

2) Connect the max pressure indicator to the indicator valve and open the valve.

3) After 3-5 seconds read the max. pressure on the gauge.

Attention: The indicator valve has to be open while reading the max. pressure on the gauge. The meas-uring period should not exceed 30 se conds.

4) Close the indicator valve and open the valve screw (5), fi g 1.

5) Disconnect the max. pressure indicator and close the valve screw (5), fi g 1.

6) Measure the remaining cylinders by following step 1 to 5.

Overhaul Intervals

1) Dismount and clean the non-return valve after 200 measuring periods. If the pressure drop is more than 5 bar within 60 seconds (test pres-sure 100 bar) it is recommended to relap the non-return valve.

2) Check the pressure gauge after 1,000 measur-ing periods or after 12 months use.

Attention: Use only exhaust gas or nitrogen gas and never oil for testing the pressure drop and the pressure gauge. By using oil carbon will deposit inside the measuring instrument.

Dismantling and Assembly

1) Dismount the valve screw (5), fi g 1.

2) Turn the screw (4) into the instrument to enable dismounting of the housing (1).

3) Loosen the screws (2) (4 pieces) for separating upper and lower part.

520-01.25Edition 01H Max. Pressure Indicator Working Card

Page 2 (2)

Fig 1 Pressure Indicator.

1

2

5

3

4

1 Housing 2 Allen screw

3 Sealing 4 Screw

5 Valve screw

4) After separation of the upper and lower part, take off the non-return valve assembly.

5) Lap the valve and the valve seat.

6) Renew the sealing ring (3) and screws (2), if necessary.

7) When mounting the upper and lower part, use only original screws.

8) Coat the screws (2) with copaslip or similar and tighten to 10 Nm.

9) After assembly the instrument can be used without any new calibration.

Check of the Pressure Gauge

10) Testing of the instrument should only be made by skilled specialists, and it is recommended to send the in stru ment to MAN Diesel for ca li-bra tion.

96.03 - ES0

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

S 051

Lifting tool for cylinder head,complete. 139 113 68 014S

Mounting tool for valves,complete. 248 ø72

Max. pressure indicator.

Spare Parts:

Valve screw

Non-return valve, complete incl.seals and housing screws.

Connecting nut incl. wedge formounting

Pressure gauge 0-180 bar.

S 109

110

122

134

146

65

Tools for Cylinder HeadPlatePage 1 (4) 52005-04H

01.17 - ES0

L23/30H

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Grinding table for cylinder head, with bracket for wall mounting, complete. 254E648426846

301E7441050833

Grinding table for cylinder head, with frame for fl oor mounting, complete.

Extractor for valve seat ring (complete). ø137 290 E 504

52005-04H Tools for Cylinder Head PlatePage 2 (4)

01.17 - ES0

L23/30H

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Grinding machine for valve seat ring, complete.

Spare Parts:

Stone

Guide

E 350

362

374

408

421

EGrinding machine for valve spindle, complete.

Spare Parts:

Stone

457E315ø78Mounting tool for valve seat rings, complete.

Tools for Cylinder HeadPlatePage 3 (4) 52005-04H

01.16 - ES0

L23/30H

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

NV17

Tools for grinding of valves. 553Sø110 95

673S110107Hand wheel for indicator valve.

Grinding tool for cylinder headand cylinder liner. 205S470399

52005-04H Tools for Cylinder Head PlatePage 4 (4)

01.17 - ES0

L23/30H

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Eye screw for lifting of piston. M12 ø30 20.5 021S

Eye bolt for piston lift at checkof connecting rod big-endbearing.

S 070

S 033Shackle for lifting of piston. 28 60

C

AB

M12 54 410

Tools for Piston , Connecting Rod and Cylinder LinerPlatePage 1 (6) 52006-06H

08.01 - ES0

L23/30H

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Back stop for cylinder liner,2 pieces. 094Sø60.3280 75

Guide ring for mounting of pi-ston.

Only for 900 rpm and720/750 Stationary

116S110ø298

52006-06H Tools for Piston , Connecting Rod and Cylinder Liner PlatePage 2 (6)

08.01 - ES0

L23/30H

Guide ring for mounting of pi-ston.

Only for 720/750 rpm Marine

117S85ø275

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Testing mandrel for piston ringand scraper ring grooves.

Grooves for piston ring.

Grooves for scraper ring.

S

S

153

165

4.43

7.43

200SPlier for piston pin lock ring.

C

B

A 25550 ø3.5

A

Tools for Piston , Connecting Rod and Cylinder LinerPlatePage 3 (6) 52006-06H

08.01 - ES0

L23/30H

141S260105Piston ring opener.

261

273

S

S

½"

¾"

463

718

Torque spanner 20-120 Nm

Torque spanner 80-360 Nm

A

B

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Socket. 24 55 ¾" S 381

52006-06H Tools for Piston , Connecting Rod and Cylinder Liner PlatePage 4 (6)

08.01 - ES0

L23/30H

Pneumatic impact spanner 415E3/4"

Lifting tool for cylinder liner. 452S370 930

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

1615ø258 S 511Funnel for honing of cylinderliner.

Tools for Piston , Connecting Rod and Cylinder LinerPlatePage 5 (6) 52006-06H

08.01 - ES0

L23/30H

50140Magnifi er (30 x). S 559

B

A

488S850ø228Honing brush incl. woodenbox

Wooden boxL x B x H = 269 x 269 x 250 mm

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

52006-06H Tools for Piston , Connecting Rod and Cylinder Liner PlatePage 6 (6)

08.01 - ES0

L23/30H

Grinding tool for cylinder liner 350 503 S 655

Inside micrometer:

Measuring range225-250 mm E 618

15

10

20275 80

DimensionsIllustration of Tools Item

noA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

S 058

Feeler gauge for inlet valves.

Feeler gauge for exhaust val-ves.

(2 sets of each)

0.5

0.9

0.6

1.0

010

022

S

S

Extractor for thrust piece onroller guide for fuel pump. 49 M24

x1.5ø29.5

PlatePage 1 (1) 52008-04H

98.51 - ES0S

L23/30H

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

S 071Distance piece 98.5 ø24.5ø30

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Spanner for adjusting ofoverspeed stop. 125 ø20 100 016S

52009-02H

01.17 - ES0

L23/30H

Tools for Control and Safety SystemsAutomatics and Instruments

PlatePage 1 (1)

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Turning rod. 925 ø42.4 011S

Dismantling tool for mainbearing, 2 pieces. S 106

S 059Crankshaft alignment gauge(autolog). 210 150

ø60 125 M12

01.17 - ES0

Tools for Crankshaft and Main BearingPlatePage 1 (2) 52010-04H

L23/30H

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Lifting straps for main and guide bearing cap, 2 pieces. 155SM161000

Dismantling tool for guide bearing shells. 202S250

15

214

226

S

S

51.5

ø2.6

ø50

ø7.9

Tool for upper main bearing.

O-ring.

32

01.17 - ES0

52010-04H Tools for Crankshaft and Main Bearing PlatePage 2 (2)

L23/30H

DimensionsIllustration of Tools Item

No.A B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Pressure testing pump, compl.GOU-G001.

Clamping bracket for fuelinjector, VTO W020.

Clamping bracket for fuelinjection pump, PYO-W017.

Fuel pipe, VTO-W021.

Fuel pipe, VWM-W007.

013

025

037

049

050

S

S

S

S

S

S 108Cleaning tool for fuel injectorconsists of:

1 pc. needles.

1 pc. holder.

1 pc. box.

84 ø22.5

Spanner for fuel injection pump.

S 204184

Tools for Fuel Oil System and Injection EquipmentPlatePage 1 (2) 52014-03H

98.35 - ES0S

L23/30H

DimensionsIllustration of Tools Item

No.A B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Grinding tool for fuel injectionvalve. 300Eø1825 ø55

Grinding tool for seat for fuelinjection valve. 361Sø18

407S185150Extractor for fuel injector valve. 240

533 ø70

52014-03H Tools for Fuel Oil System and Injection Equipment PlatePage 2 (2)

98.35 - ES0S

L23/30H

Dimensions

PlatePage 1 (1) 52015-01H

Illustration of Tools ItemNoA B C

96.03 - ES0S

L23/30H

Designation

S/E

S = Standard E = Extra

Tools for Lubricating Oil System

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Guide bar for dismantling oflubricating oil cooler. ø30 305 M20 019S

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Hydraulic ToolsPlatePage 1 (5) 52021-10H

06.25 - ES0

L23/30H

011

023

118

096

059

Pressure pump, complete, with wooden box

Manometer

Gasket for Item 096

Quick coupling

Distributor

S

155

167

179

Distributing piece for cylinder head, complete.

Gasket

Quick coupling

S

Distributing piece for main bea-ring, complete.

Gasket

Quick coupling

S 202

167

179

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

52021-10H Hydraulic Tools PlatePage 2 (5)

06.25 - ES0

L23/30H

179

275

645

657

669

633

704

716

728

741

753

621

765

777

789

586

790

S

Quick coupling

Venting screw

Ball

Adapter

Stroke indicator band

Hydraulic tools for connecting rod with wooden box, com-plete

Piston for hydraulic jack

Set of O-rings with back-up ring

Adjusting rod

Cylinder for hydraulic jack

Spacer piece

Angle piece complete, incl. item 765, 777, 789, 790

O-ring

Adapter

Coupling socket

Hydraulic jack as item nos. 179, 275, 645, 657, 669, 704, 716, 728, 741, 753

Quick coupling

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Hydraulic ToolsPlatePage 3 (5) 52021-10H

06.25 - ES0

L23/30H

179

251

263

275

287

299

309

310

800

334

358

645

657

812

S

Quick coupling

Hydraulic tools for cylinder head with wooden box, complete

Allen key, 7 mm

Venting screw

Piston for hydraulic jack

Set of O-rings with back-up ring

O-ring

Cylinder for hydraulic jack

Spacer piece

Tommy bar

Hydraulic jack as Item Nos. 179, 275, 287, 299, 309, 310, 645, 657, 812

Ball

Adapter

Stroke indicator band

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

52021-10H Hydraulic Tools PlatePage 4 (5)

05.25 - ES0

L23/30H

179

263

275

334

645

657

405

417

429

430

454

466

824

586

574

Quick coupling

Allen key, 7 mm

Venting screw

Tommy bar

Ball

Adapter

Hydraulic tools for mainbearings with wooden box,complete

Spacer piece

Cylinder for hydraulic jack

Set of O-rings with back-up ring

Piston for hydraulic jack

Hydraulic jack as Item 179, 275, 429, 430, 454, 645, 657, 824

Stroke indicator band

Disc

Guide

S

DimensionsIllustration of Tools Item

NoA B CDesignation

S/E

S = Standard E = Extra

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

Hydraulic ToolsPlatePage 5 (5) 52021-10H

06.25 - ES0

L23/30H

501

513

537

549

525

836

ø27

ø27

600

3000

3000

600

Hose for hydraulic tools, 4 pie-ces complete

Hose for hydraulic tools, 1 pie-ces complete

Hose

Quick coupling with protecting cap

Hose

Adapter

S

S

326256367Air-driven high pressure pumpfor hydraulic tools E 608

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

01.17 - ES0-G

L23/30H

Tools for Low Overhaul Height,Piston, Cylinder Liner and Connecting Rod 52050-02HPlate

Page 1 (2)

0802

8-0D

/H52

50/9

4.08

.12

MAN Diesel

L23/30H

021

033

045

057

Item No Benævnelse

Pull-lift

Løfteværktøj for cylin-derforing, komplet

Halsjern for plejlstang, komplet

Sjækel

Designation

Pull-lift

Lifting tool for cylin-der liner, complete

Collar for connecting rod, complete

Shackle

Qty

2/E

1/E

1/E

2/E

Item No DesignationQty Benævnelse

01.17 - ES0-G

Tools for Low Overhaul Height, Piston, Cylinder Liner and Connecting Rod

Ved bestilling af reservedele, se også side 500.50.

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

When ordering spare parts, see also page 500.50.

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

52050-02H PlatePage 2 (2)