Service Letter SL2016-627/MIKA

Action code: AT FIRST OPPORTUNITY

Tightening of Roller Guide

Housing
Replaces SL2016-622/MIKA

SL2016-627/MIKA
Dear Sirs September 2016

MAN Diesel & Turbo has received reports of incidents of the roller guide Concerns
housing in service. Such incidents often lead to consequential damage Owners and operators of
to the frame surface on which the housing is fixed. MAN four-stroke diesel engines.
Type:
The root cause of these incidents is the bolt connection between the L23/30H Tier I and II, L23/30H Mk2,
housing and frame. Our investigation revealed that bolts were touching L23/30S
the bottom of the threaded holes, leading to improper fastening of the
housing and eventually an incident.

These incidents have occurred in service due to an incorrect combina- Reason of replacement:
tion of the bolt connection. Wrong plate mentioned in text.
We have experienced variation in flange thickness, bolt length and size Should be P50801-20
of washers from various makers and suppliers.

As a precaution we have introduced a 10-mm washer to be installed Enclosure:

instead of the lock washer in the bolt connection. Description 500.50 (03)
Work card 507-01.20 (16)
For futher information about installation and preventive measures Work card 508-01.02 (01)
please see page 2. Plate P50801-20

New 10-mm washers can be ordered via PrimeServ Holeby.

Use the enclosed plate P50801-20 and fill in the enclosed Ordering of
Spare Parts, 500.50, and send it to PrimeServ-hol@mandieselturbo.
com

Yours faithfully

Mikael C. Jensen Jens Christensen

Vice President Manager Maturing & Testing
Engineering Four-stroke

MAN Diesel & Turbo MAN Diesel & Turbo MAN Diesel & Turbo
H. Christoffersensvej 6 Niels Juels Vej 15 Branch of MAN Diesel & Turbo SE,
4960 Holeby 9900 Frederikshavn Germany
Denmark Denmark CVR No.: 31611792
Phone: +45 54 69 31 00 Phone: +45 96 20 41 00 Head office: Teglholmsgade 41
Fax: +45 54 69 30 30 Fax: +45 96 20 40 30 2450 Copenhagen SV, Denmark
[email protected] [email protected] German Reg.No.: HRB 22056
Amtsgericht Augsburg
www.mandieselturbo.com
Service Letter SL2016-627/MIKA

When installing the new washer we recommend verification of the following dimensions:
Depth of the threaded hole must be 35 mm with 30 mm M12 thread size.
Flange thickness of the housing must be 22 mm. We have seen housings deviating from the thickness of 22 mm, and thus
with the bolt either touching the bottom of the threaded hole or having improper connection to the threads.
Hexagon bolts should be M12 and 55 mm long.

Before installation, the following measures must be verified: that is the housing and threaded hole must be longer than the bolt
length and the bolt must go at least 20 mm into the thread. Depending on measurement the bolt must be longer or shorter.
The correct tightening torque for the bolt connection is 60 Nm.

If damage is found, the damaged hole in the frame can often be repaired by applying the helicoil in the threaded hole.

At first opportunity, when the cylinder heads are dismantled from the engine, it is recommended to check the measurements
and tightening of the bolts.
With dismantled cylinder heads there is good access to the roller guide housing connection bolts.

During installation of the new washer we recommend to check the alignment of the roller guide housing, please see enclosed
work card 508-01.02.

In addition to the alignment procedure we recommend measuring the x-measurement for the fuel pump and adjust if neces-
sary, please see enclosed work card 507-01.20.

Frame surface damaged

Tightening of Roller Guide Housing. Page 2 of 2

MAN Diesel & Turbo
Description 500.50
Page 1 (3) Ordering of spare parts
Edition 03

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, L23/30DF, L16/24S,

L21/31S, L23/30S, L27/38S, L28/32S
Ordering of spare parts
Spare parts can be ordered from MAN Diesel & Turbo, Note:
PrimeServ.
Components from different engine builders
When spare parts are ordered or inquired, the following cannot be considered as interchangeable.
data must be indicated, in order to ensure correct iden- A wide number of spare parts can be orders
tification of the required parts: as spare part kits.
Name of customer Selected components may be available in both
Name of plant /vessel original and upgraded version.
Vessel IMO No
These data are necessary to ensure supply of the cor-
Engine type rect spare parts for a particular engine, even though the
Engine serial No spare part illustrations contained in this book may not
always be in complete accordance with the individual
Engine builder components of a specific engine.
Plate No and edition No
For ordering of spare parts for governor, turbocharger
Item No and alternator, please see the special chapter in the
Quantity instruction book for these components.

Designation of the item No

2014.05.28
 MAN Diesel & Turbo
500.50 Description
Ordering of spare parts Page 2 (3)
Edition 03

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, L23/30DF, L16/24S,

L21/31S, L23/30S, L27/38S, L28/32S

2014.05.28
MAN Diesel & Turbo
Description 500.50
Page 3 (3) Ordering of spare parts
Edition 03

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, L23/30DF, L16/24S,

L21/31S, L23/30S, L27/38S, L28/32S
Name of Customer Name of Plant/Vessel IMO No

Engine Type Engine No Engine Builder

Plate No Edition No Item No Designation of the Item No Qty

For ordering or inquiry for items in free text, kindly contact MAN PrimeServ Holeby at: +45 54 69 31 00 or via
e-mail [email protected]

2014.05.28
MAN Diesel & Turbo
Work Card 507-01.20
Page 1 (4) Adjustment of camshaft for valve and injection timing
Edition 16

L23/30H, L23/30S

Safety precautions Special tools

Engine stopped Plate No. Item No. Note

Shut-off starting air P52000 261 20-120 Nm
P52000 011
Shut off cooling water P52000 058
Shut off fuel oil P52000 420 Measuring device for
Shut-off cooling oil plunger lift
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Adjustment of the injection timing

Starting Position Hand Tools

Combination spanner, 19 mm
Socket spanner, 19 mm
Depth gauge
Plastic hammer

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 2-5 Plate No. Item No. Quantity
Number : 1

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

2016.08.08. - Tier II
 MAN Diesel & Turbo
507-01.20 Work Card
Adjustment of camshaft for valve and injection timing Page 2 (4)
Edition 16

L23/30H, L23/30S
When changing X it must be ensured that the dis-
tance 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 cir-
cular part of the fuel cam, please see description
500.35.
In all cases X must be checked and adjusted, if
necessary, when fuel oil pump, roller guide, roller
Measure of fuel pump lead guide housing and/or camshaft section have been
1) Dismantle covers for fuel camshaft and fuel replaced/dismantled.
pump and covers for gear wheel.
2) Check the mobility of the regulating device.
Turn engine to pos. cylinder No. 1 until the
cambase circle is reached (approx. 40 BTDC).
3) Position the support of the measuring tool on
the two bolts of the camshaft covering. Slip on
the distance sleeves and fasten to the cylinder
crankcase by means of hexagon nuts.

During attaching, pay attention to the correct fit-

ting position of the contact point, see Fig. 1.

4) Insert the dial gauge into the support.

5) Set the dial gauge to "Zero".
6) Turn the engine until the TDC mark (ignition
DC) for the actual cylinder is reached.
Read the dial gauge and note down the gauge 1 Contact point 2 Lever
value. 3 Fixing screws and discs
7) Determine the values for the other cylinders in of enclosing cover used
the same way.
Figure 1: .
Calculate the average value of all measure-
ments.
Cylinder kW/cyl rpm Average
8) Compare the calculated value determined with
value
the value mentioned below.
5-6-7-8 130 720 See section
9) If the values exceeds the limits, an adjustment
500, Descrip-
must be done in order to correct the errors, on 5-6-7-8 135 750 tion 500.35
the X-measure or reset the gear wheel, see fol- 6-7-8 160 900
lowing text for changing "X"-measuring.
To get a consistent lifting values on the plunger/ Table 1: Plunger lift (average value)
combustion pressure on the different cylinders the
"X"-measure can be changed.

2016.08.08. - Tier II
MAN Diesel & Turbo
Work Card 507-01.20
Page 3 (4) Adjustment of camshaft for valve and injection timing
Edition 16

L23/30H, L23/30S
The injection timing can be altered on each cylin-
ders by inserting or removing shims under the
thrust piece on the roller guide, thus changing the
measure X, see Fig 3.
Thinner and/or fewer shims (increase of the dis-
If several fuel oil pumps, roller guides, roller guide tance X) results in a retarded injection timing.
housings and/or camshaft sections are disman- Thicker and/or more shims (reduction of the dis-
tled at the same time it is advisable to number tance X) results in an advanced injection.
the parts in order to facilitate remounting and
adjustment. 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.
After replacement of shims the thrust piece is
remounted, see fig 4, in the roller guide (4) with a
soft hammer (5).

Figure 2: .

The gear wheel is provided with an engraved scale,

see fig 2, 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
"x" Measure "x" a Total height
crankshaft) in relation to the camshaft.
If the crankshaft is turned in the engines normal
direction of rotation the injection timin is retarded Figure 3: .
(closer to TDC).
If the crankshaft is turned against the engines nor-
mal direction of rotation the injection timing is
advanced (away from TDC).
After the adjustment the screws are fastened with a
torque wrench, please see description 500.40, and
secured.

2016.08.08. - Tier II
 MAN Diesel & Turbo
507-01.20 Work Card
Adjustment of camshaft for valve and injection timing Page 4 (4)
Edition 16

L23/30H, L23/30S

1 Extractor 2 Thrust piece

3 Shims 4 Roller guide
5 Soft hammer

Figure 4: .

10) Remove the complete measuring tool.

11) Mount all camshaft covers.
12) Plunger lift value, please see description
500.35.
Action Results
Total height on roller guide Distance "x" Injection timing Max combustion pressure
Increased Reduced Advanced Increased
Reduced Increased Delayed Reduced

2016.08.08. - Tier II
MAN Diesel & Turbo
Work Card 508-01.02
Page 1 (4) Alignment of the roller guide housing
Edition 01

L23/30H, L23/30S, L23/30DF

Safety precautions Special tools

Engine stopped Plate No. Item No. Note

Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Alignment of the roller guide housing

Starting Position Hand Tools

Ring and open end spanner, 12 mm
Plastic hammer
Depth gauge
Vernier caliper

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 3 h per cyl.
Number : 1 person

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

2016.02.15
 MAN Diesel & Turbo
508-01.02 Work Card
Alignment of the roller guide housing Page 2 (4)
Edition 01

L23/30H, L23/30S, L23/30DF

Check the alignment

For installation of the roller guide housing, this is
important to control the parallelism between the
camshaft centerline and roller guide housing center-
line.
1. Make sure that all surfaces are clean prior to
measurement and alignment. Find C-CS on the
fore and aft camshaft section. With these two
measurements, it is possible to judge the align-
ment between the camshaft and the front of the
engine.
2. Find C-RG on the roller guides for the fuel oil
pump and exhaust valves on all the cylinders. If
Figure 2: Camshaft
the difference between C-RG Fuel Oil and C-RG
Exhaust is more than 0.1 mm, realignment is
necessary, See fig. 3. D-CS Camshaft diameter see fig. 1
A-CS See fig. 2
C-CS = A-CS + (D-CS/2)

Figure 3: Roller guide

Figure 1: Camshaft and roller guide housing
D-RG Roller guide diameter
A-RG See fig. 3
C-RG = A-RG + (D-RG/2)

2016.02.15
MAN Diesel & Turbo
Work Card 508-01.02
Page 3 (4) Alignment of the roller guide housing
Edition 01

L23/30H, L23/30S, L23/30DF

If realignment is necessary, it should be done
via following instruction:
1. Dismount the roller guide housing and remove
the guide pin.
2. Mount the housing and the roller guides and
tighten the screws, so that it still will be possible
to move the housing by means of a plastic
hammer, See fig. 4.
3. Align the housing in axial direction, so that the
whole surface of the rollers is running on the
cams.
4. Check the parallelism between the roller guide
housing and camshaft centerlines by measuring
C-RG Fuel Oil and C-RG Exhaust. The differ-
ence between the two latter should not exceed
0.1 mm.
5. Tighten the screws by means of a torque span-
ner according to the instruction book. Then, drill
holes for the guide pin and mount these.
6. After having carried out a realignment of the
roller guide housing, it will be necessary to
check (adjust) the X-measuring according to the
instruction book.

Figure 4: Housing for roller guide, top view

2016.02.15
 MAN Diesel & Turbo
508-01.02 Work Card
Alignment of the roller guide housing Page 4 (4)
Edition 01

L23/30H, L23/30S, L23/30DF

M/V: Engine type:

Maker: Engine No.:

1 2 3 4
Aft Fore Aft Fore Aft Fore Aft Fore
D-CS
A-CS
C-CS
5 6 7 8
Aft Fore Aft Fore Aft Fore Aft Fore
D-CS
A-CS
C-CS

1 2 3 4
Fuel oil Exhaust Fuel oil Exhaust Fuel oil Exhaust Fuel oil Exhaust
D-RG
A-RG
C-RG
5 6 7 8
Fuel oil Exhaust Fuel oil Exhaust Fuel oil Exhaust Fuel oil Exhaust
D-RG
A-RG
C-RG

2016.02.15
MAN Diesel & Turbo
Plate
Page 1 (2) Roller guide and push rods P50801-20

L23/30H, L23/30S, L23/30DF

2016.07.06
 MAN Diesel & Turbo
Plate
P50801-20 Roller guide and push rods Page 2 (2)

L23/30H, L23/30S, L23/30DF

Item No. Qty Item Designation Item No. Qty Item Designation

016 1/C Housing for roller guides 1) 315 1/C Valve gear complete, as shown
on plate 50801 except item 161,
028 1/C Roller guide for pump 173, 185, 220, 232, 244, 256,
303, 339, 340
041 3/C Pin
053 3/C Bush 339 1/C Roller guide for pump complete,
incl item 028, 041, 053, 065,
065 3/C Roller 077, 089, 100, 112, 124

077 3/C Lock screw 340 2/C Roller guide for valve complete,
incl item 041, 053, 065, 077,
089 1/C Thrust pin 148, 281
090 1/C Washer for spring
100 1/C Spring
112 1/C Thrust pin
124 1/C 1 set of shims
136 2/C Screw
148 2/C Ball pin
161 8/C Washer
173 2/C Protecting tube
185 4/C O-ring
197 2/C Cover
207 2/C Lock screw
219 4/C Screw
220 2/C Gasket
232 1/C Gasket
244 2/C Guide pin
256 8/C Screw
268 4/C Thrust pin
281 2/C Roller guide for valve
293 2/C Push rod
303 2/C Push rod complete, incl. item
288, 293

When ordering spare parts, see also page 500.50/600.50/Pref- Note 1)

Require an individual matching before mounting, contact MAN
ace. Diesel & Turbo, Holeby
* = Only available as part of a spare parts kit/not availa-
ble separately
Qty/C = Qty/Cylinder

2016.07.06