L28-32H GenSet TierII PDF

L28/32H
Instruction Manual - Marine

Four-stroke GenSet
compliant with IMO Tier II
Complete manual
date 2012.07.17
MAN Diesel
GenSet Index
L28-2
Text Index Drawing No.
Engine data 500/600
Preface Description A6000

Warning Description A6001
Questionnaire Description A6002
Main particulars Description 600.00 (07H)
Introduction Description 600.01 (08H)
Safety Description 600.02 (06H)
Cross section Description 600.05 (07H)
Key for engine designation Description 600.10 (02H)
Designation of cylinders Description 600.11 (01H)
Engine rotation clockwise Description 600.12 (02H)
Code identification for instruments Description 600.20 (03H)
Introduction to planned maintenance programme Description 600.24 (02H)
Planned maintenance programme Description 600.25 (33H)
Operation data & set points Description 600.30 (50H)
Green Passport Description 600.33 (02H)
Data for pressure and tolerance Description 600.35 (16H)
Data for tightening torque Description 600.40 (18H)
Declaration of weight Description 600.45 (01H)
Ordering of spare parts Description 600.50 (06H)
How to return spare parts Description 600.51 (05H)
Service letters Description 600.55 (01H)
Conversion table Description 600.60 (01)
Basic symbol for piping Description 600.65 (01H)
Operation of engine 501/601
Operating Description 601.01 (21H)

Out of service Description 601.05 (17H)
Starting-up after out of service periods Description 601.10 (17H)
Guidelines for longterm low-load operation on HFO Description 601.15 (03H)
Guidelines regarding MAN Diesel GenSets operating on low Description 601.16 (02H)
sulphur fuel oil
Performance and condition 502/602
Engine performance and condition Description 602.01 (12H)

Evaluation of readings regarding combustion condition Description 602.02 (11H)
Condensate amount Description 602.05 (08H)
Engine performance data Working card 602-01.00 (03H)
Trouble shooting 503/603
Starting failure Description 603.01 (08H)

Faults in fuel oil system Description 603.02 (09H)
Disturbances during running Description 603.03 (08H)
Ignition in crankcase Description 603.04 (09H)
Trouble shooting guide for centrifugal by-pass filter Description 603.05 (08H)
Trouble shooting guide for turbine starter Description 603.06 (09H)
Trouble shooting guide for cooling water system Description 603.09 (08H)
Trouble shooting guide for lubricating oil cooler Description 603.10 (01H)
Media specification 504/604
Quality requirement for lube oil (SAE30) for heavy fuel oil operation Description 604.01 (27H)
(HFO)
MAN Diesel
Index GenSet
L28-2
Quality requirem. for lube oil (SAE30) for operation with gas oil, diesel Description 604.01 (26H)
oil (MGO/MDO) and biofuel
Treatment and maintenance of lubricating oil Description 604.03 (11H)
Criteria for cleaning/exchange of lubricating oil Description 604.04 (17H)
Lubricating points Description 604.05 (01H)
Lubricating points Description 604.05 (02H)
Lubricating oil in base frame Description 604.06 (16H)
Specific lube oil consumption - SLOC Description 604.07 (02H)
Heavy fuel oil (HFO) specification Description 3.3.3-01
Diesel oil (MDO) specification Description 3.3.2-01
Gas oil / diesel oil (MGO) specification Description 3.3.1-01
Bio fuel specification Description 3.3.1-02
Viscosity-temperature diagram (VT diagram) Description 3.3.4-01
Fuel oil cleaning Description 604.30 (01H)
Engine cooling water specifications Description 3.3.7-01
Cooling water inspecting Description 000.07-01
Cooling water system cleaning Description 000.08-01
Water specification for fuel-water emulsions Description 3.3.10-01
Specifications for intake air (combustion air) Description 3.3.11-01
Cylinder head 505/605
Cylinder head Description 605.01 (14H)

Dismantling of cylinder head Working card 605-01.00 (01H)
Inspection of inlet valve, exhaust valve and valve guide Working card 605-01.05 (06H)
Reconditioning of valve spindle seat and valve seat ring Working card 605-01.10 (01H)
Valve rotator Working card 605-01.15 (01H)
Replacement of valve guide Working card 605-01.20 (05H)
Safety valve Working card 605-01.25 (04H)
Indicator valve Working card 605-01.26 (02H)
Replacement of sleeve for fuel injector Working card 605-01.30 (04H)
Replacement of valve seat ring Working card 605-01.35 (06H)
Mounting of cylinder head Working card 605-01.40 (06H)
Inspection of cylinder head cooling water space Working card 605-01.45 (01H)
Cylinder head Plate 60501-19H
Valve spindles and valve gear Plate 60502-31H
Safety valve and indicator valve Plate 60508-11H
Cylinder head, top cover Plate 60510-12H
Piston/connecting rod 506/606
Piston, connecting rod and cylinder liner Description 606.01 (10H)

Dismounting of piston and connecting rod Working card 606-01.00 (01H)
Separation of piston and connecting rod Working card 606-01.05 (03H)
Piston Working card 606-01.10 (09H)
Connecting rod Working card 606-01.15 (04H)
Criteria for replacement of connecting rod big-end and main bearing Working card 606-01.16 (02H)
shells
Mounting of piston and connecting rod Working card 606-01.20 (01H)
Hydraulic tightening of connecting rod screws Working card 606-01.25 (04H)
In-situ inspection of connecting rod big-end bearing Working card 606-01.30 (01H)
Inspection and honing of cylinder liner Working card 606-01.35 (08H)
Replacement of cylinder liner Working card 606-01.40 (01H)
Grinding of seal face on cylinder liner and cylinder head Working card 606-01.45 (01H)
Dismounting of piston and cylinder liner at low overhaul heights Working card 606-01.50 (01H)
Piston and connecting rod (hydraulic tightened) Plate 60601-34H
Cylinder liner Plate 60610-09H
MAN Diesel
GenSet Index
L28-2
Camshaft 507/607
Camshaft and camshaft drive Description 607.01 (05H)

Camshaft and camshaft drive Working card 607-01.00 (01H)
Inspection and replacement of camshaft bearing Working card 607-01.05 (01H)
Adjustment of camshaft for valve and injection timing Working card 607-01.20 (04H)
Intermediate wheel Plate 60701-06H
Camshaft and camshaft bearing Plate 60705-22H
Operating gear 508/608
Operating gear for valves and fuel injection pumps Description 608.01 (12H)
Inspection of valve roller guides Working card 608-01.00 (01H)
Inspection of fuel injection pump roller guide Working card 608-01.05 (01H)
Control and adjustment of valve clearance Working card 608-01.10 (01H)
Roller guide and push rods Plate 60801-17H
Control/safety 509/609
Control and safety system Description 609.01 (20H)

Instruments and automatics Description 609.05 (11H)
Lambda controller Description 609.10 (15H)
Starting box Description 609.35 (06H)
Converter for engine- and turbocharger RPM signal Description 609.40 (01H)
Functional test and adjustment of safety, alarm and monitoring Working card 609-01.00 (01H)
equipment
Functional test and adjustment of overspeed trip Working card 609-01.05 (01H)
Adjustment and test of ON/OFF pressostate Working card 609-05.00 (02H)
Adjustment and test of ON/OFF thermostate Working card 609-05.01 (02H)
Function and test of level switch (LAL 25) Working card 609-05.02 (02H)
Adjustment and test of analogous transmitter Working card 609-05.03 (02H)
Adjustment and test of analogous temperature transmitter Working card 609-05.04 (02H)
Adjustment of lambda controller Working card 609-10.00 (16H)
Governor and governor drive Plate 60901-13H
Regulating mechanism Plate 60902-18H
Overspeed device Plate 60903-38H
Instrument panel Plate 60905-20H
Thermometer Plate 60907-19H
Pressostate, thermostate, diff. pressostate and pressure transmitter Plate 60907-02H
Prelubricating oil alarm (LAL 25) Plate 60919-01H
Level switch in oil sump (LAL/LAH 28) Plate 60920-01H
Local starting box - No 1 Plate 60935-13H
Local starting box - No 2 (incl. high lub. oil temp.) Plate 60935-15H
Engine control box Plate 60936-08H
Termnal box Plate 60936-07H
Converter Plate 60956-01
Crankshaft 510/610
Crankshaft and main bearings Description 610.01 (12H)

Checking of main bearings alignment (deflection), hydraulic Working card 610-01.00 (10H)
tigthened connecting rod
MAN Diesel
Index GenSet
L28-2
Inspection of main bearing shells Working card 610-01.05 (05H)

Inspection of guide bearing shells Working card 610-01.10 (08H)
Vibration damper Working card 610-04.00 (01H)
Crankshaft Plate 61001-15H
Crankshaft Plate 61001-21H
Resilient gear wheel Plate 61002-07H
Coupling for central drive lub. oil pump Plate 61002-11H
Flywheel with gear rim Plate 61003-02H
Torsional vibration damper Plate 61004-05H
Tuning wheel Plate 61004-06H
Engine frame/Oil pan 511/611
Engine frame and base frame Description 611.01 (07H)

Functional test of crankcase safety relief valves Working card 611-01.00 (04H)
Frame with main bearings Plate 61101-11H
Front cover for lubricating oil pump Plate 61102-09H
Front cover for lubricating oil pump and cooling water pump Plate 61102-07H
Front cover for lubricating oil pump and cooling water pumps Plate 61102-10H
Covers on frame Plate 61106-20H
Cover on frame Plate 61106-14H
Turbocharger 512/612
Turbocharger system Description 612.01 (28H)

Cleaning the turbocharger in service, water washing of compressor Description 612.05 (07H)
Cleaning the turbocharger in service, dry cleaning - turbine Description 612.10 (09H)
Cleaning the turbocharger in service, water washing - turbine side Description 612.15 (02H)
Overhaul of charging air cooler Working card 612-01.00 (02H)
Charge air cooler housing - draining Working card 612-01.05 (02H)
Water washing of compressor side - turbochager type NR15/R - Working card 612-05.00 (03H)
NR20/R - NR24/R - NR26/R
Dry cleaning of turbocharger - turbine side Working card 612-10.00 (02H)
Water washing of turbine side Working card 612-15.00 (01H)
Charging air cooler - freshwater Plate 61201-12H
Charging air cooler - seawater Plate 61201-16H
Charging air cooler - seawater Plate 61201-17H
Charging air cooler Plate 61201-29H
Exhaust pipe arrangement Plate 61202-23H
Exhaust pipe arrangement with welded compensator Plate 61202-32H
MAN Diesel
GenSet Index
L28-2

Water washing of compressor side Plate 61205-02H
Steam trap Plate 61208-01H
Blowgun for dry cleaning of turbocharger Plate 61210-02H
Compressed air system 513/613
Compressed air system Description 613.01 (20H)

Air filter Working card 613-01.21 (02H)
Overhaul, test and inspection of turbine starter Working card 613-01.30 (02H)
Main starting valve Working card 613-01.40 (01H)
Check of compressed air piping system Working card 613-01.90 (02H)
Turbine starter Plate 61309-05H
Main starting valve Plate 61310-03H
Muffler Plate 61312-02H
Emergency starting valve Plate 61313-03H
Starting valve Plate 61314-03H
Main stop valve Plate 61315-03H
Air strainer Plate 61316-03H
Safety valve Plate 61319-01H
ON-OFF valve for jet system Plate 61320-05H
ON-OFF valve for jet system Plate 61320-06H
Air filter Plate 61321-03H
Pressure reduction valve Plate 61322-04H
Turning gear Plate 61325-07H
Pneumatic turning gear (motor power unit) Plate 61325-08H
Pneumatic turning gear (spindle, gear case and gearing) Plate 61325-09H
Fuel oil system 514/614
Internal fuel oil system Description 614.01 (25H)

Fuel injection pump and fuel injection pipe Working card 614-01.05 (02H)
Fuel injection pump and fuel injection pipe Working card 614-01.05 (05H)
Fuel injection valve Working card 614-01.10 (03H)
Fuel oil split filter Working card 614-01.15 (01H)
Check of fuel oil piping system Working card 614-01.90 (01H)
Adjustment of the maximum combustion pressure Working card 614-05.01 (02H)
Fuel injection pump Plate 61401-03H
Fuel injection pump Plate 61401-09H
Fuel injection valve Plate 61402-04H
Fuel injection valve, cooled Plate 61402-07H
Fuel oil filter duplex Plate 61403-15H
Fuel injection pipe Plate 61404-06H
Pipes on cylinder section - forced lubrication with cooling oil pipes Plate 61430-03H
Nozzle cooling pump Plate 61440-05H
Lubricating oil system 515/615
Internal lubricating oil system Description 615.01 (29H)

Lubricating oil cooler Description 615.06 (02H)
Centrifugal by-pass filter Description 615.15 (05H)
Crankcase ventilation Description 615.31 (03H)
Lubricating oil pump, engine driven Working card 615-01.00 (01H)
Prelubricating pump Working card 615-01.05 (02H)
Lubricating oil filter Working card 615-01.10 (01H)
MAN Diesel
Index GenSet
L28-2
Lubricating oil, thermostatic valve Working card 615-01.20 (01H)

Check of lubricating oil piping system Working card 615-01.90 (01H)
Lubricating oil cooler Working card 615-06.00 (02H)
Centrifugal by-pass filter Working card 615-15.00 (01H)
Lubricating oil pump (central driven) Plate 61501-12H
Lubricating oil pump (gear driven) Plate 61501-22H
Lubricating oil filter (Type A) Plate 61502-11H
Lubricating oil filter (Type B) Plate 61502-12H
Lubricating oil filter (suppl. for plate 61502-11H/12H) Plate 61502-15H
Lubricating oil thermostatic valve Plate 61503-08H
Prelubricating pump with el-motor Plate 61504-04H
Lubricating oil cooler Plate 61506-10H
Centrifugal by-pass filter Plate 61515-09H
Hand wing pump Plate 61525-02H
Lubricating oil separator Plate 61530-07H
Lubricating oil pipes on engine Plate 61530-02H
Cooling water system 516/616
Cooling water system Description 616.01 (17H)

Cooling water thermostatic valve Description 616.04 (15H)
Check of cooling water system Working card 616-01.90 (01H)
Cooling water thermostatic valve Working card 616-04.00 (01H)
Cooling water thermostatic valve Plate 61604-07H
High temperature fresh water pump Plate 61610-05H
Low temperature fresh water pump Plate 61610-07H
Low temperature fresh water pump Plate 61610-10H
Sea water pump Plate 61615-04H
Pipes on cylinder head Plate 61625-04H
Cooling water pipes on engine Plate 61630-01H
Preheater - fresh water Plate 61635-06H
Special equipment 517/617
Kit for cylinder unit Kit 61704-02H

Kit for overspeed device Kit 61743-01H
Kit for covers on frame Kit 61751-01H
Specific plant information 519/619
Resilient mounting of generating sets Description 619.03 (10H)

Fitting instructions for resilient mountings of gensets Working card 619-03.00 (21H)
Replacement of conicals Working card 619-03.05 (01H)
Maintenance of conicals Working card 619-03.10 (01H)
Flexible external connections Plate 61902-03H
Conical element Plate 61903-04H
Tools 520/620
Introduction to spare part plates for tools Description 620.01 (01H)

Function of the hydraulic tools Working card 620-01.05 (03H)
Application of hydraulic tools Working card 620-01.06 (01H)
Hand lever pump Working card 620-01.07 (01H)
Maintenance of hydraulic tools Working card 620-01.10 (01H)
Tightening with torque spanner Working card 620-01.15 (01H)
MAN Diesel
GenSet Index
L28-2
Tool combinations for tightening of connecting rod screws Working card 620-01.20 (01H)
Max. pressure indicator Working card 620-01.25 (02H)
Tools for cylinder head Plate 62005-03H
Tools for piston, connecting rod and cylinder liner Plate 62006-11H
Tools for operating gear for inlet valves, exhaust valves and fuel Plate 62008-03H
injection pumps
Tools for control and safety systems, automatics and instruments Plate 62009-02H
Tools for crankshaft and main bearing Plate 62010-07H
Tools for fuel oil system and injection equipment Plate 62014-02H
Tools for lubricating oil system Plate 62015-02H
Hydraulic tools Plate 62021-08H
Tools for low overhaul height, piston, cylinder liner and connecting Plate 62050-01H
rod
Operating manual for testing tool (Fuel injection valve) Description GXO-D001
Engine data
500/600
MAN Diesel & Turbo
Instruction Manual for:
MAN Diesel & Turbo Identification No. for Instruction Manual.
Identification No. for Description: 000 . 00
Function
Section No.
Identification No. for Working Card: 000 - 00 . 00
Sub-function
Function
Section No.
Identification No. for Plates: 00000 - 00 H
H for Holeby
Edition
Section No. and Function
For ordering of spare parts, see page 500.50 / 600.50
All data provided in this document/manual is non-binding. This data serves informational purposes only and
is especially not guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes and
will be assessed and determined individually for each project. This will depend on the particular characteri-
stics of each individual project, especially specific site and operational conditions.
If this document/manual is delivered in another language than English and doubts arise concerning the
translation, the English text shall prevail.
Original instructions
2011.06.28
MAN Diesel & Turbo
MAN Diesel & Turbo | PrimeServ

The MAN Diesel & Turbo Group offers worldwide round-the-clock service, 365 days a year. Apart from the MAN
Diesel & Turbo service headquarters in Augsburg, Copenhagen, Frederikshavn, Holeby, Stockport, St. Nazaire, Tur-
bocharger and service centres on all continents provide comprehensive and continuous support. The long service
life associated with MAN Diesel engines dictates a spare parts programme that ensures components are available
for engines in operation for decades. Based on high-capacity machines, MAN Diesel & Turbo service production
facilities are able to comply with special customer requests with the utmost precision and flexibility.
24-hour hotline number:

+49 1801 15 15 15
http://www.mandieselturbo.com/primeserv
Copyright 2011 © MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany, registered with the Danish
Commerce and Companies Agency under CVR Nr.: 31611792, (herein referred to as “MAN Diesel & Turbo”).
This document/manual must not, either wholly or partly, be copied, reproduced, made publich or in any other way made
available to any third party without the written to this effect from MAN Diesel & Turbo.
MAN Diesel & Turbo PrimeServ Holeby MAN Diesel & Turbo
H. Christoffersensvej 6 GenSet & Powerplant Branch of MAN Diesel & Turbo SE,
4960 Holeby Service & Spare Parts Germany
Denmark CVR No.: 31611792
Phone: +45 54 69 31 00 Fax : +45 54 69 30 31 Head office: Teglholmsgade 41
Fax: +45 54 69 30 30 After office hours : +45 40 14 40 45 2450 Copenhagen SV, Denmark
[email protected] German Reg.No.: HRB 22056
[email protected] Amtsgericht Augsburg
www.mandieselturbo.com
2011.06.28
MAN Diesel & Turbo
Description
Page 1 (1) Warning
General
Warning !
(Marine engines only)
It is important that all MAN Diesel & Turbo engines

are operated within the given specifications and
performance tolerances specified in the engines'
Technical Files and are maintained according to
the MAN Diesel & Turbo 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 Federal
Regulations, Part 94, Subpart K, §94.1004 requires
that the emissions related maintenance of the die-
sel engine shall be performed as specified in MAN
Diesel & Turbo instructions including, but not limited
to, the instructions to that effect included in the
Technical File.
12.06 - ES0
MAN Diesel & Turbo Questionnaire – Technical Documentation
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Ring binders and organisation

Comments/suggestions:
Labelling of ring binders

Structuring of information and documents

Access aids (contents page, index, register, etc.)

Preparation of CDs/DVDs (navigation, etc.)

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Scope of information provided

Customer satisfaction
1 (1)
MAN Diesel & Turbo
Description
Main Particulars 600.00
Page 1 (1) Edition 07H
L28/32H
Cycle : 4-stroke
Configuration : In-line
Cyl. Nos. available : 5-6-7-8-9
Power range : 1050-1980 kW
Speed : 720/750 rpm
Bore : 280 mm
Stroke : 320 mm
Stroke/bore ratio : 1.14:1
Piston area per cyl. : 616 cm2
Swept volume per cyl. : 19.7 ltr.
Compression ratio : 13.9:1
Max. combustion pressure : 130 bar
Turbocharging principle : Constant pressure system and intercooling
Fuel quality acceptance : HFO (up to 700 cSt/50° C, RMK700)

MDO (DMB) - MGO (DMA, DMZ)
according ISO8217-2010
Power lay-out MCR version
Speed rpm 720 750
Mean piston speed m/sec. 7.7 8.0
Mean effective pressure bar 17.8 17.9
Max. combustion pressure bar 130 130
Power per cylinder kW/cyl. 210 220
Overload rating (up to 10%) allowable in 1 hour for every 12 hours
Power per cylinder kW/cyl. 230 240
11.36 - ES1 - Tier II - WB2 - GenSet

MAN Diesel & Turbo
Description 600.01
Page 1 (1) Introduction Edition 08H
General
Introduction Description
This instruction book provides general information The book is a basic instruction manual for the particu-
on the engine design, operation and maintenance. lar engine supplied, with plant-adapted information
It can also be used as a reference when ordering such as basic media-system drawings, electrical
spare parts. Reliable and economical operation of wiring diagrams and test bed reports.
the plant is conditional upon its correct operation
and maintenance in accordance with MAN Diesel & The first five sections (500-504) of the book serve
Turbo’s instructions. Emissions-related maintenance as a guide to engine operation, and the next fifteen
of the diesel engine shall be performed as speci- sections (505-519) contain technical descriptions,
fied in MAN Diesel & Turbo’s instructions and any spare parts illustrations with appurtenant parts lists,
additional instructions to that effect included in the as well as working cards.
Technical File. Consequently, it is essential that the
engine room personnel are fully acquainted with the The last section (520) comprises tools.
contents of this book and the Technical File.
The engine is divided into a number of main com-
Every care is taken to ensure that all information in ponents/assemblies, each of which is described in
this instruction book is present and correct. a section of this book (section 505-519).
This book must not, either wholly or partly, be copied, Each of these sections starts with technical de
reproduced, made public or in any other way made scriptions of the systems/components, followed by
available to any third party without the written consent working cards and the spare parts illustration plates
to this effect from MAN Diesel & Turbo. and parts lists.
If an instruction book is delivered in another language

than English and doubts arise concerning the trans-
lation, the English text shall prevail.
08028-0D/H5250/94.08.12
Fig. 1. Structuring of instruction book.
10.47 - ES0
MAN Diesel
Description
Safety 600.02
Page 1 (2)
Edition 06H
General
General Spares
Proper maintenance, which is the aim of this book, Large spare parts should, as far as possible, be pla-
constitutes the crucial point in obtaining optimum ced well strapped near the area of application and
safety in the engine room. The general measures accessible by crane. The spare parts should be well
mentioned here should therefore be a natural routine preserved against corrosion and protected against
to the entire engine room staff. mechanical damage. The stock should be checked
at intervals and replenished in time.
Cleanliness
Light
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the Ample working light should be permanently installed
engine room when the ship is in port, the ventilation at appropriate places in the engine room, and port-
should be stopped and ventilating ducts, skylights, able working light, in explosion-proof fittings, should
and doors in the engine room should be closed. be obtainable everywhere.
In particular, welding or work which causes spreading

of grit and chips must be avoided near the engine, Freezing
unless this is closed or covered, and the turbochar-
ger air intake filters are covered. If there is a risk of damage due to freezing when the
plant is out of service, engines, pumps, coolers, and
The exterior of the engine should be kept clean and pipe systems should be emptied of cooling water.
the paintwork maintained so that leakages can easily
be detected.
Warning
Fire The opening of cocks may cause discharge of hot

liquids or gases. The dismantling of parts may cause
If the crankcase is opened before the engine is cold, springs to be released.
welding and the use of naked light will involve the risk
of explosions and fire.The same applies to inspection The removal of fuel valves (or other valves in the
of oil tanks and the space below the fooler. Attention cylinder head) may cause oil to run down to the
is furthermore drawn to the danger of fire when using piston crown, and if the piston is hot, an explosion
paint and solvents with a low flash point. Porous may then blow out the valve.
insulating material drenched with oil from leakages
is easily inflammable and should be renewed. See When testing fuel valves with the hand pump, do not
also: "Ignition in crankcase" in section 603. touch the spray holes, as the jet may pierce the skin.
Think out beforehand which way the liquids, gases
or flames will move, and keep clear.
Order
08028-0D/H5250/94.08.12
Hand tools should be placed easily accessible on Crankcase work

tool boards. Special tools should be fastened to tool
panels (if supplied) in the engine room close to the Check beforehand that the starting air supply to the
area of application. No major objects must be left engine is shut off.
unfastened, and the floor and passages should be
kept clear.
91.12 - ES0U
MAN Diesel
600.02 Safety Description
Page 2 (2)
Edition 06H
General
Feeling over Turning with air
Whenever repairs or alterations have been made to After prolonged out-of-service periods or overhaul
the running gear, apply the "Feel-over sequence" work which may involve a risk of accumulation of
until ensured that there is no undue heating, oil- liquid in the combustion spaces, turning with open
mist formation, blow-by, or failure of cooling water indicator cocks should always be effected, through
or lubricating oil systems. at least two complete revolutions.
Feel-over sequence Check and maintain
Feel-over after 5-15 and 30 minutes' idle running and Lubricating oil condition, filter elements and mea-
finally when the engine is running at full load. See suring equipment.
also "Starting-up sequence" in the section 602.
91.12 - ES0U
MAN Diesel & Turbo
Description 600.05
Page 1 (1) Cross Section Edition 07H
L28/32H
10.36 - ES1
MAN Diesel
Description 600.10
Page 1 (1) Key for Engine Designation Edition 02H
General
Engine Type Identification
The engine types of the MAN B&W programme are identified by the following figures:
6 L 28/32 H MCR
No of cylinders
5, 6, 7, 8, 9
12, 16, 18
Engine Type
L : In-line
V : V-built
Cyl. diam/stroke
16/24 : 160/240
21/31 : 210/310
23/30 : 225/300
27/38 : 270/380
28/32 : 280/320
32/40 : 320/400
Design Variant
Rating
08028-0D/H5250/94.08.12
MCR : Maximum continuous rating

ECR : Economy continuous rating
04.08 - ES1
MAN Diesel
Description 600.11
Page 1 (1) Designation of Cylinders Edition 01H
L28/32H
Front End Flywheel end
Exhaust Side / Right Side
Control Side / Camshaft Side / Left Side

08028-0D/H5250/94.08.12
89.17 - ES1S-L
MAN Diesel & Turbo
Description
Page 1 (1) Engine Rotation Clockwise 600.12
Edition 02H
General
Direction of rotation seen from flywheel end “Clockwise”
Engine
Alternator
10.39 - ES1
MAN Diesel & Turbo
Description
Code Identification for Instruments 600.20
General
Explanation of Symbols
TI Measuring device
40 Local reading
Temperature Indicator
No. 40 *
Measuring device
PI Sensor mounted on engine/unit
22 Reading/identification mounted in a panel on the engine/unit
Pressure Indicator
No. 22 *
Measuring device
TAH Sensor mounted on engine/unit
12 Reading/identification outside the engine/unit
Temperature Alarm High

No. 12 *
Measureing device
PT Sensor mounted on engine/unit
22 Reading/identification in a panel on the engine/unit and reading/indication out-
side the engine/unit
Pressure Transmitting
No. 22 *
* Refer to standard location and text for instruments on the following pages.
Specification 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
11.19 - ES1
MAN Diesel & Turbo
600.20 Code Identification for Instruments Description
Edition 03H Page 2 (2)
General
Standard Text for Instruments
Diesel Engine/Alternator
LT Water System
01 inlet to air cooler 04 inlet to alternator 07 inlet to lub. oil cooler
02 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 System
10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler
10A FW inlet to engine 14A FW inlet to air cooler 18 inlet to fresh water cooler
11 outlet from each cylinder 14B FW outlet from air cooler 19 preheater
12 outlet from engine 15 outlet from HT system 19A inlet to prechamber
13 inlet to HT pump 16 outlet from turbocharger 19B outlet from prechamber
Lubricating Oil System

20 inlet to cooler 24 sealing oil - inlet engine 28 level in base frame
21 outlet from cooler / inlet to filter 25 prelubricating 29 main bearings
22 outlet from filter / inlet to engine 26 inlet rocker arms and roller guides
23 inlet to turbocharger 27 intermediate bearing / alternator bearing
Charging Air System

30 inlet to cooler 34 charge air conditioning 38
31 outlet from cooler 35 surplus air inlet 39
32 jet assist system 36 inlet to turbocharger
33 outlet from TC filter / inlet to TC compr. 37 charge air from mixer
Fuel Oil System

40 inlet to engine 44 outlet from sealing oil pump 48
41 outlet from engine 45 fuel-rack position 49
42 leakage 46 inlet to prechamber
43 inlet to filter 47
Nozzle Cooling System

50 inlet to fuel valves 54 58 oil splash
51 outlet from fuel valves 55 valve timing 59 alternator load
52 56 injection timing
53 57 earth/diff. protection
Exhaust Gas System

60 outlet from cylinder 64 68
61 outlet from turbocharger 65 69
62 inlet to turbocharger 66
63 compustion chamber 67
Compressed Air System

70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system
71 inlet to stop cylinder 75 microswitch for turning gear 79
72 inlet to balance arm unit 76 inlet to turning gear
73 control air 77 waste gate pressure
Load Speed
80 overspeed air 84 engine stop 88 index - fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocharger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine start 87 ready to start
Miscellaneous
91 natural gas - inlet to engine 94 cylinder lubricating 97 remote
92 oil mist detector 95 voltage 98 alternator winding
93 knocking sensor 96 switch for operating location 99 common alarm
100 inlet to MDO cooler 101 outlet to MDO Cooler 102 alternator cooling air
11.19 - ES1
MAN Diesel
Description
Introduction to Planned Maintenance Programme 600.24
Page 1 (1)
Edition 02H
General
General 4. Related procedures - indicates other works,
depending on this work - or works which would be
The overhaul intervals are based on operation on expedient to carry out.
a specified fuel oil quality at normal service output,
which means 70-100% of MCR. 5. Indicates x number of men in x number of hours
for accomplishing the work.
In the long run it is not possible to obtain a secure
and optimal economic running without an effective The stated consumption of hours is only intended
maintenance system. as guide.
With the structure and amount of information in the Experience with the specific station/crew may lead
maintenance programme, it can be integrated in the to a bringing up-to-date.
entire ship's/power station's maintenance system or
it can be used separately. 6. Refers to data, which are required for carrying
out the work.
The crux of the maintenance system is the key dia-
gram, see page 600.25, indicating the inspection 7. Special tools, which must be used. Please note
intervals for the components/systems, so that the that not all tools are standard equipment.
crew can make the necessary overhauls, based on
the engines' condition and/or the time criteria. 8. Various requisite hand tools.
The stated, recommended intervals are only for 9. Indicates the components/parts, which it is
guidance as different service conditions, the quality advisible to replace during the maintenance work.
of the fuel oil and the lubricating oil, treatment of the Please note, that this is a condition for the intervals
cooling water, etc, will decisively influence on the stated.
actual service results and thus the intervals between
necessary overhauls.
Experience with the specific plant/crew is to be used

for adjustment of time between overhaul. Further it
is to be used for adjusting the timetable stated for
guidance in the working cards.
1
7
Working cards
2
Each of the working cards can be divided into two:
a front page and one or several pages, describing
and illustrating the maintenance work. 3
8
The front page indicates the following:
08028-0D/H5250/94.08.12
1. Safety regulations, which MUST be carried

through before the maintenance work can start.
5
9
2. A brief description of the work. 6
3. Reference to work, which must be carried out,

if any, before the maintenance work can start.
Fig 1. Guidance instruction for working cards.
94.35 - ES0S
MAN Diesel
Description 600.25
Page 1 (4) Planned Maintenance Program Edition 33H
L28/32H
Time Between Overhaul
Overhauled parts
Working
Observations
● = Overhaul to be carried out
Description
3th month
Card
Check new/
after -hours
200
8000
16000
32000
Weekly
50
2000
Montly
■ = Check the condition
Daily
No.
Operating of Engine:
Readings of data for Engine and Generator, with refe-

rence to "Engine Performance Data", section 602-1........ ■ 602-01.00
Cylinder Head:
Inlet and exhaust valve - Overhaul and regrinding of

spindel and valve seat...................................................... ● 605-01.10
Inspection of inlet, exhaust valves and valve guide.......... ■ 605-01.05
Check of valve rotators rotation during engine rotation.... ■ 605-01.05
Sleeve for fuel injector...................................................... ■ 605-01.30
Safety valve - Overhaul and adjustment of opening
pressure........................................................................... ■ 605-01.25
Indicator valve.................................................................. ■ ■ 605-01.26
Cylinder head cooling water space - Inspection............... ■ 605-01.45

Cylinder head nut - Retightening...................................... 200 605-01.40
Piston, Connecting Rod and Cylinder Liner:
Inspection of piston.......................................................... ■ 606-01.10

Piston ring and scraper ring............................................. ● 606-01.10
Piston pin and bush for connecting rod - Check of

clearance.......................................................................... ■ 606-01.15
Connecting rod - Measuring of big-end bore.................... ■ 606-01.15
Inspection of big-end bearings shells............................... ■ 606-01.16
Connecting rod - Retightening.......................................... 200 ■ 606-01.25

Cylinder liner - Cleaning, honing and measuring............. ● 606-01.35
Cylinder liner removed - Check the water space and
08028-0D/H5250/94.08.12
guide ring in frame............................................................ ■ 606-01.40
Camshaft and Camshaft Drive:
Camshaft - Inspection of gear wheels, bolt, connections

etc..................................................................................... 200 ■ 607-01.00
Camshaft bearing - Inspection of clearance..................... ■ 607-01.05
Camshaft adjustment - Check the condition..................... ■ 607-01.20
Lubrication of camshaft bearing - Check.......................... ■ 607-01.00
09.48 - ES0
MAN Diesel
600.25 Description
Edition 33H
Planned Maintenance Program Page 2 (4)
L28/32H
Overhauled parts
Working
Observations
Description
3th month
Card
Check new/
after -hours
50
2000
8000
200
32000
Weekly
16000
Montly
Daily
No.
Operating Gear for Inlet Valves, Exhaust Valves and

Fuel Injection Pumps:
Roller guide for valve gear................................................ ■ 608-01.00

Valve gear - Valve bridge, spring, push rod, etc............... ■ 608-01.10
Roller guide for fuel injection pump.................................. ■ 608-01.05
Roller guide housing......................................................... ■ 608-01.10

Inlet and exhaust valve - Check and adjustment of valve
clearance.......................................................................... ■ 608-01.10
Lubricating of operating gear - Check.............................. ■ 608-01.00

608-01.05
Control and Safety System, Automatics and

Instruments:
Safety, alarm and monitoring equipment ......................... ■ 609-01.00
Jet system - Adjustment................................................... ■ 609-01.00

Pick-up - Adjustment........................................................ ■ 609-10.00

Governor - Check oil level, see governor instruction
book, section 609............................................................. ■
Crankshaft and Main Bearing:

Checking of main bearings aligment, (autolog)................ ■ 610-01.00
Inspection af main bearing............................................... ■ 610-01.05
Inspection of guide bearing.............................................. ■ 610-01.10
Vibration damper - Check the condition........................... ■ 610-04.00

08028-0D/H5250/94.08.12
Lubricating of gear wheel for lub. oil pump and cooling

water pump etc................................................................. ■
Counter weight - Retightening, see page 600.40............. 200 ■
Main- and guide bearing cap - Retightening.................... 200 ■ 610-01.05

610-01.10
09.48 - ES0
MAN Diesel
Description 600.25
Page 3 (4) Planned Maintenance Program Edition 33H
L28/32H
Overhauled parts
Working
Observations
Description
3th month
Card
Check new/
after -hours
50
2000
8000
200
32000
Weekly
16000
Montly
Daily
No.
Engine Frame and Bedplate:
Holding down bolts - Retightening, see page 600.40....... 200 ■

Bolts between engine frame and base frame -
Retightening, see page 600.40........................................ 200 ■
For flexible mounted engines - Check anti-vibration

mountings......................................................................... 200 ■ 619-03.00
Safety cover - Function test.............................................. ■ 611-01.00
Turbocharger System:
Dry cleaning of turbine side.............................................. ● 612-10.00

Wet cleaning of turbine side............................................. ● 612-15.00
Water washing of compressor side.................................. ● 612-05.00
Cleaning of air filter - Compressor side (see turbo-

charger instruction book)..................................................
Turbocharger complete - Dismantling, cleaning, inspec-
tion etc. (see turbocharger instruction book)....................
Charging air cooler - Cleaning and inspection................. ■ 612-01.00
Charging air cooler housing - Draining............................. ●

Exhaust pipe - Compensator............................................ ■
Compressed Air System:
Air starter motor - Dismantling and inspection................. ■ 613-01.30

Function test - Main starting valve, starting valve, main
valves and emergency start valve.................................... ■ 613-01.40

08028-0D/H5250/94.08.12
Dirt separator - Dismantling and cleaning........................ ●

Muffler - Dismantling and cleaning................................... ●
Compressed air system - Draining................................... ● 613-01.90

Compressed air system - Check of the system................ ■ 613-01.90
Drain of bowl..................................................................... ● 613-01.21

(filter element to be replaced when pressure drop
exceeds 0.7 bar)
09.48 - ES0
MAN Diesel
600.25 Description
Edition 33H
Planned Maintenance Program Page 4 (4)
L28/32H
Overhauled parts
Working
Observations
Description
3th month
Card
Check new/
after -hours
50
2000
8000
200
32000
Weekly
16000
Montly
Daily
No.
Fuel Oil System and Injection Equipment:
Fuel oil filter - Dismantling and cleaning........................... ● 614-01.15

Fuel oil feed pump............................................................ ● 614-10.00
Fuel oil injection pump - Dismantling and cleaning.......... ● 614-01.05
Fuel injection valve - Adjustment of opening pressure..... 200 ■ 614-01.10

Fuel oil high-pressure pipe - Dismantling and check........ ■ 614-01.05
Adjustment of the maximum combustion pressure........... ● 614-05.01
Fuel oil system - Check the system.................................. ■ 614-01.90

Nozzle cooling system - Check the system...................... ■ 614-01.90
Fuel oil - Oil samples after every bunkering, see sec.604.
Lubricating Oil System:
Lubricating oil pump - Engine driven................................ ■ 615-01.00

Lubricating oil filter - Cleaning and exhange.................... ● 615-01.10
Lubricating oil cooler........................................................ ● 615-06.00
Prelubricating pump - El. driven....................................... ■ 615-01.05

Thermostatic valve........................................................... ■ 615-01.20
Centrifugal filter - Cleaning and exhange of paper........... ● 615-15.00
Lubricating oil - Oil samples, see section 604.................. ■

Lubricating oil system - Check the system....................... ■ 615-01.90
Cooling Water System:
Cooling water pump - Engine driven (sea water and

fresh water)...................................................................... ■
08028-0D/H5250/94.08.12
Thermostatic valve........................................................... ■
Cooling water system - Check the system....................... ■ 616-01.90
Cooling water system - Water samples, see sec. 604...... ■ ■
09.48 - ES0
MAN Diesel & Turbo
Description
Operation Data & Set Points 600.30
L28/32H
Acceptable
Normal Value at Full load value at shop
at ISO conditions test or after Alarm Set point Autostop of engine
repair
Temp. before cooler SAE 30 TI 20 60-75° C <75° C TAH 20 90° C

(outlet engine) SAE 40 TI 20 65-82° C <82° C TAH 20 100° C
Temp. after cooler SAE 30 TI 22 45-65° C <65° C TAH 22 75° C TSH 22 85° C
(inlet engine) SAE 40 TI 22 50-72° C <72° C TAH 22 85° C TSH 22 95° C
Pressure after filter (inlet eng) PI 22 3.5-4 bar >4.0 bar PAL 22 3 bar PSL 22 2.5 bar
Elevated pressure i.g. when
centrifugal filter installed PI 22 4-5 bar >4.5 bar PAL 22 3.5 bar PSL 22 3.0 bar
Pressure drop across filter PDAH 21-22 0.5-1 bar <0.5 bar PDAH 21-22 1.5 bar
Prelubricating pressure LAL 25 level switch
Pressure inlet turbocharger PI 23 1.5 ±0.2 bar >1.5 bar
Lub. oil, level in base frame LAL 28/ low/high level
LAH 28
Temp. main bearings TE 29 75-85° C <85° C TAH 29 95° C
Fuel Oil System
Pressure after filter MDO PI 40 2.5-5 bar PAL 40 1.5 bar

HFO PI 40 5-16 bar (A) PAL 40 4 bar
Leaking oil LAH 42 leakage
Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar (B)
Temp. nozz. cool. oil, outlet eng. TI 51 80-90° C 95° C (B)
Cooling Water System
Press. LT-system, inlet engine PI 01 1-2.5 bar (D) >1.3 bar PAL 01 0.4 bar + (C)
Press. HT-system, inlet engine PI 10 1.5-4.6 bar >1.8-<6 bar PAL 10 0.4 bar + (C)
Temp. HT-system, inlet engine TI 10 60-75° C
Temp. HT-system, outl. cyl.units TI 11 70-85° C <85° C
Temp. HT-system, outlet engine TAH 12 90° C TSH 12 95° C
TAH 12-2 93° C
Temp. raise across cyl. units max. 10° C
Exhaust Gas and Charge Air
Exh. gas temp. before TC TI 62 425-475° C TAH 62 550° C

TAH 62-2 600° C
Exh. gas temp. outlet cyl. TI 60 270-380° C TAH 60 410° C
Diff. between individual cyl. average TAD 60 average (F)
±25° C ±50° C
Exh. gas temp. after TC TI 61 275-350° C TAH 61 500° C
Ch. air press. after cooler PI 31 2-2.5 bar
Ch. air temp. after cooler TI 31 35-55° C <55° C TAH 31 65° C
Compressed Air System
Press. inlet engine PI 70 7-9 bar >7.5-<9 bar PAL 70 7 bar
Specific plants will not comprise alarm equipment and autostop for all parameters listed above. For specific plants additional parameters
can be included. For remarks to some parameters, see overleaf.
10° C change in ambient temperature correspond to approx. 15° C exhaust gas temperature change
11.33 - ES1
MAN Diesel & Turbo
600.30 Operation Data & Set Points

Descriptoin
L28/32H
Acceptable
Normal Value at Full load value at shop
at ISO conditions test or after Alarm Set point Autostop of engine
repair
Speed Control System

Engine speed
GenSets for 60 Hz
Mechanical
Elec. SI 90 720 rpm 820 rpm SAH 81 815 rpm SSH 81 825 rpm
GenSets for 50 Hz SSH 81 815 rpm
Mechanical
Elec. SI 90 750 rpm 855 rpm SAH 81 850 rpm SSH 81 860 rpm
SSH 81 850 rpm
Turbocharger speed SI 89 (G) SAH 89 (E)
Remarks to individual Parameters E. Limits for Turbocharger Overspeed Alarm

(SAH 89)
A. Fuel Oil Pressure, HFO-operation.
Engine type 720 rpm 750 rpm
When operating on HFO, the system pressure must
5L28/32H 42,680 42,680
be sufficient to depress any tendency to gasification
6L28/32H 42,680 42,680
of the hot fuel.
7L28/32H 34,900 34,900
8L28/32H 34,900 34,900
The system pressure has to be adjusted according
9L28/32H 36,180 36,180
to the fuel oil preheating temperature.
B. Nozzle Cooling Oil System

F. Exhaust Gas Temperatures
The nozzle cooling oil system is only applied for Tier
II marine and stationary engines. The exhaust gas temperature deviation alarm is
normally ±50° C with a delay of 1 min., but at start-up
C. Cooling Water Pressure, Alarm Set Points. the delay is 5 min. Furthermore the deviation limit is
±100° C if the average temperature is below 200° C.
As the system pressure in case of pump failure will
depend on the height of the expansion tank above G. Turbocharger Speed
the engine, the alarm set point has to be adjusted
to 0.4 bar plus the static pressure. Normal value at full load of the turbocharger is de-
pendent on engine type (cyl. no) and engine rpm.
D. Press. LT -system, inlet engine (PI 01) The value given is just a guide line. Actual values
can be found in the acceptance test protocol.
With two-string cooling water system the normal
value can be higher, max. 4.0 bar.
11.33 - ES1
MAN Diesel & Turbo
Description
"Green Passport" 600.33
General
In 2009 IMO adopted the „Hong Kong International
Convention for the Safe and Environmentally Sound
Recycling of Ships, 2009“
Until this convention enters into force the recommen-

datory guidelines “Resolution A.962(23)” (adopted
2003) apply. This resolution has been implemented
by some classification societies as “Green Passport”.
MAN Diesel & Turbo is able to provide a list of ha-

zardous materials complying with the requirements
of the IMO Convention. This list is accepted by
classification societies as a material declaration for
“Green Passport”.
This material declaration can be provided on request.
11.08 - ES0
MAN Diesel & Turbo
Description
Data for Pressure and Tolerance 600.35
L28/32H
Section Description mm. / bar
605 Safety valve to be adjusted to 170 bar

Maximum inner diameter, valve guide 18.35 mm.
For grinding of valve spindle and valve seat ring
(see also working card 605-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H" 1 6.5 mm.
Maximum height of spindle above cylinder head, "H" 2 108.0 mm
606 Piston and piston ring grooves (see working card 606-01.10)
Clearance between connecting rod bush and piston pin 0.15 - 0.25 mm.
Maximum ovalness in big-end bore (without bearing) 0.10 mm.
New cylinder liner, inside diameter 280.03 - 280.08 mm.
Maximum inside diameter cylinder liner 280.60 mm.
607 Clearance between camshaft and camshaft bearing 0.13 - 0.22 mm.
Maximum clearance between camshaft and camshaft bearing 0.35 mm.
Clearance between tooths on intermediate wheel 0.20 - 0.30 mm
Plunger lift at TDC, injection timing:
IMO Tier II - D2, 720 rpm 8.30+0.05 mm*
IMO Tier II - D2, 750 rpm 8.27+0.05 mm*
*) for information on max settings check the engine's IMO Technical file.
Plunger Lift, World Bank II**
**) Standard injection timing value is based on ISO condition.
Special injection timing of engines can be necessary due to
Power plant size and/or Ambient conditions.
608 Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm.
Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.90 mm.
Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm.
609 Clearance between pick-up and impulse wheel 1 ±0.3 mm

Adjustment of Lambda controller.
(see working card 609-10.00)
610 Clearance (equal on both sides) between main bearing cap and frame,
before tightening of bracing screw (side screw) 0.06 ± 0.02 mm
Deflection of crankchaft (autolog) (see working card 510-01.00)
Clearance between crankshaft and sealing ring, (upper and lower part) 0.3 - 0.4 mm.
Clearance in main bearing 0,2-0,344 mm
Clearance in guide bearing (axial) 0.15 - 0.46 mm
Maximum clearance in guide bearing (axial) 0.8 mm
Clearance between bearing and gearwheel shaft:
Clearance when new bearings are mounted 0.125-0.200
Maximum clearance 0.250
Clearance axial 0.2-0.3
611 Opening pressure of safety relief valves (on crankcase), max: 0.20 bar
12.08 - ESO, Tier II

MAN Diesel & Turbo
600.35 Data for Pressure and Tolerance Description

L28/32H
Section Description mm. / bar
614 Maximum combustion pressure at full load Max 133 bar

Individual cylinders; admissible deviation from average ± 3 bar
A change of the height of the thrust piece spacer ring of 0.10 mm.
will change the maximum pressure by 1 bar
1° turning of camshaft gear wheel changes max. pressure by approx 6 bar
Measurement "X" between thrust piece and roller guide housing 11 ± 0.2 mm
Opening pressure of fuel valve 320 bar
Pressure testing, cooling oil sealing, on fuel valve 100 bar
12.08 - ESO, Tier II

MAN Diesel & Turbo
Description 600.40
Page 1 (2) Data for Tightening Torque Edition 18H
L+V28/32H
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
605 Cylinder head stud (in frame) Stud M 39 200 Loctite 243
Nut for cylinder head stud Nut M 39 x 3 700 Oil / Molykote
(Unimol gl 82)
606 Connecting rod screw

(see working card 606-01.25) Molykote
Connecting rod screw (hydraulic Stud M 39 x 3 (Unimol gl 82)
tightening) Nut M 39 x 3 700 –
Molykote
607 Camshaft assembling Nut M 12 85 (Unimol gl 82)
Gear wheel on camshaft Screw M 12 70 –
Intermediate wheel shaft Nut M 22 x 1.5 250 –
Intermediate wheel assembling Nut M 12 50 –
Gear wheel on crankshaft Nut M 12 50 –
608 Housing for valve gear Screw M 16 160 –

Rocker arm bracket Nut M 12 40 –
610 Main bearing stud (in frame) Stud M 56 200 Loctite 243
Molykote
Nut for main bearing stud Nut M 52 x 3 900 (Unimol gl 82)
Main bearing side screw - L28/32H Screw M 24 350 –
Main bearing side screw - V28/32H Screw M 30 600 –
Counterweight on crankshaft Screw M 26 x 1.5 300 –
Vibration damper on crankshaft Nut M 30 500 –
Flywheel mountng (witout fitted bolt) Nut M30 1350 oil
Flywheel mounting (with fitted bolt)
- L28/32H Nut M 30 1350 –
- V28/32H Nut M 30 480 –
Gear rim on flywheel Screw M 16 75 –
611 Frame / baseframe Nut M 24 500 –
(3 x cross-tightening
614 Fuel-pump connecting piece Screw M 10 60 20 - 40 - 60 Nm) –
Fuel-pump top flange (barrel) Screw M 12 100 –
Fuel-pump cavitation plugs Plug M 20 x 1.5 100 - 120 –
Fuel-pump mounting Screw M16 150 –
Fuel-valve (nozzle nut) Nut M 26 x 1.5 100 - 120 –
Fuel-valve mounting Nut M 16 30 –
Fuel-valve (lock nut) Nut M 16 x 1.5 100 –
High pressure pipe Nut M 22 x 1.5 60 –
09.24
MAN Diesel & Turbo
600.40 Description
Edition 18H Data for Tightening Torque Page 2 (2)
L+V28/32H
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
Molykote
615 Gear wheel on lub. oil pump Nut M 30 x 2 400 (Unimol gl 82)
616 Impeller and gear wheel on fresh-

water cooling pump - L28/32H Nut M 24 x 1.5 250 –
Impeller and gear wheel on fresh-
water cooling pump - V28/32H Nut M 33 x 2 400 –
619 Conical elements mounting

- L28/32H
Upper mounting Screw M 20 150 –
Lower mounting Screw/ M 20 320 –
Nut
Sandwich elements mounting

- V28/32H
Upper mounting Screw M 16 165 –
Lower mounting Screw M 16 165 –
09.24
MAN Diesel & Turbo
Description
Declaration of Weight 600.45
L28/32H
Section Component Plate No. Item No. Weight in Kg.
605 Cylinder Head, incl. rocker arms 60501-60502 255

60508-60510
606 Piston, complete 60601 08 40

Piston Pin 60601 01 19
Connecting Rod, complete 60601 06 81
Cylinder Liner, complete 60610 10 119
Cooling Water Jacket 60610 15 33
607 Camshaft, section 60705 02, 16, 20 29
608 Housing for Roller Guide 60801 20 17
609 Governor, complete 60901 01-09-10 28
611 Main Bearing Cap 61101 26 75

Guide Bearing Cap 61101 19 85
Front cover 61102 01 164
End cover, complete 61106 11 179
612 Turbocharger, complete See special

instruction
Intermediate piece 61202 26 9
Air Cooler 61203 38 450
Inlet Bend 61203 33 93
Charging Air Cooler Housing 61203 34 350
613 Air Starter 61309 63 40
614 Fuel Injection Pump 61401 01-02 15

Fuel Injection Valve 61402 02 5
Fuel Oil Feed Pump 61410 22 22
615 Lubricating Oil Pump 61501 35 45

Thermostatic Valve 61503 11 29
Prelubricating Oil Pump, incl. el-motor 61504 25 20
Centrifugal Filter 61515 33 24
616 Thermostatic Valve 61604 11 29

Cooling Water Pump 61610 19 30
00.32 - ES0U
MAN Diesel & Turbo
Description 600.50
Page 1 (2) Ordering of Spare Parts Edition 06H
General
Spare parts can be ordered from MAN Diesel & Note:
Turbo, PrimeServ.
• Components from different engine builders
When spare parts are ordered or inquired, the fol- cannot be considered as interchangeable.
lowing data must be indicated, in order to ensure • A wide number of spare parts can be orders
correct identification of the required parts: as spare part kits.
• Selected components may be available in both
• Name of customer original and upgraded version.
• Name of plant /vessel
• Vessel IMO No These data are necessary to ensure supply of the
• Engine type correct spare parts for a particular engine, even
• Engine serial No though the spare part illustrations contained in this
• Engine builder book may not always be in complete accordance
• Plate No and edition No with the individual components of a specific engine.
• Item No
• Quantity For ordering of spare parts for governor, turbocharger
• Designation of the item No and alternator, please see the special chapter in the
instruction book for these components.
Information found on the nameplate of the engine(s)

Example:
Name of customer Name of Plant/Vessel IMO No Engine type Engine Engine builder
serial No
Mercy Ship Africa Mercy L7803188 5L21/31 SB5L21-10799 MAN Diesel & Turbo
or Licensee
Information found on each plate at the instruction manual:
Plate No Edition No Item No Qty. Description

51435 13 440 1 Leak oil pipe
12.11 - ES0
MAN Diesel & Turbo
Description
Ordering of Spare Parts 500.50
600.50
Page 2 (2)
Edition06H
Edition 03
General

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]
12.11 - ES0
MAN Diesel & Turbo
Description 600.51
Page 1 (1) How to Return Spare Parts and/or Tools Edition 05H
General
How to return spare parts and/or tools
If the unfortunate situation occurs that your spare - If you return to Holeby instead of Frederikshavn,
parts do not fit or is damaged in any way, you need you will have to pay freight charges of minimum
to return your spare parts to us. EUR 70,-
The return procedure is as follows: Please return by cheapest mean to the below address:
Send an email to our office via - Spare Parts:

Holeby: [email protected] or MAN Diesel & Turbo
Frederikshavn: [email protected] Niels Juels Vej 15
9900 Frederikshavn
Clearly stating: Denmark
- Our order number Att: Dept.: Store (WLS-FRH)
- Item numbers
- Reason for return - Tools:
- Your reference MAN Diesel & Turbo
- Pictures of damaged parts – if any. Langerak 74
9900 Frederikshavn
Please be noted that your parts are not to be re- Denmark
turned unless there is an agreement with our Sales Att: Dept.: Service Center (DC5)
Coordinators and/or Superintendents.
For returns to Singapore warehouse please use the
When parts are received in good condition, we will following address:
issue a credit-note. Please mark the box with our
order number or attach a copy of our packing list. MAN Diesel & Turbo Singapore Pte. Ltd.
14 Tuas Avenue 1
For return of tools please mark the box withour project Singapore 639499
name and number on the box (P-xxxxx) Att.: Logistic Centre, Asia
Note: Please be aware that it is only spare parts

Remarks: that have been purchased in Singapore that can be
returned to Singapore warehouse.
Please note that spare parts and/or tools are not
to be returned unless there is a written agreement
with MAN Diesel & Turbo, PrimeServ in Holeby or
Frederikshavn.
- If you return your spare parts and/or tools with-

out a written agreement you will be charged a
fee for unauthorised returns.
08028-0D/H5250/94.08.12
11.09 - ES0
MAN Diesel
Description
Service Letters 600.55
Page 1 (1)
Edition 01H
General
Description
In order to ensure the most efficient, economical and Since new service letters might be of great impor-
up-to-date operation of our engines, we regularly send tance to the operation of the plant, we recommend
out "Service Letters" containing first-hand information that engine staff file them as supplements to the
regarding accumulated service experience. relevant chapters of this instruction book.
The service letters can either deal with specific

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 instruction books.
08028-0D/H5250/94.08.12
91.14 - ES0
MAN Diesel
Description
Conversion Table 600.60
Page 1 (3) Edition 01
General
Basic Sl Units Velocity, Speed (m/s) (3.6 km/h = 1 m/s)
Quantity Name Symbol 1 kn (knot) = 1 nautical mile/h 1.852 km/h = 0.5144 m/s
Cincerning other conversions, see table for length
length metre m
mass kilogram kg
time second s Density
electric current ampere A
absolute temperature* kelvin K 1 lb/cub. ft 16.02 kg/m3
amount of substance mole mol
luminous intensity candela cd
Force (1 kg m/s2 = 1 N)
* Also named "thermodynamic temperature"
1 kp (kilopound)* 9.807 N
Supplementary SI Units 1 poundal** 138.3 x 10-3 N
1 lbf (pound force) 4.448 N
Quantity Name Symbol
* Can occasionally be found stated as kgf (kilogram force).
plane angle radian rad Standard acceleration of free fall gn = 9.80665 m/s2
solid angle steradian sr ** Unit of force in the ft-lb-s system
Stress ( 1 N/m2 = 10 -6 N/mm2)

Additional SI Units
1 kp/mm2 = 100 kp/cm2 9.807 N/mm2
Quantity Name Symbol Definition 1 lbf/sq. in (psi) = 0.07031 at 6.895 x 10-3 N/mm2
time minute min 1 min = 60 s

time hour h 1h = 60 min Dynamic viscosity (N s/m2)
plane angle degree ° 1° = (p/180) rad
volume litre l 1l = 1 dm3 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)
pressure bar bar 1 bar = 105 Pa 1 poundal s/sq.ft 1.488 N s/m2
1 lbf/sq.ft 47.88 N s/m2
Length (m) poise is a special name taken from the CGS system. 1 P = 0.1 Pa s
1 cP = 1 mPa s = 10-3 Pa s
1 in (inch) 25.40 mm = 0.0254 m
1 ft (foot) = 12 inches 0.3048 m Kinematic viscosity (m2/s)
1 yd (yard) = 3 ft = 36 inches 0.9144 m
1 statute mile = 1760 yds 1609 m 1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *
1 n mile (international nautical mile) 1852 m
* 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name
taken from the CGS system. 1 St = 10-4 m2/s
SI Prefixes
Energy, Work (1 Nm = 1 J, Wh)
Factor Prefix Symbol Factor Prefix Symbol
1 cal I.T* 4.187 J*
1018 exa E 10-1 deci d 1 kpm 9.807 J
1015 peta P 10-2 centi c 1 hph (metric) 2.648 x 106 J = 0.7355 kWh
08028-0D/H5250/94.08.12
1012 tera T 10-3 milli m 1 ft. lbf 1.356 J

109 giga G 10-6 micro μ 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
106 mega M 10-9 nano n 1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
103 kilo k 10-12 pico p
102 hecto h 10-15 femto f * Exact value: 4.1868 J
10 deca da 10-18 atto a I.T. = International Steam Table
Area (m2)
1 sq. in (square inch) 0.6452 x 10-3 m2

1 sq. ft (square foot) 92.90 x 10-3 m2
04.37 - ES0
MAN Diesel
600.60 Conversion Table Description
Edition 01 Page 2 (3)
General
Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W) Specific heat capacity (J/(kg K))

1 kpm/s 9.807 W 1 kcalI.T./(kg x °C) 4.187 x 103 J/(kg K)
1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW 1 BTU*/(lb x °F) = 1 kcalI.T. /(kg °C) 4.187 x 103 J/(kg K)
1 kcalI.T./h 1.163 W
1 ft lbf/s 1.356 W * British Thermal Unit (see table for energy conversions)
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 BTU/h 0.2931 W
Heat conductance (W/(m K))
Moment of Force, Torque (kg m2/s2 = Nm) 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)
Can easily be derived from the above tables. 1 BTU*/(ft x h x °F) 1.731 W/(m K)
* British Thermal Unit (see table for energy conversions)

Moment of Inertia (kg m2)
1 GD2 (old notation) = 4 x I* kg m2 Heat transmission (W/(m2 K))

1 WR2 (old notation)* = 1 x I* kg m2
1 calI.T./(cm x s x °C) 41.87 x 103 W/(m2 K)
*I = ∫ dmr x r2 mr = mass at the radius r 1 kcalI.T./(m" x h x °C) 1.163 W/(m2 K)
G = W = mass in kg D = Diameter of gyration 1 BTU*/(ft2 x h x °F 5.678 W/(m2 K)
R = Radius of gyration
Specific fuel oil consumption (SFOC)

Specific fuel consumption* (g/kWh)
Reference conditions
1 g/hph (metric) 1.360 g/kWh Specific fuel oil consumption values refer to brake power,
and the following reference conditions:
* See also table for specific fuel oil consumption values
Reference conditions (ISO)
Temperature difference (K) Blower inlet temperature 25°C 298 K

Blower inlet pressure 1000 mbar
1 °C (Celsius) 1K Charge air coolant temperature 25°C 298 K
1 °F (Fahrenheit) 5/9 K Fuel oil lower calorific value (10200 kcal/kg) 42707 kJ/kgk
Temperature levels (K)

(see "Derived SI Units with special Names)
t °C (Celsius) tc + 273.15 = K
t°F (Fahrenheit) 5/9(tf - 32) + 273.15 = K
Celsius from Fahrenheit: tc = 5/9(tf - 32)
Fahrenheit from Celcius: tf = 9/5 x tc + 32
Derived Si Units with Special Names

08028-0D/H5250/94.08.12
Quantity Name Symbol Expressed in basic,

supplementary or
derived SI units
frequency hertz Hz 1 Hz = 1 s-1

force newton N 1N = 1 kg m/s2
pressure, stress pascal Pa 1 Pa = 1 N/m2*
energy, working quantity of heat joule J 1J = 1 Nm
power watt W 1W = 1 J/s
electric potential (DC) volt V 1V = 1 W/A
temperature 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
04.37 - ES0
MAN Diesel
Description
Conversion Table 600.60
Page 3 (3) Edition 01
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 l
1 gallon* (imperial, UK) 4.546 x 10-3 m3 = 4.546 l
1 gallon* (US) 3.785 x 10-3 m3 = 3.785 l
1 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 kg

1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg
1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg
1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg
1 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 bar

1 at = 735.5 mm Hg* = 10 m H2O** (T = 277 K)
750 mm Hg* 105 Pa = 1 bar
1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar
1 mm H2O** (T = 277 K) 10-4 at = 9.807 Pa = 98.07 x 10-3 mbar
1 in Hg* (T = 273 K) 3386 Pa = 33.86 mbar
1 in H2O** (T = 277 K) 249.1 Pa = 2.491 mbar
1 atm (standard atmosphere) 760 mm Hg, 1.013 x 105 Pa = 1013 mbar
1 atm = 1.033 at
1 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

Nomenclature
t = temp. in °C ΔK = temperature difference
r = density in kg/m3 Cp = heat capacity in J/(kg DK)
t ρ Cp t Cp
range
08028-0D/H5250/94.08.12
Water 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 1005
Exhaust gas 200-400 1080
* Viscosity: 100-140 cSt at 40°C
750 mm Hg = 1 bar = 105 Pa
1 atm (standard pressure at sea level) = 760 mm Hg = 1013 mbar
Gas 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/kg
Fuel oil. Lower calorific value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)
04.37 - ES0
MAN Diesel
Description
Page 1 (3) Basic Symbols for Piping 600.65
Edition 01H
General
No Symbol Symbol designation No Symbol Symbol designation

2.14 Spectacle flange
1. GENERAL CONVENTIONAL SYMBOLS
1.1 Pipe 2.15 Orifice
1.2 Pipe with indication of direction of flow 2.16 Orifice
1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint
1.4 Appliances 2.18. Snap coupling
1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere
1.6 High-pressure pipe

3. VALVES, GATE VALVES, COCKS AND FLAPS
1.7 Tracing Valve, straight through
1.8 Enclosure for several components as-sem- Valve, angle

bled in one unit
Valve, three-way
2. PIPES AND PIPE JOINTS
2.1 Crossing pipes, not connected Non-return valve (flap), straight
2.2 Crossing pipes, connected Non-return valve (flap), angle
2.3 Tee pipe Non-return valve (flap), straight screw

down
2.4 Flexible pipe Non-return valve (flap), angle, screw down
2.5 Expansion pipe (corrugated) general Safety valve
2.6 Joint, screwed Angle safety valve
2.7 Joint, flanged Self-closing valve
2.8 Joint, sleeve Quick-opening valve

08028-0D/H5250/94.08.12
2.9 Joint, quick-releasing Quick-closing valve
2.10 Expansion joint with gland Regulating valve
2.11 Expansion pipe Ball valve (cock)
2.12 Cap nut Butterfly valve
2.13 Blank flange Gate valve
05.02 - ES0
MAN Diesel
600.65 Basic Symbols for Piping

Description
Page 2 (3)
Edition 01H
General
No Symbol Symbol designation No Symbol Symbol designation

3.17 Double-seated changeover valve
4. CONTROL AND REGULATION PARTS
3.18 Suction valve chest 4.1 Fan-operated
3.19 Suction valve chest with non-return valves 4.2 Remote control
3.20 Double-seated changeover valve, straight 4.3 Spring
3.21 Double-seated changeover valve, angle 4.4 Mass
3.22 Cock, straight through 4.5 Float
3.23 Cock, angle 4.6 Piston
3.24 Cock, three-way, L-port in plug 4.7 Membrane
3.25 Cock, three-way, T-port in plug 4.8 Electric motor
3.26 Cock, four-way, straight through in plug 4.9 Electromagnetic
3.27 Cock with bottom connection 4.10 Manual (at pneumatic valves)
3.28 Cock, straight through, with bottom conn. 4.11 Push button
3.29 Cock, angle, with bottom connection 4.12 Spring
3.30 Cock, three-way, with bottom connection 4.13 Solenoid
3.31 Thermostatic valve 4.14 Solenoid and pilot directional valve
3.32 Valve with test flange 4.15 By plunger or tracer
3.33 3-way valve with remote control (actuator)

5. APPLIANCES
3.34 Non-return valve (air) 5.1 Mudbox
08028-0D/H5250/94.08.12
3.35 3/2 spring return valve, normally closed 5.2 Filter or strainer
3.36 2/2 spring return valve, normally closed 5.3 Magnetic filter
3.37 3/2 spring return valve contr. by solenoid 5.4 Separator
3.38 Reducing valve (adjustable) 5.5 Steam trap
3.39 5.6 Centrifugal pump

On/off valve controlled by solenoid and pilot
directional valve and with spring return
05.02 - ES0
MAN Diesel
Description
Basic Symbols for Piping 600.65
General
No. Symbol Symbol designation No. Symbol Symbol designation
5.7 Gear or screw pump

6. FITTINGS
5.8 Hand pump (bucket) 6.1 Funnel / waste tray
5.9 Ejector 6.2 Drain
5.10 Various accessories (text to be added) 6.3 Waste tray
5.11 Piston pump 6.4 Waste tray with plug
5.12 Heat exchanger 6.5 Turbocharger
5.13 Electric preheater 6.6 Fuel oil pump
5.14 Air filter 6.7 Bearing
5.15 Air filter with manual control 6.8 Water jacket
5.16 Air filter with automatic drain 6.9 Overspeed device
5.17 Water trap with manual control

7. READING INSTR. WITH ORDINARY DESIGNATIONS
5.18 Air lubricator 7.1 Sight flow indicator
5.19 Silencer 7.2 Observation glass
5.20 7.3 Level indicator

Fixed capacity pneumatic motor with direc-
tion of flow
5.21 Single acting cylinder with spring returned 7.4 Distance level indicator
5.22 Double acting cylinder with spring returned 7.5 Recorder
5.23 Steam trap

08028-0D/H5250/94.08.12
05.02 - ES0
Operation of engine
501/601
MAN Diesel
Description
Operating 601.01
Page 1 (3)
Edition 21H
L+V28/32H
Preparations for Starting
The following describes what to do before starting, 4. Open the fuel oil supply to the feed pump.
when the engine has been out of service for a lon-
ger period of time, or if major overhauls has been Starting on HFO: circulate preheated fuel through
made. the pumps until correct working temperatures has
been obtained. Takes normally 30-60 minutes.
1. Check the oil level in the base frame (or in
the lub. oil tank if the engine is with dry sump), air 5. Check the pressure in the starting air receiver(s)
lubricator and in the govenor. and open the starting air supply (blow-off water, if
any, drain the starting air system before opening.
Start-up the prelubricating pump.
6. Check that the sealing oil system for the injec-
The engine shall be prelubricated at least 2 minutes tion pumps are working correct.
prior to start.
7. Check in the regulating gear:
Check oil pressures before and after the filter.
- That all fuel pumps are at index "0" when the
2. Open the cooling water supply, start separate regulating shaft is in the STOP position.
cooling water pumps where installed, and check the
cooling water pressure. - That each fuel pump can be pressed by hand
to full index when the regulating shaft is in the STOP
Note: To avoid shock effects owing to large tempe- position, and that the pumps return automatically to
rature fluctuations just after the start, it is recom- the "0" index when the hand is removed.
mended:
- That the spring-loaded pull rod is working
a) to preheat the engine, cooling water of at least correctly.
60 °C should be circulated through the frame and
cylinder head for at least 2 hours before start. - That the stop cylinder for regulating shaft
works properly, both when stopping normally and
- either by means of cooling water from engines at overspeed and shut down.
which are running or by means of a built-in preheater
(if installed). - Testing is made by simulating these situati-
ons.
or
8. Open the indicator valves and turn the engine
b) When starting without preheated cooling water, some few revolutions, check that no liquid is flowing
the engine must only be started on MDO (Ma-rine out from any of the indicator valves during the tur-
Diesel Oil). ning.
The engine should not be run up to more than 50% Slow-turning must always be carried out, before the
load to begin with, and the increase to 100% should engine is started after prolonged out of-service pe-
take place gradually over 5 to 10 minutes. riods and after overhauls, which may involve a risk
of liquid having collected in the cylinders.
Note: When starting on HFO (Heavy Fuel Oil), only
item "a" should be used. 9. Close the indicator valves.
3. Open the nozzle cooling oil supply (only when 10. Disengage the turning gear, if fitted. Check
started on HFO), circulate preheated oil through the that it is locked in the "OUT" position.
nozzles for at least 15 minutes.
96.30 - ES0U
MAN Diesel
601.01 Description
Edition 21H
Operating Page 2 (3)
L+V28/32H
Starting 6. The exhaust gases should be free from smoke

at all loads. For normal exhaust temperatures, see
1. Start the engine, by activating the start but- the test sheet from shop and sea trials.
tom.
7. Keep the charging air pressure and tempera-
2. Check the lubricating oil pressure, cooling ture under control. For normal values, see the test
water pressure, fuel oil feed pressure. Check that sheet from shop and sea trials.
the prelubricating oil pump is stopped.
8. Recharge the starting air recivers when the
3. Check that all alarms are connected. pressure has dropped to about 20 bar. Stop rechar-
ging at 30 bar.
See also "checks after starting-up".
9. To ensure the greatest possible operational lia-
bility, condition of the engine should be continuously
Tending during running observed in order that preventive maintenance work
can be carried out before serious breakdowns oc-
When the engine is running, the planned maintenance cour.
program and the following should be checked:
1. The lubricating oil pressure must be within Stopping

the stated limits and must not fall below the stated
minimum pressure. The paper filtering cartridges 1. Before stopping, it is recommended to run
must be replaced before the pressure drop across the engine at reduced load, or to idle for about 5
the filter reaches the stated maximum value, or the minutes for cooling-down purposes.
pressure after the filter has fallen below the stated
minimum value. Dirty filter cartridges cannot be 2. The engine is stopped by keeping the fuel
cleaned for re-use. pump delivery rate at "0", by turning the "load- limit"
knob on the governor to "0", or by activating the
2. The lubricating oil temperature must be kept wi- remote stopping device.
thin the stated limits indicated on the data sheet.
3. The fuel oil pressure must be kept at the stated Start and Stop on HFO
value, and the filter must be cleaned before the
pressure drop across the filter reaches the stated Start and stop of the engine should take place on
maximum value. HFO in order to prevent any incompatibility problems
by change-over to MDO.
4. The cylinder cooling water temperature must be
kept within the limits indicated and the temperature MDO should only be used in connection with main-
rise across the engine should not exceed 10°C. tenance work on the engine or longer periods of
engine standstill.
5. The cooling water temperature at the charging
air cooler inlet should be kept as low as possible; Before starting on HFO the engine must be properly
however, not as low as to produce condensation preheated. as described in "Preparations for starting"
water in the charging air space. and as below.
Adjustment takes place in the external system out- Stopping the engine on HFO is no problem, but it
side the engine, and the amount of cooling water should be ensured that the temperature of fuel pipes
must be so adjusted that the temperature rise across not are reduced to a level below the pour point of
the charging air cooler is 3 - 5 °C. the fuel, otherwise reestabilishing of the circulation
might cause problems.
96.30 - ES0U
MAN Diesel
Description
Operating 601.01
Page 3 (3)
Edition 21H
L+V28/32H
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 difficult if the engine and

ambient temperature are lower than 5° C, and 15°
C cooling water temperature.
96.30 - ES0U
MAN Diesel
Description
Out-of Service 601.05
Page 1 (2)
Edition 17H
General
1. Stand-by Engines 4.3. Open up all filters to check that filter elements
are intact. Filter cartridges in the lub. oil filter is to be
During engine standstill in stand-by position, the replaced before start after repair or due to excessive
media cooling water, fuel oil and nozzle oil should differential pressure. After eremoval, dirty elements
be continuously circulated at temperatures similar can be examined for particles of bearing metal at
to the operation conditions. the bottom of the paper lamellae.
(The elements can not be used again).
The engine shall be prelubricated 2 minutes prior
to start, if there is not intermittent or continuous pre- 4.4. Check the cylinder walls.
lubricating installed. intermittent prelub. is 2 min
every 10 minutes. 4.5. Take deflection measurements of the crank-
shaft.
2. Maintenance during Standstil 4.6. A lubricating oil sample should be send to a

laboratory for immediate analysis.
in periods, duringe stand-still of the engine (not in
stand-by position) it is recommended, that the pre- 4.7. Drain plugs are unscrewed from the bottom of
lubricating oil pump is startet minimum 10 minutes turbochargers, or the drain cock is opened, if there
once every week and that the engine during the is installed drain fasilities in the exhaust gas system
prelubricating period is turnd 2-3 revolutions.. this should be opened.
3. Laid-up Vessels 5. Works during Repairs
During the lay-up period (and also when laying-up the The following should be made during the major
vessel), we recommend that our special instructions repairs.
for preservation of the engines, are followed.
5.1. Retighten all bolts and nuts in the crankcase
and check their locking devices. Also retighten
4. Works before Major Repairs foundation bolts.
4.1 After stopping the engine, while the oil is still 5.2. Check the various gear wheel drives for the
warm, start the electrically driven prelubrication camshaft(s).
pump, open up the crancase and camshaft housing
and check that the oil is flowing freely from all bea- 5.3. Remedy leakages of water and oil in the en-
rings. Also take off the top covers on the cylinder gine, and blow through blocked-up drain pipes.
heads and make sure that oil is not supplied for
lubrication of rocker arms, as non-return valves are 5.4. Drain starting air pipes of water.
fitted which do not open until the oil pressure at the
inlet to the rocker arms exceeds 1 bar. 5.5. Empty the oil sump of lubricating oil and remove
the sludge, if not done within a period of one year.
08028-0D/H5250/94.08.12
After overhaul of pistons, bearings, etc. this check Very thoroughly clean the sump and subsequently
should be repeated before starting the engine. coat with clean lubricating oil.
4.2. After stopping the prelubricating pump, check

the bottom of the oil sump for fragments of babbitt 6. Works after Repairs
from bearings, and check crankpin and main bea-
rings clearances with a feeler gauge. Measure the 6.1. If an opening-up of engine or lubricating oil
bearing clerance at the top, at the bottom, and 10 system may have caused ingress of impurities,
degrees above and below the joints at both sides. cleaning should be carried out very carefully before
starting the engine.
92.02 - ES0U
MAN Diesel
601.05 Description
Edition 17H
Out-of Service Page 2 (2)
General
The differential pressure across the lub. oil filter 6.7 b) Adjustment speed: Switch-in generator on
must be watched very carefully after cleaning and the switchboard and set the load to about 40%. On
starting-up the engine. Be sure to replace filter cart- reaching normal oil temperatures in governor and
ridges in due time. engine, increase the load instantaneously to about
80% ( by starting major pump or compressor). This
6.2. After restoring normal lubricating oil circulation, must not cause the frequency to fall by more than
turn the engine at least two revolutions by means of some 8%, and the engine must return to a constant
the turning rod to check the movability of the relevant r.p.m. about 3 seconds (although this r.p.m. will be
parts of the engine. a little lower than before owing to the speed drop
of
6.3. Close drain cocks in the turbocharger (or in the governor). If the engine is operated in parallel
the exhaust gas system if mounted). with other engines, an even sharing of load shall be
established within about 3 seconds. If the gover-
6.4. Lubricate bearings and rod connections in the nor reacts too slowly, compensating adjustment
manoeuvring gear. Disconnect the governor and is effected as indicated in Woodward's instruction
move the rod connections by hand to check that the manual (Compensating adjustment).
friction in bearings and fuel pumps is sufficiently low.
If repair of bearings or alignment of engine has been Note: It is a condition for this test that the engine
made, checks 1, 2, and 5 should be repated. and turbocharger are in perfect operating condition,
so that they can be elimated as possible sources
6.5. Cheks to be made just before starting of the of error.
engine are mentioned under 601.01.
6.7 c) Hunting: Run the engine at synchronous
6.6. Add cooling water and check with pressure r.p.m., and without load. Provided the governor oil
on the system for leakage at the upper and lower is warm, the regulating lever must not perform any
cy-linder liner sealings and at cooling water connec- major periodical movments, and neither must there
tions. be any variation up and down in the engine speed. If
that is the case, repeat the compensating adjustment
6.7. Check the governor as follows: according to Woodward's instruction manual.
Start up the engine and run it at the synchronous
number of revolutions. 6.7 d) Speed Drop: in case of unsatisfactory load
sharing between two ore more engines this can be
6.7 a) Speed setting: Check before switching-in rectified by increasing the speed drop of the engine
generator on the switchboard that the servomotor that is subject to the greatest load (or by reducing
adjusts the r.p.m. with a suitable quickness after ac- the setting of the other engines).
tuation of the synchronizer knob on the switchboard.
The range from - 5% to + 5% from the syn-chronous The setting shoul not normally be increased beyond
r.p.m. should be tested. 70 on the scale, and satisfactory parallel operation
can generally be obtained at settings between 40
and 60.
08028-0D/H5250/94.08.12
92.02 - ES0U
MAN Diesel
Description
Starting-up after Out of Service Periods 601.10
Page 1 (1)
Edition 17H
L+V28/32H
The following enumerates checks are to be made After the last feel-over, repeat check 4 page 601.05,
immediately after starting, during load increase, and see also Ignition in Crankcase page 603.04 in sec-
during normal running. The sequence has been action 603.
cordingly.
After repair or renewal of cylinder liners, piston rings
In the following it is assumed that the engine has or bearings, allowance must be made for a running-
been out of service for some time, for instance due in period, i.e. the engine load should be increased
to repairs and gradually as indicated in the tables below. The engine
output is determined on the basis of the fuel index and
- checks during out of service periods have been the load on the electric switchboard. The turbocharger
carried out as described in the previous chapter. speed gives some indication of the engine output, but
is not directly proportional to the output throughout
When starting after such an out-of-service period, the the service period.
following checks must be made in the stated order in
addition to normal surveillance and recording. Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for certain
that there areno hot spots in the engine. Then incre-
1. To be made immediately after starting: ase the speed to the normal rpm and connect to the
switchboard and put on load.
1.1. See that the turbocharger is running.
The load increase during the starting-up sequence
1.2. See that the lubricating oil pressure is in order. may, for instance, be:
1.3. See that all cylinders are firing (see exhaust 25 % load for 2 hours
temperatures). 50 % load for 2 hours
75 % load for 2 hours
1.4. See that everyting is normal for the engine speed, 100 % load may be put on.
fuel oil, cooling water and system oil.
The pump index indicated in the tables has been given
1.5. Check by simulation of the overspeed shutdown as a percentage of the index at full load. To enable
device that the engine stops. The overspeed setting the index to be read directly off the fuel pumps the
should be according to " Set Points and Operation following formula can be employed:
Data " section 600.
I = I% x IF
100
2. To be made during the starting-up, but only
if required after repairs or alterations made: IF = Index at full load (from testbed table)
2.1. If the condition of the machinery is not well-known, I% = Index expressed as % of full load index
especially after repairs or alterations, the "feel-over (stated in the preceding starting-up
sequence" should always be followed. sequence).
08028-0D/H5250/94.08.12
that is:
Following the alteration of the pump index of the one or
After 5-15 and 30 minutes' idle running, open the two cylinders concerned it must be checked that when
crankcase and the camshaft housing and feel-over in the STOP position the governor is able to move all the
on the surfaces of all moving parts where friction may fuel pumps to an average pump index not exceeding
arise and cause undue heating. 2 or 3, thus excluding the possibility of racing of the
engine when the propeller is declutched.
Feel: Main bearings, big-end bearings, (alternator),
and camshaft bearings, piston pins, cylinder liners, After completing the starting-up sequence, make
roller guides and gear wheels. 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.
96.30 - ES0U
MAN Diesel & turbo
Description
Guidelines for Longterm Low-Load Operation on HFO 601.15
General
Part load/low load operation and turbocharger. HFO-operation at loads lower than
20% MCR should therefore only take place within
In certain ship and power station operation modes the certain time limitations according to the curves.
diesel generating sets are exposed to part load/low
load operation. After a certain period of HFO-operation at loads lower
than 20% MCR, a change to MDO should take place
During manoeuvring of the ship all diesel generating in order to prevent further retardation of the engine
sets are often started up for safety reasons, result- performance condition. Alternatively, the engine load
ing in low should be raised to 70% MCR over a period of 15
load operation of all the engines. During harbour stay minutes and maintained here for some time in order
one diesel generator could be low-loaded when only to burn off the carbon deposits, thus re-establishing
hotel purposes are consuming electricity. adequate performance condition. After such a "clean
burning period" low load operation on HFO can be
Island mode operation of diesel generating sets in continued.
power stations is frequently exposed to low load
operation like on a ship. However, the operator must be aware of the fact
that fouling in the combustion air inlet channels,
At part load/low load it is important to maintain if any, will not be cleaned at high load operation.
constant media temperatures, i.e. for cooling water, Extensive low load running can therefore result in
lubricating oil and fuel oil in order to ensure adequate the need for manual cleaning of the combustion air
combustion chamber temperature and thus complete inlet channels.
combustion.
If special application conditions require continuous
At loads lower than 20% MCR there is a risk of time HFO-operation at loads lower than 20% MCR and
dependant retardation of the engine performance occasionally performed "clean-burning" periods are
condition due to fouling of the exhaust gas channels inconvenient or impossible, special equipment and
and combustion air channels, combustion chambers arrangements must be established.
Load %
20
dmissible low-load operation
A Necessary operating period
(load percent/period) on HFO. with min. 70% load after low-
load operation on HFO.
15 Running-up period to 70%

load: approx. 15 min.
a b 70% load
10 HFO or MDO
5
a b
Operating period (h) Operating period (h)

Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to MDO
or 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.
Fig 1 Low-load operation.
08.20 - ES1
MAN Diesel & Turbo
Description Guidelines Regarding MAN Diesel & Turbo GenSets 601.16

Page 1 (1) Operating on Low Sulphur Fuel Oil Edition 02H
General
Exhaust emissions from marine diesel engines have Low sulphur distillates
been the focus of recent legislation. Apart from nitrous
oxides (NOx), sulphur oxides (SOx) are considered In general our GenSet is developed for continuous
to be the most important pollution factor. A range of operation on HFO as well as on MDO/MGO. Occa-
new regulations have been implemented and others sionally changes in operation mode between HFO
will follow (IMO, EU Directive, and CARB). These and MDO/MGO are considered to be within normal
regulations demand reduction of SOx emissions operation procedures for our engine types and do
by restricting the sulphur content of the fuel. That is thus not require special precautions.
to say sulphur limits for HFO as well as mandatory
use of low sulphur distillate fuels for particular ap- Running on low sulphur fuel (< 0.1% S) will not cause
plications. This guideline covers the engine related problems, but please notice the following restrictions:
aspects of the use of such fuels.
In order to avoid seizure of the fuel oil injection pump
Low sulphur HFO components the viscosity at engine fuel oil inlet must
be > 2.0 cSt. In order achieve this it may be necessary
From an engine manufacturer’s point of view there to install a fuel oil cooler, when the engine is running
is no lower limit for the sulphur content of HFO. We on MGO. This is both to ensure correct viscosity and
have not experienced any trouble with the currently avoid heating up the service tank, which is important
available low sulphur HFO, that are related to the as the fuel oil injection pumps are cooled by the fuel.
sulphur content or specific to low sulphur HFO. This
may change in the future if new methods are applied When operating on MDO/MGO a larger leak oil
for the production of low sulphur HFO (desulphuriza- amount from fuel oil injection pumps and fuel oil
tion, uncommon blending components). MAN Diesel injection valves can be expected compared to op-
& Turbo will monitor developments and inform our eration on HFO.
customers if necessary.
In order to carry out a quick change between HFO
If the engine is not operated permanently on low and MDO/MGO the change over should be carried
sulphur HFO, then the lubricating oil should be se- out by means of the valve V1-V2 installed in front
lected according to the highest sulphur content of of the engine.
the fuels in operation.
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.
10.16 - ES1
Performance and
condition
502/602
MAN Diesel & Turbo
Description
Engine Performance and Condition 602.01
L+V28/32H
Performance Data and Engine Condition An increase in charge air temperature involves a cor-
responding increase in the exhaust gas temperature
During operation small changes in the engine condi- level by a ratio of about 1:1.5, i.e. 1°C higher charge
tion take place continuously as a result of combustion, air temperature causes about 1.5°C higher exhaust
including fouling of airways and gasways, formation gas temperature.
of deposits, wear, corrosion, etc. If continuously
recorded, these changes in the condition can give Reduction of the charge air pressure results in a cor-
valuable information about the operational and responding reduction of the compression pressure
maintenance condition of the engine. Continuous and max. combustion pressure.
observation can contribute to forming a precise and
valuable basis for evaluation of the optimum operation When checking the max. pressure adjustment of the
and maintenance programmes for the individual plant. engine, it is therefore to be ensured that the existing
charge air pressure is correct.
Engine Performance Data

Fuel Injection Pump
If abnormal or incomprehensible deviations in opera-
tion are recorded, expert assistance in the evaluation The amount of fuel injected is equivalent to the
thereof should be obtained. supplied energy and is thus an expression of the
load and mean effective pressure of the engine. The
We recommend taking weekly records of the most fuel pump index can therefore be assumed to be
important performance data of the engine plant. Dur- proportional to the mean pressure. Consequently,
ing recording (working card 502-01.00 can be used) it can be assumed that the connected values of the
the observations are to be compared continuously in pump index are proportional to the load.
order to ascertain alterations at an early stage and
before these exert any appreciable influence on the The specific fuel consumption, SFOC (measured by
operation of the plant. weight) will, on the whole, remain unchanged whether
the engine is operating on HFO or on MDO, when
As a reference condition for the performance data, considering the difference in calorimetric heat value.
the testbed measurements of the engine or possibly However, when operating on HFO, the combination
the measurements taken during the sea trial on the of density and calorific value may result in a change
delivery of the ship can be used. If considerable de- of up to 6% in the volumetric consumption at a given
viations from the normal conditions are observed, it load. This will result in a corresponding change in
will be possible, in a majority of cases, to diagnose the fuel pump index, and attention should be paid to
the cause of such deviations by means of a total this when adjusting the overload preventive device
evaluation and a set of measurements, after which of the engine.
possible adjustment/overhauls can be decided on
and planned. To avoid overloading of the engine the charge air
pressure and turbine speed recorded at the shop
test should not be exceeded.
Evaluation of Performance Data
At the Power Control Synchronizing (PCS) panel in the
Air Cooler engine control room it is possible to reduce the load
by adjusting the setting for maximum MCR load limit
Fouling of the air side of the air cooler will manifest
itself as an increasing pressure drop, lower charge Abrasive particles in the fuel oil result in wear of fuel
air pressure and an increased exhaust/charge air injection pumps and fuel valve nozzles. Effective
temperature level (with consequential influence on treatment of the fuel oil in the purifier can keep the
the overhaul intervals for the exhaust valves). content of abrasive particles to a minimum. Worn
fuel injection pumps will result in an increase of the
index on account of an increased loss in the pumps
due to leakage.
12.04 - ES0
MAN Diesel & Turbo
602.01 Engine Performance and Condition Description

Page 2 (3)
Edition 12H
L+V28/32H
When evaluating operational results, a distinction is If, for any reason, the surface temperature of the fuel
to be made between changes which affect the whole valve nozzle is lower than the condensation tempera-
engine (all cylinder units) and changes which occur ture of sulphuric acid, sulphuric acid condensate
in only one or a few cylinders. can form and corrosion take place (cold corrosion).
The formation of sulphuric acid also depends on the
Deviations occuring for a few cylinders are, as a rule, sulphur content in the fuel oil.
caused by malfunctioning of individual components,
for example a fuel valve with a too low opening pres- Normally, the fuel nozzle temperature will be higher
sure, blocked nozzle holes, wear or other defects, an than the approx. 180°C at which cold corrosion
inlet or exhaust valve with wrongly adjusted clearance, starts to occur.
burned valve seat, etc.
Abrasive particles in the fuel oil involve heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
Turbochargers Therefore, abrasive particles are to the greatest pos-
sible extent to be removed at the purification.
Fouling of the turbine side of the turbocharger will,
in its first phase, manifest itself in increasing turbo-
charger revolutions on account of increased gas Exhaust Valves
velocity through the narrowed nozzle ring area. In
the long run, the charging air quantity will decrease The overhaul intervals for exhaust valves is one of
on account of the greater flow resistance through the the key parameters when the reliability of the entire
nozzle ring, resulting in higher wall temperatures in engine is to be judged. The performance of the
the combustion chambers. exhaust valves is therefore extremely informative.
Service experience has shown that the turbine side is Especially under unfavourable conditions, fuel quali-
exposed to increased fouling when operating on HFO. ties with a high vanadium and sodium content will
promote burning of the valve seats. Combinations of
The rate of fouling and thereby the influence on vanadium and sodium oxides with a corrosive effect
the operation of the engine is greatest for small will be formed during combustion. This adhesive ash
turbochargers where the flow openings between the may, especially in the event of increased valve tem-
guide vanes of the nozzle ring are relatively small. peratures, form deposits on the seats. An increasing
Deposits occur especially on the guide vanes of the sodium content will reduce the melting point and
nozzle ring and on the rotor blades. In the long run, thereby the adhesive temperature of the ash, which
fouling will reduce the efficiency of the turbocharger will involve a greater risk of deposits. This condition
and thereby also the quantity of air supplied for the will be especially unfavourable when the va na weight
combustion of the engine. A reduced quantity of air ratio increases beyond 1:3.
will result in higher wall temperatures in the combus-
tion spaces of the engine. The exhaust valve temperature depends on the actual
maintenance condition and the load of the engine.
Detailed information and instructions regarding With correct maintenance, the valve temperature is
water washing of the turbocharger are given in the kept at a satisfactory low level at all loads. The air
instruction manual. supply to the engine (turbocharger/air cooler) and the
maximum pressure adjustment are key parameters
in this connection.
Fuel Valves
It is important for the functioning of the valves that
Assuming that the fuel oil is purified effectively and the valve seats are overhauled correctly in accord-
that the engine is well-maintained, the operational ance with our instructions.
conditions for the fuel valves and the overhaul in-
tervals will not normally be altered essentially when The use of rotocaps ensures a uniform distribution
operating on HFO. of temperature on the valves.
12.04 - ES0
MAN Diesel & Turbo
Description
Page 3 (3) Engine Performance and Condition 602.01
Edition 12H
L+V28/32H
Air Inlet Valves Engine Room Ventilation, Exhaust System
The operational conditions of the air inlet valves are Good ventilation of the engine room and suitable loca-
not altered substantially when using residual fuel. tion of the fresh air intake on the deck are important.
Sea water in the intake air might involve corrosive
attack and influence the overhaul intervals for the
Fuel Injection Pumps exhaust valves.
Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room
operation of the fuel injection pumps will not be very should correspond to approximately 1.5 times the air
much affected. consumption of the engines and possible boilers in
operation. Under-pressure in the engine room will
The occurrence of increasing abrasive wear of plunger involve an increased exhaust temperature level.
and barrel can be a consequence of insufficient
purification of the fuel oil, especially if a fuel which The exhaust back-pressure measured after the turbo-
contains residues from catalytic cracking is used. chargers at full load must not exceed 300 mm water
Water in the fuel oil increases the risk of cavitation in column. An increase in the exhaust back-pressure will
connection with pressure impulses occurring at the also cause an increased exhaust valve temperature
fuel injection pump cut-off. A fuel with a high asphalt level, and increased fuel consumption.
content has deteriorating lubricating properties and
can, in extreme cases, result in sticking of the fuel
injection pump plungers.
12.04 - ES0
MAN Diesel & Turbo
Description Evaluation of Readings Regarding 602.02

Page 1 (1)
Combustion Condition Edition 11H
General
PRESSURE DROP
INCREASING
(limit 50%)
Air filters
fouled.
PRESSURE DROP
INCREASING
(limit 50%)
Air side of
ALL CYLINDERS cooler fouled.
Exhaust temp. increa-
sing:
Air system fouled TEMP. DIFFERENCE
(Air filter-blower-cooler). TOO LARGE
Exhaust system fouled Water flow too small
(nozzle ring, turbine
wheel).
TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.
ONE CYLINDER DECREASING CHARGE

Exhaust temp. in AIR PRESSURE:
creasing: Fuel valve Decreasing air amount.
needs overhaul. Fouled turbocharger,
Compression too low air filter or charge
owing to leakage of Pcomp and Pmax are measured by means air cooler (air side).
exhaust valve or of max. pressure gauge.
piston ring blow-by. Pcomp too low: Leaky combustion chamber,
charging air pressure too low.
Pmax too low: to late injection timing, low
charge air press., low comp. press., worn
fuel pump
P comp too low, ignition too late.
Please also see Description 602.01,

Engine Performance and Condition
11.23 - ES0
MAN Diesel
Description
Condensate Amount 602.05
General
Ambient air temperature (1 bar)
(Above atmospheric)
10 20 30 40 50 60 70
0.10
of air in kg water / kg air
r
ba
1.0
r
0.08
ba
0
2.
air pressure
0.06
r
ba
Max. water content
Charge
0
of atmosphere
3.
Water content
I %
%
0%
%
%
60
70
80
90
10
0.04
A B
in air tank
Pressure
0.02
II
30 bar
III
Relative 0
air humidity 30 40 50 60 70
Charge air temperature after cooler.

Air temperature in tank.
Fig. 1. Nomogram for calculation of condensate amount.
General Condensation of water in the engine's charge air

receiver is consequently dependent on the humidity
There is always a certain amount of water in air. and the temperature of the ambient air. To find out
When the air is saturated with aqueous vapour, the if condensation in the charge air receiver will occur
humidity is said to be 100% and there is as much the diagram can be used.
water in the air as it can absorb without condensing.
The amount of water in kg/kg air can be found from Example:
08028-0D/H5250/94.08.12
the diagram. The ability to absorb the water depends

on the pressure and temperature of the air. 6L28/32H, 720 rpm (P) 1260 kW
Ambient air condition:
air temperature 35 °C
Amount of Condensation Water in The Charge relative air humidity 90 %
Air Receiver Charge air temperature 50 °C
Charge air pressure 2.6 bar
Both higher pressure and lower temperature reduce
the ability to absorb water. A turbocharged diesel As a guidance, an air consumption of 8.2 kg/kWh
engine takes air from outside, compresses and (Le) at full load can be used for MAN Diesel A/S,
cools the air. Then, normally, the air cannot absorb Holeby engines.
the same amount of water as before.
91.37 - ES1S
MAN Diesel
602.05 Condensate Amount

Description
General
Solution according to diagram: Amount of Condensate Water in Air Tanks.
Water content of air (l) 0.033 kg/kg The volume of condensate in the air tank is determin-
Max. water cont. of air (ll) 0.021 kg/kg ed by means of the curve at the bottom to the right
of the diagram, representing an operating pressure
Amount of condensate in charge air recceiver. of 30 bar.
= (l - ll) x le x P Example:
= (0.033 - 0.021) x 8.2 x 1260 = 123 kg/h
Amount of condensate in air tank.
Draining of Condensation Water. Volumetric capacity of tank(V) 4000 dm³

Temperature in tank (T) 40 °C=313K
This phenomenon will occur on all turbocharged Internal press. of tank (p) 30 bar
engines. For MAN B&W Holeby 4-stroke engine, = 31 x 105 N/m²(abs.)
there is no risk with a small amount of water in the Gas constant for air (R) 287 Nm/kg.K
charge air receiver. But if the charge air receiver is Ambient air temperature 35 °C
filled with water, there is a risk of getting water into Relative air humidity 90 %
the cylinder. This water have to be drained away. As Weight of air in tank
standard a valve is mounted on the charge air receiv-
er/cooler on the engine. This valve is to be used for pxV 31 x 105 x 4
draining of the water. If there is a great amount, the m= = = 138 kg
RxT 287 x 313
valve can be left half-open. If the amount is small, the
charge air receiver can be drained periodically.
Solution acc. to above diagram:
Water content of air (l) 0.033 kg/kg

Max. 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.
08028-0D/H5250/94.08.12
91.37 - ES1S
MAN Diesel & Turbo
Working Card 602-01.00

Page 1 (4) Engine Performance Data Edition 03H
L28/32H
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water 62005 10 Max. pressure
Shut-off fuel oil indicator
Shut-off cooling oil
Stopped lub. oil circul.
Description: Hand tools:
Measurements of engine performance data.
Starting position:
Engine is running.
Related procedure:
Man power: Replacement and wearing parts:
Working time : ½ hour Plate no. Item no. Qty. /

Capacity : 1 man

Data:
Data for pressure and tolerance (Page 600.35)

Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)
11.25 - ES0
MAN Diesel & Turbo
602-01.00 Engine Performance Data Working Card

L28/32H
Engine Performance Data
M/V Engine Type Engine No. Date/Year Hour Total Engine

1 2 3 4 5 6 running Hours
Engine RPM Fuel Type Turbocharger Turbocharger
7 8
Visc. 9
Density Type Serial No. 10 RPM
Switchboard
Effect (kW) Voltage (V) Current (A) cos ϕ /kVAr
11 12 13 14
Cylinder Data
Ave-
15 Cylinder No. 1 2 3 4 5 6 7 8 9 16 rage
17 Fuel Pump Index
18 Maximum Pressure (bar)
19 Compress. Pressure (bar)
20 Exhaust Temp. (° C)
21 Cooling Water (°C)
Turbocharger
Temp. inlet blower (° C) Pressure before blower (mmWC) Temp. after blower (° C)
22 23 24
∇
Press. air cooler (mmWC) Temp. charge air (° C) Press. charge air (bar)
25 26 27
Temp. exhaust gas before TC (° C) Temp. exhaust gas after TC (° C) Press. exhaust gas after TC (mmWC)
28 29 30

Temp. after engine (° C) Press. before filter (bar) Press. after filter (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)
37 38 39
LT temp. inlet lub. oil cooler (° C) LT temp. outlet lub. oil cooler (° C) LT temp. inlet alternator (° C)
40 41 42
LT temp. outlet alternator (° C) HT FW temp. inlet engine (° C) HT FW press. inlet engine (bar)
43 44 45
Fuel Oil System

Fuel oil temp. inlet engine (° C) Fuel oil press. before engine (bar)
46 47
Nozz. cool. oil press. inlet engine (bar) Nozz. cool. oil temp. outlet engine (° C) Sign.
48 49 50
11.25 - ES0
MAN Diesel & Turbo
Working Card
Engine Performance Data 602-01.00
L28/32H
The Instruction for Filling in the Diagram "Engine Cylinder Data.

Performance Data".
15. Cylinder no. - can be read on engine plate.
The numbers in the instruction are commensurate A/B is used for V-engines.
with the numbers on the diagram.
16. Average for all engine cylinders for point: 17-
The automatic symbols mentioned in the instruction 18-19-20-21.
TI 01, TI 03, PI 01 etc, refer to the diagrams printed
in the instruction books for specified plants. 17. Fuel pump index - can be read on each of
the high pressure fuel oil injection pumps.
Engine Performance Data. 18. Max pressure (bar) can be read for each
cylinder by means of indicator or Pmax gauge.
1. Name of ship, if stationary name of plant.
19. Compression pressure (bar) - can be read for
2. Engine type. each cylinder by means of the indicator measure-
ment, which is carried out during idling by nominal
3. Engine no. RPM.
4. Date/year of observations. 20. Exhaust temperature (°C)

- Thermometer TI 60.
5. Hour, time of observations.
21. Water outlet cylinder (°C) (jacket cooling)
6. Total engine running hours - engineer's log- - Thermometer TI 11.
book.
7. Engine revolutions per minute (RPM) - can be Turbocharger.

read on tachometer SI 90.
22. Thermometer inlet blower (°C) can be read
8. Fuel oil type: The viscosity must be stated (in by means of a thermometer placed in the engine
cSt) and the temperature by which the viscosity has room near the air filter of the TC.
been measured f.inst. 180 cSt/50°C. Density must
be stated: g/cm³. 23. Pressure before blower (mmWC) - can be
read by means of a mmWC instrument placed in
9. Turbocharger: Type and serial number are the engine room near the TC.
stated on the rating plate of turbocharger.
24. Temperature after blower (°C) - can be read
10. Turbocharger revolutions per minute (RPM) - by means of a thermometer TI 30.
can be read on the tachometer SI 89.
25. ∆ Pressure air cooler (mm/WC).
Switchboard. 26. Charge air temperature (°C). Temperature of

the charge air in the charge air receiver.
11. Effect alternator (kW) - can be read on the - Thermometer TI 31.
main switchboard.
27. Pressure charge air (bar). Pressure of the
12. Voltage (V) - can be read on the switchboard. charge air in the charge air receiver.
- Pressure gauge PI 31.
13. Current (A) - can be read on the switchboard.
28. Tempereture of the exhaust gas before TC
14. Cos ϕ/kVAr - can be read on the switchboard. (°C) - Thermometer TI 62.
11.25 - ES0
MAN Diesel & Turbo
602-01.00 Engine Performance Data Working Card

L28/32H
29. Temperature of the exhaust gas after TC (°C) 40. Temperature of the low temperature (LT) cool-
- Thermometer TI 61. ing water (sea, raw or fresh) at inlet lub. oil cooler
(°C)
30. Pressure of the exhaust gas after the TC (bar) - Thermometer TI 07.
41. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at outlet lub. oil cooler
Lubricating Oil System. °C)
31. Temperature of the lub. oil inlet cooler (°C)
- Thermometer TI 20. 42. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at inlet alternator (°C)
32. Pressure of the lub. oil before the filter (bar) - Thermometer TI 04.
43. Temperature of the low temperature (LT) cool-
33. Pressure of the lub. oil after the filter (bar) ing water (sea, raw or fresh) at outlet alternator (°C)
- Pressure gauge PI 22. - Thermometer TI 05.
The filter element should be replaced with a pres- 44. Temperature of the high temperature (HT)
sure drop across the filter of 1.5 bar. fresh water (FW) at inlet engine (°C)
34. Temperature of the lub. oil inlet engine (°C)
- Thermometer TI 22. 45. Pressure of the high temperature (HT) fresh
water (FW) of outlet engine (°C)
35. Pressure of the lub. oil before the turbocharger - Thermometer TI 10.
(bar).
Fuel Oil System.
Cooling Water System. 46. Temperature of the fuel oil at inlet engine (°C)
37. Temperature of low temperature (LT) cooling
water (sea, raw or fresh) at inlet charge air cooler 47. Pressure of the fuel oil before engine (bar)
(°C) - Pressure gauge PI 40.
48. Nozzle cooling oil pressure at inlet engine
38. Temperature of low temperature (LT) cooling (bar)
water (sea, raw or fresh) at outlet charge air cooler - Pressure gauge PI 50.
(°C)
- Thermometer TI 02. 49. Nozzle cooling oil pressure at outlet engine
(bar)
39. Pressure of the low temperature (LT) cooling - Pressure gauge PI 51.
water (sea, raw or fresh) at inlet charge air cooler
(bar) 50. Signature.
11.25 - ES0
Trouble shooting
503/603
MAN Diesel
Description
Starting Failures 603.01
Page 1 (1)
Edition 08H
General
Trouble Possible cause Trouble shooting
Engine turns as soon as shut-off Faults in electrical system Check electrical parts
valve is opened, without start
but-ton being activated
Engine does not turn when start Air pressure in starting air recei- Start compressors, re-charge air
button is activated ver too low receiver
Main valve(s) closed Open valve at receiver and stop

valve interposed in line between
receiver and engine
Pinion does not engage the fly Check the air starter for broken
wheel clutch jaws or other broken parts
Air motor runs, pinion engages Check the air motor for broken
but does not rotate shafting, bearing or clutch jaws
Faults in electrical system Check electrical parts
Engine turns too slowly or ir- Worn air motor parts Remove and disassemble the
regularly when start but-ton is air motor. Examine all parts and
depressed re-place any that are worn or
damag-ed. Use the guidelines for
determi-ning unserviceable parts
Start valve is sticking in close Check start valve

position
08028-0D/H5250/94.08.12
90.46 - ES0U
MAN Diesel
Description
Faults in Fuel Oil System 603.02
Page 1 (3)
Edition 09H
L+V28/32H
Engine turns on starting air, but Sluggish movement of Lubricate and mobilize rod con-
ignition fails. Fuel pumps are not manoeuvring gear nections in manoeuvring gear
actuated
Governor setting incorrect Adjust governor, see special in-
struction manual
Overspeed or another shutdown Cancel shutdown function

function is activated
Piston in Lambda controller is Check that piston is not sticking.

actuated Check that pressure in cylinder is
relieved. Check that the over-
speed trip is not actuated.
Piston in Lambda controller is Check pressures and tempera-tu-

actuated owing to uncancelled shut- res. Check for faults in shut-down
down function (1) devices
Failures in governor Check that governor is working

properly. For further fault location,
see special instr. manual
Incorrect adjustment of Check rod connec. Check that

manoeuvring gear fuel pump index is corresponding
to "Adjustments after trials" in
testbed chart
Engine turns on starting air, but Incorrect adjustment of limiter Adjust setting of limiter cylinder
no fuel is injected owing to failu- cylinder
res in fuel system
Fuel oil service tank empty Pump oil into the tank
Air in fuel pumps and fuel injection Vent the fuel pumps unitl fuel
valves (2) 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.
Worn-out fuel pump Change fuel pumps

08028-0D/H5250/94.08.12
Defective fuel injection valves or Change defective fuel valves

valve nozzles (4)
Too low pressure before fuel injec- Increase the fuel oil feed pump
tion pumps (3) pressure
Engine turns on starting air, fuel Water in the fuel Drain off water and repeat venting
is injected, but ignition fails of fuel pumps
Fuel valves or nozzles defective (4) Change defective fuel valves, see
Working Card 614-01.10.
Cont.
02.47 - ES0
MAN Diesel
603.02 Faults in Fuel Oil System Description

L+V28/32H
Compression during start too low (5) Check intake and exhaust valve
for tight closing. Check cyl. wear
and piston rings
Incorrect timing of camshaft (6) Check fuel pump timing advance,

and fuel valve opening pressure
as well as camshat adjustment
First ignitions are too violent (sa- Oil has collected on piston crown (7) Slow turning with open indicator
fety valves are opening). Engine valves, to locate defective fuel val-
runs erratically ve, remove oil
Sluggish movement of manoeuvring
gear Lubricate and mobilize rod con-
nections and bearings in mano-
euvring gear
Fuel pump index to high Check rod connection in mano-

euvring gear. Check that gover-
nor is working properly. Limiter
cylinder to be set lower
Remarks
1) If the shut-down function is due to overspeed, 4) If the fuel is forced into the cylinder through
the shut-down activation is cancelled by reset- a defective fuel valve or through worn-out
ting the overspeed device and thus venting the atomizer holes, no or too sluggish atomization
Lambda controller/air cylinder. may prevent ignition, possibly followed by too
violent ignition.
2) Whether air is present in the fuel oil system is

seen be repeating the venting of fuel pumps. 5) To obtain ignition temperature in the cylinders,
The cause may be that a fuel valve is kept in the compression pressure during star ting
open position (spindle sticking or spring bro- should be normal, see the testbed chart. This
ken). Heating of fuel to a too high temperature can be checked by measuring the compression
may have a similar effect owing to formation pressure during starting. Cylinders having too
of gas in the fuel. If a sticking valve is found, it low compression should be inspected.
08028-0D/H5250/94.08.12
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 6) Major alterations of the combustion charac-
the result of the fuel oil feed pump sucking-in teristics of the fuel may demand adjustment
air through a defective stuffing box or a leaky of the timing of the fuel pumps. One or more
seal. cam-shaft sections may be incorrectly fitted
(after dismantling). Too high opening pressure
of the fuel valves will also delay the injection.
3) If the fuel oil pressure drops, the filter may be
clogged up, or the by-pass at the feed pump
may have opened.
02.47 - ES0
MAN Diesel
Description
Faults in Fuel Oil System 603.02
Page 3 (3)
Edition 09H
L+V28/32H
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
lea-kage should be found and remedied before
the engine is started again.
08028-0D/H5250/94.08.12
02.47 - ES0
MAN Diesel
Description
Disturbances during Running 603.03
Page 1 (3)
Edition 08H
L+V28/32H
Exhaust temperature(s) (All cyls.) Increased charging air See Working Card 612-01.00.
increase(s) temperature due to ineffective air
coolers
(All cyls.) Fouling or air and gas Reduce load and water-wash tur-
passages bine. Clean air filters and coolers
(All cyls.) Insufficient cleaning of See Description 604.25.

fuel oil or changed combustion
characteristics
(All cyls.) Wrong position of cam- Check Pmax. Check camshaft ad-
shaft (Maladjustment) justment
(Single cyls.) Fuel valve or valve See Working Card 614-01.10.

nozzle defective
(Single cyls.) Leaky exhaust Check the valve clearance. Repla-

valves (1) ce cyl. head with defective valve
(Single cyls.) Blow-by-leaky com- See Working Card 606-01.00.

bustion chamber (2)
(Single cyls.) Damaged fuel pump Check timing advance of fuel

cam pump
Exhaust temperature(s) (All cyls.) Decreased charging air Check that thermostatic valve (by-
decrease(s) temperature pass valve) in cold water system
is working properly and correctly
set
(Single cyls.) Air in fuel pump(s) Venting of fuel pump(s) until fuel
and fuel injection valve(s) without air bubbles appears.
Check feed pump pressure
(Single cyls.) Spindle in fuel valve Change and overhaul defective

sticking (3) fuel valve
(Single cyls.) Fuel pump plunger Change fuel pump plunger/barrel

sticking or leaking assembly
08028-0D/H5250/94.08.12
Engine RPM decreases Pressure before fuel pumps too Raise fuel oil feed pump pressure
low to normal. Check filter
Fuel valve or fuel pump defective Change defective valve or pump
Water in the fuel Drain off water and vent the fuel
pumps
Governor defective (4) Replace defective governor
Increased internal friction in See "Ignition in Crankcase"

engine (5)
Cont.
05.08 - ES0
MAN Diesel
603.03 Description
Edition 08H
Disturbances during Running Page 2 (3)
L+V28/32H
Engine stops Shut-down Check pressure and temperatu-

res. If OK, check for faults in shut-
down devices. See also Starting
Failures
Smoky exhaust Turbine RPM lagging behind en- Reasonably smoke is normal
gine RPM when RPM increases; no measu-
res cal-led for. If smoky exhaust
during normal running, clean
turbine(s) and check valves
Air supply too low Fouling of air and gas passages,

see section 612.
Fuel valves or nozzles defective See Working Card 614-01.10.
"Trumpets" at nozzle holes. Fai- Overhaul fuel valves. Re-establish

lure of cooling (especially during nozzle-cooling
hea-vy-oil operation) (6)
Exhaust valve knocking Adjsuting screw for valve set- Inspect and replace defective
ting loose. Push rod thrust disc parts as necessary
da-maged
Rising cooling water temperature Pump stopped. Increased friction Stop the engine. Check the
(7) cooling water. Find cause of incre-
ased friction and remedy fault
Lubricating oil pressure fails Lubricating oil pump defective. (8) Stop the engine. For further de-
Filters/cooler fouled tails, see "Ignition in crankcase"
Alternator Short circuit Flywheel must be dismounted and

guide pin replaced
08028-0D/H5250/94.08.12
Remarks
1) This manifests itself by rise of the exhaust 2) Blow-by means a serious danger of piston
temperature and falling of the compression seizure, and the engine must if possible be
and maximum combustion pressure of the stopped and the piston in question pulled. If
respective cylinder. this is not possible, the fuel pump index must,
as described above, be moved to stop. Leaky
To limit the damage to the valves, these should piston rings will normally result in a heavy
be changed immediately, if possible, or the fuel excess pressure in the crankcase.
pump of the cylinder concerned should be put
out of operation by moving the index to stop
and locking it in this position.
05.08 - ES0
MAN Diesel
Description
Disturbances during Running 603.03
Page 3 (3)
Edition 08H
L+V28/32H
3) If this happens the fuel pump barrel and plun- 6) If the cooling of the atomizers fails (if arranged
ger must be changed, and if, to obtain full for oil cooling) while running, carbon deposits
load of the respective cylinder, it is necessary will build up round the nozzle holes, sometimes
to increase the fuel pump index by more than in the shape of small cones or trumpets which
10 index degrees, the fuel pump is in most causes the engine to smoke, or ot will cause
cases worn out. Usually this is confirmed by sticking of the valve spindle. For this reason the
inspection of the fuel pump plunger on which nozzle cooling should be well maintained.
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 7) If the cooling water temperature for the entire
new barrel and plunger. engine has risen to 90-100° C, it should be
checked - by opening the test cocks, if fitted on
the discharge from cylinders - whether steam
4) The governor will not reduce the fuel pump has developed. If this is the case, there is no
delivery to zero in case of, for instance, failure water on the cooling surfaces, which may the-
of the governor oil pump, but the engine speed refore be heated unduly. To avoid heat stresses
will start fluctuating. arising in cylinder liners and cylinder heads, if
the water returns too early, the engine should
When the governor is defective the engine be stopped and left to cool, while the discharge
is protected against racing by the overspeed valve is closed. After 15 minutes it is opened
trip, i.e. the engine is stopped automatically in a little to allow the water to rise slowly in the
case of excessive speed. It is essential, there- cooling jackets. Check filling at test cocks. Make
fore, that the overspeed trip is kept in perfect crankcase inspection to ascertain that internal
order. Regarding governor failure, see special water leakage has not arisen. Remember slow
instruction book. turning withopen indicator valves at subsequent
starting-up.
5) Usually a bearing failure will not slow down the

engine appreciably, but the seizure of a piston in 8) If the lubricating oil pressure drops below the
the cylinder liner might do so. If a PG-governor minimum mentioned in Data; Find the cause
is employed, the index will increase and exhaust of the pressure drop and remedy the defect
temperatures rise. If such cases occur, repair before re-starting the engine. Feel over 5-15-
is necessary before starting the engine again. 30 minutes after starting, and again when full
Feel over and look out for oil mist. load is obtained. See section 602.
08028-0D/H5250/94.08.12
05.08 - ES0
MAN Diesel
Description
Ignition in Crankcase 603.04
Page 1 (1)
Edition 09H
L+V28/32H
Cause 1. Stop the engine
During running, the atmosphere in the crankcase 2. Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of coarse oil drops is flung around everywhere.
If undue friction and thus heating arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is transmitted otherwise after stopping of the engine. When opening up,
to the crankcase, the heated surface will cause keep clear of possible flames. Do not use naked
evaporation of the lubricating oil splashed on to it. light and do not smoke.
When the oil vapours condense they form a multi-
tude of minute drops suspended in the atmosphere, 3. Take off all doors on one side of the crankcase.
i.e. a milky white oil mist is formed, able to nourish Cut off starting air. Engage turning gear, if fitted.
and spread a flame if ignited. Such ignition may be
caused by the same "hot spot" which produced the 4. Locate the hot spot. Powerful lamps should be
oil mist. If a large quantity of oil mist has developed employed at once (in explosion-proof fittings). Feel
before ignition, the burning may cause considerable over all sliding surfaces (bearings, liners, pistons,
pressure rise in the crankcase, forsing the relief roller guides, etc.).
valves to open. In a few cases, when presumably
the whole crankcase has been filled with oil mist, the Look for squeezed-out bearing metal and discolo-
consequential explosion has thrown off crankcase ration by heat (blistered paint, burned oil, heated
doors and caused fire in the engine room. steel).
Every precaution should therefore be taken to (A) 5. Prevent further heating, preferably by making
avoid "hot spots" and (B) discover oil mist in time. a permanent repair. Special attention should be
given to ensure lubricating oil supply and satisfac-
tory condition of the frictional surfaces involved.
A. "Hot spots" in crankcase. It is equally important to replace filter elements in
time.
Overheating of bearings is a result of too bad or
failing lubrication possibly caused by pullution of 6. Start electrically driven lubricating oil pump and
the lubricating oil. check oil flow from all bearings and splash pipes in
crankcase while turning the engine through at least
It is therefore important that the lubricating oil filtration two revolutions. See Description 601.05, Point 4.1.
equipment is in perfect condition. Filter cartridges
must not be used again, if they have been removed 7. Stop and feel over. Look out for oil mist.
from the filter. Check of the oil condition by analysis
is recommended. 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). See
B. Oil mist in crankcase. Description 601.10, Point 2.
08028-0D/H5250/94.08.12
Presence of oil mist may by noted at the vent pipe, 8. In case it has not been possible to locate the
which is usually fitted to the top of the engine hot spot, point 7 should be intensified and repeated
frame. until the cause of the oil mist has been found and
remedied. In very rare cases oil mist could be due
Measures (in case of white oil mist). to "atomization" of lubricating oil by the action of
an air jet (for instance blow-by, or blow-by through
Warning: Keep away from doors and relief valves on cracked piston).
crankcase. Do not stay unnecessarily in doorways
near doors of the engine room casing.
96.30 - ES0U
MAN Diesel
Description
Trouble Shooting Guide for Centrifugal By-pass Filter 603.05
Page 1 (1)
Edition 08H
L+V28/32H
Tabulated below are the corresponding remedial

actions to be taken if the following faults are obser-
ved:
Oil leakage through cover nut Missing or damaged O-ring (see Replace O-ring
Item 29, Plate 61515)
Seal face damaged Replace O-ring
Excessive vibrations Rotor out of balance owing to un-

even build-up of deposit on rotor
walls resulting from:
Missing or damaged O-ring, al- Replace O-ring

lowing leakage (see Item 23, Plate
61515)
O-ring seat on rotor joint faces Replace rotor assembly

damaged
Rotor assembly inadequately Tighten and bring to notice of main-

tightened tenance staff
Standtube incorrectly seated or Re-fit or replace if damaged

damaged
Dirt deposit not completely remo- Clean and bring to notice of main-
ved tenance staff
Rotor castings distorted through Replace rotor assembly

maltreatment
Rotor assembly components fitted Follow sequence in Working Card

in wrong sequence 615-15.00 in section 615.
Bushes loose or worn in tube as- Fit nes bearing tube assembly
sembly
96.30 - ES0U
MAN Diesel
Description 603.06
Page 1 (2) Trouble Shooting Guide for Turbine Starter Edition 09H
L+V28/32H
Motor will not run. No air supply. Check for blockage or damage to
air supply lines or tank.
Damaged motor assembly (12). Inspect motor assembly and power

train and repair power train or re-
place motor assembly if necessary.
Foreign material in motor and/or Remove motor assembly and piping

piping. and remove the blockage.
Blocked exhaust system. Remove housing exhaust cover (1)

and check for blockage.
Defective control or relay valve. Replace control valve or relay valve.
Loss of power Low air pressure to starter. Check air supply.
Restricted air supply line. Check for blockage or damage to

air lines.
Relay valve malfunctioning. Clean or replace lines or relay

valve. Lubricate relay valve.
Exhaust flow restricted. 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.
Damaged motor assembly. Replace motor assembly.
Drive (36) of (57) will not engage. No pressure to drive housing port. Check air supply.
Internal drive housing ports Remove blockage.

blocked.
Fluid in drive unit components. Remove fluid.
Damaged or worn piston assembly Replace damaged or worn parts.

(54), o-rings or seals.
O-rings and seals dry. Relubricate o-rings and seals.

08028-0D/H5250/94.08.12
Motor runs, pinion engages, but Damaged or broken drive train. Disassemble drive train and replace
does not rotate flywheel. worn or damaged parts.
Excessive butt engagement. Damaged drive pinion (36) or (63) Inspect drive pinion and flywheel
or flywheel. and replace if necessary.
Damaged starter drive (36) or (57) Inspect drive components and

components. replace worn or damaged parts.
Cont. ....
94.34 - ES0U-G
MAN Diesel
603.06 Description
Edition 09H
Trouble Shooting Guide for Turbine Starter Page 2 (2)
L+V28/32H
Low air pressure. Check air supply.
Wrong drive pinion. Replace with proper drive pinion.
Oil blowing out of exhaust. Oil in air supply line. Inspect air line and remove source
of oil.
Splash deflector retaining screw (5) Install splash deflector retaining

or pipe plug missing. screw or pipe plug.
Worn or damaged rotor seals or Replace static seals on outside of

static o-rings. motor or send motor to Inger-soll-
Rand to be rebuilt.
Oil leaking from gear case (28). Worn or damaged o-rings. Replace o-rings.
Loose joints. Make sure that joints fit properly

and starter assembly cap screws
are tightened to 60 ft-lb (81 Nm)
torque. Make sure all seals and
o-rings fit and seal properly at their
perimeters. If they do not replace
with new seals and o-rings.
Excessive high-speed operation. Operate according to recommen-

dations.
High number of start cycles. Replace worn components.
Loose or leaking pipe plugs (10) Tighten or replace pipe plugs using
or (11). Ingersoll-Rand No SMB-441 pipe
sealant.
Splash deflector retaining screw Tighten splash deflector retaining

loose or pipe plug missing. screw or replace pipe plug.
Air or gas leakage. Loose joints. Make sure that joints fit properly
and starter assembly cap screws
are tightened to 60 ft-lb (81 Nm)
torque. Make sure all seals and
o-rings fit and seal properly at their
perimeters. If they do not replace
with new seals and o-rings.
Excessive high-speed operation. Operate according to recommen-

dations.
High number of start cycles. Replace worn components.
Loose or leaking pipe plugs. Tighten or replace pipe plugs.
Splash deflector retaining screw Tighten splash deflector retaining

loose or pipe plug missing. screw or replace pipe plug.
94.34 - ES0U-G
MAN Diesel
Description
Trouble Shooting for Cooling Water System 603.09
Page 1 (1)
Edition 08H
General
Description The pump bearings are lubricated automatically with

oil from the lubricating oil system of the engine.
The built-on fresh water pump in the high tempera-
ture (HT) circuit is of the centrifugal type and is If the pump leaks and the shaft sealing rings are
mounted on the front cover of the engine and is worn, it is recommended to replace the shaft seal,
driven through a gearing. see work card 616-02.00.
The pump does not work after Pump draws in air at suction side Check packings and pipes for
start tightness
The system is not filled-up Check the level in the expansion

tank
Air cannot escape on delivery side Vent the system
Leaking shaft seal Check the shaft seal
Pump capacity drops after nor- Air leakages of shaft seal Overhaul the shaft seal
mal operation
Fouled impeller Clean the impeller
Pump does not give maximum Suction valve not fully open Open the suction valve
delivery
Defective seals Replace the seals
Worn impeller and worn wear rings Overhaul the pump
Note! Running troubles with the pump, apart from

mechanical faults, are most often due to leaks in the
suction line. It is essential, therefore, that all packings
and gaskets are in order and that they are renewed
when necessary. Even a thiny hole in the suction line
will reduce the pump capacity.
08028-0D/H5250/94.08.12
91.14 - ES0U
MAN Diesel
Description 603.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01H
General
Trouble Shooting. In case of fatigue fracture, this will normally neces-
sitate a replacement of all plates and gaskets - as
In case of damage to plates or gaskets, it will often there may be a risk of fatigue fracture in all the
be necessary to replace them. material.
First examine very carefully the external conditions In case of corrosion, all plates must be examined
around the plate heat exchanger in order to localize carefully!
the cause of the damage! For work to be carried out see working card 615-
05.00.
Visible Leakage
Leakage. Too high pressure. Reduce the pressure to the correct

working pressure, see page 600.30
"Operating Data & Set Points".
Leakage. Insufficient tightening Tighten up the plate heat exchanger

(Phase 1) - however, not under 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,

procede with phase 2.
Leakage. Fouled or deformed plates. Separate the plate heat exchanger

(Phase 2) Inelastic or deformed gaskets. 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 very carefully
all plates and gaskets.
Assemble the plate heat exchanger
and start it up again.
Note! Even tiny impurities such as sand
grains may cause leakage.
Leakage. Gaskets. Separate the plate heat exchanger.

08028-0D/H5250/94.08.12
(Even after tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension) Replace the gaskets.
Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the plate. Replace defective plates and gaskets,
gaskets) if any.
92.08 - ESOU
MAN Diesel
603.10 Description
Edition 01H Trouble Shooting for Lubricating Oil Cooler Page 2 (2)
General
Non-Visible Leakage
Reduced heat transmission and/or Fouled plates or choked plate chan- Separate the plate heat exchanger and
increasing pressure drop. nels. check if the plates are fouled.
Clean the plates very carefully.
Leakage. Holes in plates. A suspected leakage can be localized

(The fluids get mixed) Corrosion or fatigue fracture. in the following way:
(Phase 1) Remove one of the lower pipe con-
nections.
Then put the opposite side under
pressure.
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 ex-
changer.
Separate the plate heat exchanger and
check the plates very carefully.
Check suspected plates with a dye
penetrant.
Check defective plates and gaskets.
Before assembling, clean all plates
and gaskets.
and check to find more defective
plates, if any, by putting one side under
pressure.
Start up again.
Leakage. Holes in plates. Close down the plate heat ex-

(The fluids get mixed) Corrosion or fatigue fracture. changer.
Separate the plate heat exchanger.
(Phase 2)
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
unpressurised 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!
08028-0D/H5250/94.08.12
By a careful study of the plates it will

be possible to find moist areas, if any,
on the otherwise dry plate sides.
Check these areas with a dye pen-
etrant!
Replace defective plates and gas-
kets.
Before assembling, clean all plates
and gaskets.
and check to find more defective
plates, if any, by putting one side under
pressure.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!
92.08 - ES0U
Media specification
504/604
MAN Diesel & Turbo
Description Specification for lubricating oils (SAE30) for 604.01

Page 1 (5) heavy fuel oil operation (HFO) Edition 27H
L28/32H
V28/32H
The specific output achieved by modern diesel en- Only lubricating oils that have been approved by
gines combined with the use of fuels that satisfy MAN Diesel & Turbo may be used. These are listed
the quality requirements more and more frequently in the table entitled "Lubricating oils approved for
increase the demands on the performance of the use in heavy fuel oil-operated MAN Diesel & Turbo
lubricating oil which must therefore be carefully se- four-stroke engines".
lected.
Specifications
Medium alkalinity lubricating oils have a proven
track record as lubricants for the moving parts and Base oil
turbocharger cylinder and for cooling the pistons.
Lubricating oils of medium alkalinity contain addi- The base oil (doped lubricating oil = base oil + addi-
tives that, in addition to other properties, ensure a tives) must have a narrow distillation range and be
higher neutralisation reserve than with fully doped refined using modern methods. If it contains par-
engine oils (HD oils). affins, they must not impair the thermal stability or
oxidation stability.
International specifications do not exist for medium
alkalinity lubricating oils. A test operation is there- The base oil must comply with the limit values in
fore necessary for a corresponding period in ac- the table below, particularly in terms of its resist-
cordance with the manufacturer's instructions. ance to ageing:
Properties/characteristics Unit Test method Limit values

Make-up   Ideally paraffin based
Low temperature behaviour, still flowable °C ASTM D 2500  15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of
 MAN ageing oven * 
heating up to 135 °C
ASTM D 4055 or
insoluble nheptane Weight % < 0.2
DIN 51592
Evaporation loss Weight %  < 2
Precipitation of resins orasphalt-
MAN Diesel &
Spot test (filter paper)  like ageing products must not be
Turbo test
identifiable.
Table 1 Base oils - target values
* Works' own method
11.01 - ES1 - 3.3.6 (2011-01-04)

MAN Diesel & Turbo
604.01 Specification for lubricating oils (SAE30) for Description

Edition 27H heavy fuel oil operation (HFO) Page 2 (5)
L28/32H
V28/32H
Medium-alkaline lubricating oil For tips on selecting the base number, refer to the
table entitled “Base number to be used for various
The prepared oil (base oil with additives) must have operating conditions".
the following properties:
Evaporation tendency
Additives
The evaporation tendency must be as low as pos-
The additives must be dissolved in the oil and their sible as otherwise the oil consumption will be ad-
composition must ensure that as little ash as pos- versely affected.
sible is left over, even if the engine is provisionally
operated with distillate oil. Additional requirements
The ash must be soft. If this prerequisite is not met, The lubricating oil must not contain viscosity index
it is likely the rate of deposition in the combustion improver. Fresh oil must not contain water or other
chamber will be higher, particularly at the exhaust contaminants.
valves and at the turbocharger inlet casing. Hard
additive ash promotes pitting of the valve seats and Lubricating Oil Selection
causes the valves to burn out, it also increases me-
chanical wear of the cylinder liners.
Engine SAE–Class
Additives must not increase the rate at which the 23/30H, 28/32H, 23/30A, 28/32A
filter elements in the active or used condition are At cooling water temperatures > 32° C a
30
blocked. SAE40 oil can be used.
In this case please contact MAN Diesel
Washing ability Table 2 Viscosity (SAE class) of lube oils
The washing ability must be high enough to prevent

the accumulation of tar and coke residue as a result Neutralisation properties (BN)
of fuel combustion. The lubricating oil must not ab-
sorb the deposits produced by the fuel. Lubricating oils with medium alkalinity and a range
of neutralisation capabilities (BN) are available on
Dispersibility the market. According to current knowledge, a re-
lationship can be established between the antici-
The selected dispersibility must be such that com- pated operating conditions and the BN number as
mercially-available lubricating oil cleaning systems shown in the table entitled "Base number to be
can remove harmful contaminants from the oil used for various operating conditions". However,
used, i.e. the oil must possess good filtering prop- the operating results are still the overriding factor in
erties and separability. determining which BN number produces the most
efficient engine operation.
Neutralisation capability
The neutralisation capability (ASTM D2896) must

be high enough to neutralise the acidic products
produced during combustion. The reaction time of
the additive must be harmonised with the process
in the combustion chamber.
11.01 - ES1 - 3.3.6 (2011-01-04)

MAN Diesel & Turbo

L28/32H
V28/32H
approx. BN of fresh Engines / Operating conditions
oil (mg KOH/g oil)
Marine diesel oil (MDO) with a lower quality (ISO-F-DMC) or heavy fuel oil with a sulphur
20 content of less than 0.5 %
generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
30 For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF
with exclusive HFO operation only with sulphur content < 1.5 %.
With unfavourable operating conditions 23/30A, 28/32A and 28/32S and also where corre-
sponding requirements in relation to the oil service life and washing ability exist. In general
40 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF with
exclusive HFO operation providing the sulphur content is greater than 1.5 %.
32/40, 32/44CR, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is
50 insufficient with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil
consumption).
Table 3 Base number to be used for various operating conditions
Operation with low sulphur fuel Speed controller
To comply with the emissions regulations, the sul- Multigrade oil 5W40 should ideally be used in me-
phur content of fuels used nowadays varies. Fuels chanical-hydraulic controllers with a separate oil
with a low-sulphur content must be used in envi- sump. If this oil is not available when filling, 15W40
ronmentally-sensitive areas (SECA). Fuels with a oil can be used instead in exceptional cases. In this
high sulphur content may be used outside SECA case, it makes no difference whether synthetic or
zones. In this case, the BN number of the lubricat- mineral-based oils are used.
ing oil selected must satisfy the requirements for
operation using fuel with a high-sulphur content. The military specification for these oils is O-236.
A lubricating oil with low BN number may only be
selected if fuel with a low-sulphur content is used Lubricating oil additives
exclusively during operation.
The use of other additives with the lubricating oil, or
However, the results obtained in practise that dem- the mixing of different brands (oils by different man-
onstrate the most efficient engine operation are the ufacturers), is not permitted as this may impair the
factor that ultimately decides which additive fraction performance of the existing additives which have
is permitted. been carefully harmonised with each another and
also specifically tailored to the base oil.
Cylinder lubricating oil
Selection of lubricating oils / warranty
In engines with separate cylinder lubrication, the
pistons and cylinder liners are supplied with lubri- The majority of mineral oil companies are in close
cating oil via a separate lubricating oil pump. The regular contact with engine manufacturers and can
quantity of lubricating oil is set at the factory ac- therefore provide information on which oil in their
cording to the quality of the fuel to be used and the specific product range has been approved by the
anticipated operating conditions. engine manufacturer for the particular application.
Irrespective of the above, lubricating oil manufac-
Use a lubricating oil for the cylinder and lubricating turers are liable in any case for the quality and char-
circuit as specified above. acteristics of their products. If you have any ques-
tions, we will be happy to provide you with further
information.
11.01 - ES1 - 3.3.6 (2011-01-04)

MAN Diesel & Turbo
604.01 Specification for lubricating oils (SAE30) for Description

Edition 27H heavy fuel oil operation (HFO) Page 4 (5)
L28/32H
V28/32H
Oil during operation If the engine is operated provisionally with low-sul-
phur diesel fuel for more than 1000 h and is sub-
There are no prescribed oil change intervals for sequently operated once again with HFO, a lubri-
MAN Diesel & Turbo medium speed engines. The cating oil with a BN of 20 must be used. If the BN
oil properties must be regularly analysed. The oil 20 lubricating oil by the same manufacturer as the
can be used for as long as the oil properties remain lubricating oil used for HFO operation with higher
within the defined limit values (see table entitled BN (30 or 40), an oil change will not be required
"Limit values for used lubricating oil“). An oil sample when effecting the changeover. It will be sufficient
must be analysed every 1-3 months (see mainte- to use BN 20 oil when replenishing the used lubri-
nance schedule). The quality of the oil can only be cating oil.
maintained if it is cleaned using suitable equipment
(e.g. a separator or filter). If you wish to operate the engine with HFO once
again, it will be necessary to change over in good
Temporary operation with gas oil time to a lubricating oil with a higher BN (30 – 40).
If the lubricating oil with higher BN is by the same
Due to current and future emission regulations, manufacturer as the BN 20 lubricating oil, the
heavy fuel oil cannot be used in designated regions. changeover can also be effected without an oil
Low-sulphur diesel fuel must be used in these re- change. In doing so, the lubricating oil with higher
gions instead. BN (30 – 40) must be used to replenish the used
lubricating oil roughly 2 weeks prior to resuming
If the engine is operated with low-sulphur diesel HFO operation.
fuel for less than 1000 h, a lubricating oil which is
suitable for HFO operation (BN 30 – 40 mg KOH/g)
can be used during this period.
Limit value Procedure
Viscosity at 40 °C 75-160 mm2/s ISO 3104 or ASTM D 445
Base Number (BN) at least 50% of fresh oil ISO 3771
Flash Point (PM) at least 185 °C ISO 2719
Water Content max. 0.2% (max. 0.5% for brief periods) ISO 3733 or ASTM D 1744
nHeptan Insoluble max. 1.5% DIN 51592 or IP 316
depends on engine type and operating

Metal Content
conditions
Guide value only

Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Table 4 Limit values for used lubricating oil
11.01 - ES1 - 3.3.6 (2011-01-04)

MAN Diesel & Turbo

L28/32H
V28/32H
Examinations Note!
No liability when using these oils
We can analyse heavy fuel oil for customers at our
laboratory. A 0.5 l sample is required for the test. MAN Diesel & Turbo does not assume liability for
problems that occur when using these oils.
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 Taro 20DP30 Taro 30DP30 Taro 40XL 30

(TEXACO, CALTEX) Taro 20DP30X Taro 30DP30X Taro 40XL30X
Mobilgard M330 Mobilgard M340

EXXON MOBIL 
EXXMAR 30 TP 30 EXXMAR 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 X 30
Aurelia XL 3030 Aurelia XL 3040

TOTAL Lubmarine 
Aurelia TI 3030 Aurelia TI 3040
Table 5 Approved lubricating oils for heavy fuel oil-operated MAN Diesel & Turbo fourstroke engines.
11.01 - ES1 - 3.3.6 (2011-01-04)

MAN Diesel & Turbo
Description Quality Requirements for Lube Oil (SAE30) for Opera- 604.01
Page 1 (5) tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Edition 26H
L28/32H
V28/32H
The specific output achieved by modern diesel en- Only lubricating oils approved by MAN Diesel may
gines combined with the use of fuels that satisfy be used. These are listed in the tables below.
the quality requirements more and more frequently
increase the demands on the performance of the
lubricating oil which must therefore be carefully se- Specifications
lected.
Base oil
Doped lubricating oils (HD oils) have a proven track
record as lubricants for the drive, cylinder, turbo- The base oil (doped lubricating oil = base oil + addi-
charger and also for cooling the piston. Doped lu- tives) must have a narrow distillation range and be
bricating oils contain additives that, amongst other refined using modern methods. If it contains par-
things, ensure dirt absorption capability, cleaning of affins, they must not impair the thermal stability or
the engine and the neutralisation of acidic combus- oxidation stability.
tion products.
The base oil must comply with the following limit
values, particularly in terms of its resistance to age-
ing.
Properties/characteristics Unit Test method Limit values

Make-up   Ideally paraffin based
Low temperature behaviour, still flowable °C ASTM D 2500  15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of
 MAN ageing oven * 
heating up to 135 °C
ASTM D 4055 or
insoluble nheptane Weight % < 0.2
DIN 51592
Evaporation loss Weight %  < 2
Precipitation of resins or asphalt-
Spot test (filter paper)  MAN Diesel test like ageing products must not be
identifiable.
Table 1 Base oils - target values
* Works' own method
08028-0D/H5250/94.08.12
10.20 - ES1 - 3.3.5 (2010-02-25)

MAN Diesel & Turbo
604.01 Quality Requirements for Lube Oil (SAE30) for Opera- Description
Edition 26H tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Page 2 (5)
L28/32H
V28/32H
Doped lubricating oils (HD-oils) Additional requirements
The base oil to which the additives have been add- The lubricating oil must not contain viscosity index
ed (doped lubricating oil) must have the following improver. Fresh oil must not contain water or other
properties: contaminants.
Additives Lubricating Oil Selection
The additives must be dissolved in the oil and their

Engine SAE–Class
composition must ensure that as little ash as pos-
sible remains following combustion. 23/30H, 28/32H, 23/30A, 28/32A
At cooling water temperatures > 32° C a
30
The ash must be soft. If this prerequisite is not met, SAE40 oil can be used.
it is likely the rate of deposition in the combustion In this case please contact MAN Diesel
chamber will be higher, particularly at the exhaust Table 2 Viscosity (SAE class) of lube oils
valves and at the turbocharger inlet casing. Hard
additive ash promotes pitting of the valve seats and
causes the valves to burn out, it also increases me- Doped oil quality
chanical wear of the cylinder liners.
We recommend doped lubricating oils (HD oils)
Additives must not increase the rate at which the according to international specifications MIL-L
filter elements in the active or used condition are 2104 or API-CD with a base number of BN 10 – 16
blocked. mgKOH/g. Military specification O-278 lubricating
oils can be used.
Washing ability
The operating conditions of the engine and the
The washing ability must be high enough to prevent quality of the fuel determine which additive frac-
the accumulation of tar and coke residue as a result tions the lubricating oil contains. If marine diesel
of fuel combustion. oil with a sulphur content of up to 2.0 % by weight
according to ISO-F-DMC and coke residues of up
Dispersibility to 2.5 % by weight is used, you should choose a
base number of roughly 20. However, the operating
The selected dispersibility must be such that com- results that ensure the most efficient engine opera-
mercially-available lubricating oil cleaning systems tion ultimately decide the additive content.
can remove harmful contaminants from the oil
used, i.e. the oil must possess good filtering prop- Cylinder lubricating oil
erties and separability.
In engines with separate cylinder lubrication, the
Neutralisation capability pistons and cylinder liners are supplied with lubri-
cating oil via a separate lubricating oil pump. The
The neutralisation capability (ASTM D2896) must quantity of lubricating oil is set at the factory ac-
08028-0D/H5250/94.08.12
be high enough to neutralise the acidic products cording to the quality of the fuel to be used and the
produced during combustion. The reaction time of anticipated operating conditions.
the additive must be harmonised with the process
in the combustion chamber. Use a lubricating oil for the cylinder and lubricating
circuit as specified above.
Evaporation tendency
The evaporation tendency must be as low as pos-

sible as otherwise the oil consumption will be ad-
versely affected.
10.20 - ES1 - 3.3.5 (2010-02-25)

MAN Diesel & Turbo
L28/32H
V28/32H
Speed controller Temporary operation with gas oil
Multigrade oil 5W40 should ideally be used in me- Due to current and future emission regulations,
chanical-hydraulic controllers with a separate oil heavy fuel oil cannot be used in designated regions.
sump. If this oil is not available when filling, 15W40 Low-sulphur diesel fuel must be used in these re-
oil can be used instead in exceptional cases. In this gions instead.
case, it makes no difference whether synthetic or
mineral-based oils are used. If the engine is operated with low-sulphur diesel
fuel for less than 1000 h, a lubricating oil which is
The military specification for these oils is O-236. suitable for HFO operation (BN 30 – 40 mg KOH/g)
can be used during this period.
Lubricating oil additives
If the engine is operated provisionally with low-sul-
The use of other additives with the lubricating oil, or phur diesel fuel for more than 1000 h and is sub-
the mixing of different brands (oils by different man- sequently operated once again with HFO, a lubri-
ufacturers), is not permitted as this may impair the cating oil with a BN of 20 must be used. If the BN
performance of the existing additives which have 20 lubricating oil by the same manufacturer as the
been carefully harmonised with each another and lubricating oil used for HFO operation with higher
also specifically tailored to the base oil. BN (30 or 40), an oil change will not be required
when effecting the changeover. It will be sufficient
Selection of lubricating oils / warranty to use BN 20 oil when replenishing the used lubri-
cating oil.
The majority of mineral oil companies are in close
regular contact with engine manufacturers and can If you wish to operate the engine with HFO once
therefore provide information on which oil in their again, it will be necessary to change over in good
specific product range has been approved by the time to a lubricating oil with a higher BN (30 – 40).
engine manufacturer for the particular application. If the lubricating oil with higher BN is by the same
Irrespective of the above, lubricating oil manufac- manufacturer as the BN20 lubricating oil, the
turers are liable in any case for the quality and char- changeover can also be effected without an oil
acteristics of their products. If you have any ques- change. In doing so, the lubricating oil with higher
tions, we will be happy to provide you with further BN (30 – 40) must be used to replenish the used
information. lubricating oil roughly 2 weeks prior to resuming
HFO operation.
Oil during Operation
There are no prescribed oil change intervals for

MAN Diesel medium speed engines. The oil prop-
erties must be regularly analysed. The oil can be
used for as long as the oil properties remain within
the defined limit values (see table entitled "Limit
08028-0D/H5250/94.08.12
values for used lubricating oil“). An oil sample must

be analysed every 1-3 months (see maintenance
schedule). The quality of the oil can only be main-
tained if it is cleaned using suitable equipment (e.g.
a separator or filter).
10.20 - ES1 - 3.3.5 (2010-02-25)

MAN Diesel & Turbo
604.01 Quality Requirements for Lube Oil (SAE30) for Opera- Description
Edition 26H tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Page 4 (5)
L28/32H
V28/32H
Tests Approved lubricating oils SAE 30
Base Number
We can analyse heavy fuel oil for customers at our Manufacturer
10161) [mgKOH/g]
laboratory. A 0.5 l sample is required for the test.
Cladium 120  SAE 30
AGIP
Sigma S SAE 30 2)
Danger!
BP Energol DS 3153
Improper handling of fuels Castrol MLC 30
CASTROL Castrol MHP 153
If fuels are improperly handled, this can pose a Seamax Extra 30
danger to health, safety and the environment. The Taro 12 XD 30
relevant safety information by the fuel supplier must CHEVRON
Delo 1000 Marine SAE 30
(Texaco, Caltex)
be observed. Delo SHP30
Exxmar 12 TP 30
Note! Mobilgard 312
EXXON MOBIL
Mobilgard ADL 30 2)
No liability assumed if these oils are used Delvac 1630
PETROBRAS Marbrax CCD310
MAN Diesel SE will not assume liability for any
Q8 Mozart DP30
problems associated with using these oils.
REPSOL Neptuno NT 1530
Gadinia 30
Gadinia AL30
SHELL
Sirius FB30 2)
Sirius/Rimula X30 2)
MarWay 1530
STATOIL
MarWay 1030
TOTAL Lubmarine Disola M3015
Table 3 Lubricating oils (SAE30) which have been ap-
proved for the use in MAN Diesel four-stroke engines running
on gas oil and Diesel oil
1)
If marine diesel oil with a low quality (ISO-F-DMC) is used,
a base number (BN) of roughly 20 should be used.
2)
with a sulphur content of less than 1%
08028-0D/H5250/94.08.12
10.20 - ES1 - 3.3.5 (2010-02-25)

MAN Diesel & Turbo
L28/32H
V28/32H
Limit value Procedure
Viscosity at 40 °C 75-160 mm /s2
ISO 3104 or ASTM D445
Base Number (BN) at least 50% of fresh oil ISO 3771
Flash Point (PM) at least 185 °C ISO 2719
Water Content max. 0.2% (max. 0.5% for brief periods) ISO 3733 or ASTM D 1744
nHeptan Insoluble max. 1.5% DIN 51592 or IP 316
depends on engine type and operating
Metal Content
conditions
Guide value only
Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
When operating with biofuels:
max 12% FT-IR
biofuel fraction
Table 4 Limit values for used lubricating oil
08028-0D/H5250/94.08.12
10.20 - ES1 - 3.3.5 (2010-02-25)

MAN Diesel & Turbo
Description 604.03
Page 1 (4) Treatment and maintenance of lubricating oil
Edition 11H
L32/40, L28/32H, V28/32H

General Operation on Heavy Fuel Oil (HFO)
During operation of trunk engines the lubricating oil HFO-operated engines require effective lubricating
will gradually be contaminated by small particles oil cleaning. In order to ensure a safe operation it is
originating from the combustion. necessary to use supplementary cleaning equip-
Engines operated on heavy fuels will normally ment together with the built-on full flow depth filter.
increase the contamination due to the increased It is mandatory to run bypass separators continu-
content of carbon residues and other contaminants. ously for engines operated on HFO, as an optimal
Contamination of lubricating oil with either freshwa- lubricating oil treatment is fundamental for a reliable
ter or seawater can also occur. working condition. Therefore it is mandatory to
clean the lubricating oil with a bypass separator, so
A certain amount of contaminants can be kept sus- that the wear rates are reduced and the lifetime of
pended in the lubricating oil without affecting the the engine is extended.
lubricating properties.
The condition of the lubricating oil must be kept Bypass equipment
under observation (on a regular basis) by analyzing
oil samples. See Section 504.04 "Criteria for Clean- As a result of normal operation, the lubricating oil
ing/Exchange of Lubricating Oil". contains abraded particles and combustion resi-
dues which have to be removed by the bypass
The moving parts in the engine are protected by the cleaning system and to a certain extent by the
built-on duplex full-flow lubricating oil filter. The duplex full-flow lubricating oil filter as well.
replaceable paper filter cartridges in each filter
chamber have a fineness of 10-15 microns. The With automatic mesh filters this can result in an
safety filter, at the centre of each filter chamber, is a undesirable and hazardous continuous flushing. In
basket filter element, with a fineness of 60 microns view of the high cost of cleaning equipment for
(sphere passing mesh). removing micro impurities, this equipment is only
rated for a certain proportion of the oil flowing
The pressure drop across the replaceable paper fil- through the engine since it is installed in a bypass.
ter cartridges is one parameter indicating the con-
tamination level. The higher the dirt content in the The bypass cleaning equipment is operated
oil, the shorter the periods between filter cartridge ▪ continuously when the engine is in operation or
replacement and cleaning. at standstill
The condition of the lubricating oil can be main- For cleaning of lubricating oil the following bypass
tained / re-established by exchanging the lubricat- cleaning equipment can be used:
ing oil at fixed intervals or based on analyzing oil
▪ Separator unit
samples.
▪ Decanter unit
Operation on Marine Diesel Oil (MDO) & ▪ Self cleaning automatic bypass mesh filter
Marine Gas Oil (MGO) ▪ Centrifugal bypass filter (Holeby Gensets can be
delivered with this built-on filter)
For engines exclusively operated on MDO/MGO we
recommend to install a built-on centrifugal bypass ▪ Bypass depth filter
filter as an additional filter to the built-on full flow The separator unit, decanter unit, the self-cleaning
depth filter. automatic bypass mesh filter and the bypass depth
It is advisable to run bypass separators continu- filter capacity must be adjusted according to
ously for engines operated on MDO/MGO as sepa- maker’s recommendations.
rators present the best cleaning solution. Mesh fil- In case full flow filtration equipment is chosen, this
ters have the disadvantage that they cannot remove must only be installed as in-line cleaning upstream
water and their elements clog quickly. to the duplex full-flow lubricating oil filter, built onto
the engine.
2012.05.15 - ES1
MAN Diesel & Turbo
604.03 Description
Treatment and maintenance of lubricating oil Page 2 (4)
Edition 11H
L32/40, L28/32H, V28/32H

The most appropriate type of equipment for a par- Lubricating oil preheating
ticular application depends on the engine output,
the type and amount of combustion residues, the The installed heater on the separator unit ensures
annual operating time and the operating mode of correct lubricating oil temperature during separa-
the plant. Even with a relatively low number of oper- tion. When the engine is at standstill, the heater can
ating hours there can be a great deal of combustion be used for two functions:
residues if, for instance, the engine is inadequately ▪ The oil in the sump can be preheated to 95 –
preheated and quickly accelerated and loaded. 98 °C by the heater and cleaned continuously
by the separator.
Separator ▪ The heater can also be used to maintain an oil
temperature of at least 40 °C, depending on
Continuous lubricating oil cleaning during engine
installation of the lubricating oil system.
operation is mandatory. An optimal lubricating oil
treatment is fundamental for a reliable working con-
dition of the engine. Cleaning capacity
If the lubricating oil is circulating without a separator Normally, it is recommended to use a self-cleaning
in operation, the lubricating oil will gradually be con- filtration unit in order to optimize the cleaning period
taminated by products of combustion, water and/or and thus also optimize the size of the filtration unit.
acid. In some instances cat-fines may also be Separators for manual cleaning can be used when
present. the reduced effective cleaning time is taken into
In order to prolong the lubricating oil lifetime and consideration by dimensioning the separator
remove wear elements, water and contaminants capacity.
from the lubricating oil, it is mandatory to use a by-
pass separator. The required flow
The separator will reduce the carbon residue con-
tent and other contaminants from combustion on In order to calculate the required lubricating oil flow
engines operated on HFO, and keep the amount through the separator, the separator maker’s rec-
within MDT’s recommendation, on condition that ommendation must be followed.
the separator unit is operated according to maker's As a guidance, the following formula should form
recommendations. the basis for choosing the required flow for the sep-
When operating a cleaning device, the following arator capacity:
recommendations must be followed:
Q = P x 1.36 x n
▪ The optimum cleaning effect is achieved by
T
keeping the lubricating oil in a state of low vis-
cosity for a long period in the separator bowl. Q = required flow (l/h)
▪ Sufficiently low viscosity is obtained by preheat- P = engine output kW)
ing the lubricating oil to a temperature of 95°C - t = actual effective separator operating
98°C, when entering the separator bowl. time per day (hour)
▪ The separator unit capacity must be adjusted n = number of turnovers per day of the
according to maker’s recommendations. theoretical oil volume correspond-
Slow passage of the lubricating oil through the sep- ing to 1.36 l/kW or 1 l/HP
arator is obtained by using a reduced flow rate and The following values for "n" are recommended:
by operating the separator 24 hours a day, stop-
ping only for maintenance, according to maker's n = 5 for HFO operation (residual)
recommendation. n = 4 for MDO operation
n = 3 for distillate fuel
2012.05.15 - ES1
MAN Diesel & Turbo
Description 604.03
Page 3 (4) Treatment and maintenance of lubricating oil
Edition 11H
L32/40, L28/32H, V28/32H

Example 1 Three 1000 kW engines operating on HFO connec-
For multi-engine plants, one separator per engine in ted to a common self-cleaning separator with a
operation is recommended. daily effective separating period of 23 hours:
Separator installation
With multi-engine plants, one separator per engine
in operation is recommended, but if only one sepa-
rator is in operation, the following layout can be
used:
▪ A common separator can be installed, with one
in reserve if possible for operation of all engines
Figure 1: Example 1
through a pipe system, which can be carried
out in various ways. The aim is to ensure that
One 1000 kW engine operating on HFO connected the separator is only connected to one engine
to a self-cleaning separator with a daily effective at a time. This to ensure that there is no suction
separating period of 23 hours: and discharging from one engine to another.
It is recommended that inlet and outlet valves are
connected, so that they can only be changed over
simultaneously.
Example 2 With only one engine in operation there are no
As alternative one common separator can be instal- problems with separating, but if several engines are
led, with one in reserve if possible, for multi-engine in operation for some time it is recommended to
plants. split up the time so that there is separation on all
engines, which are operating in turns.
The capacity of the separator has to correspond
with the separating of oil on the single engine n
times during the available time, every 24 hours. See
section regarding required flow.
Check of lubricating oil system

For cleaning of the lubricating oil system after over-
hauls and inspection of the lubricating oil piping
system the following checks must be carried out:
1. Examine the piping system for leaks.
2. Retighten all bolts and nuts in the piping sys-
tem.
3. Move all valves and cocks in the piping system.
Lubricate valve spindles with graphite or similar.
4. Blow through drain pipes.
5. Check flexible connections for leaks and dam-
1 Interconnected valves ages.
6. Check manometers and thermometers for pos-
Figure 2: Example 2 sible damages.
2012.05.15 - ES1
MAN Diesel & Turbo
604.03 Description
Treatment and maintenance of lubricating oil Page 4 (4)
Edition 11H
L32/40, L28/32H, V28/32H

rous particles and rust are active. Furthermore, the
Deterioration of oil lacquer and varnish oxidation products of the oil
itself have an accelerating effect. Continuous clean-
Oil seldomly loses its ability to lubricate, i.e. to form ing of the oil is therefore important to keep the
a friction-decreasing oil film, but it may become cor- sludge content low.
rosive to the steel journals of the bearings in such a
way that the surface of these journals becomes too
rough and wipes the bearing surface.
Water washing
In that case the bearings must be renewed, and the Water washing of HD oils (heavy duty) must not be
journals must also be polished. The corrosiveness carried out.
of the lubricating oil is either due to far advanced
oxidation of the oil itself (TAN) or to the presence of Water in the oil
inorganic acids (SAN). In both cases the presence
If the TAN is low, a minor increase in the fresh water
of water will multiply the effect, especially sea water
content of the oil is not immediately detrimental
as the chloride ions act as an inorganic acid.
while the engine is in operation. Naturally, it should
be brought down again as quickly as possible
Signs of deterioration (below 0.2% water content, which is permissible,
If circulating oil of inferior quality is used and the oxi- see description "B 12 15 0/504.04 criteria for
dative influence becomes grave, prompt action is exchange of lube oil”). If the engine is stopped while
necessary as the last stages in the deterioration will corrosion conditions are unsatisfactory, the crank-
develop surprisingly quickly, within one or two shaft must be turned ½ - ¾ revolution once every
weeks. Even if this seldomly happens, it is wise to hour. Please make sure that the crankshaft stops in
be acquainted with the signs of deterioration. different positions, to prevent major damage to
bearings and journals. The lubricating oil must be
These may be some or all of the following: circulated and separated continuously to remove
▪ Sludge precipitation in the separator multiplies water.
▪ Smell of oil becomes acrid or pungent Water in the oil may be noted by steam formation
on the sight glasses, by appearance, or ascertained
▪ Machined surfaces in the crankcase become
by immersing a piece of glass or a soldering iron
coffee-brown with a thin layer of lacquer
heated to 200-300°C in an oil sample. If there is a
▪ Paint in the crankcase peels off or blisters hissing sound, water is present. If a large quantity of
▪ Excessive carbon is formed in the piston cool- water has entered the lubricating oil system, it has
ing chamber to be removed. Either to suck up sediment water
from the bottom, or replace the oil in the sump. An
In a grave case of oil deterioration the system must
oil sample must be analysed immediately for chlor-
be cleaned thoroughly and refilled with new oil.
ide ions.
Oxidation of oils
At normal service temperature the rate of oxidation
is insignificant, but the following factors will acceler-
ate the process:
High temperature
If the coolers are ineffective, the temperature level
will generally rise. A high temperature will also arise
in electrical pre-heaters if the circulation is not con-
tinued for 5 minutes after the heating has been
stopped, or if the heater is only partly filled with oil.
Catalytic action
Oxidation of the oil will be accelerated considerably
if catalytic particles are present in the oil. Wear par-
ticles of copper are especially harmful, but also fer-
2012.05.15 - ES1
MAN Diesel & turbo
Description 604.04
Page 1 (2) Criteria for Cleaning/Exchange of Lubricating Oil Edition 17H
General
Replacement of Lubricating Oil Unit : cSt (mm2/s)

The expected lubricating oil lifetime in operation is Possible test
difficult to determine. The lubricating oil lifetime is methods : ASTM D-445, DIN 51562/53018,
depending on the fuel oil quality, the lubricating oil ISO 3104
quality, the lubricating oil consumption, the lubricating
oil cleaning equipment efficiency and the engine Increasing viscosity indicates problems with inso-
operational conditions. lubles, HFO contamination, water contamination,
oxidation, nitration and low load operation. Decrea-
In order to evaluate the lubricating oil condition a sing viscosity is generally due to dilution with lighter
sample should be drawn on regular basis at least viscosity oil.
once every three month or depending on the latest
analysis result. The lubricating oil sample must be
drawn before the filter at engine in operation. The 2. Flash Point
sample bottle must be clean and dry, supplied with
sufficient indentification and should be closed im- Min. value : 185° C
mediately after filling. The lubricating oil sample
must be examined in an approved laboratory or in Possible test
the lubricating oil suppliers own laboratory. method : ASTM D-92, ISO 2719

A lubricating oil replacement or an extensive lubri- Normally used to indicate fuel dilution.
cating oil cleaning is required when the MAN Diesel
exchange criteria's have been reached.
3. Water Content

Evaluation of the Lubricating Oil Condition Max. value : 0.2 %
Based on the analysis results, the following guidance Unit : Weight %

are normally sufficient for evaluating the lubricating
oil condition. The parameters themselves can not be Possible test
jugded alonestanding, but must be evaluated together method : ASTM D4928, ISO 3733
in order to conclude the lubricating oil condition.
Water can originate from contaminated fuel oil, an
engine cooling water leak or formed as part of the
1. Viscosity combustion process. If water is detected also Sodium,
Glycol or Boron content should be checked in order
Limit value : to confirm engine coolant leaks.

Normal min. max.
value value value 4. Base Number (BN)
SAE 30 [cSt@40° C] 95 - 125 75 160
Min. value : The BN value should not be lower
SAE 30 [cSt@100° C] 11 - 13 9 15 than 50% of fresh lubricating oil
value, but minimum BN level never
SAE 40 [cSt@40° C] 135 - 165 100 220 to be lower than 10-12 at operat-
ing on HFO!
SAE 40 [cSt@100° C] 13.5 - 15.0 11 19
Unit : mg KOH/g
Possible test
method : ASTM D-2896, ISO 3771
07.11 - ES1
MAN Diesel & turbo
604.04 Description
Edition 17H Criteria for Cleaning/Exchange of Lubricating Oil Page 2 (2)
General
The neutralization capacity must secure that the acidic Unit : Weight %
combustion products, mainly sulphur originate from
the fuel oil, are neutralized at the lube oil consumption Possible test
level for the specific engine type. Gradually the BN method : ASTM D-893 procedure B in n-
will be reduced, but should reach an equilibrium. Heptane, DIN 51592
Additionally
5. Total Acid Number (TAN) test : If the level in n-Heptane insolubles
is considered high for the type of
Max. value : 3.0 acc. to fresh oil value oil and application, the test could
be followed by a supplementary
Unit : mg KOH/g determination in Toluene.
Possible test Total insolubles is maily derived from products of

method : ASTM D-664 combustion blown by the piston rings into the crank-
case. It also includes burnt lubricating oil, additive
TAN is used to monitor oil degradation and is a ash, rust, salt, wear debris and abrasive matter.
measure of the total acids present in the lubricating
oil derived from oil oxidation (weak acids) and acidic
products of fuel combustion (strong acids). 7. Metal Content
Metal content Remarks Attention limits

6. Insolubles Content
Iron Depend upon max. 50 ppm
Max. value : 1.5 % generally, depending upon Chromium engine type and max. 10 ppm
Copper operating condi- max. 15 ppm
actual dispersant value and the Lead tions max. 20 ppm
increase in viscosity. Tin max. 10 ppm
Aluminium max. 20 ppm
Silicon max. 20 ppm
07.11 - ES1
MAN Diesel
Description 604.05
Page 1 (1) Lubricating Points Edition 01H
General
Lubricating Oil Types used in the Engine.
Description Lub. Oil Type
Engine system lubricating oil. SAE 30 oil according to lubricating oil specification on page 604.01.
Turbocharger Engine system lubricating oil.
Governor See Governor instruction in section 609.
Air lubricator SAE 10W non-detergent oil.
Alternator See special instructions in section 618 or separate instruction.
Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12
92.02 - ES0U
MAN Diesel
Description 604.05
Page 1 (1) Lubricating Points Edition 02H
General
Lubricating Oil Types used in the Engine.
Description Lub. Oil Type
Engine system lubricating oil. SAE 40 oil according to lubricating oil specification on page 604.01.
Turbocharger Engine system lubricating oil.
Governor See Governor instruction in section 609.
Air lubricator SAE 10W non-detergent oil.
Alternator See special instructions in section 618 or separate instruction.
Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12
93.05 - ES0U
MAN Diesel
Description
Page 1 (1) Lubricating Oil in Base Frame 604.06
Edition 16H
L28/32H
Type L28/32H 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.
Min. level H2 (mm) 265 265 265 265 265

08028-0D/H5250/94.08.12
Max. level H3 (mm) 365 365 365 365 365
Min. litre H2 792 935 1078 1220 1362
Max. litre H3 1111 1311 1511 1710 1910
06.39 - ES1
MAN Diesel
Description 604.07
Page 1 (2) Specific Lubricating Oil Consumption - SLOC Edition 02H
General
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 0.7 - 1.1
Please note that only maximum continuous rating The engine maximum continuous design rating (PMCR)
(PMCR (kW)) should be used in order to evaluate the must always be used in order to be able to compare
SLOC, see the description 504.07. the individual measurements, and the running hours
since the last lubricating oil adding must be used
Please note, during engine running-in the SLOC may in the calculation. Due to inaccuracy *) at adding
exceed the values stated. lubricating oil, the SLOC can only be evaluated
after 1,000 running hours or more, where only the
The following formula is used to calculate the average values of a number of lubricating oil addings
SLOC: are representative.
SLOC [g/kWh] = Note *)

A deviation of ± 1 mm with the dipstick measurement
(lubricating oil added [dm3]) * ρlubricating oil [kg/m3] must be expected, witch corresponds uptill ± 0.1
run.hrs period * PMCR [kW] g/kWh, depending on the engine type.
The lubricating oil density, ρ @ 15°C must be known

08028-0D/H5250/94.08.12
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)
04.46 - ES1
MAN Diesel
Description 604.07
Page 2 (2) Specific Lubricating Oil Consumption - SLOC Edition 02H
General
08028-0D/H5250/94.08.12
04.46 - ES0
MAN Diesel & Turbo 3.3.3
Heavy fuel oil (HFO) specification
6680 3.3.3-01
Prerequisites
MAN four-stroke diesel engines can be operated with any heavy fuel oil
obtained from crude oil that also satisfies the requirements in Table 1, pro-
viding the engine and fuel processing system have been designed accord-
ingly. To ensure that the relationship between the fuel, spare parts and
repair / maintenance costs remains favorable at all times, the following points
should be observed.
Heavy fuel oil (HFO)

Origin/Refinery process The quality of the heavy fuel oil largely depends on the quality of crude oil
and on the refining process used. This is why the properties of heavy fuel oils
with the same viscosity may vary considerably depending on the bunker
positions. Heavy fuel oil is normally a mixture of residual oil and distillates.
The components of the mixture are normally obtained from modern refinery
processes, such as Catcracker or Visbreaker. These processes can
adversely affect the stability of the fuel as well as its ignition and combustion
properties. The processing of the heavy fuel oil and the operating result of
the engine also depend heavily on these factors.
Bunker positions with standardised heavy fuel oil qualities should preferably
be used. If oils need to be purchased from independent dealers, also ensure
that these also comply with the international specifications. The engine oper-
ator is responsible for ensuring that suitable heavy fuel oils are chosen.
Specifications Fuels intended for use in an engine must satisfy the specifications to ensure
sufficient quality. The limit values for heavy fuel oils are specified in Table 1.
The entries in the last column of Table 1 provide important background infor-
mation and must therefore be observed.
Different international specifications exist for heavy fuel oils. The most impor-
tant specifications are ISO 8217-2010 and CIMAC-2003, which are more or
less identical. The ISO 8217 specification is shown in Fig. 1. All qualities in
these specifications up to K700 can be used, providing the fuel preparation
system has been designed accordingly. To use any fuels, which do not com-
ply with these specifications (e.g. crude oil), consultation with Technical Serv-
ice of MAN Diesel & Turbo SE in Augsburg is required. Heavy fuel oils with a
maximum density of 1,010 kg/m3 may only be used if up-to-date separators
are installed.
Important Even though the fuel properties specified in the table entitled "The fuel speci-
fication and corresponding properties for heavy fuel oil" satisfy the above
requirements, they probably do not adequately define the ignition and com-
bustion properties and the stability of the fuel. This means that the operating
behaviour of the engine can depend on properties that are not defined in the
specification. This particularly applies to the oil property that causes forma-
tion of deposits in the combustion chamber, injection system, gas ducts and
2012-05-16 - de
exhaust gas system. A number of fuels have a tendency towards incompati-

bility with lubricating oil which leads to deposits being formed in the fuel
delivery pump that can block the pumps. It may therefore be necessary to
exclude specific fuels that could cause problems.
General
Blends The addition of engine oils (old lubricating oil, ULO –used lubricating oil) and
additives that are not manufactured from mineral oils, (coal-tar oil, for exam-
ple), and residual products of chemical or other processes such as solvents
6680 3.3.3-01 EN 1 (12)

3.3.3 MAN Diesel & Turbo
(polymers or chemical waste) is not permitted. Some of the reasons for this
are as follows: abrasive and corrosive effects, unfavourable combustion
6680 3.3.3-01
characteristics, poor compatibility with mineral oils and, last but not least,
adverse effects on the environment. The order for the fuel must expressly
state what is not permitted as the fuel specifications that generally apply do
not include this limitation.
If engine oils (old lubricating oil, ULO – used lubricating oil) are added to fuel,
this poses a particular danger as the additives in the lubricating oil act as
emulsifiers that cause dirt, water and catfines to be transported as fine sus-
pension. They therefore prevent the necessary cleaning of the fuel. In our
experience (and this has also been the experience of other manufacturers),
this can severely damage the engine and turbocharger components.
The addition of chemical waste products (solvents, for example) to the fuel is
prohibited for environmental protection reasons according to the resolution
of the IMO Marine Environment Protection Committee passed on 1st January
1992.
Leak oil collector Leak oil collectors that act as receptacles for leak oil, and also return and
overflow pipes in the lube oil system, must not be connected to the fuel tank.
Leak oil lines should be emptied into sludge tanks.
Viscosity (at 50 ℃) mm2/s (cSt) max. 700 Viscosity/injection viscosity
Viscosity (at 100 ℃) max. 55 Viscosity/injection viscosity
Density (at 15 °C) g/ml max. 1.010 Heavy fuel oil processing
Flash point °C min. 60 Flash point
(ASTM D 93)
Pour point (summer) max. 30 Low-temperature behaviour
(ASTM D 97)
Pour point (winter) max. 30 Low-temperature behaviour
(ASTM D 97)
Coke residue (Conrad- Weight % max. 20 Combustion properties
son)
Sulphur content 5 or Sulphuric acid corrosion
legal requirements
Ash content 0.15 Heavy fuel oil processing
Vanadium content mg/kg 450 Heavy fuel oil processing
Water content Vol. % 0.5 Heavy fuel oil processing
Sediment (potential) Weight % 0.1

Aluminium and silicium mg/kg max. 60 Heavy fuel oil processing
content (total)
Acid number mg KOH/g 2.5
Hydrogen sulphide mg/kg 2
Used lubricating oil mg/kg The fuel must be free of lubri-
(ULO) cating oil (ULO = used lubricat-
2012-05-16 - de
ing oil, old oil). Fuel is consid-

ered as contaminated with
lubricating oil when the follow-
ing concentrations occur:
General
Ca > 30 ppm and Zn > 15

ppm or Ca > 30 ppm and P >
15 ppm.
2 (12) 6680 3.3.3-01 EN

Asphaltene content Weight % 2/3 of coke residue Combustion properties
6680 3.3.3-01
(according to Conradson)
Sodium content mg/kg Sodium < 1/3 Vanadium, Heavy fuel oil processing
Sodium<100
The fuel must be free of admixtures that cannot be obtained from mineral oils, such as vegetable or coal-tar oils. It
must also be
free of tar oil and lubricating oil (old oil), and also chemical waste products such as solvents or polymers.
Table 1: Table_The fuel specification and corresponding characteristics for heavy fuel oil

2012-05-16 - de
General
6680 3.3.3-01 EN 3 (12)

6680 3.3.3-01
2012-05-16 - de
General
Figure 1: ISO 8217-2010 specification for heavy fuel oil
4 (12) 6680 3.3.3-01 EN

6680 3.3.3-01
2012-05-16 - de
General
Figure 2: ISO 8217-2010 specification for heavy fuel oil (continued)
6680 3.3.3-01 EN 5 (12)

6680 3.3.3-01
Additional information
The purpose of the following information is to show the relationship between
the quality of heavy fuel oil, heavy fuel oil processing, the engine operation
and operating results more clearly.
Selection of heavy fuel oil Economic operation with heavy fuel oil within the limit values specified in the
table entitled "The fuel specification and corresponding properties for heavy
fuel oil" is possible under normal operating conditions, provided the system is
working properly and regular maintenance is carried out. If these require-
ments are not satisfied, shorter maintenance intervals, higher wear and a
greater need for spare parts is to be expected. The required maintenance
intervals and operating results determine, which quality of heavy fuel oil
should be used.
It is an established fact that the price advantage decreases as viscosity
increases. It is therefore not always economical to use the fuel with the high-
est viscosity as in many cases the quality of this fuel will not be the best.
Viscosity/injection viscosity Heavy fuel oils with a high viscosity may be of an inferior quality. The maxi-
mum permissible viscosity depends on the preheating system installed and
the capacity (flow rate) of the separator.
The prescribed injection viscosity of 12 - 14 mm2/s (for GenSets, 23/30H and
28/32H: 12 - 18 cSt) and corresponding fuel temperature upstream of the
engine must be observed. This is the only way to ensure efficient atomisation
and mixture formation and therefore low-residue combustion. This also pre-
vents mechanical overloading of the injection system. For the prescribed
injection viscosity and/or the required fuel oil temperature upstream of the
engine, refer to the viscosity temperature diagram.
Heavy fuel oil processing Whether or not problems occur with the engine in operation depends on how
carefully the heavy fuel oil has been processed. Particular care should be
taken to ensure that highly-abrasive inorganic foreign matter (catalyst parti-
cles, rust, sand) are effectively removed. It has been shown in practice that
wear as a result of abrasion in the engine increases considerably if the alumi-
num and silicium content is higher than 15 mg/kg.
Viscosity and density influence the cleaning effect. This must be taken into
account when designing and making adjustments to the cleaning system.
Settling tank Heavy fuel oil is precleaned in the settling tank. The longer the fuel remains in
the tank and the lower the viscosity of heavy fuel oil is, the more effective the
precleaning process will be (maximum preheating temperature of 75 °C to
prevent the formation of asphalt in heavy fuel oil). A settling tank is sufficient
for heavy fuel oils with a viscosity of less than 3802/s at 50 °C. If the heavy
fuel oil has a high concentration of foreign matter, or if fuels in accordance
with ISO-F-RM, G/H/K380 or H/K700 are to be used, two settling tanks will
be required one of which must be sized for 24-hour operation. Before the
content is moved to the service tank, water and sludge must be drained from
the settling tank.
Separators A separator is particularly suitable for separating material with a higher spe-
cific density – water, foreign matter and sludge, for example. The separators
2012-05-16 - de
must be self-cleaning (i.e. the cleaning intervals must be triggered automati-

cally).
Only new generation separators should be used. They are extremely effective
General
throughout a wide density range with no changeover required, and can sep-
arate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 °C.
6 (12) 6680 3.3.3-01 EN

Table "Achievable proportion of foreign matter and water (following separa-

tion)" shows the prerequisites that must be met by the separator. These limit
6680 3.3.3-01
values are used by manufacturers as the basis for dimensioning the separa-
tor and ensure compliance.
The manufacturer's specifications must be complied with to maximize the
cleaning effect.
Application in ships and stationary use: parallel installation

1 Separator for 100 % flow rate 1 Separator (reserve) for 100 % flow
rate
Figure 3: Location of heavy fuel oil cleaning equipment and/or separator

The separators must be arranged according to the manufacturers' current
recommendations (Alpha Laval and Westfalia). The density and viscosity of
the heavy fuel oil in particular must be taken into account. If separators by
other manufacturers are used, MAN Diesel should be consulted.
If processing is carried out in accordance with the MAN Diesel specifications
and the correct separators are chosen, it may be assumed that the results
stated in the table entitled "Achievable proportion of foreign matter and
water" for inorganic foreign matter and water in the heavy fuel oil will be ach-
ieved at the engine inlet.
Results obtained during operation in practiсe show that the wear occurs as a
result of abrasion in the injection system and the engine will remain within
acceptable limits if these values are complied with. In addition, an optimum
lubricating oil treatment process must be ensured.
Definition Particle size Quantity

Inorganic foreign matter < 5 µm < 20 mg/kg
including catalyst particles
Al+Si content -- < 15 mg/kg
Water content -- < 0.2 % by vol. %
Table 2: Achievable proportion of foreign matter and water (after separation)
Water It is particularly important to ensure that the water separation process is as
2012-05-16 - de
thorough as possible as the water takes the form of large droplets, and not a
finely distributed emulsion. In this form, water also promotes corrosion and
sludge formation in the fuel system and therefore impairs the supply, atomi-
sation and combustion of the heavy fuel oil. If the water absorbed in the fuel
General
is seawater, harmful sodium chloride and other salts dissolved in this water
will enter the engine.
6680 3.3.3-01 EN 7 (12)

Water-containing sludge must be removed from the settling tank before the
separation process starts, and must also be removed from the service tank
6680 3.3.3-01
at regular intervals. The tank's ventilation system must be designed in such a

way that condensate cannot flow back into the tank.
Vanadium/Sodium If the vanadium/sodium ratio is unfavorable, the melting point of the heavy
fuel oil ash may fall in the operating area of the exhaust-gas valve which can
lead to high-temperature corrosion. Most of the water and water-soluble
sodium compounds it contains can be removed by pretreating the heavy fuel
oil in the settling tank and in the separators.
The risk of high-temperature corrosion is low if the sodium content is one
third of the vanadium content or less. It must also be ensured that sodium
does not enter the engine in the form of seawater in the intake air.
If the sodium content is higher than 100 mg/kg, this is likely to result in a
higher quantity of salt deposits in the combustion chamber and exhaust-gas
system. This will impair the function of the engine (including the suction func-
tion of the turbocharger).
Under certain conditions, high-temperature corrosion can be prevented by
using a fuel additive that increases the melting point of the heavy fuel oil ash
(also see "Additives for heavy fuel oils”).
Ash Fuel ash consists for the greater part of vanadium oxide and nickel sulphate
(see above chapter for more information). Heavy fuel oils containing a high
proportion of ash in the form of foreign matter, e.g. sand, corrosion com-
pounds and catalyst particles, accelerate the mechanical wear in the engine.
Catalyst particles produced as a result of the catalytic cracking process may
be present in the heavy fuel oils. In most cases, these are aluminium silicate
particles that cause a high degree of wear in the injection system and the
engine. The aluminium content determined, multiplied by a factor of between
5 and 8 (depending on the catalytic bond), is roughly the same as the pro-
portion of catalyst remnants in the heavy fuel oil.
Homogeniser If a homogeniser is used, it must never be installed between the settling tank
and separator as otherwise it will not be possible to ensure satisfactory sepa-
ration of harmful contaminants, particularly seawater.
Flash point (ASTM D 93) National and international transportation and storage regulations governing
the use of fuels must be complied with in relation to the flash point. In gen-
eral, a flash point of above 60 °C is prescribed for diesel engine fuels.
Low-temperature behaviour The pour point is the temperature at which the fuel is no longer flowable
(ASTM D 97) (pumpable). As the pour point of many low-viscosity heavy fuel oils is higher
than 0 °C, the bunker facility must be preheated, unless fuel in accordance
with RMA or RMB is used. The entire bunker facility must be designed in
such a way that the heavy fuel oil can be preheated to around 10 °C above
the pour point.
Pump characteristics If the viscosity of the fuel is higher than 1000 mm2/s (cST), or the tempera-
ture is not at least 10 °C above the pour point, pump problems will occur.
For more information, also refer to “Low-temperature behaviour
(ASTM D 97)”.
Combustion properties If the proportion of asphalt is more than two thirds of the coke residue (Con-
2012-05-16 - de
radson), combustion may be delayed which in turn may increase the forma-
tion of combustion residues, leading to such as deposits on and in the injec-
tion nozzles, large amounts of smoke, low output, increased fuel consump-
General
tion and a rapid rise in ignition pressure as well as combustion close to the
cylinder wall (thermal overloading of lubricating oil film). If the ratio of asphalt
to coke residues reaches the limit 0.66, and if the asphalt content exceeds
8%, the risk of deposits forming in the combustion chamber and injection
8 (12) 6680 3.3.3-01 EN

system is higher. These problems can also occur when using unstable heavy
fuel oils, or if incompatible heavy fuel oils are mixed. This would lead to an
6680 3.3.3-01
increased deposition of asphalt (see "Compatibility”).
Ignition quality Nowadays, to achieve the prescribed reference viscosity, cracking-process
products are used as the low viscosity ingredients of heavy fuel oils although
the ignition characteristics of these oils may also be poor. The cetane num-
ber of these compounds should be > 35. If the proportion of aromatic hydro-
carbons is high (more than 35 %), this also adversely affects the ignition
quality.
The ignition delay in heavy fuel oils with poor ignition characteristics is longer;
the combustion is also delayed which can lead to thermal overloading of the
oil film at the cylinder liner and also high cylinder pressures. The ignition delay
and accompanying increase in pressure in the cylinder are also influenced by
the end temperature and compression pressure, i.e. by the compression
ratio, the charge-air pressure and charge-air temperature.
The disadvantages of using fuels with poor ignition characteristics can be
limited by preheating the charge air in partial load operation and reducing the
output for a limited period. However, a more effective solution is a high com-
pression ratio and operational adjustment of the injection system to the igni-
tion characteristics of the fuel used, as is the case with MAN Diesel piston
engines.
The ignition quality is one of the most important properties of the fuel. This
value does not appear in the international specifications because a standar-
dised testing method has only recently become available and not enough
experience has been gathered at this point in order to determine limit values.
The parameters, such as the calculated carbon aromaticity index (CCAI), are
therefore aids that are derived from quantifiable fuel properties. We have
established that this method is suitable for determining the approximate igni-
tion quality of the heavy fuel oil used.
A testing instrument has been developed based on the constant volume
combustion method (fuel combustion analyser FCA) and is currently being
tested by a series of testing laboratories.
The instrument measures the ignition delay to determine the ignition quality
of a fuel and this measurement is converted into a an instrument-specific
cetane number (FIA-CN or EC). It has been established that in some cases,
heavy fuel oils with a low FIA cetane number or ECN number can cause
operating problems.
As the liquid components of the heavy fuel oil decisively influence the ignition
quality, flow properties and combustion quality, the bunker operator is

responsible for ensuring that the quality of heavy fuel oil delivered is suitable
for the diesel engine. (Also see illustration entitled "Nomogram for determin-
ing the CCAI – assigning the CCAI ranges to engine types").
2012-05-16 - de
General
6680 3.3.3-01 EN 9 (12)

6680 3.3.3-01
V Viscosity in mm2/s (cSt) at 50° C A Normal operating conditions

D Density [in kg/m3] at 15° C B The ignition characteristics can
be poor and require adapting the
engine or the operating condi-
tions.
CCAI Calculated Carbon Aromaticity C Problems identified may lead to
Index engine damage, even after a
short period of operation.
1 Engine type 2 The CCAI is obtained from the
straight line through the density
and viscosity of the heavy fuel
oils.
Figure 4: Nomogram for determining the CCAI – assigning the CCAI ranges to engine
types
The CCAI can be calculated using the following formula:
CCAI = D - 141 log log (V+0.85) - 81
Sulphuric acid corrosion The engine should be operated at the cooling water temperatures prescribed
in the operating handbook for the relevant load. If the temperature of the
2012-05-16 - de
components that are exposed to acidic combustion products is below the

acid dew point, acid corrosion can no longer be effectively prevented, even if
alkaline lubricating oil is used.
The BN values specified in Section 3.3.6 are sufficient, providing the quality
General
of lubricating oil and the engine's cooling system satisfy the requirements.
10 (12) 6680 3.3.3-01 EN

Compatibility The supplier must guarantee that the heavy fuel oil is homogeneous and
remains stable, even after the standard storage period. If different bunker oils
6680 3.3.3-01
are mixed, this can lead to separation and the associated sludge formation in
the fuel system during which large quantities of sludge accumulate in the
separator that block filters, prevent atomisation and a large amount of resi-
due as a result of combustion.
This is due to incompatibility or instability of the oils. Therefore heavy fuel oil
as much as possible should be removed in the storage tank before bunker-
ing again to prevent incompatibility.
Blending the heavy fuel oil If heavy fuel oil for the main engine is blended with gas oil (MGO) to obtain
the required quality or viscosity of heavy fuel oil, it is extremely important that
the components are compatible (see "Compatibility").
Additives for heavy fuel oils MAN Diesel & Turbo SE engines can be operated economically without addi-
tives. It is up to the customer to decide whether or not the use of additives is
beneficial. The supplier of the additive must guarantee that the engine opera-
tion will not be impaired by using the product.
The use of heavy fuel oil additives during the warranty period must be avoi-
ded as a basic principle.
Additives that are currently used for diesel engines, as well as their probable
effects on the engine's operation, are summarised in the table below "Addi-
tives for heavy fuel oils – classification/effects".
Precombustion additives ▪ Dispersing agents/stabil-
isers
▪ Emulsion breakers
▪ Biocides
Combustion additives ▪ Combustion catalysts
(fuel savings, emissions)
Post-combustion additives ▪ Ash modifiers (hot corro-
sion)
▪ Soot removers (exhaust-
gas system)
Table 3: Additives for heavy fuel oils – Classification/effects
Heavy fuel oils with low From the point of view of an engine manufacturer, a lower limit for the sul-
sulphur content phur content of heavy fuel oils does not exist. We have not identified any
problems with the low-sulphur heavy fuel oils currently available on the mar-
ket that can be traced back to their sulphur content. This situation may
change in future if new methods are used for the production of low-sulphur
heavy fuel oil (desulphurisation, new blending components). MAN Diesel &
Turbo will monitor developments and inform its customers if required.
If the engine is not always operated with low-sulphur heavy fuel oil, corre-
sponding lubricating oil for the fuel with the highest sulphur content must be
selected.
2012-05-16 - de
Improper handling of operating fluids

If operating fluids are improperly handled, this can pose a danger to
health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.
General
6680 3.3.3-01 EN 11 (12)

6680 3.3.3-01
Tests
Sampling To check whether the specification provided and/or the necessary delivery
conditions are complied with, we recommend you retain at least one sample
of every bunker oil (at least for the duration of the engine's warranty period).
To ensure that the samples taken are representative of the bunker oil, a sam-
ple should be taken from the transfer line when starting up, halfway through
the operating period and at the end of the bunker period. “Sample Tec" by
Mar-Tec in Hamburg is a suitable testing instrument which can be used to
take samples on a regular basis during bunkering.
Analysis of samples Our department for fuels and lubricating oils (Augsburg factory, department
EQC) will be pleased to provide further information on request.
We can analyse fuel for customers at our laboratory. A 0.5 l sample is
required for the test.
2012-05-16 - de
General
12 (12) 6680 3.3.3-01 EN

Diesel oil (MDO) specification
6680 3.3.2-01
Marine diesel oil
Other designations Marine diesel oil, marine diesel fuel.
Origin Marine diesel oil (MDO) is supplied as heavy distillate (designation ISO-F-
DMB) exclusively for marine applications. MDO is manufactured from crude
oil and must be free of organic acids and non-mineral oil products.
Specification
The suitability of fuel depends on the design of the engine and the available
cleaning options, as well as compliance with the properties in the following
table that refer to the as-delivered condition of the fuel.
The properties are essentially defined using the ISO 8217-2010 standard as
the basis. The properties have been specified using the stated test proce-
dures.
Properties Unit Testing method Designation
ISO-F specification DMB
Density at 15 °C kg/m3 ISO 3675 900
Kinematic viscosity at 40 °C mm2/s ≙ cSt ISO 3104 > 2,0
< 11 *
Pour point (winter quality) °C ISO 3016 <0
Pour point (summer quality) °C <6
Flash point (Pensky Martens) °C ISO 2719 > 60
Total sediment content % by weight ISO CD 10307 0.10
Water content % by vol. ISO 3733 < 0.3
Sulphur content % by weight ISO 8754 < 2.0
Ash content % by weight ISO 6245 < 0.01
Carbon residue (MCR) % by weight ISO CD 10370 < 0.30
Cetane number or cetane index - ISO 5165 > 35
Hydrogen sulphide mg/kg IP 570 <2
Acid value mg KOH/g ASTM D664 < 0.5
Oxidation resistance g/m3 ISO 12205 < 25

Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Copper strip test - ISO 2160 <1
Other specifications:
2012-03-21 - de
British Standard BS MA 100-1987 Class M2

ASTM D 975 2D
ASTM D 396 Nr. 2
General
Table 1: Marine diesel oil (MDO) – characteristic values to be adhered to

* For engines 27/38 with 350 resp. 365 kW/cyl the viscosity must not exceed
6 mm2/s @ 40 °C, as this would reduce the lifetime of the injection system.
6680 3.3.2-01 EN 1 (2)

6680 3.3.2-01
During transshipment and transfer, MDO is handled in the same manner as
residual oil. This means that it is possible for the oil to be mixed with high-
viscosity fuel or heavy fuel oil – with the remnants of these types of fuels in
the bunker ship, for example – that could significantly impair the properties of
the oil.
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
The fuel must be free of lubricating oil (ULO – used lubricating oil, old oil).
Fuel is considered as contaminated with lubricating oil when the following
concentrations occur:
Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and P > 15 ppm.
The pour point specifies the temperature at which the oil no longer flows. The
lowest temperature of the fuel in the system should be roughly 10 °C above
the pour point to ensure that the required pumping characteristics are main-
tained.
A minimum viscosity must be observed to ensure sufficient lubrication in the
fuel injection pumps. The temperature of the fuel must therefore not exceed
45 °C.
Seawater causes the fuel system to corrode and also leads to hot corrosion
of the exhaust valves and turbocharger. Seawater also causes insufficient
atomisation and therefore poor mixture formation accompanied by a high
proportion of combustion residues.
Solid foreign matter increase mechanical wear and formation of ash in the
cylinder space.
We recommend the installation of a separator upstream of the fuel filter. Sep-
aration temperature: 40 – 50°C. Most solid particles (sand, rust and catalyst
particles) and water can be removed, and the cleaning intervals of the filter
elements can be extended considerably.


Analyses
2012-03-21 - de

General
2 (2) 6680 3.3.2-01 EN

Gas oil / diesel oil (MGO) specification
6680 3.3.1-01
Diesel oil
Other designations Gas oil, marine gas oil (MGO), diesel oil
Gas oil is a crude oil medium distillate and therefore must not contain any
residual materials.
Military specification
Diesel oils that satisfy specification F-75 or F-76 may be used.
Specification
The suitability of fuel depends on whether it has the properties defined in this
specification (based on its composition in the as-delivered state).
The DIN EN 590 and ISO 8217-2010 (Class DMA or Class DMZ) standards
have been extensively used as the basis when defining these properties. The
properties correspond to the test procedures stated.
Properties Unit Test procedure Typical value
Density at 15 °C ≥ 820.0
kg/m3 ISO 3675 ≤ 890.0
Kinematic viscosity at 40 °C ≥2
mm2/s (cSt) ISO 3104 ≤ 6.0
Filterability*
in summer and °C DIN EN 116 ≤0
in winter °C DIN EN 116 ≤ -12
Flash point in closed cup °C ISO 2719 ≥ 60
Sediment content (extraction method) weight % ISO 3735 ≤ 0.01
Water content Vol. % ISO 3733 ≤ 0.05
Sulphur content ISO 8754 ≤ 1.5
Ash weight % ISO 6245 ≤ 0.01 Gas oil / diesel oil (MGO) specification
Coke residue (MCR) ISO CD 10370 ≤ 0.10
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Cetane number or cetane index - ISO 5165 ≥ 40
Copper strip test - ISO 2160 ≤1
2011-07-06 - de
Other specifications:
British Standard BS MA 100-1987 M1
ASTM D 975 1D/2D
General
Table 1: Diesel fuel (MGO) – properties that must be complied with.
6680 3.3.1-01 EN 1 (2)

* The process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining
6680 3.3.1-01
the cloud point in accordance with ISO 3015
Use of diesel oil If distillate intended for use as heating oil is used with stationary engines
instead of diesel oil (EL heating oil according to DIN 51603 or Fuel No. 1 or
no. 2 according to ASTM D 396), the ignition behaviour, stability and behav-
iour at low temperatures must be ensured; in other words the requirements
for the filterability and cetane number must be satisfied.
Viscosity To ensure sufficient lubrication, a minimum viscosity must be ensured at the
fuel pump. The maximum temperature required to ensure that a viscosity of
more than 1.9 mm2/s is maintained upstream of the fuel pump, depends on
the fuel viscosity. In any case, the fuel temperature upstream of the injection
pump must not exceed 45 °C.
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
You can ensure that these conditions will be met by using motor vehicle die-
sel fuel in accordance with EN 590 as this characteristic value is an integral
part of the specification.

Analyses
Gas oil / diesel oil (MGO) specification

2011-07-06 - de
General
2 (2) 6680 3.3.1-01 EN

Bio fuel specification
6680 3.3.1-02
Biofuel
Other designations Biodiesel, FAME, vegetable oil, rapeseed oil, palm oil, frying fat
Origin Biofuel is derived from oil plants or old cooking oil.
Provision
Transesterified and non-transesterified vegetable oils can be used.
Transesterified biofuels (biodiesel, FAME) must comply with the standard EN
14214.
Non-transesterified biofuels must comply with the specifications listed in
Table 1.
These specifications are based on experience to d/ate. As this experience is
limited, these must be regarded as recommended specifications that can be
adapted if necessary. If future experience shows that these specifications are
too strict, or not strict enough, they can be modified accordingly to ensure
safe and reliable operation.
When operating with bio-fuels, lubricating oil that would also be suitable for
operation with diesel oil (see Sheet 3.3.5) must be used.
Properties/Characteristics Unit Test method
Density at 15 °C 900 - 930 kg/m 3
DIN EN ISO 3675,
EN ISO 12185
Flash point > 60 °C DIN EN 22719
lower calorific value > 35 MJ/kg DIN 51900-3
(typical: 37 MJ/kg)
Viscosity/50 °C < 40 cSt (corresponds to a viscos- DIN EN ISO 3104
ity/40 °C of < 60 cSt)
Cetane number > 40 FIA
Coke residue < 0.4% DIN EN ISO 10370
Sediment content < 200 ppm DIN EN 12662
Oxidation stability (110 °C) >5h ISO 6886
Phosphorous content < 15 ppm ASTM D3231
Na and K content < 15 ppm DIN 51797-3
Ash content < 0.01% DIN EN ISO 6245
Water content < 0.5% EN ISO 12537
Iodine number < 125g/100g DIN EN 14111
TAN (total acid number) < 5 mg KOH/g DIN EN ISO 660

Filterability < 10 °C below the lowest temper- EN 116
ature in the fuel system
2011-03-25 - de
Table 1: Non-transesterified bio-fuel - Specifications

General
6680 3.3.1-02 EN 1 (2)


6680 3.3.1-02

Analyses
2011-03-25 - de
General
2 (2) 6680 3.3.1-02 EN

Viscosity-temperature diagram (VT diagram)

Explanations of viscosity-temperature diagram

Figure 1: Viscosity-temperature diagram (VT diagram)
In the diagram, the fuel temperatures are shown on the horizontal axis and
the viscosity is shown on the vertical axis.
The diagonal lines correspond to viscosity-temperature curves of fuels with
different reference viscosities. The vertical viscosity axis in mm2/s (cSt)
applies for 40, 50 or 100 °C.
Determining the viscosity-temperature curve and the required preheating temperature

Example: Heavy fuel oil with
2011-03-25 - de
Prescribed injection viscosity Required temperature of heavy fuel oil

180 mm²/s at 50 °C in mm²/s at engine inlet* in °C
≥ 12 126 (line c)
General
≤ 14 119 (line d)
Table 1: Determining the viscosity-temperature curve and the required preheating
temperature
6680 3.3.4-01 EN 1 (2)

* With these figures, the temperature drop between the last preheating
device and the fuel injection pump is not taken into account.
A heavy fuel oil with a viscosity of 180 mm2/s at 50 °C can reach a viscosity
of 1000 mm2/s at 24 °C (line e) – this is the maximum permissible viscosity of
fuel that the pump can deliver.
A heavy fuel oil discharge temperature of 152 °C is reached when using a
recent state-of-the-art preheating device with 8 bar saturated steam. At
higher temperatures there is a risk of residues forming in the preheating sys-
tem – this leads to a reduction in heating output and thermal overloading of
the heavy fuel oil. Asphalt is also formed in this case, i.e. quality deterioration.
The heavy fuel oil lines between the outlet of the last preheating system and
the injection valve must be suitably insulated to limit the maximum drop in
temperature to 4 °C. This is the only way to achieve the necessary injection
viscosity of 14 mm2/s for heavy fuel oils with a reference viscosity of 700
mm2/s at 50 °C (the maximum viscosity as defined in the international specifi-
cations such as ISO CIMAC or British Standard). If heavy fuel oil with a low
reference viscosity is used, the injection viscosity should ideally be 12 mm2/s
in order to achieve more effective atomisation to reduce the combustion resi-
due.
The delivery pump must be designed for heavy fuel oil with a viscosity of up
to 1 000 mm2/s. The pour point also determines whether the pump is capa-
ble of transporting the heavy fuel oil. The bunker facility must be designed so
as to allow the heavy fuel oil to be heated to roughly 10 C above the pour
point.
Viscosity
The viscosity of gas oil or diesel oil (marine diesel oil) upstream of the
engine must be at least 1.9 mm2/s. If the viscosity is too low, this may
cause seizing of the pump plunger or nozzle needle valves as a result
of insufficient lubrication.
This can be avoided by monitoring the temperature of the fuel. Although the
maximum permissible temperature depends on the viscosity of the fuel, it
must never exceed the following values:
▪ 45 °C at the most with MGO (DMA) and MDO (DMB) and

▪ 60 °C at the most with MDO (DMC).
A fuel cooler must therefore be installed.
If the viscosity of the fuel is < 2 cSt at 40 °C, consult the technical service of
MAN Diesel & Turbo SE in Augsburg.
2011-03-25 - de
General
2 (2) 6680 3.3.4-01 EN

MAN Diesel
Description 604.30
Page 1 (2) Fuel Oil Cleaning Edition 01H
General
Purification Recommendations. Especially for fuels above 180 cST/50°C (1500 sec.
RW/100°F) the highest possible temperature 98°C
Fuel oils are always contaminated and should there- (208°F) should be maintained in the centrifuge oil
fore be thoroughly cleaned for solid as well as liquid preheater.
contaminants before use. The solid contami-nants
in the fuel are mainly rust, sand, dust and re-finery The fuel is kept in the centrifuge as long as possible
catalysts. Liquid contaminants are mainly water, i.e. by adjusting the flow rate through the centrifuge so
either fresh water or salt water. that it corresponds to the amount of fuel required by
the engine without excessive re-circulating. Conse-
The impurities can cause damage to fuel pumps quently, the centrifuge should operate for 24 hours
and fuel valves, can result in increased cylinder a day except during necessary cleaning.
liner wear and deteriorate the exhaust valve seats.
Also increased fouling of gas ways and turbocharger Taking today's fuel qualities into consideration the
blends may result from the use of inadequately need for cleaning centrifuges ("shooting frequency")
cleaned fuel oils. should not be underestimated. Correct choice and
adjustment of the regulating screws and/or the grav-
Effective cleaning can only be ensured by means ity discs are of special importance for efficient water
of a centrifuge. We recommend the capacity of the removal. The centrifuge manual states the disc or
installed centrifuges to be at least according to the screw adjustment which should be chosen on the
centrifuging maker's recommendations. To obtain basis of the specific gravity of the fuel.
optimum cleaning it is of the utmost importance to
operate the centrifuge with as low a viscosity of the Normal practice is to have at least two centrifuges
fuel oil as possible and allow the fuel oil to remain in available for fuel cleaning. Results from experimen-
the centrifuge bowl as long time as possible. 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 fines
is achieved when the centrifuges are operated in
Cleaning of H.F.O. by Centrifuging
series, in purifier/clarifier mode.
Single centrifuge as purifier.
Operating Therefore - series operation of centrifuges ensuring
options Two centrifuges in parallel.
Two centrifuges in series. a maximum of safety is a fully accepted alternative
to the previously recommended parallel operation,
Optimum operating configurations provided the operating capacity of each individual
centrifuge can handle the total amount of fuel re-
Water content Parallel operation quired by the engine, without exceeding the flow
below 1 % Purifier / Purifier rate recommended by the centrifuge maker for the
Normal operating mode in question.
or
conditions
Density at 15°C Series operation
below 0.991 Purifier + Clarifier If the installed centrifuge capacity is on the low side
corresponding to the specific viscosity of the used
08028-0D/H5250/94.08.12
Water content fuel oil and if more than one centrifuge is available,
below 1 % Parallel operation parallel operation in order to obtain an even lower
flow rate may be considered. However, in view of the
Extreme Density at 15°C Purifier / Purifier above results and recommendations serious consid-
conditions below 0.991 erations should be given to installing new equipment
in correspondance with today's fuel qualities and flow
High content Series operation recommendation.
of catalyst fines Purifier + Clarifier
Table 1. Cleaning of HFO.
92.04 - ES0S
MAN Diesel
604.30 Description
Edition 01H Fuel Oil Cleaning Page 2 (2)
General
For the determination of centrifuging capacity, we Flow Rate

generally advise to follow the recommendations of Related to Rated Capacity of Centrifuge
the centrifuge maker, but the curves on fig. 1, can %
be used as a guidance. 100
80
A Homogenizer may be installed in the fuel oil system
60
as a supplement to the centrifuges to homogenize
possible water and sludge still present in the fuel 40
after centrifuging. 20
Separation Temperature
°F °C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
100
15 25 45 75 130 cSt/80°C
Log scales 30 60 80 180 380 600 cST/50°C
200 400 600 1500 3500 6000 sec. RI/100°F
Fig. 1. Flowrate through centrifuge related to nominel capa-

city of centrifuge.
08028-0D/H5250/94.08.12
92.04 - ES0S
Engine cooling water specifications
6680 3.3.7-01
Preliminary remarks
As is also the case with the fuel and lubricating oil, the engine cooling water
must be carefully selected, handled and checked. If this is not the case, cor-
rosion, erosion and cavitation may occur at the walls of the cooling system in
contact with water and deposits may form. Deposits obstruct the transfer of
heat and can cause thermal overloading of the cooled parts. The system
must be treated with an anticorrosive agent before bringing it into operation
for the first time. The concentrations prescribed by the engine manufacturer
must always be observed during subsequent operation. The above especially
applies if a chemical additive is added.
Requirements
Limit values The properties of untreated cooling water must correspond to the following
limit values:
Properties/Characteristic Properties Unit
Water type Distillate or fresh water, free of foreign matter. -
The following are prohibited: Seawater, brack-
ish water, river water, brines, industrial waste
water and rainwater.
Total hardness max. 10 °dH*
pH value 6.5 - 8 -
Chloride ion content Max. 50 mg/l**
Table 1: Cooling water - properties to be observed
*) 1°dH (German hard- ≙ 10 mg CaO in 1 litre of water ≙ 17.9 mg CaCO3/l

ness)
≙ 0.357 mval/l ≙ 0.179 mmol/l
**) 1 mg/l ≙ 1 ppm
Testing equipment The MAN Diesel water testing equipment incorporates devices that deter-
mine the water properties referred to above in a straightforward manner. The
manufacturers of anticorrosive agents also supply user-friendly testing equip-
ment. For information on monitoring cooling water, refer to Work Card
000.07.
Distillate If distilled water (from a fresh water generator, for example) or fully desalina-
ted water (from ion exchange or reverse osmosis) is available, this should
ideally be used as the engine cooling water. These waters are free of lime
and salts which means that deposits that could interfere with the transfer of
heat to the cooling water, and therefore also reduce the cooling effect, can-
2012-05-09 - de
not form. However, these waters are more corrosive than normal hard water
as the thin film of lime scale that would otherwise provide temporary corro-
sion protection does not form on the walls. This is why distilled water must
General
be handled particularly carefully and the concentration of the additive must

be regularly checked.
6680 3.3.7-01 EN 1 (8)

Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. The proportion of calcium and magnesium salts is of
6680 3.3.7-01
overriding importance. The temporary hardness is determined by the carbo-

nate content of the calcium and magnesium salts. The permanent hardness
is determined by the amount of remaining calcium and magnesium salts (sul-
phates). The temporary (carbonate) hardness is the critical factor that deter-
mines the extent of limescale deposit in the cooling system.
Water with a total hardness of > 10°dGH must be mixed with distilled water
or softened. Subsequent hardening of extremely soft water is only necessary
to prevent foaming if emulsifiable slushing oils are used.
Damage to the cooling water system

Corrosion Corrosion is an electrochemical process that can widely be avoided by
selecting the correct water quality and by carefully handling the water in the
engine cooling system.
Flow cavitation Flow cavitation can occur in areas in which high flow velocities and high tur-
bulence is present. If the steam pressure is reached, steam bubbles form
and subsequently collapse in high pressure zones which causes the destruc-
tion of materials in constricted areas.
Erosion Erosion is a mechanical process accompanied by material abrasion and the
destruction of protective films by solids that have been drawn in, particularly
in areas with high flow velocities or strong turbulence.
Stress corrosion cracking Stress corrosion cracking is a failure mechanism that occurs as a result of
simultaneous dynamic and corrosive stress. This may lead to cracking and
rapid crack propagation in water-cooled, mechanically-loaded components if
the cooling water has not been treated correctly.
Processing of engine cooling water

Formation of a protective The purpose of treating the engine cooling water using anticorrosive agents
film is to produce a continuous protective film on the walls of cooling surfaces
and therefore prevent the damage referred to above. In order for an anticor-
rosive agent to be 100 % effective, it is extremely important that untreated
water satisfies the requirements in the Section Requirements.
Protective films can be formed by treating the cooling water with an anticor-
rosive chemical or an emulsifiable slushing oil.

Emulsifiable slushing oils are used less and less frequently as their use has
been considerably restricted by environmental protection regulations, and
because they are rarely available from suppliers for this and other reasons.
Treatment prior to initial Treatment with an anticorrosive agent should be carried out before the
commissioning of engine engine is brought into operation for the first time to prevent irreparable initial
damage.
Treatment of the cooling water

2012-05-09 - de
The engine must not be brought into operation without treating the
cooling water first.
General
2 (8) 6680 3.3.7-01 EN

6680 3.3.7-01
Additives for cooling water
Only the additives approved by MAN Diesel and listed in the tables under the
section entitled "Approved cooling water additives“ may be used.
Required approval A cooling water additive may only be permitted for use if tested and
approved as per the latest directives of the ICE Research Association (FVV)
"Suitability test of internal combustion engine cooling fluid additives.” The test
report must be obtainable on request. The relevant tests can be carried out
on request in Germany at the staatliche Materialprüfanstalt (Federal Institute
for Materials Research and Testing), Abteilung Oberflächentechnik (Surface
Technology Division), Grafenstraße 2 in D-64283 Darmstadt.
Once the cooling water additive has been tested by the FVV, the engine
must be tested in the second step before the final approval is granted.
Only in closed circuits Additives may only be used in closed circuits where no significant consump-
tion occurs, apart from leaks or evaporation losses.
Chemical additives
Sodium nitrite and sodium borate based additives etc. have a proven track
record. Galvanised iron pipes or zinc sacrificial anodes must not be used in
cooling systems. This corrosion protection is not required due to the prescri-
bed cooling water treatment and electrochemical potential reversal can occur
due to the cooling water temperatures which are normally present in engines
nowadays. If necessary, the pipes must be deplated.
Slushing oil
This additive is an emulsifiable mineral oil with added slushing ingredients. A
thin film of oil forms on the walls of the cooling system. This prevents corro-
sion without interfering with the transfer of heat and also prevents limescale
deposits on the walls of the cooling system.
The significance of emulsifiable corrosion-slushing oils is fading. Oil-based
emulsions are rarely used nowadays for environmental protection reasons
and also because stability problems are known to occur in emulsions.
Anti-freeze agents
If temperatures below the freezing point of water in the engine cannot be
excluded, an anti-freeze solution that also prevents corrosion must be added
to the cooling system or corresponding parts. Otherwise, the entire system
must be heated. (Military specification: Sy-7025).
Sufficient corrosion protection can be provided by adding the products listed
in the table entitled "Anti-freeze solutions with slushing properties" while
observing the prescribed concentration. This concentration prevents freezing
at temperatures down to -22 °C. However, the quantity of anti-freeze solu-
tion actually required always depends on the lowest temperatures that are to
be expected at the place of use.
2012-05-09 - de
Anti- freezes are generally based on ethylene glycol. A suitable chemical anti-
corrosive agent must be added if the concentration of the anti-freeze solution
prescribed by the user for a specific application does not provide an appro-
priate level of corrosion protection, or if the concentration of anti-freeze solu-
General
tion used is lower due to less stringent frost protection requirements and
does not provide an appropriate level of corrosion protection. For information
on the compatibility of the anti-freeze solution with the anticorrosive agent
6680 3.3.7-01 EN 3 (8)

and the required concentrations, contact the manufacturer. As regards the

chemical additives indicated in the table „Nitrite-Containing Chemical Addi-
6680 3.3.7-01
tives“, their compatibility with ethylene glycol-based antifreezes has been

proved. Anti-freeze solutions may only be mixed with one another with the
consent of the manufacturer, even if these solutions have the same composi-
tion.
Before an anti-freeze solution is used, the cooling system must be thoroughly
cleaned.
If the cooling water contains an emulsifiable slushing oil, anti-freeze solution
must not be added as otherwise the emulsion would break up and oil sludge
would form in the cooling system.
Observe the applicable environmental protection regulations when disposing
of cooling water containing additives. For more information, consult the addi-
tive supplier.
Biocides
If you cannot avoid using a biocide because the cooling water has been con-
taminated by bacteria, observe the following steps:
▪ You must ensure that the biocide to be used is suitable for the specific
application.
▪ The biocide must be compatible with the sealing materials used in the
cooling water system and must not react with these.
▪ The biocide and its decomposition products must not contain corrosion-
promoting components. Biocides whose decomposition products con-
tain chloride or sulphate ions are not permitted.
▪ Biocides that cause foaming of cooling water are not permitted.
Prerequisite for effective use of an anticorrosive agent
Clean cooling system

As contamination significantly reduces the effectiveness of the additive, the
tanks, pipes, coolers and other parts outside the engine must be free of rust
and other deposits before the engine is started up for the first time and after
repairs are carried out on the pipe system. The entire system must therefore
be cleaned with the engine switched off using a suitable cleaning agent (see
Work Cards 000.03 and 000.08 by MAN Diesel).

Loose solid matter in particular must be removed by flushing the system
thoroughly as otherwise erosion may occur in locations where the flow veloc-
ity is high.
The cleaning agents must not corrode the seals and materials of the cooling
system. In most cases, the supplier of the cooling water additive will be able
to carry out this work and, if this is not possible, will at least be able to pro-
vide suitable products to do this. If this work is carried out by the engine
operator, he should use the services of a specialist supplier of cleaning
agents. The cooling system must be flushed thoroughly following cleaning.
2012-05-09 - de
Once this has been done, the engine cooling water must be treated immedi-
ately with anticorrosive agent. Once the engine has been brought back into
operation, the cleaned system must be checked for leaks.
General
4 (8) 6680 3.3.7-01 EN

Regular checks of the cooling water condition and cooling water
6680 3.3.7-01
system
Treated cooling water may become contaminated when the engine is in
operation, which causes the additive to loose some of its effectiveness. It is
therefore advisable to regularly check the cooling system and the cooling
water condition. To determine leakages in the lube oil system, it is advisable
to carry out regular checks of water in the compensating tank. Indications of
oil content in water are, e.g. discoloration or a visible oil film on the surface of
the water sample.
The additive concentration must be checked at least once a week using the
test kits specified by the manufacturer. The results must be documented.
Concentrations of chemical additives

The chemical additive concentrations shall not be less than the
minimum concentrations indicated in the table „Nitrite-containing
chemical additives“.
Excessively low concentrations can promote corrosion and must be avoided.

If the concentration is slightly above the recommended concentration this will
not result in damage. Concentrations that are more than twice the recom-
mended concentration should be avoided.
Every 2 to 6 months send a cooling water sample to an independent labora-
tory or to the engine manufacturer for integrated analysis.
Emulsifiable anticorrosive agents must generally be replaced after abt. 12
months according to the supplier's instructions. When carrying this out, the
entire cooling system must be flushed and, if necessary, cleaned. Once filled
into the system, fresh water must be treated immediately.
If chemical additives or anti-freeze solutions are used, cooling water should
be replaced after 3 years at the latest.
If there is a high concentration of solids (rust) in the system, the water must
be completely replaced and entire system carefully cleaned.
Deposits in the cooling system may be caused by fluids that enter the cool-
ing water, or the break up of emulsion, corrosion in the system and limescale
deposits if the water is very hard. If the concentration of chloride ions has
increased, this generally indicates that seawater has entered the system. The
maximum specified concentration of 50 mg chloride ions per kg must not be
exceeded as otherwise the risk of corrosion is too high. If exhaust gas enters
the cooling water, this may lead to a sudden drop in the pH value or to an
increase in the sulphate content.
Water losses must be compensated for by filling with untreated water that
meets the quality requirements specified in the section Requirements. The
concentration of the anticorrosive agent must subsequently be checked and
adjusted if necessary.
2012-05-09 - de
Subsequent checks of cooling water are especially required if the cooling

water had to be drained off in order to carry out repairs or maintenance.
General
6680 3.3.7-01 EN 5 (8)

6680 3.3.7-01
Protective measures
Anticorrosive agents contain chemical compounds that can pose a risk to
health or the environment if incorrectly used. Comply with the directions in
the manufacturer's material safety data sheets.
Avoid prolonged direct contact with the skin. Wash hands thoroughly after
use. If larger quantities spray and/or soak into clothing, remove and wash
clothing before wearing it again.
If chemicals come into contact with your eyes, rinse them immediately with
plenty of water and seek medical advice.
Anticorrosive agents are generally harmful to the water cycle. Observe the
relevant statutory requirements for disposal.
Auxiliary engines
If the same cooling water system used in a MAN Diesel & Turbo two-stroke
main engine is used in a marine engine of type 16/24, 21/ 31, 23/30H, 27/38
or 28/32H, the cooling water recommendations for the main engine must be
observed.
Analysis
We analyse cooling water for our customers in our chemical laboratory. A 0.5
l sample is required for the test.
Permissible cooling water additives
Nitrite-containing chemical additives

Manufacturer Product designation Initial dosing for Minimum concentration ppm
1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)
Drew Marine Liquidewt 15 l 15,000 700 1,050

One Drew Plaza Maxigard 40 l 40,000 1,330 2,000
Boonton
New Jersey 07005
USA
Wilhelmsen (Unitor) Rocor NB Liquid 21.5 l 21,500 2,400 3,600

KJEMI-Service A.S. Dieselguard 4.8 kg 4,800 2,400 3,600
P.O.Box 49/Norway
3140 Borgheim
Nalfleet Marine Nalfleet EWT Liq 3l 3,000 1,000 1,500
Chemicals (9-108)
P.O.Box 11 Nalfleet EWT 9-111 10 l 10,000 1,000 1,500
Northwich Nalcool 2000 30 l 30,000 1,000 1,500
Cheshire CW8DX, U.K.
2012-05-09 - de
Nalco Nalcool 2000 30 l 30,000 1,000 1,500

TRAC 102 30 l 30,000 1,000 1,500
TRAC 118 3l 3,000 1,000 1,500
General
Maritech AB Marisol CW 12 l 12,000 2,000 3,000

P.O.Box 143
S-29122 Kristianstad
6 (8) 6680 3.3.7-01 EN

Manufacturer Product designation Initial dosing for Minimum concentration ppm
6680 3.3.7-01
1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)
Uniservice N.C.L.T. 12 l 12,000 2,000 3,000

Via al Santuario di N.S.
della Guardia 58/A Colorcooling 24 l 24,000 2,000 3,000
16162 Genova, Italy
Marichem – Marigases D.C.W.T. - 48 l 48,000 2,400 -
64 Sfaktirias Street Non-Chromate
18545 Piraeus, Griechen-
land
Marine Care Caretreat 2 16 l 16,000 4,000 6,000
3144 NA Maasluis
The Netherlands
Vecom Cool Treat NCLT 16 l 16,000 4,000 6,000
Schlenzigstraße 7
21107 Hamburg
Deutschland
Table 2: Nitrite-containing chemical additives
Nitrite-free additives (chemical additives)

Manufacturer Product designation Initial dosing Minimum concentration
for 1 000 litres
Arteco
Technologiepark Havoline XLI 75 l 7.5 %
Zwijnaarde 2
B-9052 Gent, Belgium
Total Lubricants WT Supra 75 l 7.5 %
Paris, France
Q8 Oils Q8 Corrosion Inhibitor 75 l 7.5 %
Long-Life
Table 3: Chemical additives - nitrite free
Emulsifiable slushing oils

Manufacturer Product
(designation)
BP Marine, Breakspear Way, Hemel Hempstead, Diatsol M
Herts HP2 4UL Fedaro M
Castrol Int., Pipers Way, Swindon SN3 1RE, UK Solvex WT 3
Deutsche Shell AG, Überseering 35, Oil 9156
22284 Hamburg, Germany
Table 4: Emulsifiable slushing oils
2012-05-09 - de
General
6680 3.3.7-01 EN 7 (8)

Anti-freeze solutions with slushing properties

6680 3.3.7-01
Manufacturer Product designation Minimum concentration

BASF Glysantin G 48
Carl-Bosch-Str. Glysantin 9313
67063 Ludwigshafen, Glysantin G 05
Rhein
Deutschland
Castrol Int. Antifreeze NF, SF
Pipers Way
Swindon SN3 1RE, UK
BP, Britannic Tower Anti-frost X2270A
Moor Lane,
London EC2Y 9B, UK
35%
Deutsche Shell AG Glycoshell
Überseering 35
22284 Hamburg
Deutschland
Mobil Oil AG Frostschutz 500
Steinstraße 5
20095 Hamburg
Deutschalnd
Arteco, Technologiepark Havoline XLC
Zwijnaarde 2
B-9052 Gent, Belgium
Total Lubricants Glacelf Auto Supra
Paris, France Total Organifreeze
Table 5: Anti-freeze solutions with slushing properties
2012-05-09 - de
General
8 (8) 6680 3.3.7-01 EN

MAN Diesel & Turbo 000.07
Cooling water
6682 000.07-01
inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The fresh water used to fill the cooling water circuits must satisfy the specifi-
cations. The cooling water in the system must be checked regularly in
accordance with the maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the concentration of the anti-
corrosive agent.
Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality ▪ The MAN Diesel & Turbo water testing kit, or similar testing kit, with all
necessary instruments and chemicals that determine the water hardness,
pH value and chloride content (obtainable from MAN Diesel & Turbo or
Mar-Tec Marine, Hamburg)
Equipment for testing the When using chemical additives:
concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used to
determine the fresh water quality.
Testing the typical values of water

Short specification
Typical value/property Water for filling Circulating water
and refilling (without additive) (with additive)
Water type Fresh water, free of foreign matter Treated cooling water
Total hardness ≤ 10°dGH 1) ≤ 10°dGH 1)
pH value 6.5 - 8 at 20 °C ≥ 7.5 at 20 °C
Chloride ion content ≤ 50 mg/l ≤ 50 mg/l 2)
Table 1: Quality specifications for cooling water (abbreviated version)
1)
dGH German hardness
1°dGh = 10 mg/l CaO
= 17.9 mg/l CaCO3
= 0.179 mmol/L
2)
1mg/l = 1 ppm
2011-06-21 - de
Cooling water
General
6682 000.07-01 EN 1 (2)

000.07 MAN Diesel & Turbo
6682 000.07-01
Testing the concentration of anticorrosive agents

Short specification
Anticorrosive agent Concentration
Chemical additives according to the quality specification in Volume 010.005 Engine - Operating Instructions,
Chapter 3, Sheet 3.3.7
Anti-freeze agents according to the quality specification in Volume 010.005 Engine - Operating Instructions,
Chapter 3, Sheet 3.3.7
Table 2: Concentration of the cooling water additive
Testing the concentration of The concentration should be tested every week, and/or according to the
chemical additives maintenance schedule, using the testing instruments, reagents and instruc-
tions of the relevant supplier.
Chemical slushing oils can only provide effective protection if the right con-
centration is precisely maintained. This is why the concentrations recommen-
ded by MAN Diesel & Turbo (quality specifications in Volume 010.005 Engine
– Operating Instructions, Chapter 3, Page 3.3.7) must be complied with in all
cases. These recommended concentrations may be other than those speci-
fied by the manufacturer.
Testing the concentration of The concentration must be checked in accordance with the manufacturer's
anti-freeze agents instructions or the test can be outsourced to a suitable laboratory. If in
doubt, consult MAN Diesel & Turbo.
Regular water samplings Small quantities of lubricating oil in cooling water can be found by visual
check during regular water sampling from the expansion tank.
Testing We test cooling water for customers in our laboratory. To carry out the test,
we will need a representative sample of abt. 0.5 l.
2011-06-21 - de
Cooling water
General
2 (2) 6682 000.07-01 EN

Cooling water system
6682 000.08-01
Cleaning
Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-
tive cooling of parts. Contamination and deposits must be regularly elimina-
ted.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.
Cleaning
The cooling water system must be checked for contamination at regular
intervals. Cleaning is required if the degree of contamination is high. This
work should ideally be carried out by a specialist who can provide the right
cleaning agents for the type of deposits and materials in the cooling circuit.
The cleaning should only be carried out by the engine operator if this cannot
be done by a specialist.
Oil sludge Oil sludge from lubricating oil that has entered the cooling system or a high
concentration of anticorrosive agents can be removed by flushing the system
with fresh water to which some cleaning agent has been added. Suitable
cleaning agents are listed alphabetically in the table entitled "Cleaning agents
for removing oil sludge". Products by other manufacturers can be used pro-
viding they have similar properties. The manufacturer's instructions for use
must be strictly observed.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew HDE - 777 4 - 5% 4 h at 50 – 60 °C
Nalfleet MaxiClean 2 2 - 5% 4 h at 60 °C
Unitor Aquabreak 0.05 – 0.5% 4 h at ambient temperature
Vecom Ultrasonic 4% 12 h at 50 – 60 °C
Multi Cleaner
Table 1: Cleaning agents for removing oil sludge
Lime and rust deposits Lime and rust deposits can form if the water is especially hard or if the con-
centration of the anticorrosive agent is too low. A thin lime scale layer can be
left on the surface as experience has shown that this protects against corro-
sion. However, limescale deposits with a thickness of more than 0.5 mm
obstruct the transfer of heat and cause thermal overloading of the compo-
nents being cooled.

Rust that has been flushed out may have an abrasive effect on other parts of
the system, such as the sealing elements of the water pumps. Together with
2010-02-09 - de
the elements that are responsible for water hardness, this forms what is
known as ferrous sludge which tends to gather in areas where the flow
velocity is low.
General
Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
"Cleaning agents for removing lime scale and rust deposits". Products by
6682 000.08-01 EN 1 (3)

000.08 MAN Diesel & Turbo
other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to clean-
6682 000.08-01
ing, check whether the cleaning agent is suitable for the materials to be
cleaned. The products listed in the table entitled "Cleaning agents for remov-
ing lime scale and rust deposits" are also suitable for stainless steel.
Manufacturer Product Concentration Duration of cleaning procedure/temperature
Drew SAF-Acid 5 - 10% 4 h at 60 - 70 °C
Descale-IT 5 - 10% 4 h at 60 - 70 °C
Ferroclean 10% 4 - 24 h at 60 - 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 h at 60 – 75 ℃
Unitor Descalex 5 - 10% 4 - 6 h at approx. 60 °C
Vecom Descalant F 3 – 10% Approx. 4 h at 50 – 60°C
Table 2: Cleaning agents for removing limescale and rust deposits
In emergencies only Hydrochloric acid diluted in water or aminosulphonic acid may only be used
in exceptional cases if a special cleaning agent that removes limescale
deposits without causing problems is not available. Observe the following
during application:
▪ Stainless steel heat exchangers must never be treated using diluted
hydrochloric acid.
▪ Cooling systems containing non-ferrous metals (aluminium, red bronze,
brass, etc.) must be treated with deactivated aminosulphonic acid. This
acid should be added to water in a concentration of 3 - 5 %. The tem-
perature of the solution should be 40 - 50 °C.
▪ Diluted hydrochloric acid may only be used to clean steel pipes. If hydro-
chloric acid is used as the cleaning agent, there is always a danger that
acid will remain in the system, even when the system has been neutral-
ised and flushed. This residual acid promotes pitting. We therefore rec-
ommend you have the cleaning carried out by a specialist.
The carbon dioxide bubbles that form when limescale deposits are dissolved
can prevent the cleaning agent from reaching boiler scale. It is therefore
absolutely necessary to circulate the water with the cleaning agent to flush
away the gas bubbles and allow them to escape. The length of the cleaning
process depends on the thickness and composition of the deposits. Values
are provided for orientation in the table entitled "Detergents for removing lime
scale and rust deposits“.
Following cleaning The cooling system must be flushed several times once it has been cleaned
using cleaning agents. Replace the water during this process. If acids are
used to carry out the cleaning, neutralise the cooling system afterwards with
suitable chemicals then flush. The system can then be refilled with water that
has been prepared accordingly.
Only carry out the cleaning operation once the engine has
cooled down
Start the cleaning operation only when the engine has cooled down.
2010-02-09 - de
Hot engine components must not come into contact with cold water.
Open the venting pipes before refilling the cooling water system.
Blocked venting pipes prevent air from escaping which can lead to
thermal overloading of the engine.
General
2 (3) 6682 000.08-01 EN

Cleaning products can cause damage
6682 000.08-01
The products to be used can endanger health and may be harmful to
the environment.
Follow the manufacturer's handling instructions without fail.
The applicable regulations governing the disposal of cleaning agents or acids

must be observed.

2010-02-09 - de
General
6682 000.08-01 EN 3 (3)

Water specification for fuel-water emulsions
Water specification for fuel-water emulsions

Prerequisites
The water used for the fuel-water emulsion is an operating fluid that must be
carefully selected, processed (if necessary) and monitored. If this is not done,
deposits, corrosion, erosion and cavitation may occur on the fuel system
components that come into contact with the fuel-water emulsion.
Specifications
Limit values The characteristic values of the water used must be within the following limit
values:
Properties/ Characteristic value Unit
Characteristic
Water type Seawater, brackish water, river water, brines, -
industrial waste water and rainwater, distilled
or fresh water
Total hardness max. 10 ºdH*
pH value 6.5 - 8 -
Chloride ion content max. 50 mg/l
Table 1: Fuel-water emulsion - characteristic values to be observed
*) 1º dH (German hard- ≙ 10 mg CaO ≙ 17.9 mg CaCO3/l

ness) in 1l water
≙ 0.357 mval/l ≙ 0.179 mmol/l
Testing instruments The MAN Diesel water testing kit contains instruments that allow the water
characteristics referred to above (and others) to be easily determined.
Distillate If distillate (e.g. from the fresh water generator) or fully desalinated water (ion
exchanger) is available, this should ideally be used for the fuel-water emul-
sion. These types of water are free of lime and salts. Water specification for fuel-water emulsions
Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. It is largely determined by the calcium and magnesium
salts. The temporary hardness depends on the hydrocarbonate content in
the calcium and magnesium salts. The lasting (permanent) hardness is deter-
mined by the remaining calcium and magnesium salts (sulphates).
Water with hardness greater than 10°dH (German total hardness) must be
blended or softened with distillate. It is not necessary to increase the hard-
ness of extremely soft water.
2011-03-25 - de
Treatment with anticorrosive agents not required

Treatment with anticorrosive agents is not required and must be
omitted.
General
6680 3.3.10-01 EN 1 (1)

Specifications for intake air (combustion air)
Specifications for intake air (combustion air)

General
The quality and condition of intake air (combustion air) have a significant
effect on the power output, wear and emissions of the engine. In this regard,
not only are the atmospheric conditions extremely important, but also con-
tamination by solid and gaseous foreign matter.
Mineral dust in the intake air increases wear. Chemicals and gases promote
corrosion.
This is why effective cleaning of intake air (combustion air) and regular main-
tenance/cleaning of the air filter are required.
When designing the intake air system, the maximum permissible overall pres-
sure drop (filter, silencer, pipe line) of 20 mbar must be taken into considera-
tion.
Requirements
Gas engines or dual-fuel engines may only be equipped with a dry filter. An
oil filter should not be installed, because they enrich air with oil mist, which is
not permissible for gas operated engines. Filters of efficiency class G4
according to EN 779 must be used. The concentrations downstream of the
air filter and/or upstream of the turbocharger inlet must not exceed the fol-
lowing limit values:
Properties Typical value Unit *
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm3
Chlorine max. 1.5
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 5
Salt (NaCl) max. 1
* One Nm3 corresponds to one cubic meter of
gas at 0 °C and 101.32 kPa. Specifications for intake air (combustion air)
Table 1: Intake air (combustion air) - typical values to be observed
Intake air shall not contain any flammable gases

Intake air shall not contain any flammable gases. Make sure that the
combustion air is not explosive.
2012-01-17 - de
General
6680 3.3.11-01 EN 1 (1)

Cylinder head
505/605
MAN Diesel & Turbo
Description 605.01
Page 1 (1) Cylinder head
Edition 14H
L28/32H, V28/32H
General and is encased by the seating collar (5) which over-
laps it. The assembled valve rotator is held
The cylinder head is made of cast iron and is tight- together, when removed, by the retaining ring (6).
ened to form a gas-tight seal against a sealing ring
on the cylinder liner by means of 6 nuts and 6
studs, which are screwed into the engine frame.
The nuts are tightened by means of hydraulic jacks.
Each cylinder head is equipped with two air inlet
and two exhaust valves which are actuated by
rocker arms running in bearings on a shaft suppor-
ted in a bracket on top of the cylinder head.
The fuel injection valve (see section 614) is located
in a interchangeable sleeve in the center of the cyl-
inder head.
Furthermore the cylinder head is equipped with an
indicator valve and a safety valve.
The cylinder head has a screwed-on coaming
which encloses the valves. The coaming is closed 1 Retainer body 2 Balls
with a top cover and thus provides an oil tight 3 Ball race 4 Spring washer
enclosure for the valve gear. The coaming is equip-
5 Seating collar 6 Retainer ring
ped with an inspection cover for the rotators.
7 Valve spindle
Air inlet and exhaust valves

Figure 1: Valve rotator
The inlet valve spindles are identical to the exhaust
spindles. As the valve starts to open, the increasing valve
The valves are made of heat-resistant material. spring-load causes the spring washer to flatten, and
Hard metal is welded on to the valve spindle seats the load applied to the balls in the pockets of the
to avoid depressions by combustion particles. retainer body forces the balls in the ball race to roll
down the inclined races. The transfer of the reaction
The valve spindles are fitted with valve rotators
load of the ball race to the spring washer reduces
which turn the spindles a little each time the valves
the reaction load of the spring washer on the inner
open.
rim of the retainer body. Ball race, spring washer,
The cylinder head is equipped with interchangeable seating collar and valve springs are, however, force-
seat rings and valve guides for inlet and exhaust locked by friction grip. The reaction load of the balls
valves.The valve seat rings and valve guides for inlet on the inclined races induces rotation to the retainer
and exhaust valves are identical. body and valve with relation to the seating collar
The seat rings are made of heat-resistant steel, and the valve springs. As the valve closes, load is
directly hardened on the seating surface and the released from the spring washer and thus from the
seat rings are directly water cooled in order to balls, allowing them to be returned to their original
assure low valve temperature. positions without rolling by the tangential force of
the coil springs.
Valve rotator
The retainer body of the valve rotator (1) has a num-
ber of pockets, arranged in circumferential direc-
tion, with balls that are forced against the upper
end of an inclined race by coil springs acting in tan-
gential direction. The ball race (3) serves as ball
track in the opposite direction. The spring washer
(4) seats against the inner rim of the retainer body
1990.10.29 - ES0
MAN Diesel & Turbo

Page 1 (2) Dismantling of Cylinder Head Edition 01H
L/V28/32H

Shut-off cooling water 62021 10
Shut-off fuel oil 62021 01 Oil injector,
Shut-off cooling oil (complete)
62021 50 6 Piece
62021 51 1 Piece
62021 15
Description: 62005 01
62021 25 Hydraulic tools
Dismantling of cylinder head for inspection 62014 15
and/or overhaul.
Starting position:
Cooling water has been drained from engine. Hand tools:
Ring and open end spanner 14 mm.

Related procedure:
Dismounting of piston and connecting

rod, 606-01.00
Dismounting and inspection of inlet valve,
exhaust valve and valve guide, 605-01.05
Safety valve, 605-01.25
Dismantling, overhaul and test
pressure of fuel oil valve, 614-01.10
Working time : 1 Hour Plate no. Item no. Qty./

Capacity : 2 men
Data:

91.45 - ES0S
MAN Diesel & Turbo
605-01.00 Working Card
Edition 01H Dismantling of Cylinder Head Page 2 (2)
L/V28/32H
1) Open the drain cock and vent cock for cool
ing water. 8) Remove the exhaust pipe flange screws.
2) Take off the rocker arm top cover. 9) Remove the cylinder head nuts, as shown,
by means of hydraulic jacks, see working card
3) Take off the cover which gives access to the 620-01.05.
injection pump.
10) Mount the lifting tool on the cylinder head.
4) Disconnect the fuel oil high-pressure pipe.
11) Attach the hook to the lifting tool and lift the
5) Disconnect the cooling oil pipes, (inlet and cylinder head away.
outlet.

6) Disconnect the rocker arm lubricating oil pi
pe. V28/32H
L28/32H
7) Remove the thermometer attachment bran-
ch (cooling water outlet pipe).
Fig. 2
Fig. 1
91.45 - ES0S
MAN Diesel & Turbo
Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05

Page 1 (3) Valve Guide Edition 06H
L+V28/32H
Safety precautions Special tools
Stopped engine Plate no Item no Note

Shut-off fuel oil 62005 05
Shut-off cooling oil 62005 25/30 Extra tools
Stopped lub. oil circul. 62005 55

Description
Dismounting of inlet and exhaust valve, inspec-

tion of valve guide and mounting of inlet and
exhaust valve. Hand tools
Ring and open end spanner, 19 mm.

Starting position Small screw driver.
Measuring tools.
Cylinder head, dismantled from
engine 605-01.00
Related procedure
Reconditioning of valve spindle seat

and valve seat ring, 605-01.10
Valve rotator, 605-01.15
Replacement of valve guide, 605-01.20
Replacement of valve seat ring, 605-01.35
Mounting of cylinder head, 605-01.45
Man power Replacement and wearing parts
Working time : 1 hour Plate no Item no Qty. /

Capacity : 1 man
60501 017 4/cyl.
Data

00.43 - ES0
MAN Diesel & Turbo
605-01.05 Inspection of Inlet Valve, Exhaust Valve and Working Card

Edition 06H Valve Guide Page 2 (3)
L+V28/32H
Dismantling of Inlet and Exhaust Valve 3) Turn back the rocker arm and remove the spring-
Spindles loaded valve bridge over the valve spindles.
1) Land and fasten the cylinder head upon the spe 4) After having removed the valve bridge and
cial work table and remove the lifting tool. turned the rocker arm back, the tool should
be fitted by means of the screws (A), see fig 2
tightened in the threaded holes in the cylinder
Or as an Alternative: head.
and the cylinder head on the floor upon wooden

L
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.
V28/32H
L28/32H
Fig 2
5) Now compress the valve springs by tighten

ing the nut (B), after which the cone rings can
be re-moved, see fig 3.
Fig 1 Fig 3
00.43 - ES0
MAN Diesel & Turbo
Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05

Edition 06H
Page 3 (3)
Valve Guide
L+V28/32H
6) Release the springs again. Remove the nut Inspection of valve guide
(B) and the traverse (C). Now valve rotator
and springs can be removed. 10) Too much clearance between valve spindle
and spindle guide may cause increased lub. oil
7) Remove the supporting devices under the work consumption, fouling up of the spindle guide and
table and take out the valve spindle. thus give the risk of a sticking valve spindle.
8) Repeat point 4 - 7 to remove the two other Too much clearance also means insufficient
valve spindles. guid-ance of the valve spindle, and thus bad
alignment between spindle head and valve
seat ring. In connection with overhaul of the
Inspection of Valves/Valve Seats cylinder head, the valve spindle guides should
be cleaned, inspected and measured for wear.
9) A slight grinding of valve/valve seat can be If the inner diameter of the valve spindle guide
carried out by means of the handle as shown, exceeds the tolerance, see page 600.35 the
see fig 4. valve spindle guide must be replaced. See
working card 605-01.20.
I f the valve seat is heavily burnt or scarred, it should
be ground using the valve seat grinder according to 11) For mounting of valve spindle follow the in-
working card 605-01.10. structions in point 4 - 7 in reversed order.
Fig 4 Fig 5
00.43 - ES0
MAN Diesel & Turbo
Working Card Reconditioning of Valve Spindle Seat 605-01.10

Page 1 (3) and Valve Seat Ring Edition 01H
L/V28/32H

Shut-off cooling water 62005 40 Grinding machine
Shut-off fuel oil for valve spindle.
Shut-off cooling oil 62005 35 Grinding machine
Stopped lub. oil circul. for valve seat ring.
(Extra tools).
Description:
Reconditioning of valve spindle seat and valve

seat ring, with special grinding machine.
Hand tools:
All the hand tools and new stones, are included

in the tools box for grinding machine.
Starting position:
Valve spindle has been removed, 605-01.05
Related procedure:
Mounting of valve spindle, 605-01.05
Working time : 6 Hours Plate no. Item no. Qty./

Capacity : 1 man

Data:

91.45 - ES0S
MAN Diesel & Turbo
605-01.10 Reconditioning of Valve Spindle Seat Working Card

Edition 01H and Valve Seat Ring Page 2 (3)
L/V28/32H
Reconditioning of Valve Seat Ring. However when the seat "S" has been ground to such
an extent, that the recess "R" disappears, the valve
Reconditioning of valve seat rings by machining is seat ring has to be scrapped and a new one to must
carried out by means of a grinding machine, the installed, see working card 605-01.35
pilot spindle of which is to be mounted in the valve
spindle guide. For operation of the grinding machine,
see separate instructions. Reconditioning of Valve Spindle.
The grinding of the valve seat ring should be carried Reconditioning by machining is carried out with the
out according to the following sequence: valve spindle being rotated in a turning lathe and a
special grinding machine mounted on the tool post
1) The seating surface itself is ground with a feed of the turning latch.
at an angle "A" of 30° ± 0,10°.
0.
For operation of the grinding machine, see separa
The grinding should be continued until a clean and ted instructions.
uniform surface condition has been obtained.
1) The seating surface itself is ground with a feed
Carry out the final grinding with a feed in direction at an angel "A" of 30° ± 0.0,25°.
from inside to outwards, as normally the best surface
quality is obtained in this way. 2) The grinding shoud be continued until a clean
and uniform surface condition has been obtained.
3) After completing the grinding, the height "H"1

of the valve head should be checked.
"A" 30 ± 0,10°
0
"H"1 has to be at least, see page 600.35.
"R"
"S" If measured to be less, the spindle has to be scrap

ped.
"H"1
Fig. 1.
"A" 30° ± 0,25°

0
2) Normally the valve seat ring can be recondi

tioned several times.
Fig. 2.
91.45 - ES0S
MAN Diesel & Turbo
Working Card Reconditioning of Valve Spindle Seat 605-01.10

Page 3 (3) and Valve Seat Ring Edition 01H
L/V28/32H
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 does not exceed the maximum
value, see page 600.35.
"H"2
Fig. 3.
91.45 - ES0S
MAN Diesel & Turbo

Page 1 (2) Valve Rotator Edition 01H
L/V28/32H

Shut-off fuel oil
Description:
Dismantling, inspection and mounting of valve

rotator. Hand tools:
Small screw driver.

Starting position:
Valve spindles has been removed, 605-01.05
Related procedure:
Mounting of valve spindles, 605-01.05
Working time : 1/2 Hour Plate no. Item no. Qty./

Capacity : 1 man
Data:

91.45 - ES0S
MAN Diesel & Turbo

Edition 01H Valve Rotator Page 2 (2)
L/V28/32H
Inspection of Rotocap. When inserting the balls and the tangential springs,
note that all balls on the inclined races of the ball
Dirt especially in the ball pockets due to residues in pockets point in the same direction, see fig. 1.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and hinder the
movement of the balls.
Rotocap valve rotators need no servicing under

normal operating conditions.
Unusual operating conditions may lead to disturban

ces. Rotation of the valve should be checked at the
intervals specified in the "Maintenance program".
Rotator performance is satisfactory when the valve
rotates visibly and evenly.
Fig. 1.
Dismantling of Rotocap.
See working card 605-01.05, point 3 to 6. The inner ring of the spring washer should rest on
the retainer body.
Overhauls Note ! Having assembled the valve rotator in dry

condition it should be placed in clean lubricating
Valve rotators should be cleaned and inspected for oil for a short period of time.
wear and ball impressions whenever the valves are
removed. The individual parts can be disassembled
after removal of the retaining ring, by means of which Mounting of Rotocap
the seating collar is fastened to the retainer body.
See working card 605-01.05, point 3 to 6 , opposite
Parts showing wear grooves or depressions formed direction.
by the balls should be replaced.
91.45 - ESOS
MAN Diesel & Turbo

Page1 (2) Replacement of Valve Guide Edition 05H
L+V28/32H

Shut-off cooling water 62005 60 Lytra tools
Shut-off fuel oil
Description
Dismantling and mounting of valve guide, for inlet

and exhaust valve. Hand tools
Hammer.
Nitrogen (N2), or similar.
Starting position
Valve spindle has been removed, 605-01.05
Related procedure
Working time : 3/4 Hour Plate no. Item no. Qty. /

Capacity : 1 man
60501 017 4/cyl.
Data 60501 029 4/cyl.

00.43 - ES0
MAN Diesel & Turbo

Edition 05H Replacement of Valve Guide Page 2 (2)
L+V28/32H
If the clearance exceeds the shown max. limit, (see 3) Before mounting the new valve guide, it has to
page 600.35), the valve guide must be replaced. be cooled down to approx. -70°C with nitrogen
or similar.
Dismounting of valve guide When the new valve guide has been inserted
into the bore be sure that the shoulder bears
1) The valve guide is knocked out from the bottom against the cylinder head, by knocking slightly
of the cylinder head,by means of a mandrel, with the mandrel and a hammer.
which has a shoulder turning that fits into the
valve guide, see fig. 1. 4) Before mounting of the valve spindle insert a
new o-ring in the valve guide.
Valve seat ring
Mandrel
Fig 2.
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
Fig 1 for pushing the o-ring downwards.
Screw drivers or other sharp tools should never be

2) After having knocked out the valve guide, caused for this purpose.
refully clean the bore of the cylinder head and
inspect for marks that can prvent mounting of 5) For mounting of valve spindle, see working
a new valve guide. card 605-01.05.
00.43 -ESO
MAN Diesel & Turbo
Working Card
Safety Valve 605-01.25
L+V28/32H

Shut-off cooling water 62014 01 Pressure test
Shut-off fuel oil pump.
Shut-off cooling oil 62014 04 Pipe for fuel
Stopped lub. oil circul. injector
Dismantling, inspection, reassembling and Open end spanner, 32 mm.

pressure testing of safety valve. Small hammer.
Copaslip.
Starting position:
Related procedure:
Indicator valve 605-01.26
Working time : 1 hour Plate no Item no Qty. /

Capacity : 1 man
60508 14 1/cyl.
Data:

96.27 - ES0S
MAN Diesel & Turbo

Edition 04H Safety Valve Page 2 (3)
L+V28/32H
Maintenance and Checking. 2. Reassembling.
During extended periods of standstill and at general 2.1 Lubricate the threads on valve housing (2)
engine overhauls, the safety valves should be tho with copaslip or similar.
roughly cleaned.
2.2 Reassemble the safety valve, reverse se-
Note: Do not attempt to stop a safety valve from quence of operations outlined above, point 1.1 to
leaking by increasing the spring load. 1.5.
The setting of the opening pressure is stamped onto

the cap nut (1), see fig 1. 3. Test of Safety Valve.
The valve is to be tested after each overhaul by

1. Dismantling. making a leakage test and testing the opening
pres-sure.
1.1 Screw the safety valve out of the cylinder
head. 3.1 Mount the safety valve in the fuel injection
test pump by using the test pipe for fuel injections.
3.2 Vent the system by pumping until the oil

flows free of air bubbles through the valve ports (7)
in the valve housing (2).
Leakage Test
3.3 Increase the pressure to 135 bar.
3.4 Check that the pressure do not sink below

135 bar within 1 minute.
1. Cap nut 5. Split pin
2. Valve housing 6. Valve cone
3. Pressure spring 7. Valve ports
4. Valve spindle
If the pressure is Then
Fig 1. Safety valve

OK Continue with point 3.5.
below 135 bar Scrap the valve.

1.2 Clamp valve in vice.
or
1.3 Unscrew cap nut (1).
Lap the valve cone and
1.4 Remove pressure spring (3), valve spindle seat.
(4) and valve cone (6).
1.5 Inspect and carefully clean all parts and

condition valve, if necessary.
96.27 - ES0S
MAN Diesel & Turbo

Page 3 (3) Safety Valve Edition 04H
L+V28/32H
Test of Opening Pressure 4. Adjustment of Opening Pressure
3.5 Increase the pressure to the opening pres- 4.1 Increase the pressure to the opening pres-
sure. sure.
4.2 Turn the cap nut (1) to the correct opening

pressure.
If the opening pressure is Then
4.3 Drill a new hole for mounting of split pin
(5).
OK The procedure is ended.
Not OK The valve must be 5. Mounting of Safety Valve

adjusted, see point 4.
5.1 Lubricate the threads on the valve housing
(2) with copaslip or similar.
5.2 Mount the safety valve on the cylinder

head.
96.27 - ES0S
MAN Diesel & Turbo

Page 1 (2) Indicator Valve Edition 02H
L+V28/32H
Stopped engine Plate No Item No Note

Shut-off cooling water
Shut-off fuel oil
Description:
Dismounting, inspection and mounting of indi-

cator valve. Hand tools:
Ring and open end spanner 10 mm

Steel brush
Copaslip
Starting position:
Related procedure:
Safety valve 605-01.25
Man power:
Working time : 1/2 hour

Capacity : 1 man
Replacement and wearing parts:
Data: Plate No Item No Qty./
Data for pressure and tolerance (Page 600.35) 60508 16 1/Cyl.

Data for torque momen (Page 600.40)
94.26 - ES0S
MAN Diesel & Turbo

Edition 02H Indicator Valve Page 2 (2)
L+V28/32H
Maintenance
By normal working conditions the indicator valve

require very little maintenance except an inspec-
tion in connection with the normal cylinder cover
overhaul.
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. 1. Indicator valve, complete
2. Connecting piece
3. Clean and lubricate all components before
remounting.
Fig 1 Indicator valve.
4. Ensure that the spindle is in "OPEN" position
when assembling the valve.
NOTE: Otherwise cone and seat may be dama-

ged.
94.26 - ES0S
MAN Diesel & Turbo

Page 1 (2) Replacement of Sleeve for Fuel Injector Edition 04H
L+V28/32H

Shut-off fuel oil
Description
Dismounting, inspection and mounting of sleeve

for fuel injector. Hand tools
Brass mandrel.
Hammer.
Lub. oil.
Starting position Two small screw driver.
Loctite 572.
The cylinder head has been dis-
mounted from engine, 605-01.00
The fuel injector has been removed, 614-01.10
Related procedure
Mounting of fuel valve, 614-01.10

Capacity : 1 man
60501 125 1/cyl.
Data 60501 137 1/cyl.
60501 149 1/cyl.
00.43 - ES0
MAN Diesel & Turbo

Edition 04H Replacement of Sleeve for Fuel Injector Page 2 (2)
L+V28/32H
Dismounting of Sleeve for Fuel Injector 4) Coat the sealing ring zone in the bore with
grease or lub. oil.
1) Remove the snap ring by means of two screw
drivers.
2) The sleeve can now be driven out of the bo Snap ring
re by use of a brass mandrel and a hammer. O-ring
Sleeve
Loctite 572
Brass mandrel
Fig 2
5) Install new sealing rings on the sleeve.
6) Coat the sealing surfaces on the sleeve with

Fig 1 loctite 572.
7) Insert the sleeve in the bore.

Inspection of Bore in Cylinder Head and
mounting of the Sleeve: 8) Mount the snap ring.
3) Clean and inspect the bore in the cylinder head.

Any marks which could prevent mounting of
the sleeve, should be gently smoothed.
00.43 - ES0
MAN Diesel & Turbo

Page 1 (4) Replacement of Valve Seat Ring Edition 06H
L+V28/32H

Shut-off fuel oil 62021 50 1 piece
Shut-off cooling oil 62005 45 Extra tools
Stopped lub. oil circul. 62005 50 Extra tools
62021 46 1 piece

Description
Replacement of valve seat ring, for inlet and

exhaust valve.
Starting position
Inlet and exhaust valves have been Hand tools

removed, 605-01.05
Hammer.
Loctite, 648.
Lub. oil.
Related procedure
Working time : 1 1/2 Hours Plate no. Item no. Qty. /

Capacity : 1 man
60501 245 4/cyl.
Data 60501 257 4/cyl.

00.43 - ES0
MAN Diesel & Turbo

Edition 06H Replacement of Valve Seat Ring Page 2 (4)
L+V28/32H
Dismounting of Valve Seat Rings Procedure for Dismounting a Valve Seat
Ring
When reconditioning of a valve seat ring no longer is
possible due to dimensions exceeding the scrapping 1) By means of the guide pin (7) the guide disc
criteria, the seat ring has to be replaced. (5) is led vertically through the valve seat ring.
Then the guide disc (5) is lifted with the guide
Dismounting of a valve seat ring is carried out by pin (7) until the latter is guided by the valve
means of a special extractor tool set somprising seat ring. The stud (1) is then screwed in until
following components, see fig 1. it rests in the valve guide.
9
3
5
10
6
1 Stud 6 Eye screw

2 Collar nut hexagon 7 Guide pin Fig 2
3 Guide disc 8 Valve guide
4 Disc 9 Hydraulic jack
5 Guide disc 10 Valve seat ring

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
Fig 1
collar nut hexagon (2), see fig 1. The hydraulic
jack is the one used for main bearing caps.
00.43 - ES0
MAN Diesel & Turbo
605-01.35
Working Card
Page 3 (4) Replacement of Valve Seat Ring Edition 06H
L+V28/32H
3) By pumping up the pack, see working card 3) To facilitate mounting of the valve seat ring it is
620-01.05 for the use of hydraulic tools, the cooled down, however to no more than -25°C
valve seat is pressed out max. 6 mm, and the or the O-ring can be damaged.
pressure is released again.The collar nut hexa-
gon is tightenied and the operation is continued 4) Place the O-ring on the valve seat ring and
until the valve seat ring can be removed. coat with oil/loctite as shown in fig 4, just before
positioning it in the bore.
Mounting of Valve Seat Rings
1) Prior to mounting of a new valve seat ring, the

bore must be cleaned thoroughly and inspected
Coat with
for marks. Marks that can hinder mounting of loctite 648
the valve seat ring must be removed.
Valve seat ring
2) Tools for mounting of valve seat rings are shown
in fig 3.
O-Ring
Coat with oil
Fig 4
5) The valve seat ring is positioned in the bore,

handle with stud inserted as shown in fig 5,
and washer with screw is screwed tight.
1
3
4
1 Handle 2 Stud
3 Washers 4 Hexagon nut
with collar
Fig 5
Fig 3
00.43 - ES0
MAN Diesel & Turbo

Edition 06H Replacement of Valve Seat Ring Page 4 (4)
L+V28/32H
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 of valve guide and valve seat ring.
This can be done according to working card
605-01.05 or 605-01.10.
00.43 - ES0
MAN Diesel & Turbo

Page 1 (2) Mounting of Cylinder Head Edition 06H
L+V28/32H

Shut-off cooling oil 62021 50 6 Pieces
Stopped lub. oil circul. 62021 51 1 Piece
62021 15
62005 01
62010 01
Description 62021 25
62014 15
Mounting of cylinder head after inspection and/or
overhaul.

Hand tools
Starting position
Cylinder head is completely Ring and open end spanner, 17 mm.
assembled, 605-01.05 to 605-01.35 Ring and open end spanner, 24 mm.
Valve gear of respective cylinder is in right posi- Lub. oil and copaslip.
tion (valve closed).
Control of the surface on the
cylinder liner, 606-01.45
Related procedure
Adjustment of valve clearance 608-01.10
Replacement and wearing parts

Man power
Plate no. Item no. Qty. /
Working time : 1 1/2 Hour
Capacity : 2 men 60501 269 2/cyl.
60510 08 1/cyl.
Data 60610 01 2/cyl.
61202 31 1/cyl.
Data for pressure and tolerance (Page 600.35) 61625 01 2/cyl.
00.44 - ES0
MAN Diesel & Turbo

Edition 06H Mounting of Cylinder Head Page 2 (2)
L+V28/32H
1) Check the jointing surfaces of the cylinder Place the spacer ring around the nuts with the slot in
head/cylinder liner to see that they are clean such a position that the tommy bar can be used.
and without damage marks, see working card
606-01.45, Fit new o-rings on the water pas- Tighten the hydraulic jacks and make sure that the
sage, lubricate the o-rings with a little oil. cylinder of the jacks bears firmly against the spacer
ring. Tighten up all the nuts, see page 600.40. For
2) Check all contact faces on the cylinder head using the hydraulic tools, see working card 620-
and nuts, including threads, and make sure that 01.05.
these are plane and smooth and absolutely
free from foreign particles.
3) Attach the lifting tool to the cylinder head that

has been made ready for installation, and
position it carefully on the cylinder liner.
V28/32H
L28/32H
Fig 2
7) If new studs or nuts have been fitted, 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.
8) Adjust the valve clearance, see working card

608-01.10.
Fig 1
9) Fit the pipes for fuel oil, lub. oil, cooling oil.
cooling water and the flange for exhaust
4) Make sure that the nuts run easily on the threads pipe.
and that they bear on their entire contact sur-
faces. 10) Prior to start up check for leakages, and after
start up check for leakages and oil flow.
5) Coat threads and contact faces with copaslip
before fitting the nuts. 11) Mount the cover for rocker arm and the front
cover for fuel pump.
6) Screw nuts onto the studs and tighten lightly
with the tommy bar.
00.44 - ES0
MAN Diesel & Turbo

Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 01H
L/V28/32H

Shut-off fuel oil
Description:
Inspection of cylinder head cooling water

space. Hand tools:
Steel brush
Starting position:
The cylinder head dismantled

from engine, 605-01.00
Related procedure:
Man power:
Working time : ¼ Hour Replacement and wearing parts:

Capacity : 1 man
Plate no. Item no. Qty./
Data:

93.20 - ES0S
MAN Diesel & Turbo

Edition 01H Inspection of Cylinder Head Cooling Water Space Page 2 (2)
L/V28/32H
Inspection of Cylinder Head Cool. Water Space.
1) Inspect the cooling water inlet at the bottom

and the cooling water outlet in the top of the cylinder Cooling water,
head, see fig. 1. outlet
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) Clean if necessary the cooling water inlet and

outlet by means of a steel brush. Flush the cooling
water space after cleaning.
Cooling
water, inlet
5) Should the cylinder head cooling water space
contrary to expectation be blocked with deposits,
contact MAN B&W Diesel, Holeby for further instruc- Fig. 1. Cylinder Head
tions.
93.20 - ES0S
MAN Diesel
Plate
Page 1 (2) Cylinder Head 60501-19H
L+V28/32H
091 125
101
137
113
149
101
017
113 029
054 162
174
066
186
078
198
208
270
221
233
245
030
042 257
269
304
282
294
03.44 - ES0
MAN Diesel
Plate
60501-19H Cylinder Head Page 2 (2)
L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
017 4/C O-ring O-ring 304 Cylinder head (as 294) Cylinderdæksel (som
with brackets and 294) monteret med buk-
029 4/C Valve guide, inlet and Ventilstyr, indstr. og rockerarms installed ke og vippearne.
exhaust udstr.
030 6/C Plug screw Propskrue
042 6/C Gasket Pakning
054 2/C Nut Møtrik
066 2/C Distance pipe Afstandsrør
078 2/C Stud Tap
091 2/C Thrust collar Trykflange
125 1/C Snap ring Låsering
137 1/C Sleeve for fuel valve Foring for br. ventil
149 1/C O-ring O-ring
162 8/C Nut Møtrik
174 8/C Stud Tap
186 4/C Stud Tap
198 4/C Spring pin Fjederstift
221 2/C Screw Skrue
233 2/C Coupling Kobling
257 4/C Valve seat ring, Ventilsædering,

(inlet and exhaust) (indstr. og udstødning)
282 Cylinder head with Cylinderdæksel mon-

valve guide sleeve for teret med spindelstyr,
fuel valve and valve foring for br. ventil og
seat rings ventilsæderinge
294 Cylinder head (as 282) Cylinderdæksel (som

with valve spindles 282), monteret med
installed ventilspindler
When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
03.44 - ES0
MAN Diesel
Plate
Page 1 (2) Valve Spindles and Valve Gear 60502-31H
L+V28/32H
19
20
21
32
03
27
28
29
01
34
30
02
35
36 31
38 13
19
04
14
05
06
06 07
07
15
16
08 17
08
09
09
10 10
11
11
33
08028-0D/H5250/94.08.12
22/23
25
26
12
12
37
08.28 - ES0
MAN Diesel
Plate
60502-31H Valve Spindles and Valve Gear Page 2 (2)
L+V28/32H
Item Item
01 2/C Thrust piece Trykstykke 28 2/C Rocker arm Vippearm
02 2/C Nut Møtrik 29 2/C Thrust screw Trykskrue
03 4/C Plug screw Propskrue 30 2/C Bearing bush Lejebøsning
04 1/C Valve bridge, Ventilbro, 31 2/C Thrust pin Trykskrue

inlet indstrømning
32 /I Loctite 572 Loctite 572
05 2/C Thrust screw Trykskrue
33 1/C Cylinder head as Cylinderdæksel som
06 4/C Circlip Fjederring Plate 60501 + Plate 60501 +
Plate 60502 Plate 60502
07 4/C Thrust piece Trykstykke
34 1/C Valve bridge, inlet Ventilbro, indstrømning
08 4/C Conical ring in 2/2 Konisk ring 2/2 complete incl. item komplet inkl. item
01, 02, 04, 05, 06, 07, 01, 02, 04, 05, 06, 07,
09 4/C Rotocap, complete Rotationsgiver, kom- 14, 15, 16 and 17 14, 15, 16 og 17
incl. item 22, 23, 25, plet inkl. item 22, 23,
26 25, 26 35 1/C Valve bridge, exhaust Ventilbro, udstødning
complete incl. item komplet inkl. item
10 4/C Inner spring Indvendig fjeder 01, 02, 05, 06, 07, 13, 01, 02, 05, 06, 07, 13,
14, 15, 16 and 17 14, 15, 16 og 17
11 4/C Outer spring Udvendig fjeder
36 4/C Screw Skrue
12 4/C Valve spindle, inlet Ventilspindel, inds.
and exhaust (valve og uds. (ventilspindel 37 2/C Valve spindle, Ventilspindel, uds.
spindle exh. only for uds. kun for marine exhaust (only for (kun for stationære
marine engines) motorer) stationary engines) motorer)
13 1/C Valve bridge,exhaust Ventilbro, udstødning 38 /I Loctite 243 Loctite 243
14 2/C Thrust piece Trykstykke
15 2/C Spring Fjeder
16 2/C Ball guide Kuglestyr
17 2/C Securing ring Sikring
19 4/C Rocker arm bracket Buk for vippearm inkl

incl spring pin spændstift
20 2/C Rocker arm shaft Aksel for vippearm
21 2/C Rocker arm, compl. Vippearm, komplet

(Item 03, 27, 28, 29, (Item 03, 27, 28, 29
30, 31) 30, 31)

08028-0D/H5250/94.08.12
23 24/C Ball Kugle
25 4/C Spring washer Fjederskive
26 4/C Retainer ring Låsering
27 2/C Nut Møtrik
Qty./ = Qty./Individual Antal/I = Antal/Individuelt
08.28 - ES0
MAN Diesel
Plate
Page 1 (2) Safety Valve and Indicator Valve 60508-11H
L+V28/32H
18
16
17
15
94.25 - ES0S
MAN Diesel
Plate
60508-11H Safety Valve and Indicator Valve Page 2 (2)
L+V28/32H
Item Item
03* 1/C Valve cone Ventilkugle
06* 1/C Pressure spring Trykfjeder
13 1/C Safety valve, com- Sikkerhedsventil,

plete incl. item 03, komplet inkl. item 03,
06, 25, 26, 27, 28 06, 25, 26, 27, 28
17 1/C Connecting piece Forbindelsesstykke
18 1/C Indicator valve, Indikatorventil,

complete komplet
25* 1/C Valve housing Ventilhus
26* 1/C Valve spindle Ventilspindel
27* 1/C Cap nut Dækselmøtrik
28* 1/C Split pin Fjedernot
94.25 - ES0S
MAN Diesel
Plate
Page 1 (2) Cylinder Head, Top Cover 60510-12H
L+V28/32H
01
02
05, 16
06
07
15
13
08
09
10
11
06.32 - ES0S
MAN Diesel
Plate
60510-12H Cylinder Head, Top Cover Page 2 (2)
L+V28/32H
Item Item
01 4/C Handle Håndtag
05 4/C Nut Møtrik
06 1/C Top cover Topdæksel
07 1/C Top cover, compl. Topdæksel, kompl.

incl. item Nos. inkl. pos. nr.
01, 02, 05, 06 01, 02, 05, 06
10 1/C Coaming Karm
13 18/C Washer Skive
15 18/C Screw Skrue
06.32 - ES0S
Piston/connecting rod
506/606
MAN Diesel
Description
Piston, Connecting Rod and Cylinder Liner 606.01
Page 1 (1)
Edition 10H
L/V28/32H
Piston
The piston, which is oil-cooled and of the monobloc The big-end bearing is of trimetal type, i.e. steel shells
type made of nodular cast iron, is equipped with 3 lined with tin-aluminium or lead-bronze coated with
compression rings and 1 scraper ring. a running layer. Design as plain type or rillentype.
The bearing shells are of the precision type and are
By the use of a combination of compression rings therefore to be fitted without scraping or any other
with different barrel-shaped profiles and chrome- kind of adaption.
plated running surface on all rings, the piston ring
pack is optimized for maximum sealing effect and The small-end bearing is of trimetal type and is pres-
minimum wear rate. sed into the connecting rod.
The piston has a cooling oil space close to the piston

crown and the piston ring zone.The heat transport and Cylinder Liner
thus the cooling effect is based on the shaker effect
arising during the piston movement. As cooling oil is The cylinder liner is made of fine-grained, pearlite
used oil from the engine's lubricating oil system. cast iron and is fitted in a bore in the engine frame.
Between the liner and the cylinder head and between
the liner and the frame there are fitted replaceable
Piston Pin cast iron sealing rings. The liner is clamped by the
cylinder head and is guided by a bore at the bot-
The piston pin is fully floating which means that it tom of the cooling water space of the engine frame.
can turn freely in the pin bosses of the piston as The liner can thus expand freely downwards, when
well as in the connecting rod bush. The piston pin heated during the running of the engine. Sealing for
is upwords in place in axial direction by two circlips the cooling water is obtained by means of silicone
(seeger rings). rubber rings which are fitted in grooves machined
in the liner.
Connecting Rod Tell-tale borings in the frame, starting from a level

between the sealing rings and leading to the exterior
The connecting rod is die-forged. The big-end has an will reveal any sealing malfunction by sign of leaking
inclined joint in order to facilitate the piston and con- water or lubricating oil mist.
necting rod assembly to be withdrawn up through the
cylinder liner. The joint faces on connecting rod and
bearing cap are serrated to ensure precise location
and to prevent relative movement of the parts.
08028-0D/H5250/94.08.12
90.43 - ES0U
MAN Diesel
Page 1 (3) Dismounting of Piston and Connecting Rod Edition 01H
L28/32H

Shut-off cooling oil 62006 09 2 pieces
62006 28 140 - 760 Nm
62010 01
Description: Tool combination for dismounting of connecting

rod screw, see working card 620-01.20.
Dismounting of piston and connecting rod as-
sembly, for inspection and/or overhaul.
Starting position: Hand tools:
Cylinder head has been dismounted Threaded pin M16.

from engine, 605-01.00 Open end spanner 32 mm.
Crank case open. Wire.
Scraper or similar.
Small adjustable spanner.
Related procedure:
Separation of piston and connecting

rod, 606-01.05
Inspection and honing of cylinder
liner, 606-01.35
08028-0D/H5250/94.08.12

Capacity : 2 men
Data:

96.06 - ES0S
MAN Diesel
Edition 01H Dismounting of Piston and Connecting Rod Page 2 (3)
L28/32H
1) Clean the upper part of the cylinder, if not, the e) Turn the piston in top, in order to push the flame
piston may get stuck during removal in the carbon ring out of the cylinder by means of the tool.
deposited in this area.
Info: It is the used piston ring which pushes the flame
If the liner is mounted with a flame ring then start ring out of the cylinder, while the flame ring tool guides
with item No a to e. the piston ring out against the cylinder liner.
If the liner is not mounted with a flame ring then 2) Remove the gangway, if any installed, in order
continue with item No 2. to improve the access conditions.
a) Turn the piston to the buttom. 3) Turn the crankshaft to bring the crank throw
concerned into a position approx. 50 degrees before
b) Mount the tool for dismounting of the flame TDC.
ring in the cylinder at the top of the piston.
This position is identifiable by the connecting rod shaft
c) Place a used piston ring on top of the flame being very close to cylinder liner shirt, see fig. 1.
ring tool.
4) Clean the threaded hole in the piston top, and
d) Mount the tube (for holding down the cylinder mount the eye screw.
liner during the piston withdrawal) on one of the
cylinder head studs, screw on the nut and tighten it Mount the tube (for holding down the cylinder liner
slightly. during the piston withdrawal) on one of the cylinder
head studs, screw on the nut and tighten it slightly.
08028-0D/H5250/94.08.12
Fig. 2. Removal of bearing cap.
5) Attach a wire rope to the eye bolt by means of

Fig. 1. Mounting of tools. (placing). a shackle, hook the wire on to a tackle and pull the
wire rope tight.
96.06 - ES0S
MAN Diesel
Page 3 (3) Dismounting of Piston and Connecting Rod Edition 01H
L28/32H
Fig. 3. Removal of upper big-end bearing shell.
If minor adjustment of the crank throw position ap-

pears necessary for acces 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.
6) Unload the connecting rod screws and unscrew

one of the upper screws.
7) Mount the guide pin for the bearing cap in one Fig. 4. Lift of piston and connecting rod assembly.
of the threaded holes and fit a screwdrive or similar in
the hole in the guide pin, and unscrew the screws.
11) Lift the piston and connecting rod assembly
8) Remove the screwdriver from the guide pin, up through the cylinder liner and out of the engine,
and dismount the bearing cap by sliding it along see fig. 4.
the guide pin, see fig. 2.
NOTE: The purpose of the guide pin is to prevent
9) Remove the guide pin from the connecting any damage of crank journal, joint faces or bearing
rod. surface to occur during dismounting of the bearing
08028-0D/H5250/94.08.12
cap, and to facilitate easy handling when removing

10) Pull the piston and connecting rod assembly the bearing cap from the crankcase.
upwards and remove the upper big-end bearing shell,
see fig. 3.
96.06 - ES0S
MAN Diesel
Page 1 (2) Separation of Piston and Connecting Rod Edition 03H
L/V28/32H

Shut-off cooling water 62006 01 L28/32H
Shut-off fuel oil 62006 03 L28/32H
Shut-off cooling oil 62006 05 V28/32H
Description:
Separation of piston and connecting rod for in-

spection or/and overhaul.
Assembly of the piston and connecting rod after
inspection or/and overhaul.
Piston and connecting rod are dismounted Open end spanner, 32 mm.
from engine, 606-01.00 Wooden wedge, 2 pieces.
Wooden support.
Wire.
Related procedure:
Inspection or/and overhaul of piston, 606-01.10

Inspection or/and overhaul of
connecting rod, 606-01.15
Inspection of connecting rod
big-end bearing, 606-01.16
08028-0D/H5250/94.08.12
Working time : 1/4 hour Plate no. Item no. Qty./

Capacity : 1 man
Data:

92.08 - ES0S
MAN Diesel

Edition 03H Separation of Piston and Connecting Rod Page 2 (2)
L/V28/32H
Separation of the Piston and Connecting Rod: Wooden wedges should be used to prevent the con-
necting rod from swinging out and thus impact the
1) Land the piston and connecting rod carefully piston skirt during the lifting into upright position.
on wooden support to prevent damage of piston and
scraper ring, see fig. 1 or 2. 5) Place a wire around the big-end of the con-
necting rod, attach a tackle and tighten the wire rope,
see fig. 3
6) Take out the securing ring, (seeger circlips),

push out the piston pin and lift the connecting rod
away.
Fig. 1. L28/32H
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 fig. 1 or 2.
Fig. 3.
Assembly of the Piston and Connecting Rod.

08028-0D/H5250/94.08.12
Fig. 2. V28/32H
7) For assembly of the piston and connecting rod,

see point 1-6 in opposite direction.
3) Remove the shackle and eye screw/lifting tool
from the piston crown, see fig. 1 or 2.
8) Lubricate the piston pin before assembling.
4) Place the piston and connecting rod assembly
in upright position resting on the top face of the piston
crown, see fig. 3.
92.08 - ES0S
MAN Diesel

Page 1 (4) Piston (with flame ring) Edition 09H
L+V28/32H
Stopped engine Plate no Item no Note.

Shut-off cooling oil 62006 16
Description Hand tools
Cleaning and inspection of piston. Control of piston Tools for cleaning of piston, steel brush,
ring, scraper ring and ring grooves. scraper etc.
Starting position
Piston has been dismantlet from

connecting rod 606-01.05
Related procedure
Mounting of piston and

connecting rod 606-01.20
08028-0D/H5250/94.08.12
Working time : 1/2 Hour Plate no Item no Qty. /

Capacity : 1 man
Data

01.16 - ES0
MAN Diesel

Edition 09H Piston (with flame ring) Page 2 (4)
L+V28/32H
Removal of Piston Ring Inspection of Piston
For removal of piston rings, which are to be used 1) Remove the piston and scraper rings.
again, and for all mounting of rings, only the special
ring opener which prevents local over stressing of 2) Clean and examine the piston rings to determine
the rings should be used. if reuse is acceptable, see page 3.
Straps to expand the ring gap or tools working on 3) Clean the piston outside and inside.
the same principle must not be used, as this would
result in permanent deformation which might cause 4) Inspect the piston ring and scraper ring grooves
blow-by or broken rings. for wear, see page 3.
08028-0D/H5250/94.08.12
01.16 - ES0
MAN Diesel

Page 3 (4) Piston (with flame ring) Edition 09H
L+V28/32H
The piston has to be scrapped if: Piston and oil New ring
Ring grooves.
scraper ring. grooves.
A) The wear limit on the testing mandrel is exceed- Nominal size. Tolerances.
Max. wear limit.
ed, see fig 1A
Piston ring New +0.18
or no 1 5.0 mm
5.0 mm
+0.16
5.43 mm
B) The clearance between the new piston/scraper Piston ring New +0.14
ring and ring groove is exceeded, see fig 1B. no 2 5.0 mm
5.0 mm
+0.12
5.43 mm
Piston ring New +0.14

Note: At each piston overhaul: no 3 4.95 mm
5.0 mm
+0.12
5.43 mm
- The piston and scraper ring must be ex- New +0.12

changed. Scraper ring 8.0 mm 8.43 mm
8.0 mm +0.10
- The cylinder liner must be honed according
to the instructions. Table 1 Nominal size, new ring groove tolerance and wear
limit for ring grooves
A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove
If the wear limit (2 mm mark) on the testing

mandrel is exceeded, the specified max. wear
limits are exceeded, and the piston must be
scrapped.
0.45
Wear limit line.
Maximum vertical clearance

between new piston ring/scraper
ring and ring groove: 0.45 mm.
The handle is marked

with the nominal size.
08028-0D/H5250/94.08.12
Fig 1 Wear limits for ring grooves
01.16 - ES0
MAN Diesel

Edition 09H Piston (with flame ring) Page 4 (4)
L+V28/32H
Position of Piston and Scraper Rings
Piston Ring No 1:
marked with ident.
no "top 1619394-4"
or "1242".
Piston Ring No 2:
marked with ident.
no "top 1619394-4"
or "1242".
Piston Ring No 3:
marked with ident.
no "top 1600381-8"
or "0950".
Scraper ring:
marked with ident.
no "top 1600387-9"
or "0121".
Marking of Piston and Scraper Rings

08028-0D/H5250/94.08.12
Marking
Identification marks to face upwards against the piston crown when mounted.
Note: The marking may include other figures than mentioned above, for instance trade mark and
production codes.
01.16 - ES0
MAN Diesel

Page 1 (4) Connecting Rod Edition 04H
L/V28/32H

Shut-off cooling water 62006 28 140-760 Nm
Shut-off fuel oil
Description:
Cleaning, inspection and test measurement of

connecting rod.
Hand tools:
Starting position: Inside micrometer (242 mm).

Feeler gauge 0,15 - 0,20 mm.
Connecting rod has been
dismantlet from piston, 606-01.05
Related procedure:

08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

97.24 - ES0S
MAN Diesel

Edition 04H Connecting Rod Page 2 (4)
L/V28/32H
Cleaning and Inspection of Big-end Bore. Screws, which are damaged as mentioned above or
cannot be turned into the threaded holes by hand,
The connecting rod is cleaned on all machined must be renewed.
surfaces.
The serrated joint faces and threaded screw holes Measurement of Big-end Bore.
are to be degreased with a volatile solvent and blown
dry with working air.
The serrated joint faces are inspected.
The serration on the connecting rod may, due to

relative movements between the mating surfaces,
30 mm
show damages in form of wear marks and pittings CL of serration B
or even cracks in highly loaded zones. A B

x
x C
x
x C
Observed damages should be registered in the schem
D
"Connecting Rod Inspection". See page 4.
Wear marks are visible but not appreciable at a

fingernail. Pittings are not only visible but also noti-
ceable at a fingernail.
Single distinctly raised spots caused by pitting should

Fig. 1. Point of measurement
be gently smoothed by careful, local treatment with
a file.
For check of roundness the big-end bore has to be
The serration on the connecting rod and on the measured in a condition, where the connecting rod
bearing cap can be damaged by improper handling is mounted with the bearing cap but without bearing
during dismounting, transport and overhaul work. shells, and the connecting rod screws are tightened
up with the prescribed torque, see working card
Note ! The connecting rod and bearing cap must 606-01.25.
therefore be handled with care.
Note ! The ident no. on the connecting rod and the
Single dent marks caused by impact can be rectified bearing cap, must always be the same, see fig. 3.
by gentle and careful local treatment with a file.
Measurements must be taken 30 mm from seration
In case of damage of the serration, reuse must centerline. See fig. 1.
be rejected, and a new connecting rod assembly
including new bearing shells must be mounted in The measuring is executed with an inside micro-
the engine. meter.
08028-0D/H5250/94.08.12
The connecting rod screws are to be carefully clean- Five different diameters are measured in the middle
ed. of the boring, see fig. 1 and registered in the scheme
"Connecting Rod Inspection". See page 4.
The threads are inspected for seizures and tested
in the threaded holes in the connecting rod. The test The maximum ovalnees is calculated as the dif-
must confirm, that the screws can be turned into ference between biggest and smallest diamenter
bottom position by hand. The contact surface of the measured. For maximum allowable ovalness see
screw heads is inspected for seizure and pittings. page 600.35.
97.24 - ES0S
MAN Diesel
Page 3 (4) Connecting Rod Edition 04H
L/V28/32H
If the ovalness exceeds this value, reuse must be Please note that squares for statement of information
rejected and a new complete connecting rod, inclu- and identification, should also be properly filled in.
ding new screws and new bearing shells has to be
mounted in the engine.
Connecting Rod Bush.
Inspect the surface of the piston pin and the connec-

ting rod bush. Measure the clearance between the
piston pin and bush, max. clearance between pin
and bush, see page 600.35.
In case the specified clearance is exceeded, contact

- 0,5 - 3,0 MAN B&W Diesel A/S, Holeby for replacement.
- 2,0 - 7,0
- 1,5 - 5,0
+ 5,0 + 5,5 Bearing Shells for Big-end.
+ 3,0 + 3,5
7,0 12,5 Criteria for replacement of connecting rod big-end
bearing, see working card 606-01.16.
to be to be
reused rejected
Fig. 2. "Connecting rod inspection".
The example, see fig. 2 shows measurements and

damage observations for two connecting rods, on the
scheme "Connecting Rod Inspection", (In case the
specified maximum ovalness is exceeded, contact
MAN B&W Diesel A/S, Holeby for overhaul).
For connecting rod no. 1 the maximum ovalness is

Connecting rod
0,07 mm and reuse thus acceptable. Ident no.
08028-0D/H5250/94.08.12
For connecting rod no. 2 the maximum ovalness is

0,125 mm and therefore the connecting rod is being
rejected. Fig. 3.
97.24 - ES0S
MAN Diesel

Edition 04H Connecting Rod Page 4 (4)
L/V28/32H
08028-0D/H5250/94.08.12
97.24 - ES0S
MAN Diesel
Working Card Criteria for Replacement of 606-01.16
Page 1 (8) Connecting Rod Big-end and Main Bearing Shells Edition 02H
L+V28/32H

Shut-off starting air 62006 55
Shut-off fuel oil
Description:
Inspection of bearing shells.

Hand tools:
Magnifier (x30).
Starting position:
Bearing shells removed from engine:

Big-end bearing, 606-01.00 and 606-01.30
or
Main bearing, 610-01.05
Guide bearing, 610-01.10
Related procedure:
Mounting af bearing shells:

Big-end bearing, 606-01.20 and 606-01.30
Main bearing, 610-01.05
Guide bearing, 610-01.10
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

96.41 - ES0S
MAN Diesel
606-01.16 Criteria for Replacement of Working Card

Edition 02H Connecting Rod Big-end and Main Bearing Shells Page 2 (8)
L+V28/32H
This paper gives information about the evaluation of Wear of the bearings running surface starts primarily
the connecting rod big-end and main bearing shells in the soft overlay, where the overlay in the slots is
when wear appears on the running surface under reduced approx. 0.001 mm. The difference between
normal operating conditions. the light-alloy metal and the overlay is by further wear
almost constant, i.e. approx. 0.005 mm.
Bearing damages caused by incorrect running con-
ditions, like The gravity of the running surface’s wear must be
determined with a magnifier (x30), hereby the over-
- Scoring of the running surface due to foreign lay can be seen as the dark area and the light-alloy
particles in the lubricating oil. metal as the light area.
- Cavitation.
- Corrosion The ratio between the width of the light-alloy metal
- Overloading, overheating a.s.o. and the width of the slot as well as the dimension
of the worn area are important for determining the
are not described in this paper. wear of the bearing.
In these cases, the bearing shells must be exchang- The bearing can also operate although part of the
ed, of course, and in order to avoid further bearing overlay is missing in the slots. Practice has shown, that
failures, the cause of the failure must be found and bearings with partly empty slots can run without any
eliminated. negative influence on the operation of the bearing.
By determining the condition of the bearing shell,

the overlay at a minor stressed area must be used
as comparison.
Overlay
(~75%) The valuation of the bearing shell condition is divided
Light metal into 5 groups:
(~25%)
Nickel strike 1. Re-use
(max.5%) 2. Limiting case - wear
3. Limiting case - local levelling
4. Limiting case - permanent breakage on the
overlay
5. Empty slots.
In case of a combination of the above mentioned

conditions, the lowest possible limits are valid.
Fig. 1. Running surface of the bearing shell.
08028-0D/H5250/94.08.12
A new bearing shell has a running surface with approx.

75 % galvanic overlay and approx. 25 % light-alloy
metal, see fig. 1.
96.41 - ES0S
MAN Diesel
MAN Diesel
MAN Diesel
MAN Diesel

L+V28/32H
3. Limit Case - Levelling Valuation: If the limits shown in fig. 11 and 12 are
exceeded the bearing shells must be exchanged.
Condition: The slots are locally totally levelled as
shown in fig. 10.
max. 10% of width
Fig. 10.
max. 5%
of extent
max. 10% of width or
max. 5 mm
Fig. 12.
Fig. 11.
08028-0D/H5250/94.08.12
96.41 - ES0S
MAN Diesel
MAN Diesel

L+V28/32H
5. Limit Case - Empty Slots Valuation: If the limits shown in the below fig. 18
and 19, are exceeded, the bearing shells must be
Condition: In some areas there is no overlay in the exchanged.
slots, see fig. 17.
max. 10% of width or
max. 5 mm
Fig. 17.
max. 30% of width

extent
Fig. 19.
of
max. 15%
Fig. 18.
08028-0D/H5250/94.08.12
96.41 - ES0S
MAN Diesel
Page 1 (4) Assembling of Piston and Connecting Rod Edition 01H
L28/32H

62006 22
Description:
Mounting of piston and connecting rod assembly,

after overhaul and/or inspection.
Piston mounted on the connecting rod, crank-shaft Open end spanner 32 mm.
turned in the right position and the cylinder liner Clean lubricating oil.
is OK, see working card 606-01.35.
Related procedure:
Tightening of connecting rod screws,606-01.25

08028-0D/H5250/94.08.12
Working time : 1 1/2 Hours Plate no. Item no. Qty./

Capacity : 2 men
60601 09 1/cyl.
Data: 60601 10 1/cyl.
60601 11 1/cyl.
91.49 - ES0S
MAN Diesel
Edition 01H Assembling of Piston and Connecting Rod Page 2 (4)
L28/32H
1) Mount the lifting device comprising eye screw, A crank throw position of approx 50 degrees before
shackle and wire rope on the piston. TDC will ensure this and also be suitable for the
further mounting procedure.
2) Lift up the piston and connecting rod and
mount the piston and scraper rings, see point 14, 6) Lower the piston further down, lubricate the
and working card 606-01.10. ends of the bearing shells (a in fig. 2) with copaslip,
molycote pasta or similar and mount the upper shell
3) Remove the backstop for cylinder liner and of the big-end bearing.
place the piston guide ring on top of the cylinder
liner, see fig. 1.
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.
Fig. 2.
08028-0D/H5250/94.08.12
7) Coat the crank journal with clean lubricating

Fig. 1. oil.
8) Now lower the piston and connecting rod slowly

5) Make sure that the crank throw is in a position into correct landing on the journal.
allowing the connecting rod to go clear of both crank
journal and cylinder liner skirt during further lower- During this the connecting rod must be guided by
ing. hand to ensure correct approach and landing on the
journal, see fig. 3.
91.49 - ES0S
MAN Diesel
Page 3 (4) Assembling of Piston and Connecting Rod Edition 01H
L28/32H
9) Mount the bearing cap with inserted lower shell
of the big-end bearing, using the guide pin, see fig.
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. 3.
Note ! The ident no. on the connecting rod and on the

bearing cap, must always be the same, see fig. 4.
Fig. 5.
13) Tighten the screws according to "Tightening

08028-0D/H5250/94.08.12
Procedure for Connecting Rod Screws", see working

card 606-01.25.
Fitting of Piston and Scraper Rings.
14) Piston rings should only be removed from and

Con. Rod - Ident No. fitted to the piston by the use of a special tool, the
socalled piston ring opener.
Fig. 4.
91.49 - ES0S
MAN Diesel
Edition 01H Assembling of Piston and Connecting Rod Page 4 (4)
L28/32H
If the rings are opened further than necessary there Before fitting the coil spring loaded scraper ring, the
is a risk of overstressing, which means that rings will coil spring is dismantled from the ring by removal of
become permanently distorted and will not confirm the joint pin. The coil spring is placed and assembled
to the cylinder inner running surface. in the ring groove then the scraper ring is fitted in the
groove in such a way that the ring joint is approxima-
The piston rings should be installed with the identifi- tely 180° offset to the spring joint.
cation mark, which is stamped into the ring close to
the ring joints, facing upwords. Ascertain correct assembling by checking the back
clearance.The back clearance is suffient when the
face of the ring is below the groove edge, when the
ring is pressed against the bottom of the groove.
Joint pin for

When installed on the piston, the rings should be
Coil spring joint to be pla- pushed back and forth in the grooves to make sure
coil spring
ced opposite to ring joint 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 of the feeler gauge

can be moved all the way round.
Ring joint 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.
Fig. 6.
08028-0D/H5250/94.08.12
91.49 - ES0S
MAN Diesel

Page 1 (2) Hydraulic Tightening of Connecting Rod Screws Edition 04H
L+V28/32H
Safety Precautions: Special Tools:

Shut-off cooling water 62021
Shut-off fuel oil
Description:
Tightening procedure for connecting rod

screws. Hand Tools:
Check of connecting rod screws, tightening
condition.
Starting Position:
Piston, connecting rod, bearing shells and bearing

cap preassembled. 606-01.20
Related Procedure:
Man Power: Replacement and Wearing Parts:

08028-0D/H5250/94.08.12
Working time : 1/2 Hour Plate No Item No Qty./

Capacity : 2 men
Data:

97.43 -ES0S
MAN Diesel

Edition 04H Hydraulic Tightening of Connecting Rod Screws Edition 2 (2)
L+V28/32H
1) Tighten the screw pos. 3 home to the connecting
rod by hand.
2) Mount the lower part pos. 2 and fasten the

lower part with the nuts, pos. 4.
3) Tighten the nuts by hand.
4) Mount the hydraulic tool, pos. 5.
Be aware of the max. lifting heigt of the tool and

adjust the distance between the piston and the
cylinder before adding pressure to the tool. Please
see Working Card 620-01.05
5) Connect the tool to the hydraulic tool.
6) Add the prescribed hydraulic pressure, (to both

screws simultaneously). Please see Description
600.40, and tighten the screws by using a handle,
pos 6.
2
7) Relieve the hydraulic pressure on the tool. 1 6
8) Add the hydraulic pressure to the tool.
9) Tighten the nuts again.
Note: The Points 7 to 9 are to be followed in order 5

to remove tensions in the screws, if any.
3
10) If there still is a distance and the nuts still can 4
be tightened then repeat the points 7, 8 and 9.
11) Relieve the pressure on the tool and remove

Fig. 1
it from the screws.
Note: General instruction about hydraulic tightening.

Please see Working Card 620-01.10
08028-0D/H5250/94.08.12
97.43 - ES0S
MAN Diesel
Page 1 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 01H
L28/32H

Shut-off cooling oil 62006 28 140 - 760 Nm
Tool combination for tightening of connecting

rod screw, see working card 620-01.20.
Description:
In-situ inspection and/or replacement of con-

necting rod big-end bearing, dismounting and
moun-ting.
Hand tools:
Open end spanner 32 mm.

Starting position:
Fuel injector dismounted, 614-01.00

Crankcase open.
Top cover for cylinder head removed.
Related procedure:
Inspection of connecting rod

big-end bearing 606-01.16
Tightening and check of connecting
rod screws, 606-01.25
08028-0D/H5250/94.08.12
Working time : 1 1/2 Hours Plate no. Item no. Qty. /

Capacity : 1 man
Data:

91.22 - ES0S
MAN Diesel
Edition 01H In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
L28/32H
The big-end bearing shells can be inspected and/or
replaced in-situ i.e. without dismounting the piston
and connecting rod assembly from the engine.
Dismounting.
1) The crankshaft of the engine is turned into a

position allowing the connecting rod screws to be lo-
sened. Having loosened the connecting rod screws,
the crankshaft is turned until the piston in a position
thus allowing the connecting rod bearing cap to be
dismounted, see fig. 1.
Fig. 2.
3) Having tightened the tackle slightly, the con-

necting rod bearing cap and bearing shell are dis-
mounted, see working card 606-01.00, for use of
guide pin.
4) When connecting rod bearing cap and bearing

shell have been dismounted, the piston/connecting
rod is lifted from the bearing journal. Piston/connec-
ting rod should not be lifted further than just to allow
dismounting of the upper bearing shell, see fig. 3.
Fig. 1.
08028-0D/H5250/94.08.12
2) Before removing connecting rod bearing cap,

the especially long eye bolt is mounted. It is inserted
through the fuel injector sleeve and is screwed into
the thread hole in the piston, see fig. 2. Then by
means of a tackle it is slightly tightened.
91.22 - ES0S
MAN Diesel
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 01H
L28/32H
While lowering the connecting rod, it must be guided
by hand to ensure correct approach and landing on
the journal, see fig. 4.
4) Mount the bearing cap with inserted lower

big-end bearing shell, using the guide pin.
5) Lubricate threads and contact face of the con-

necting rod screws with copaslip or similar.
6) Mount the screws and tighten them slightly

using an open-end spanner.
7) Slacken the tackle and dismount the eye screw

from the piston crown.
8) Tighten the screws according to "Tightening

Procedure for Connecting Rod Screw", see working
card 606-01.25.
Fig. 3.
5) For inspection of bearing shell, see working

card 606-01.16
Mounting.
Before remounting of inspected or new bearing, all

components must be cleaned.
Note: See also working card 606-01.20.
1) The bearing shell is placed in the bore, the

contact surfaces of the shells to be in parallel to the
08028-0D/H5250/94.08.12
contact surface of the connecting rod, the bearing

cap respectively.
2) Ascertain that the crank throw concerned is in

a position of approx 50 degrees before TDC. Fig. 4.
3) Coat the journal with clean lubricating oil and

lower the piston and connecting rod assembly slowly
into correct landing on the journal.
91.22 - ES0S
MAN Diesel
Page 1 (4) Inspection and Honing of Cylinder Liner Edition 08H
L+V28/32H

Shut-off cooling water 62006 50 Extra tools
Shut-off fuel oil 62006 51 Extra tools
Shut-off cooling oil 62006 60 Extra tools
Description:
Inspection and honing of cylinder liner with ho-

ning brush. Hand tools:
Drilling machine 60-180 rpm.

Honing oil.
Gas oil.
Starting position:
Piston and connecting rod is

removed, 606-01.00
Related procedure:

Replacement of cylinder liner, 606-01.40
Grinding of seal face on cylinder
head and cylinder liner, 606-01.45
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

05.28
MAN Diesel

Edition 08H Inspection and Honing of Cylinder Liner Page 2 (4)
L+V28/32H
Measurement of Cylinder Diameter. Prior to the honing, deposits of coke and possible
wear edges in the top of the liner must be removed
While the piston is removed from the cylinder, the by scraping.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, If the cylinder is of the flame ring type, the used
with measuring points at TDC-position for uppermost flame ring has to be cleaned in water. Subsequently,
piston ring, halfway down and at the bottom of the the flame ring is remounted in the cylinder before
cylinder liner, see fig. 1. carrying out the honing process.
Note: After the honing process has taken place the

used flame ring is discarded. A new flame ring is
always mounted in the cylinder when replacing a
piston ring.
80-160 rpm.
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
08028-0D/H5250/94.08.12
indicated on page 600.35, i.e. when it becomes

too troublesome to maintain satisfactory service
con-ditions, the cylinder liner in question should be
ex-changed.
Fig. 2.
Honing the Cylinder Liner.

The honing is made by means of a flex-honer with
The renovation can be made either with dismantled finess grains 80-120. A revolution speed between
liner in the workshop or with liner mounted in the 80 and 160 rpm is chosen.
engine frame and by the use of the belonging fun-
nel.
05.28
MAN Diesel
page 3 (4) Inspection and Honing of Cylinder Liner Edition 08H
L+V28/32H
In order to achieve the required angle between the
honing grooves, see fig. 2, the vertical speed is ad-
justed to about 1 m/sec. which corresponds to about
2 sec. for one double movement (the flex honer is
lead from below up and down in 2 sec.)
The procedure is to be continued until the cylinder 60°

wall is covered by honing grooves and the surface
has a slight matt appearance and without any signs
of glaze .
During the honing it is important to lubricate freely

with honing oil or cutting oil.
Fig. 3.
After the honing, the liner is carefully cleaned with
gas oil, and make sure that all abrasive particles
have been removed.
08028-0D/H5250/94.08.12
05.28
MAN Diesel
Edition 08H Inspection and Honing of Cylinder Liner Page 4 (4)
L+V28/32H
Measurements of Cylinder Liner
Plant/ship: Engine Type: Engine No.:
Date: Sign.: Cyl. A-side B-side

no. Pos. A B C D
Running hours: 1
Fuel: cSt 1 2
Separator: Yes 3
2 2
3 2
4 2
5 2
6 2
7 2
3
08028-0D/H5250/94.08.12
8 2
Tem. of cyl. liner 25°C 3
Nom. diameter 280H8 1
Minimum 280.0 9 2
Maximum 280.60 3
05.28
MAN Diesel
Page 1 (3) Replacement of Cylinder Liner Edition 01H
L/V28/32H

Shut-off fuel oil
Description:
Replacement of cylinder liner.

Dismounting and mounting of cooling water Hand tools:
guide jacket.
Allen key, 8 mm.
Adjustable spanner.
Starting position:
Cylinder head and piston/connecting rod dis-

mantled,working card 605-01.00 and 606-
01.00.
Related procedure:

Grinding of seal face on cylinder
head and cylinder liner, 606-01.45
08028-0D/H5250/94.08.12
Working time : 2 Hours Plate no. Item no. Qty. /

Capacity : 2 men
60610 04 1/cyl.
Data: 60610 07 12/cyl.
60610 08 2/cyl.
Declaration of weight (Page 600.45) See also plate 60610.
91.22 - ES0S
MAN Diesel

Edition 01H Replacement of Cylinder Liner Page 2 (3)
L/V28/32H
Dismounting of Cylinder Liner.
1) Dismount the cooling water guide jacket.

L28/32H
2) Prior to mounting of the lifting tool and dismoun- V28/32H
ting from the frame, it must be ensured that the liner
and frame have been marked to match, for the sake
of a posible remounting of the liner, see fig. 1.
Hole for charging air
Hole for roller guide house
Marking scratch frame
Marking scratch liner
Fig. 2.
Fig. 1.
5) Attach a tackle hook to the eye nut or the wire
and the cross bar, and lift the liner out from the engine
3) Mount the lifting tool as shown, see fig. 2. frame and stand it careful onto wooden supports.
4) Turn the lifting eye nut to pull out the liner, until 6) Clean all parts and inspect for damage and
the upper edge of the liner lie aligned against the wear, according to the description. For measurement
copper protecting pieces of the cross bar. of cylinder liner, see working card 606-02.00.
08028-0D/H5250/94.08.12
91.22 - ES0S
MAN Diesel

Page 3 (3) Replacement of Cylinder Liner Edition 01H
L/V28/32H
Mounting of Cylinder Liner. 12) Mount the cooling water jacket, (for torque mo-
ment see page 600.40), piston/connecting rod and
7) Check that the sealing surfaces on engine, cylinder head according to working card 606-01.20
cylinder liner, and sealing rings are perfectly clean. and 605-01.40.
8) Mount the lifting tool, attach a tackle hook to 13) When preparing the start-up, check for possible
the eye nut or to the wire in the cross bar and lift the leakages of water and oil, including the inspection
liner. hole in the frame, see fig. 3.
9) Check that the o-ring grooves are clean. Mount

the o-rings and lubricate with a little oil. Place a new
sealing on top of the frame.
10) Lower the cylinder liner carefully into the engine

frame.
When the first o-ring touches the sealing face, align

the liner so that the scratch mark on the liner flange
points to the scratch mark on the frame as illustrated,
or align the liner so that the milling groove in the liner Inspection
flange coinside with the fixing piece on the engine hole
frame control side (if mounted).
11) After having cleaned and inspected the cool-

ing water jacket, mount new o-rings on the cooling
water connections and change air connections.
Fit a new sealing ring and mount the jacket.
Fig. 3.
08028-0D/H5250/94.08.12
91.22 - ES0S
MAN Diesel
Working Card Grinding of Seal Face on 606-01.45
Page 1 (2) Cylinder Liner and Cylinder Head. Edition 01H
L/V28/32H

Shut-off fuel oil
Description:
Grinding of seal face on cylinder liner and cylinder

head by hand, with grinding tools and grinding Hand tools:
pasta.
Grinding pasta.
Starting position:
Cylinder head has been removed

from the engine, 605-01.00
Cooling water guide jacket, removed.
Related procedure:

08028-0D/H5250/94.08.12
Working time : 1 Hour Plate no. Item no. Qty. /

Capacity : 1 man
60610 08 1/cyl.
Data:

91.45 - ES0S
MAN Diesel
606-01.45 Grinding of Seal Face on Working Card

Edition 01H Cylinder Liner and Cylinder Head Page 2 (2)
L/V28/32H
Note: The grinding tool is used for both grinding the
groove in the liner flange (1) and the seating surface
on the cylinder head (2), see fig. 1.
Fig. 3.
Fig. 1.
3) After grinding, remove all traces of abrasive

Grinding. and grinding compound.
1) Loosen the sealing ring in liner flange and take 4) When having ground the contact faces, it must
it out. be observed that the gap between cylinder head and
liner is no less than 0,5 mm, that is, the difference
2) Face-grind sealing groove in cylinder liner between measurements y and z must not be less
flange, see fig. 2 and sealing surface on the cylinder than 0,5 mm, see fig. 4.
head, see fig. 3. With the use of grinding pasta and
the grinding tool.
08028-0D/H5250/94.08.12
y - z = 0,5 mm, min.

Fig. 2.
To do so, move the tool back and forth and lift it out
from time to time, to allow the grinding compound Fig. 4.
to distribute evenly.
91.45 - ES0S
MAN Diesel
Working Card Dismounting of Piston and Cylinder Liner 606-01.50
at Low Overhaul Heights
L+V28/32H

Shut-off cooling water 62050
Shut-off cooling oil 62006 09 2 pieces
62006 24
62006 28
62006 65
Description: 62010 01 If necessary
Dismounting of piston, connecting rod and cylinder Tool combination for dismounting of conncting
liner for inspection and/or overhaul. rod screw, 620-01.20
Cylinder head has been dismounting from the Inside micrometer (195 mm).
engine. Feeler gauge 0,15 - 0,20 mm.
Crankcase open.
Related procedure:
Separation of piston and connecting rod.

Inspection and honing of cylinder liner.
Manpower:
Working time : 2 ½ Hours

08028-0D/H5250/94.08.12
Capacity : 2 men
Data: Plate no Item no Qty/

94.38 - ES0S-G
MAN Diesel
606-01.50 Dismounting of Piston and Cylinder Liner Working Card

at Low Overhaul Heights
L+V28/32H
Dismantling of Piston at Low Overhaul Dismantling of Cylinder Liner at Low Overhaul
Heights. Heights.
1) Lift up the piston and the connecting rod through 1) Mount normal lifting tool for cylinder liners.
the cylinder liner until the piston is clear of the
liner. 2) Carefully pull the cylinder liner half-way out of
the frame.
2) Mount collar on the connecting rod, see plate
62050, item 1896. 3) Mount special lifting tool for cylinder liners at
low overhaul heights, see plate 62050, item
3) Place the piston with the collar on the cylinder 1895.
liner.
4) Attach pull-lifts on the lifting tool for the cylinder
4) Mount pull-lifts on the collar. liner, see plate 62050, item 1895
If Then 5) Take out the liner over the camshaft side.
The overhaul height is Dismount the piston from

too low to pull out piston the connecting rod, re-
and connecting rod in move the piston and pull
one piece. out the connecting rod by
the pull-lifts.
The overhaul height is Remove the piston and

sufficient to pull out the connecting rod by means
piston and the connect- of the pull-lifts.
ing rod in one piece.
08028-0D/H5250/94.08.12
94.38 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 60601-34H
L28/32H
07.01 - ES0
MAN Diesel
Plate
60601-34H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)
L28/32H
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse
01 1/C Piston pin incl. Stempelpind inkl.

item No 02 pos. nr. 02
02 4/C Socket screw Kraterskrue
03 2/C Retaining ring Sikringsring
05 1/C Bush for Plejlstangs-

connecting rod bøsning
06 1/C Connecting rod Plejlstang inkl.

incl. item Nos pos. nr.
04, 05, 14, 15, 16 04, 05, 14, 15, 16
08 1/C Piston Stempel
09 1/C Piston ring Stempelring
12 1/C Oil scraper ring Olieskrabering
13 1/C Connecting rod Plejlstangs-

bearing 2/2 leje 2/2
15 2/C Connecting rod stud Plejlstangsbolt
16 2/C Nut Møtrik
07.01 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Cylinder Liner and Water Guide Jacket 60610-09H
L28/32H
94.07 - ES0S
MAN Diesel & Turbo
Plate
60610-09H Cylinder Liner and Water Guide Jacket Page 2 (2)
L28/32H

Item Item
No Qty. Designation Beskrivelse No Qty Designation Beskrivelse
02 1/C Sleeve Muffe
03 1/C Water guide Kølekappe

jacket
05 6/C Sealing ring Tætningsring
09 6/C Cooling water Kølevands-

connection overgang
10 1/C Cylinder liner Cylinderforing
12 4/C Hexagon screw Unbracoskrue
13 4/C Washer Skive
14 4/C Sleeve Foring
15 1/C Water guide jacket Kølekappe inkl. item nr.

incl. item no. 05 and 05 og 06
06.
17 1/C Flame ring Flammering
When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt
94.07 - ES0S
Camshaft
507/607
MAN Diesel
Description
Camshaft and Camshaft Drive 607.01
Page 1 (1)
Edition 05H
L28/32H
General The lubricating oil pipes for the gear wheels are
equipped with nozzles which are adjusted to apply
The camshaft which controls the actuation of inlet the oil at the points where the gear wheels are in
valves, exhaust valves and fuel injection pumps is mesh. The position of the nozzles is determined by
driven by a gear wheel on the crankshaft through an direction of rotation of the engine.
intermediate wheel, and rotated by a speed which is
half of that of the crankshaft, see fig. 1.
The camshaft is placed in the engine frame at the Engine seen from aft - fly wheel end
control side, (left side, seen from the flywheel end)
and is carried in bearing bushes which are fitted in
bores in the engine frame, each bearing is replace-
able and locked in position in the engine frame by
means of lock screws.
The camshaft is built-up of sections, one for each

cylinder unit. Each section is equipped with fixed
cams for operation of fuel injection pump, air inlet
valve and exhaust valve.The sections are assembled
by bolting of the ample dimensioned and precision
made flange connections, which also act as bearing
journals.
Except for the foremost and the aftmost ones, the

sections are identical and therefore interchangeable.
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 Clockwise rotation direction
aftmost section.
Fig. 1. Intermediate wheel

08028-0D/H5250/94.08.12
91.03 - ES0S
MAN Diesel

Page 1 (2) Camshaft and Camshaft Drive Edition 01H
L/V28/32H

Shut-off cooling water 62006 26 20 - 120 Nm.
Shut-off fuel oil
Description:
Checking of gear wheels, bolted connections

and lubricating system. Hand tools:
Allen key, 12 mm.

Socket spanner, 19 mm.
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
60705 12 6/eng.
Data: 60705 24 3/eng.
61106 11 1/cyl.
Data for torque moment (Page 600.40) 61106 14 1/eng.
92.13 - ES0U
MAN Diesel

Edition 01H Camshaft and Camshaft Drive Page 2 (2)
L/V28/32H
1) Dismount the covers which give access to the 3) Examine all lubricating oil spray pipe nozz-
gear wheels, camshaft and crankcase. les.
Examine all gear wheels for cracks, wear and defor- 4) Start the electrical lubricating oil pump and
mations. While turning the engine to enable inspec- check the oil flow everywhere. Be particularly careful
tion allover the circumference of the gear wheels. to check that the oil jet hits the gear wheels correctly
at the points where the wheels mesh.
2) Check all screws, nuts and bolted connections,
including locking devices everywhere in the gear
wheel housing, camshaft housing and crankcase to
check that they have not worked loose. Tightening
torques, see page 600.40.
08028-0D/H5250/94.08.12
92.13 - ES0U
MAN Diesel

Page 1 (2) Inspection and Replacement of Camshaft Bearing Edition 01H
L+V28/32H

Shut-off fuel oil
Description
Check of roller path of cams and check of cam-

shaft bearing. Hand tools
Replacement of camshaft bearing.
Feeler gauge.
Starting position Big screw driver.
Cover for camshaft and gear wheel has been

removed.
Related procedure
Camshaft and camshaft drive, 607-01.00

08028-0D/H5250/94.08.12
Working time : 2 Hours Plate No Item No Qty. /

Capacity : 2 men
60705 01 1/eng.
Data 60705 03 1/cyl.
60705 21 1/cyl.
01.51 - ES0
MAN Diesel

Edition 01H Inspection and Replacement of Camshaft Bearing Page 2 (2)
L+V28/32H
To Check Roller Path of Cams.
1) While turning the engine, examine the cam Camshaft bearing

discs and in particular, check the roller path of all Hole for lubricating oil
cams for cracks, crackles and ruffle. Also examine
the rollers of the roller guides.
Note: if there are flat spots on the roller and if some

of the rollers may be blocked, if so, the roller must
be replaced by a new one, see working card 608-
01.00.
To Check Camshaft Bearings.
2) The wearing surface of the camshaft bear- Locating screw

ings cannot be checked without dismounting the
Frame
camshaft. 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 Fig. 1.
be discoloured, as well.
The bearing clearance is measured with a feeler Mount a new camshaft bearing in the bore and make
gauge, see data sheet 600.35. 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
To Replace Camshaft Bearing. provided with a new gasket. To facilitate the fitting
of the bearing it can be cooled down with Co2.
3) If one or several of the camshaft bearings
should be replaced the camshaft must be wholly Inspect the camshaft journal for seizures.
or partly dismantled.
If necessary, the camshaft section must be entirely
Dismount the fuel oil feed pump, if mounted and removed from the engine, and the journal concerned
check that the camshaft sections are marked in must be polished.
relation to each other. Disassemble the camshaft
aft (toward flywheel) of the bearing that is to be Coat all the journals of the camshaft section with
replaced. Dismount all roller guides that are located clean lubricating oil and push the camshaft into
forward of the disassembling position, see working position, making sure that the marks on the flanges
card 608-01.00 and 608-01.05. coincide.
08028-0D/H5250/94.08.12
Pull the disconnected sections of the camshaft so Assemble the sections and fit the bolts (coated with
far a head that the bearing which is to be replaced Molycote or similar).
is free.
Tighten the nuts with a torque spanner, see data
Take out the locating screw of the camshaft bearing sheet 600.40.
concerned and push the bearing out of the bore in
the engine frame, see fig. 1. Mount all roller guides as well as the fuel oil feed
pump.
Check the lubricating oil ducts to the bearing for
free flow.
01.51 - ES0
MAN Diesel & Turbo
Working Card
Adjustment of Camshaft for Valve and Injection Timing 607-01.20
L28/32H


Description
Adjustment of the injection timing.
Hand tools
Starting position Ring and open end spanner, 19 mm.

Depth gauge.
Plastic hammer.
Related procedure
Manpower Replacement and wearing parts
Working time : 2-5 hours Plate no Item no Qty /

Capacity : 1 man
60801 23 1 set/cyl
Data:

11.37 - ES0 - Tier II

MAN Diesel & Turbo
607-01.20 Adjustment of Camshaft for Valve and Injection Timing

Working Card
L28/32H
Measure of fuel pump lead 4) Insert the dial gauge into the support.
1) Dismantle covers for fuel camshaft and fuel 5) Set the dial gauge to "Zero".
pump and covers for gear whell
6) Turn the engine until the TDC mark (ignition
2) Check the mobility of the regulating device. DC) for the actual cylinder is reached.
Turn engine to pos. cylinder No. 1 until the Read the dial gauge and note down the gauge
cambase circle is reached (approx. 40° BTDC). value.
3) Position the support of the measuring tool on 7) Determine the values for the other cylinders in
the two bolts of the camshaft covering. Slip on the same way.
the distance sleeves and fasten to the cylinder
crankcase by means of hexagon nuts. Calculate the average value of all measure-
ments.
Note: During attaching, pay attention to the correct
fitting position of the contact point, see fig 1.
1. Contact point
2 Lever
Fixing screws and
discs of enclosing
2 cover used
Fig 1 Fitting position of the contact point.
11.37 - ES0 - Tier II

MAN Diesel & Turbo
Working Card
Page 3 (4) Adjustment of Camshaft for Valve and Injection Timing 607-01.20
Edition 04H
L28/32H
8) Compare the calculated value determined with

the value mentioned below.
9) If the values exceeds the limits, an adjustment

must be done in order to correct the errors, on
the X-measure or reset the gear wheel, see
following text for changing "X"-measuring.
Cyl. kW/Cyl. rpm Average value
5-6-7-8-9 210 720 See section 600,

5-6-7-8-9 220 750 Desription
600.35
Fig 2 Plunger lift (average value)
To get a consistent lifting values on the plunger/

combustion pressure on the different cylinders the
"X"-measure can be changed. Fig 3 Gear wheel with engraved scale.
When changing “X” it must be ensured that the di-

stance between the upper edge of the roller guide The gear wheel is provided with an engraved scale,
housing and the thrust piece on the roller guide is not see fig 3, and the hub of the cam shaft is provided
exceeded, when the roller is resting on the circular with a mark.
part of the fuel cam, please see description 500.35.
When the screws, which fasten the gear wheel, are
In all cases “X” must be checked and adjusted, if loosened the gear wheel is turned (by turning the
necessary, when fuel oil pump, roller guide, roller crankshaft) in relation to the camshaft.
guide housing and/or camshaft section have been
replaced/dismantled. If the crankshaft is turned in the engines normal
direction of rotation the injection timin is retarded
Note: If several fuel oil pumps, roller guides, roller (closer to TDC).
guide housings and/or camshaft sections are dis-
mantled at the same time it is advisable to number the If the crankshaft is turned against the engines normal
parts in order to facilitate remounting and adjustment. 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.
11.37 - ES0 - Tier II

MAN Diesel & Turbo
607-01.20 Adjustment of Camshaft for Valve and Injection Timing Working Card
L28/32H
The injection timing can be altered on each cylinders Thicker and/or more shims (reduction of the distance
by inserting or removing shims under the thrust piece “X”) results in an advanced injection.
on the roller guide, thus changing the measure “X”,
see Fig 4. If the distance “X” is to be changed the trigger (1) is
used for dismantling of the thrust piece (2), where-
Thinner and/or fewer shims (increase of the distance after the thickness and/or the number of shims (3)
“X”) results in a retarded injection timing. can be changed.
After replacement of shims the thrust piece is re-

mounted, see fig 5, in the roller guide (4) with a soft
hammer (5).
Measure "x"
1 5
1
2 2
3 2
Total height 3
3
4
4 4
1 Extractor 2 Thrust piece

3 Shims 4 Roller guide
5 Soft hammer
Fig 4 Measure "X" Fig 5 Remounting of thrust piece.
Action Results
Total height Distance Injection Max. combustion

on roller guide "x" timing pressure
increased ↑ Reduced ↓ Advanced ↑ increased ↑

Reduced ↓ increased ↑ Delayed ↓ Reduced ↓
Fig 6
10) Remove the complete measuring tool.
11) Mount all camshaft covers.
2) Plunger lift value, please see description

1
500.35.
11.37 - ES0 - Tier II

MAN Diesel
Plate
Page 1 (2) Intermediate Wheel 60701-06H
L28/32H
09
10
01
13
02
14
07
03 15 11
16
17
04
12+
05 08+
06
06.28 - ES0
MAN Diesel
Plate
60701-06H Intermediate Wheel Page 2 (2)
L28/32H
Item Item
01 6/E Screw Skrue
02 6/E Lock plate Sikringsplade
03 3/E Gasket Pakning
04 1/E Union Vinkelforskruning
05 1/E Pipe Rør
06 1/E Union Vinkelforskruning
07 1/E Spray pipe Sprøjterør
08+ 3/E Fitted bolt Pasbolt
09 3/E Self locking Selvlåsende

nut møtrik
10 1/E Cover Dæksel
11 1/E Gear wheel, Tandhjul, kompl.

complete
12+ 1/E Axle journal Lejetap
13 4/E Self locking nut Selvlåsende møtrik
14 1/E Spur gear Tandhjul
15 1/E Spur gear Tandhjul
16 4/E Bolt Bolt
17 1/E Bearing bush Lejebøsning
+ Item No. 08 and + Item nr. 08 og 12

12 require an indivi- kræver en individuel
dual matching, before tilpasning, før monte-
mounting, contact ring kontakt MAN B&W,
MAN B&W, Holeby Holeby
Qty./E = Qty./Engine Antal/E = Antal/Motor
06.28 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft and Camshaft Bearing 60705-22H
L28/32H
11
06
13
04
05 19
06
07
08
01 20
02, 29, 32, 33, 34 26
03 27 03
28
14 29
15 21
22
16 29 29 29 29
14
5 cyl.
16
03 03 01
03 03 03
35 20 20 20 20 02
6 cyl. 03
03 03 03 01
03 03 03
36 26 26 26 26 26 32 23
7 cyl. 06
03 03 03 01
03 03 03 03 25
37 27 27 27 27 27 27 33
8 cyl.
03 03 03 03 01
03 03 03 03
38 28 28 28 28 28 28 28 34
9 cyl.
03 03 03 03 01
03 03 03 03 03
06.43 - ES0
MAN Diesel
Plate
60705-22H Camshaft and Camshaft Bearing Page 2 (2)
L28/32H
Item Item
01 1/E Camshaft bearing Styreakselleje 26 5/E Camshaft, Styreaksel,

intermediate, mellem
02 1/E Camshaft section Styreakselssektion 7 cyl. engine 7 cyl. motor
"aft", 6 cyl. engine "agter", 6 cyl. motor
27 6/E Camshaft, Styreaksel,
03 1/C Camshaft bearing Styreakselleje intermediate, mellem
8 cyl. engine 8 cyl. motor
04 1/E Hub Nav
05 6/E Screw Skrue intermediate, mellem
06 24/E Disc spring Skivefjeder
29 4/E Camshaft section Styreakselsektion
07 1/E Guide ring Styrering "aft", 5 cyl. engine "agter", 5 cyl. motor
08 1/E Shaft pin Akseltap 32 1/E Camshaft section Styreakselssektion

"aft", 7 cyl. engine "agter", 7 cyl. motor
11 12/E Screw Skrue
33 1/E Camshaft section Styreakselssektion
13 1/E Gear wheel Tandhjul "aft", 8 cyl. engine "agter", 8 cyl. motor
14 Self locking nut Selvlåsende møtrik 34 1/E Camshaft section Styreakselssektion

70/E 6 cyl. engine 6 cyl. motor "aft", 9 cyl. engine "agter", 9 cyl. motor
52/E 7 cyl. engine 7 cyl. motor
66/E 8 cyl. engine 8 cyl. motor 35 1/E Camshaft "Fore" Styreaksel "For"
92/E 9 cyl. engine 9 cyl. motor 6 cyl. engine 6 cyl. motor
Screw Skrue 36 1/E Camshaft "Fore" Styreaksel "For"

15 60/E 6 cyl. engine 6 cyl. motor 7 cyl. engine 7 cyl. motor
56/E 8 cyl. engine 8 cyl. motor 37 1/E Camshaft "Fore" Styreaksel "For"
82/E 9 cyl. engine 9 cyl. motor 8 cyl. engine 8 cyl. motor
16 1/E Camshaft "Fore" Styreaksel "For" 38 1/E Camshaft "Fore" Styreaksel "For"
5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor
19 10/E Screw Skrue

intermediate, mellem,
21 Gasket Pakning
22 Guide screw Styreskrue

23 1/E Coupling flange Koblingssflange
25 6/E Screw Skrue
06.43 - ES0
Operating gear
508/608
MAN Diesel
Description
Operating Gear for Valve and Fuel Injection Pumps 608.01
Page 1(1)
Edition 12H
L/V28/32H
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 Valve bridge Rocker arm
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 fitted 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

Valve spring
Valve spindle
The injection pumps which is mounted directly on
the roller guide housing is activated via thrust pieces Push rod
from the roller guide.
Protecting Tube
The roller is pressed down on to the cam by a spring, Roller guide

which is fixed between the roller guide and the foot housing
plate of the fuel injection pump.
Roller guide
Operating Gear for Inlet and Exhaust Valves Pin
The movment from the roller guides for inlet and Roller
exhaust is transmitted via the push rods the rocker
arms and spring-loaded valve bridges to each of
the two valve sets. The bridge is placed between Camshaft
the valve spindles and in the one end it is provided
with a pressed-on thrust shoe and in the other end
it is fitted with a thrust screw for adjustment of the
valve clearance. Fig. 1. Valve Operating Gear.
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.
08028-0D/H5250/94.08.12
91.13 - ES0S
MAN Diesel & Turbo
Working Card
Inspection of Valve Roller Guides 608-01.00
L/V28/32H

Shut-off cooling water 62006 26 20 - 120 Nm
Shut-off fuel oil
Dismounting, inspection and/or overhaul, and Ring and open end spanner, 19 mm.
mounting of valve roller guides. Socket spanner, 19 mm.
Inspection of roller guide housing. Socket spanner, 24 mm.
Allen key, 3 mm.
Ratchet spanner.
Hammer.
Starting position: Drift.
Top cover for cylinder head and cover for fuel

injection pump removed.
Related procedure:
Inspection of fuel injection pump

roller guide, 608-01.05
Control and adjusting of valve
clearance, 608-01.10

Capacity : 1 man
60801 04 4/cyl.
Data: 60801 08 2/cyl.
60801 09 1/cyl.
Data for torque moment (Page 600.40) See also plate 60801.
12.24 - ES0
MAN Diesel & Turbo

Edition 01H Inspection of Valve Roller Guides Page 2 (2)
L/V28/32H
Dismounting of Roller Guide. 5) Dismount the screws (3) which secure the
roller guide top cover, take off the cover, and lift out
1) Turn the engine so that the roller, rests on the the roller guide (5).
circular part of the cam.
Disconnect any pipes that may be in the way (lub.
2) Unscrew the nuts which secure the rocket arm oil and fuel oil pipes).
brackets, and lift off the rocker arm with brackets.
6) If the roller guide housing is to be dismantled,
3) Remove the push rods (1), see fig. 1. the fuel injection pump and the fuel injection pump
roller guide are to be dismounted, see working card
614-01.05 and a number af lubricating oil and fuel
oil pipes are also to be disconnected.
1 The roller guide housing (6) cannot be dismantled

with the roller guides fitted.
7) If the event of any marks or scores from sezu-

2 res, these must be polished away.
8) Inspect the spherical stud for deformations

3 (replace as necessary).
4 Examine the surface of the roller for marks and other

deformations.
6
Make sure that there is free rotation between the
roller and the bush and the shaft pin, and replace
the bush, if necessary.
5 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.
0) Blow through the lubricating ducts in roller guide

1
and roller guide housing, and clean the lubricating
grooves.
Mounting of Roller Guide.
Fig. 1. 1) When assembling the parts, which is carried

1
out in the reverse order to the above care must be
exercised not to damage the o-rings when mounting
4) Loosen the lock screw for the push rod pro the proctecting tube.
tecting tube, see plate 60801, item 07, on the roller
guide top cover and lift up and remove the protecting 2) Adjusting of valve clearance, see working card
1
tube (2). 608-01.10.
12.24 - ES0
MAN Diesel & Turbo

Page 1 (2) Inspection of Fuel Injection Pump Roller Guide Edition 01H
L/V28/32H

Shut-off fuel oil
Dismounting, inspection and/or overhaul, and Allen key, 3mm.

mounting af roller guide for fuel injection pump. Hammer.
Drift.
Starting position:
Cover for fuel injection pump removed.

Fuel injection pump has been
removed, 614-01.05
Related procedure:
Adjustment and/or check of max.

combustion pressure, 614-01.20

Capacity : 1 man

Data:

12.24 - ES0
MAN Diesel & Turbo

Edition 01H Inspection of Fuel Injection Pump Roller Guide Page 2 (2)
L/V28/32H
Dismounting of Roller Guide. 3) Inspect the spherical stud for deformations
(replace as necessary).
1) Remove the support ring (1) and spring (2)
and take up the roller guide (3), see fig. 1. Examani the surface of the roller for marks and other
deformations.
Make sure that there is free rotation between the

roller and the bush and the shaft pin, and replace
the bush if necessary.
1
Replacement of Roller, Bush and Shaft Pin.
2
4) Remove the lock screw which secures the roller
guide shaft pin and push out the shaft pin.
3
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 lubricating
grooves.
Mounting of Roller Guide.
6) When assembling the parts which is carried

out in the reverse order.
Fig. 1.
7) For adaption of the thrust piece of the roller
guide, see working card 614-01.20.
Inspection of Roller Guide.
2) If the event of any marks or scores from sezu-

res, these must be polished away.
12.24 - ES0
MAN Diesel & Turbo

Page 1 (3) Control and Adjusting of Valve Clearance Edition 01H
L/V28/32H

Shut-off cooling water 62008 02 Exhaust
Shut-off fuel oil 62008 01 Inlet
Control and/or adjusting of valve clearance. Ring and open end spanner, 30 mm.
Big screw driver.
Starting position:
Cover for rocker arm are removed.

All indicator valves open.
Related procedure:

Capacity : 1 man

Data:
Data for pressure and tolerance (Page 600.35) See also plate 60502.
91.45 - ES0S
MAN Diesel & Turbo

Edition 01H Control and Adjusting of Valve Clearance Page 2 (3)
L/V28/32H
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 fig. 1.
Fig. 2.
8) Check that the clearance is correct simultaneo

usly at both valve spindles.
Adjusting af Exhaust Valve Clearance.

Fig. 1.
9) Carry out adjusment in the same way as dese-
ribed for the inlet valves, but using the feeler gauge
for exhaust valve clearance o,90 mm.
3) Clearance between valve bridge and valve
spindle, see page 600.40.
4) Place the feeler gauge marked with "correct"

o,4 mm above the valve spindle nearest to the rocker
arm bracket, see fig. 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.
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

o,40 mm above the other valve spindle, see fig. 2.
Fig. 3.
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 fig.
2.
91.45 - ES0S
MAN Diesel & Turbo

Page 3 (3) Control and Adjusting of Valve Clearance Edition 01H
L/V28/32H
0) The feeler gauges for checking the clearance
1
have two gauges which are marked "incorrect" and
"correct", the latter to be used when adjusting the
valve clearance, see fig. 4.
After tightening up the counter nuts on rocker arms

and valves bridge, be sure that the feeler gaugs mar-
ked "correct" can be inserted into the two clearances
simultaneously as where it must not be possible to
insert the gauges marked "incorrect".
Fig. 4.
91.45 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Roller Guide and Push Rods 60801-17H
L28/32H
01
02*
38
04
03 01
04
16
05
17
06
18
07
19
08
20+
28
09
22
23
10
24
11 12
12
26 25 27
13 13
14 14
15 15
11.36 - ES0
MAN Diesel & Turbo
Plate
60801-17H Roller Guide and Push Rods Page 2 (2)
L28/32H
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse
01 4/C Thrust piece Trykstykke 27 1/C Roller guide for fuel Rullestyr for brændsels
injection pump, com- pumpe, komplet inkl.
02* 2/C Pipe Rør plete incl. item 12, 13, item 12, 13, 14, 15,
14, 15, 24, 25 24, 25
03 2/C Protecting tube Skærmrør
28 4/C Screw Skrue
38 2/C Push rod, complete Stødstang, komplet inkl.
05 4/C Screw Skrue incl. item 01, 02 item 01, 02
06 2/C Cover Dæksel
07 2/C Screw Skrue

+ Item no 20 require + Item nr. 20 kræver
08 2/C Gasket Pakning an individual match en individuel tilpasning
ing before mounting, før montering, kontakt
09 1/C Gasket Pakning contact MAN Diesel & MAN Diesel & Turbo,
Turbo, Holeby Holeby
10 2/C Ball pin Kugletap
11 2/C Roller guide Rullestyr
12 3/C Pin Tap
13 3/C Stop screw Stopskrue
14 3/C Bush Foring
15 3/C Roller Rulle
16 1/C Washer for spring Skive for fjeder
18 2/C Guide pin Styrestift
19 8/C Screw Skrue
20+ 1/C Housing for Hus for

roller guides rullestyr
22 1/C Thrust piece Tryktap
23 1/C 1 set shims (0.1, 0.3, 1 sæt shims (0,1, 0,3,

0.5 and 1.0 mm) 0,5 og 1,0 mm)
24 1/C Thrust piece Tryktap
25 1/C Roller guide Rullestyr
26 2/C Roller guide for Rullestyr for ventilbe

valve gear, complete vægelse, komplet inkl.
incl. item 10, 11, 12, item 10, 11, 12, 13,
13, 14, 15 14, 15
11.36 - ES0
Control/safety
509/609
MAN Diesel
Description
Control and Safety Systems 609.01
Page 1 (2)
Edition 20H
L+V28/32H
Governor Should a fuel pump plunger seize in its barrel, thus

blocking the regulating guide, governing of the
The engine speed is controlled by a hydraulic go- remaining fuel pumps may continue un impaired
vernor. The purpose of the governor is to regulate owing to the spring-loaded linkage between the
the rate of delivery from the fuel pumps, so that the blocked pump and the regulating shaft.
engine speed is kept within certain limits, indepen-
ding on the load.
Stop Screw for Max. Delivery Rate
Information about the design, function and operation
of the governor is found in the special governor The bracket for stop cylinder/limiting cylinder is fitted
instruction book. with a stop screw which prevents the fuel pumps
from being set to a higher delivery rate than what
The governor is mounted on the fly wheel end of corresponds to the permissible overload rating.
the engine and is driven from the camshaft via a
cylindrical gear wheel and a set of bevel gears. This is effected by the arm on the regulating shaft
being stopped by the stop screw, see fig. 1.
Pick-up for Engine RPM

Mechanical Overspeed (SSH 81)
The pick-up for transfer of signal to the tachometer
instrument for engine RPM is mounted on the fly The engine is protected against overspeeding in the
wheel end cover of the engine. event of, for instance, governor failure by means of
an overspeed trip.
A signal varying proportionally to engine RPM is
created in the pick-up by the rotating toothed im- The engine is equipped with a stopping device
pulse wheel mounted on the camshaft end. which starts to operate if the maximum permissible
revolution number is exceeded.
Pick-up for Turbocharger RPM The overspeed tripping device is fitted to the end
cover of the lubricating oil pump and is driven
See turbocharger instruction book, section 612. through this pump.
If the pre-set tripping speed is exceeded, the spring-

Regulating Shaft loaded fly weight (1), see fig. 1, will move outwards
and press down the arm (2).
The governor movements are transmitted through a
spring-loaded pull rod to the fuel pump regulating The arm is locked in its bottom position by the lock
shaft which is fitted along the engine. pin (3) which is pressed in by the spring (4).
The spring-loaded pull rod permits the governor to At the same time the arm (2) presses down the
give full deflection even if the stop cylinder of the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keep the fuel pump regulating whereby compressed air will be led to the Lambda
shaft at "no fuel" position. cylinder , see Description 609.10, in which the
piston is pressed forward and turns the fuel pump
Each fuel pump is connected to the common, lon- regulating rod to STOP position, thereby the engine
gitudinal regulating shaft by means of a two-piece, stops, the spring-loaded pull rod connection to the
spring-loaded arm. governor being compressed.
08.43 - ES0
MAN Diesel
609.01 Description
Edition 20H
Control and Safety Systems Page 2 (2)
L+V28/32H
The engine can be stopped manually by pressing The overspeed alarm (SAH 81) is activated by means
down the button (7), see fig. 1, which will activate the of the micro switch (9).
spring-loaded fly 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).
3 8
1
5
2
6
1. Flyweight
1
2. Arm
3. Lock pin
9
4. Spring
5. Spindle
6. Pneumatic valve
Normal Overspeed
poisition activated 7. Button
8. Lever
9. micro switch
10. Button
2 5 3 4 10 10
Fig 1 Mechanical overspeed (SSH 81).
08.43 - ES0
MAN Diesel
Description
Instruments and Automatics 609.05
Page 1 (3)
Edition 11H
L28/32H
Main instrument panel
As standard the engine is equipped with an instru- The instrument panel is mounted flexibly on rubber
ment panel, comprising instruments for visual indi- elements and all manometer connections are con-
cation of the most essential pressures. nected to the panel by means of flexible hoses, as
Illustrated on fig. 1. shown on fig. 2.
Flexible hose
Rubber element
Valves
Push button
On the engine is as standard mounted an instrument

panel.
The following incorporating pressure gauges for the most Fig. 2. Cross section of instrument panel
essential pressures.
08028-0D/H5250/94.08.12
Pressure gauge for:
PI 01 LT fresh water, inlet to air cooler

PI 10 HT fresh water, inlet engine The connecting pipes to the manometers are equip-
PI 21/22 Lubricating oil, inlet/outlet to filter ped with valves which make it possible to replace
PI 23 Lub. oil, inlet to turbocharger the manometers during operation.
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
PI 50 (*) Nozz. cool. oil, inlet to fuel valves In the charging air and nozzle oil piping damping
Switch for PI 21/22 filters are inserted for levelling out pressure fluctua-
(*) If nozzle cooling oil applied only. tions.
Fig. 1. Lay-out of instrument panel
94.28 - ES2S
MAN Diesel
609.05 Instruments and Automatics Description
Page 2 (3)
Edition 11H
L28/32H
Instrumentation - too high press. drop across lub. oil filter
- too high HT FW temperature - outlet engine
As standard the engine is supplied with the following - too low starting air pressure - inlet engine
instrumentation mounted local on the engine: - too high engine speed (overspeed)
Thermometer TI 01 LT water - inlet air cooler The actual number and type of the alarm- and shut-
Thermometer TI 02 LT water - outlet from air cooler down switches for the plant can be seen in the list
Thermometer TI 03 LT water - outlet from lub. oil cooler "Engine Automatic part list" in this section.
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 Leakage Alarm (LAH 42)
Thermometer TI 22 Lubricating oil - outlet from filter
Thermometer TI 30 Charge air - inlet to cooler Waste and leak oil from the comparement, for the
Thermometer TI 31 Charge air - outlet from cooler injection equipment, fuel valves, high-pressure pipes
Thermometer TI 40 Fuel oil - inlet to engine and engine feed pump (if mounted) is led to a fuel
Thermometer*) TI 51 Nozz. cool. oil - outlet from fuel valves leakage alarm unit.
Thermometer TI 60 Exhaust gas - outlet each cylinder
Thermometer TI 61 Exhaust gas - outlet turbocharger
*) If nozzle cooling oil applied only. Normal leakage
C
The actual number of the instrumentation for the
plant can be seen on the diagrams for the specific
plant in the sections 612-613-614-615-616.
For code identification see 600.20. B
Leak alarm
Normal level
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, A
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 High level
a shut-down is given if the engine could be severe
damage by running on these conditions.
Leakoil
As standard the engine is equipped with:
08028-0D/H5250/94.08.12
Alarm
Shut-down Switches for Normal
- too low lubricating oil pressure - inlet engine

- too high HT FW temperature - outlet engine
- too high engine speed (over speed)
Alarm Switches for

Waste oil outlet
- leaking fuel oil
- too low lubricating oil pressure - inlet engine
- too low prelubricating oil pressure Fig. 4. Fuel oil leakage alarm.
(level alarm)
94.28 - ES2S
MAN Diesel
Description
Instruments and Automatics 609.05
Page 3 (3)
Edition 11H
L28/32H
The alarm unit consist of a box with a float switch Alarm for Prelubricating (LAL 25)
for level monitoring, see fig. 4.
Alarm for missing prelubricating, when the engine
The supply fuel oil to the engine is led through the is stopped is given by means of a level switch (LAL
unit in order to keep heated up, thereby ensuring 25) mounted in the main lubricating oil pipe.
free drainage passage even for high-viscous wa-
ste/leak oil.
Alarm and Shut-down for Overspeed
Under normal conditions there will always be a smal-
ler amount of waste/leak oil from the comparement, When the mechanical overspeed is activated, see
this will be led out through the bore "A" in the pipe 609.01 fig. 2, a micro-switch will release the alarm
"B" as illustrated. for overspeed (SAH 81) and activate the shut-down
solenoid in the governor.
In case of a larger then normal leakage, the level
in the box will rise and the level switch "C" will be The latter function is a back-up for the mechanical
activated. The larger amount of leak oil will be lead overspeed.
out through the top of the pipe "B".
08028-0D/H5250/94.08.12
94.28 - ES2S
MAN Diesel
Description
Lambda Controller 609.10
Page 1 (2)
Edition 15H
L28/32H
Purpose Thus the solenoid valve (4) opens. The jet system is
activated, the turbocharger accelerates and increases
The purpose with the lambda controller is to prevent the charge air pressure, thereby pressing the piston
injection of more fuel in the combustion chamber than (3) backwards in the lambda cylinder (5). When the
can be burned during a momentary load in-crease. lambda ratio is satisfactory, the jet system will be
This is carried out by controlling the relation between de-activated.
the fuel index and the charge air pressure.
At a 50% load change the system will be activated
The Lambda controller is also used as stop cylin- for about 3-8 seconds.
der.
If the system is activated more than 10 seconds,
the solenoid valve will be shut off and there will be
Advantages a remote signal for "jet system failure".
The lambda controller has the following advan-

tages: Fuel oil limiting during start procedure
- Reduction of visible smoke in case of sudden During the start procedure the lambda controller is
momentary load increases. used as an index limiter.
- Improved load ability. Hereby heavy smoke formation is prevented during

start procedure and further the regulating device
- Less fouling of the engine's exhaust gas ways. cannot over-react.
- Limitation of fuel oil index during starting

procedure. Air Consumption
At 50% step load the air consumption will be as

Principles for functioning follows:
Figure 1 illustrates the controller's operation mode.

In case of a momentary load increase, the regulat- Cyl. no. 5 6 7 8 9
ing device will increase the index on the injection
pumps and hereby the regulator arm (1) is turned, Nm3 1.12 1.35 1.57 1.80 2.02
the switch (2) will touch the piston arm (3) and be
pushed downwards, whereby the electrical circuit
will be closed.
08028-0D/H5250/94.08.12
04.15 - ES0
MAN Diesel
609.10 Lambda Controller Description

Page 2 (2)
Edition 15H
L28/32H
1. Regulating arm
2. Switch (Pick-up)
3. Piston
4. Solenoid valve
5. Lambda controller
6. Overspeed device
(mecanical activated 3/2 valve)
5 Charge air
receiver
3
2
1
~
4 Engine's
compression
air system
Fig 1 Lambda controller incl. start limitation
04.15 - ES0
MAN Diesel & Turbo
Description
Starting Box 609.35
L28/32H
Description Engine / Turbocharger RPM
The starting box is mounted on the engine's control By activating the "Engine RPM/TC RPM" button, the
side. On front of the box there are the following in- indication is changed.
dications/pushbuttons:
Engine RPM indication is green light-emitting diodes
– Indication of engine or turbocharger RPM and turbocharger RPM indication is red light-emitting
– Indication of electronic overspeed diodes.
– Pushbutton for "Manual Start"
– Pushbutton for "Manual Stop" External Indications
– Pushbutton for "Remote" *
– Pushbutton for "Local" * There are output signals for engine RPM and tur-
– Pushbutton for "Blocking" * bocharger RPM.
– Pushbutton for change-over between engine Engine: 0 - 1200 RPM ~ 4-20 mA
and turbocharger RPM TC: 0 - 60000 RPM ~ 4-20 mA
* The function chosen is indicated in the pushbutton. The pushbuttons for "Remote", "Local" and "Blocking"
See fig. 1. have potential free switches for external indication.
Manual Start All components in the starting box are wired to the
built-on terminal box.
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 solenoid
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 110 RPM. If the start button is
disengaged before the diesel engine has exceeded
110 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.
12.01 - ES1
MAN Diesel
Description 609.40
Page 1 (1) Converter for Engine- and Turbocharger RPM Signal Edition 01H
L+V28/32H
Engine RPM signal The "engine run" signals will be given through a relay.
One for synchronizing and one for start/stop of pre.
For measuring the engine's RPM, a pick-up mounted lub. oil pump or alarm blocking at start/stop.
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 Safe start
is sent through an f/I converter (frequency/current
converter), where the signal is transformed into a When the safe start signal is activated the engine
proportional 4-20 mA ~ 0-1200 RPM signal. can start. When the engine reach 140 RPM the air
starter will be shut-off.
Further, the converter has following signals:
Further, the safe start signal is a blocking function
- overspeed for the air starter during rotation.
- engine run
- safe start
- tacho fail Tacho fail
The tacho fail signal will be on when everything is

normal. If the pick-up or the converter failes 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
Fig 1. Converter for engine RPM. turbocharger's RPM on an analogue tachometer,
the frequency signal is sent through a f/I converter
(frequency/current converter), where the signal is
Overspeed transferred into a proportional 4-20 mA ~ 0-60000
RPM.
When the engine speed reach the setpoint for elec-
tronic overspeed the converter gives a shutdown
signal and a alarm signal through a relay.
08028-0D/H5250/94.08.12
Engine run
When the engine speed reach 710 RPM or 200

RPM + 10 seconds, the converter gives a "engine
run" signal.
Fig 2. Converter for TC RPM.
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 The converter is mounted in the terminal box on
at 200 RPM. engine.
96.30 - ES2S
MAN Diesel
Working Card Functional Test and Adjustment of Safety, 609-01.00
Alarm and Monitoring Equipment
General
Stopped engine Plate No Item No Note.

Shut-off cooling water See Related Procedure
Shut-off fuel oil
Description
Function test and adjustment of safety, alarm and

monitoring equipment. Hand tools
See Related Procedure
Starting position
Related procedure
Overspeed trip 609-01.05

Pressostate 609-05.00
Thermostate 609-05.01
Level switch (LAL 25) 609-05.02
Analog pressure transmitter 609-05.03
Analog temperature transmitter 609-05.04
08028-0D/H5250/94.08.12
Working time : hours Plate No Item No Qty. /

Capacity : man
Data

03.32 - ES0U
MAN Diesel
609-01.00 Functional Test and Adjustment of Safety, Working Card
Alarm and Monitoring Equipment
General
Maintenance of monitoring and safety sy- For check of these functions use the working cards
stems mentioned under related procedure on page 1.
One of the most important parameters in the pre-

ventive work is that the alarm system as well as the Alarm System
shutdown and overspeed devices are functioning
100%. It is important that all alarms lead to prompt investi-
gation and remedy of the error.
If some of these functions are out of operation, No alarm is insignificant. It is therefore important that
they have to be repaired immediately. If this is not all engine crew members are
possible because of the present working situation, familiar with and well trained in the use and impor-
the engine has to be under constant observation tance of the alarm system.
until it can be stopped. The most serious alarms are equipped with slowdown
and/or shutdown functions.
It is recommended that all functions are tested
every three month according to the mentioned working
cards.
The extent of the alarm and safety functions is vari-

able from plant to plant.
08028-0D/H5250/94.08.12
03.32 - ES0U
MAN Diesel
Page 1 (2) Functional Test and Adjustment of Overspeed Trip Edition 01H
General

Shut-off fuel oil
Description:
Functional test and adjustment of overspeed

trip. Hand tools:
Allen key, 4 mm.

Allen key, 2 mm.
Starting position:
Functional test and adjustment of safety

alarm and monitoring equipment, 609-01.00
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.45 - ES0S
MAN Diesel
Edition 01H Functional Test and Adjustment of Overspeed Trip Page 2 (2)
General
1) The engine is run up manually, (on governor Turn the engine until the adjusting screw is opposite
"synchronizer") and at no load, while watching the the opening on the side of the housing. Now loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular pin spanner supplied, se fig. 2.
On reaching the revolution number indicated on
page 600.30 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 divice trip at a revolution

number different from that stated on page 600.30
or in the "Test Report" the overspeed device must
be adjusted.
Fig. 2.
Turn the adjusting screw outwards (slacken flyweight

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) Refit the covers when the overspeed device

functions at correct revolution number.
5) The overspeed device can be tested manually

Fig. 1. by depressing the button on top af the housing,see
fig. 1. This will activate the flyweight and the arm for
release of the air valve for the stop cylinders and
Adjustment of Overspeed Trip. the engine should thus stop. (This test must also be
carried out without load).
08028-0D/H5250/94.08.12
3) Remove both covers on the housing of the

overspeed tripping device, see fig. 1. 6) It is recommended now and then, while the
engine is at a standstill, to move the flyweight by
means of the push button to ensure that the flyweight
can always move with sufficient ease.
91.45 - ES0S
MAN Diesel
Page 1 (2) Adjustment and Test of On/Off Pressostate Edition 02H
General

Shut-off fuel oil
Description:
Adjustment and test of on/off pressostate. (lub.

oil,fuel oil, water etc.). Hand tools:
Screw driver.
Testing pump.
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.45 - ES0S
MAN Diesel
Edition 02H Adjustment and Test of On/Off Pressostate Page 2 (2)
General
Adjustment:
1) When the pressostate cover is removed and

locking screw pos. 5, fig. 1 is loosened, the range
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read.
1. Trial flange.
2. Drain screw.
3. Valve.
1. Range spindle.
2. Range scale.
3. Differential spindle.
4. Differential scale. Fig. 2.
5. Locking screw.
4) Remove the screw pos. 2.

Fig. 1.
5) Mount the testing pump on the trial flange pos.
1.
2) In pressostates having an adjustable differen-
tial, the spindle pos. 3 must be used to make the
adjusment. The differential obtained can be read Alarm for Falling Pressure:
directly on the scale pos. 4.
6) Pump up the pressure until the switch has
Set points, see page 600.30. 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.
08028-0D/H5250/94.08.12
Test:
It is possible to make a functional test of the pres- Alarm for Rising Pressure:
sure switch. This is to be carried out according to
the following procedure. 7) Pump up the pressure until the switch chang-
es, and check that it happens at the stated alarm
3) Shut off system pressure with the valve pos. point.
3, fig. 2.
8) After the final check and adjustment, remove
the testing pump, mount the screw pos. 2 and open
the valve pos. 3.
91.45 - ES0S
MAN Diesel

Page 1 (2) Adjustment and Test of On/Off Thermostate Edition 02H
L+V28/32H

Shut-off fuel oil
Description:
Adjustment and test of on/off thermostate. (lub.

oil, fuel oil, water etc.). Hand tools:
Screw driver.
Special testing devices.
Starting position:

Related procedure:

Capacity : 1 man
Data:

96.26 - ES0S
MAN Diesel

Edition 02H Adjustment and Test of On/Off Thermostate Page 2 (2)
L+V28/32H
Adjustment: Test:
1) When the thermostate cover is removed and 3) The funcional test of the thermostate is to be
locking screw pos. 5, fig. 1 is loosened, the range carried out according to the following procedure.
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read. 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 tempera-
ture stated in the list page 600.30.
Alarm for Rising temperature:

1. Range spindle.
2. Range scale.
7) Raise the temperature until the switch chang-
3. Differential spindle. es and check that is happens at the stated alarm
4. Differential scale. points.
5. Locking screw.
8) Adjust if necessary.
9) The sensor is mounted again.

Fig. 1.
2) Thermostates having an adjustable differential,

the spindle pos. 3 can be used while the scale pos.
4 is read.
Set points, see page 600.30.
96.26 - ES0S
MAN Diesel
Page 1 (2) Function and Test of Level Switch (LAL 25) Edition 02H
General

Shut-off fuel oil
Description:
Function and test of level switch, LAL 25, in

lubricating oil system. Hand tools:
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.03 - ES0S
MAN Diesel
Edition 02H Function and Test of Level Switch (LAL 25) Page 2 (2)
General
The level switch LAL 25, which is mounted on the

main lubricating oil pipe of the engine, gives alarm
for missing prelubricating oil. Vent pipe
Function.
1) By starting the prelubricating oil pump the main

lubricating oil pipe will be filled with lubricating oil,
which means that the level switch is lifted and the
alarm is disconnected.
Level switch
2) When the prelubricating is interrupted, the lub.
oil will run out of the system through the bearings, Main lubricating oil pipe
which means that level switch is lowered and the
alarm starts.
Fig. 1.
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.
08028-0D/H5250/94.08.12
91.03 - ES0S
MAN Diesel
Page 1 (2) Adjustment and Test of Analogous Pressure Transmitter Edition 02H
General

Shut-off fuel oil
Description:
Adjustment and test of analogous pressure

transmitter. Hand tools:

Testing pump.
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.45 - ES0S
MAN Diesel
Edition 02H Adjustment and Test of Analogous Pressure Transmitter Page 2 (2)
General
The pressure transmitter registers the actual pres- Adjustment:

sure and marks the change to an electrical signal,
which adjusts the pressure. 1) The pressure transmitter shall not be adjust-
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 600.30.
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 flange

pos. 1. and pump on a pressure within the working
area of the transmitter.
If the alarm plant has an instrument unit, the pres-

1. Trial flange. sure can be read on this. Other wise the test can
2. Drain screw. be carried out by watching if the alarm plant gives
3. Valve. any alarm, when the alarm limit which is stated
on page 600.30 is exceeded (if the alarm plant is
adjusted).
Fig. 1.
6) The screw pos. 2 is mounted, and the valve
pos. 3. is opened after the test is finished.
08028-0D/H5250/94.08.12
91.45 - ES0S
MAN Diesel
Working Card Adjustment and Test of 609-05.04

Page 1 (2) Analogous Temperature Transmitter Edition 02H
L+V28/32H

Shut-off fuel oil
Description:
Adjustment and test of analogous temperature

transmitter, (PT 100 sensor). Hand tools:
Special testing devices.
Starting position:

Related procedure:

Capacity : 1 man
Data:

96.26 - ES0S
MAN Diesel
609-05.04 Adjustment and Test of Working Card

Edition 02H Analogous Temperature Transmitter Page 2 (2)
L+V28/32H
The PT 100 sensor consist of a resistance wire Otherwise the test can be carried out by watching
which changes resistance depending on the tem- if the alarm plant gives any alarm, when the alarm
perature. limit which is stated on page 600.30 is exceeded
(if the alarm plant is adjusted).
Look and design varify depending on the place of
measurement and manufacture. 5) The sensor is mounted again.
Adjustment:
1) The PT 100 sensor connot be adjusted, but

the alarm limit must be set on the alarm plant.
Set point, see page 600.30.
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 tempe- Fig. 1.

rature can be read on this.
96.26 - ES0S
MAN Diesel
Page 1 (2) Lambda Controller Edition 16H
L28/32H

Shut off starting air
Shut off cooling water
Shut off fuel oil
Shut off cooling oil
Adjustment of lambda controller. Allen key.
Starting position:
Related procedure:
Manpower: Replacement and wearing parts:
Working time : 1 hour Plate no Item no Qty /

Capacity : 1 man
Data:

10.23 - ES0
MAN Diesel
Edition 16H
Lambda Controller Page 2 (2)
L28/32H
Adjustment of the Lamda Controller
All adjustments are made when the engine is in 1. Compressed air from
overspeed device
1
standstill position. 2. Lambda cylinder
3. Charge air pressure
4. Piston of the
2
1. Check that the free space between the pick- lambda cylinder
5. Regulating arm
up and the band steel on the regulating arm 6. Adjustment screw
is min. 1 mm, see fig 1.
6
5
Fig 3.
2. Turn the lever (fig 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 24
mm at the fuel pump.
Note: Be sure that the fuel index is 24 mm at the fuel

pump when the engine is started.
Fig 1.
3. In case of large deviation from index 24 ad-
justment is done by turning the regulating arm
(5), fig 3. Finally adjustment is done at the
adjustment screw (6), fig 3.
4. Adjustment completed.
Adjustment of the stop screw
5. Remove pipe for charge air pressure, see fig 3.
6. Supply air pressure until the piston rod reaches

its upper position.
7. Adjust the stop screw, see fig 2, to 110% load

according to the test bed, plus 1.5 index.
Use the index arm on the fuel pump nearest to the
lambda controller as control for the index.
Fig 2. 8. Adjustment finished.
10.23 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 60901-13H
L28/32H
For actuator,
see special
instruction book
10
11
12
13
14
16 15
17
02
18
03
20
19+
04
05 21
06 22
07 23
08 24
25
26
27
30
29
06.33 - ES0
MAN Diesel
Plate
60901-13H Governor and Governor Drive Page 2 (2)
L28/32H
Item Item
02 1/E Plug screw Propskrue

29 1/E Wear disc Slidskive
30 1/E Key Feder
04 4/E Nut Møtrik
05 2/E Stud Tap + Item No. 19 require + Item nr. 19 kræver

an individual match- en individual tilpasning
06 1/E O-ring O-ring ing (by shims) before (med shims) før monte-
mounting, contact, ring, kontakt MAN B&W,
07 1/E Castle nut Kronemøtrik MAN B&W, Holeby Holeby.
08 1/E Split pin Split
10 1/E Actuator Aktuator
11 4/E Screw Skrue
12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 -

0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)
13 1/E Disc Skive
14 1/E Ball bearing Kugleleje
15 1/E Bevel gear wheel Konisk tandhjul
16 1/E Key Feder
17 1/E Castle nut Kronemøtrik
19+ 1/E Housing Hus
20 2/E Stud Tap
21 2/E Pin Stift
22 1/E Plug Prop
23 1/E Plug Prop
24 1/E Axle journal Akseltap
25 1/E Bush Bøsning
27 1/E Gear wheel Tandhjul
06.33 - ES0
MAN Diesel
Plate
L28/32H
01 09
For governor, 10
see special
instruction book
11
12
13
14
16 15
17
02
18
03
20
19+
04
05 21
06 22
07 23
08 24
25
26
27
30
29
06.33 - ES0
MAN Diesel
Plate
L28/32H
Item Item
01 1/E Synchronnizing Synchroniserings- 29 1/E Wear disc Slidskive

motor motor
30 1/E Key Feder
03 1/E Gasket Pakning + Item No. 19 require + Item nr. 19 kræver

an individual match- en individual tilpasning
04 4/E Nut Møtrik ing (by shims) before (med shims) før monte-
mounting, contact, ring, kontakt MAN B&W,
05 2/E Stud Tap MAN B&W, Holeby Holeby.
06 1/E O-ring O-ring
09 1/E Shut down Shut-down

solenoid spole
10 1/E Governor - incl. Regulator - inkl.

item 01, 09 and 12 item 01, 09 og 12
11 4/E Screw Skrue

0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)
13 1/E Disc Skive
16 1/E Key Feder
19+ 1/E Housing Hus
20 2/E Stud Tap
21 2/E Pin Stift
22 1/E Plug Prop
23 1/E Plug Prop
06.33 - ES0
MAN Diesel
Plate
L28/32H
09
31 For governor,
see special
instruction book
10
11
12
13
14
16 15
17
02
18
03
20
19+
04
05 21
06 22
07 23
08 24
25
26
27
30
29
06.47 - ES0
MAN Diesel
Plate
L28/32H
Item Item
02 1/E Plug screw Propskrue 30 1/E Key Feder
03 1/E Gasket Pakning 31 1/E Shutdown solenoid Shutdown spole
04 4/E Nut Møtrik

+ Item No. 19 require + Item nr. 19 kræver
05 2/E Stud Tap an individual match- en individual tilpasning
ing (by shims) before (med shims) før mon-
06 1/E O-ring O-ring mounting, contact, tering, kontakt MAN
MAN Diesel A/S. Diesel A/S.
09 1/E Synchronizing motor Synkroniseringsmotor
10 1/E Governor, Europa Regulator, Europa

(720/750 rpm) (720/750 rpm)
11 4/E Screw Skrue

0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)
13 1/E Disc Skive
16 1/E Key Feder
19+ 1/E Housing Hus
20 2/E Stud Tap
21 2/E Pin Stift
22 1/E Plug Prop
23 1/E Plug Prop
29 1/E Wear disc Slidskive
06.47 - ES0
MAN Diesel
Plate
Page 1 (3) Regulation Mechanism 60902-18H
L28/32H
Governor Plate 60901
17
15, 70
18
01 13
19 16
02
03
04
05 14
19
06 25 20
07 26 18
08 27 17
09 28 21
24 22
10
25 23
11
12
64
13
65
02
66
67
56, 92, 93, 94, 95

68
48
49 69
57 50
58 51
52
55 53
61 54
62 59
63
60
06.35 - ES0
MAN Diesel
Plate
60902-18H Regulation Mechanism Page 2 (3)
L28/32H
Item Item
01 1/R Split pin Split 28 2/R Spring pin Fjederstift
02 2/R Pull rod head Trækstangshoved 48 1/C Linkage Lænkeled
03 1/R Pull rod end Trækstangsende 49 1/C Pin Stift
04 1/R Cylindrical pin Cylindrisk stift 50 1/C Spring Fjeder
05 1/R Spring housing Fjederhus 51 1/C Spring arm Fjederarm
06 1/R Pointed screw Pinolskrue 52 3/C Spring pin Fjederstift
07 1/R Spring Fjeder 53 1/C Arm holder Armholder
08 1/R Pull rod Trækstang 54 1/C Screw Skrue
09 1/R Cylindrical pin Cylindrisk stift 55 1/C Spring loaded Fjederbelastet

lever, complete arm, komplet
10 1/R Guide ring Styrering
56 1/E Regulating shaft Reguleringsaksel
11 1/R Guide ring Styrering 5 cyl. engine 5 cyl. motor
12 1/R Nut Møtrik 57 1/C Split pin Split
13 2/R Locking plate Låseblik 58 1/C Pin Stift
14 1/R Spring loaded pull Fjederbelastet træk- 59 1/C Bush Bøsning

rod, complete stang, komplet
60 1/C Bearing bracket Lejeblik
15 1/R Governor arm, Regulator arm, incl. item 59 inkl. item 59
Woodward Woodward
61 2/C Screw Skrue
16 1/R Screw Skrue
62 2/C Washer Skive
17 2/R Split pin Split
18 2/R Self locking nut Selvlåsende møtrik
64 1/E Stop ring Stopring
19 2/R Screw for ball head Skrue for kuglehoved
65 1/E Screw Skrue
20 1/R Arm Arm
66 2/E Screw Skrue
21 1/R Spring pin Fjederstift
67 2/E Screw Skrue
22 1/R Locking plate Låseblik
68 1/E Bracket Konsol
23 1/R Screw Skrue
69 2/E Nut Møtrik
24 1/R Bearing housing Lejehus
incl. item 25 inkl. item 25 70 1/E Governor arm, Regulator arm,
Europa Europa
25 2/R Bush Bøsning
92 1/E Regulting shaft Reguleringsaksel
26 2/R Screw Skrue 6 cyl. engine 6 cyl. motor
27 2/R Washer Skive 93 1/E Regulating shaft Reguleringsaksel

Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme
06.35 - ES0
MAN Diesel
Plate
Page 3 (3) Regulation Mechanism 60902-18H
L28/32H
Item Item


Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme
06.35 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Overspeed Device 60903-38H
L+V28/32H
01
02
03
04
05
06
07
09
08 10
11
12
13
16 14
17 15
18
21 46 19
20
24 48
22
25
23
30
26
33
27 31
32
34
37 35
39 36
38
40
41
42
43
47 44
45
11.02 - ES0
MAN Diesel & Turbo
Plate
60903-38H Overspeed Device Page 2 (2)
L+V28/32H

Item Item
01 1/E Socket Muffe 32 1/E Button Knap
02 1/E Button Knap 33 1/E Nipple Nippel
03 1/E Spring pin Fjederstift 34 1/E Spindle Spindel
04 1/E Spring Fjeder 35 1/E Spring (left) Fjeder (venstre)
05 4/E Screw Skrue 36 1/E Spindle Spindel
06 1/E Screw Skrue 37 2/E Washer Skive
07 1/E Cover Dæksel 38 2/E Screw Skrue
08 1/E Spindle Spindel 39 1/E Ball bearing Kugleleje
09 1/E Spring pin Fjederstift 40 1/E Elastic coupling Elastisk kobling
10 1/E Cylindrical pin Cylindrisk stift 41 1/E Spring (right) Fjeder (højre)
11 1/E Lever Arm 42 1/E Valve attachment Ventilholder
12 1/E Screw Skrue 43 4/E Screw Skrue
13 1/E Flyweight housing Hus for svingvægt 44 1/E Pneumatic valve Pneumatisk ventil
14 1/E Adjusting screw Justeringsskrue 45 1/E Silencer Lyddæmper
15 1/E Spring Fjeder 46 1/E Overspeed device, Overspeed anordning,

complete excl. item 27, komplet eksl. item 27,
16 1/E Circlip Sikringsring 37, 38, 44 37, 38, 44
17 1/E Flyweight Svingvægt 47 1/E Spare parts kit for Reservedelskit for
item 44 item 44
18 1/E Key Not
48 1/E Limit switch (optinal) Afbryder (option)
20 1/E Housing Hus
22 4/E Washer Skive
23 4/E Screw Skrue
24 1/E Pin Stift
25 1/E Lever Arm
26 1/E Nut Møtrik
30 1/E Spindle Spindel
31 1/E Spring Fjeder
11.02 - ES0
MAN Diesel
Plate
Page 1 (2) Instrument Panel 60905-20H
L28/32H
33 33A 04 04 03
01
16
09
10
03 04
07
04 29
08
24-26
13
05 05
14
06 19
20
25
12
30
28 15
02
06 11 18 02A

PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
PI 23 Lub. oil, inlet to turbocharger
PI 50 Nozz. cool. oil, inlet to fuel valves
06.35 - ES0S
MAN Diesel
Plate
60905-20H Instrument Panel Page 2 (2)
L28/32H
Item Item
01 1/E Housing for instru- Hus for instrument pa- 28 1/E Washer Skive
ment panel nel
29 1/E Pressure gauge 0-10 Manometer 0-10 bar,
02 1/E Bracket for instrument Konsol for instrument bar, PI 40 PI 40
panel , L23/30H panel, L23/30H
30 4/E Packing ring Pakningsring
02A 1/E Bracket for instrunent Konsol for instrument
panel, L28/32H panel, L28/32H 33 1/E Instrument panel, Instrument panel, kom-
complete, L23/30H plet, L23/30H
03 2/E Pressure gauge 0-3 Manometer 0-3 bar (PI
bar (PI 31 and PI 23) 31 og PI 23) 33A 1/E Instrument panel, Instrument panel, kom-
complete, L28/32H plet, L28/32H
04 4/E Pressure gauge 0-6 Manometer 0-6 bar,
bar, PI 01, PI 10, PI 50, PI 01, PI 10, PI 50, PI
PI 21-22 21-22
05 8/E Needle valve Nåleventil
06 1/E 3-way valve for PI 3-vejsventil for PI 21-

21-22 22
07 3/E Pressure gauge hose Manometer slange

195 mm 195 mm

140 mm 140 mm

300 mm 300 mm

340 mm 340 mm
11 1/E Damper Dæmper

(charging air) (ladeluft)
12 1/E Damper (fuel oil) Dæmper (fuel oil)
13 4/E Rubber clutch Gummikobling
14 2/E Union Forskruning
15 1/E Screwed connection Skrue forbindelse
20 3/E Screw Skrue
24 8/E Nut Møtrik
25 4/E Serrated washer Stjerneskrue
26 8/E Washer Skive
06.35 - ES0S
MAN Diesel
Plate
L28/32H

94.28 - ES0S
MAN Diesel
Plate
L28/32H
Item Item
01 1/E Housing for instru- Hus for instrument- 23 1/E Damper (charging air) Dæmper (ladeluft)
ment panel panel
43 4/E Screw Skrue
02 1/E Bracket for instru- Konsol for instrument-
ment panel panel 44 4/E Serrated lock washer Stjernefjederskive
03 4/E Rubber clutch Gummikobling 45 2/E Screw Skrue
04 8/E Nut Møtrik 46 2/E Serrated lock washer Stjernefjederskive
05 8/E Spring lock Fjederskive 47 8/E Screw Skrue
06 2/E Pressure gauge Manometer 48 1/E Side plate Sideplade

0-3 bar 0-3 bar
(PI 31 and PI 23) (PI 31 og PI 23) 49 1/E Instrument panel, Instrument panel,
complete komplet
07 4/E Pressure gauge Manometer
0-6 bar 0-3 bar
(PI 01, PI 10, PI 50, (PI 01, PI 10, PI 50,
PI 21-22) PI 21-22)

0-10 bar (PI 40) 0-10 bar (PI 40)
10 1/E 3-way valve for 3-vejsventil for

PI 21-22 PI 21-22
11 1/E Washer Skive
12 1/E Pipe Rør
13 1/E Angle union Vinkelforskruning
14 2/E Straight union Ligeforskruning

195 mm 195 mm

140 mm 140 mm

300 mm 300 mm

340 mm 340 mm
20 2/E Reduction Reduktion
22 2/E Coupling for mano- Kobling for manometer

meter
94.28 - ES0S
MAN Diesel
Plate
L28/32H
49 19 07 06 07
01
17
18
47 07 08
16
48 07 06
15
04-05
03 02
14
09
10
11
43-44-45 20 20
12 23 21
13
14 22 22

95.20 - ES0S
MAN Diesel
Plate
L28/32H
Item Item
01 1/E Housing for instru- Hus for instrument- 23 1/E Damper (charging air) Dæmper (ladeluft)
ment panel panel
43 4/E Screw Skrue
02 1/E Bracket for instru- Konsol for instrument-
ment panel panel 44 4/E Lock washer Låseskive
03 4/E Rubber clutch Gummikobling 45 4/E Nut Møtrik
04 8/E Nut Møtrik 47 8/E Screw Skrue
05 8/E Spring lock Fjederskive 48 1/E Side plate Sideplade
06 2/E Pressure gauge Manometer 49 1/E Instrument panel, Instrument panel,

0-3 bar 0-3 bar complete komplet
(PI 31 and PI 23) (PI 31 og PI 23)

0-6 bar 0-3 bar
(PI 01, PI 10, PI 50, (PI 01, PI 10, PI 50,
PI 21-22) PI 21-22)

0-10 bar (PI 40) 0-10 bar (PI 40)
10 1/E 3-way valve for 3-vejsventil for

PI 21-22 PI 21-22
11 1/E Washer Skive
12 1/E Pipe Rør
13 1/E Angle union Vinkelforskruning
14 2/E Straight union Ligeforskruning

195 mm 195 mm

140 mm 140 mm

300 mm 300 mm

340 mm 340 mm
20 2/E Reduction Reduktion
22 2/E Coupling for mano- Kobling for manometer

meter
95.20 - ES0S
MAN Diesel
Plate
Page 1 (3) Thermometer 60907-19H
L28/32H
Scale Length Item
Fig. Code
°F °C L L1 No
40-240 0-120 110 100 TI 01 01
TI 02
TI 31
L 40-240 0-120 110 63 TI 22 02
TI 20
40-600 0-300 150 100 TI 30 03

L1
40-400 0-200 110 40 TI 40 04
TI 51
40-220 0-120 110 100 TI 03 05
TI 10
TI 11
L1
04.11 - ES0
MAN Diesel
Plate
60907-19H Thermometer Page 2 (3)
L28/32H
Scale Length Item
Fig. Code
°F °C L L1 No.
100-
1300 50-650 100 115 TI 60 06
°C°F
L1
L1
Pocket 115 07
100-
1300 50-650 65 215 TI 61 08
° C° F
Pocket 215 09
04.11 - ES0
MAN Diesel
Plate
Page 3 (3) Thermometer 60907-19H
L28/32H
Scale Length Item
Fig. Code
°F °C L L1 No.
120-1200 50-650 140 215 TI 61 10
TI 62
Thermo-
meter 11
Feeler
NiCr-Ni 12
Pocket 100 13
120-1200 50-650 165 115 TI 60 14
120-1200 50-650 190 115 TI 60 15
Feeler
NiCr-Ni 16
Thermo-
meter 17
Pocket 200 18
04.11 - ES0
MAN Diesel
Plate Pressostate, Thermostate
Page 1 (2)
Difference Pressostate and Pressure Transmitter 60907-02H
General
Fig. and Description Range Code L Item No.
0-8 bar PSL 22 01

PAL 10
PAL 22
6-18 bar PAL 70 02

PAL 24
10-35 bar 03
1-10 bar PAL 40 04

Pressostate
20-60°C TAL 10 2m 05
5m 06
50-100°C 2m 07
5m 08
8m 09
70-120°C TAH 12 2m 10
TSH 12 5m 11
TAH 20 8m 12
L TSH 22
TSH 12
Thermostate
0.2-2.5 bar PDAH 21-22 13
Difference Pressostate
99.33 - ES0S
MAN Diesel
Pressostate, Thermostate Plate

60907-02H Difference Pressostate and Pressure Transmitter Page 2 (2)
General
Fig. and Description Range Code L Item No.
0-2.5 bar PT 31 14
0-4 bar PT 10 15
0-6 bar PT 22 16
0-10 bar PT 40 17
0-16 bar PT 70 18
0-40 bar 19
0-400 bar 20
Pressure Transmitter
Needle Valve with 3/8" pipe thread 25
Needle valve with 1/2" pipe thread 26
Needle Valve
99.33 - ES0S
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Alarm (LAL 25) 60919-01H
L+V28/32H
01
02
03
Switch point
04
08028-0D/H5250/94.08.12
07.11 - ES0
MAN Diesel
Plate
60919-01H Prelubricating Oil Alarm (LAL 25) Page 2 (2)
L+V28/32H
Item Item
03 1/E Loctite 577 Loctite 577
04 1/E Level switch Niveauafbryder
08028-0D/H5250/94.08.12
07.11 - ES0
MAN Diesel
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 60920-01H
L28/32H
09 10
05 04
07 02
13 03
16
MAX
06
15
13
08
15
MIN
08
01
04
08028-0D/H5250/94.08.12
07.12 - ES0
MAN Diesel
Plate
60920-01H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
L28/32H
Item Item
01 1/E Level alarm Niveaualarm
02 1/E Flange Flange
03 1/E Packing Pakning
04 4/E Screw Skrue
05 4/E Nut Møtrik
06 1/E Pipe, LAL Rør, LAL
07 1/E Pipe, LAH Rør, LAH
08 2/E Level switch Niveaukontakt
09 2/E Reduction adaptor Reduktionsadapter
10 1/E Dipstick complete Pejlestok komplet
13 2/E Reduction adaptor Reduktionsadapter
08028-0D/H5250/94.08.12
07.12 - ES0
MAN Diesel
Plate
Page 1 (2) Local Starting Box - No 1 60935-13H
L+V28/32H
07.45 - ES0
MAN Diesel
Plate
60935-13H Local Starting Box - No 1 Page 2 (2)
L+V28/32H
Item Item
017 1/E Panel Panel
029 1/E Starting box Startboks
Qty./E = Qty./Enigne. Qty./E = Qty./Motor
07.45 - ES0
MAN Diesel
Plate
L28/32H
600
OVERSPEED 720
750
30000
20000 40000
300 900 029
10000 50000
140 TC
0 60000
ENG. 0 1200
RPM
ENGINE RPM
START STOP
TC RPM
REMOTE LOCAL BLOCKING
017
08028-0D/H5250/94.08.12
07.45 - ES0 - TCR lader

MAN Diesel
Plate
L28/32H
Item Item
017 1/E Panel Panel
08028-0D/H5250/94.08.12
07.45 - ES0 - TCR lader

MAN Diesel
Plate
L+V28/32H
07.45 - ES0
MAN Diesel
Plate
L+V28/32H
Item Item
017 1/E Panel Panel
07.45 - ES0
MAN Diesel
Plate
Page 1 (2) Local Starting Box - No 2 (incl. high lub. oil temp.) 60935-15H
L+V28/32H
07.45 - ES0
MAN Diesel
Plate
60935-15H Local Starting Box - No 2 (incl. high lub. oil temp.) Page 2 (2)
L+V28/32H
Item Item
017 1/E Panel Panel
07.45 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Engine Control Box 60936-08H
General
ELECTRONICS
Beijer
T70
EXTER
536
727 715 703
345 345
0 4 0 4
1 5 1 5
OUTPUT
AC/DC OUT
AC/DC OUT
OK OK
INPUT
2 6 2 6
095 585
3 7 3 7
DC INPUTS ANALOG ANALOG

ISOLATED RELAY ISOLATED RELAY
Allen-Bradley 0
1
4
5
8 12
9 13
2 6 10 14
3 7 11 15
DC/RELAY OUT
573 -K6.6
0
2
1
4
5
6 10
8
9 333
3 7 11
-K8.0 -K7.0 -K9.0 -K9.6
644
656
404 -K9.2
11 12 13 14
394 GND 0 GND 274

GND 0 GND
-F3.0.1
-F3.0
416 561
GND 0 GND
142 548
41 42 43 44
10.51 - ES0
MAN Diesel & Turbo
Plate
60936-08H Engine Control Box Page 2 (2)
General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
095 1/E Safety system, Sikkerhedssystem,

Base unit Base unit
142 1/E Terminal, earth Jordklemme
274 3/E End stop Endestop
333 1/E Analog Analog

output module outputmodul
345 2/E Digital Digital

output module outputmodul
394 2/E Fuse terminal Sikringsklemme
404 1/E End plate Endeplade
416 4/E Fuse Sikring
536 1/E Panel Panel
548 50/E Terminal double Klemme, dobbelt
561 1/E End plate Endeplade
573 1/E Processor unit (CPU) Processor unit (CPU)
585 1/E End cap Endestykke
644 1/E Analog Analog

input module inputmodul
656 1/E Converter Konverter
668 1/E Cable Kabel
703 8/E Cable union Kabelforskruning
Qty/E = Qty/Engine Qty/E = Qty/Motor
10.51 - ES0
MAN Diesel
Plate
Page 1 (2) Terminal Box 60936-07H
L28/32H
619
607 620 250
)
SSH 81
SAH 81
597 X:2
UX 95
632
(
5K6
3K2
3K3
3K9
4K2
4K3
4K4
4K5
4K6
4K7
5K4
5K9
4P1
274
644
225 668
F1/1
F1/2
394 X:1
416
536
681
693 490 477 453 274
500 489 465 656
08028-0D/H5250/94.08.12
07.45 - ES0
MAN Diesel
Plate
60936-07H Terminal Box Page 2 (2)
L28/32H
Item Item
225 1/E Conduit Ledningskanal
250 1/E Conduit Ledningskanal
274 4/E End stop Endestop
394 2/E Fuse terminal Sikringsklemme
416 2/E Fuse 2A Sikring 2A
453 2/E Cable union M16 Kabelunion M16
465 2/E Nut M16 Møtrik M16
536 1/E Panel Panel
597 1/E Speed converter, Speed converter,

engine 720 rpm motor 720 omdr
607 1/E Timer Timer
619 11/E Aux. relay Hjælperelæ
620 11/E Socket Sokkel
632 1/E Speed converter, Speed converter,

engine 750 rpm motor 750 omdr
644 12/E Terminal Klemme
656 54/E Terminal Klemme
668 2/E Diode terminal Diode klemme

08028-0D/H5250/94.08.12
07.45 - ES0
MAN Diesel
Plate
Page 1 (2) Converter 60956-01
General
(RS-232)
021
ADAM ADAM-4520
RS-232 TO RS-422/RS-485
CONVERTER
(B) GND 10
(RS 485)
(RS 422)
(R) +Vs
DATA +
DATA -
RX +
TX +
RX -
TX -
033
045
08028-0D/H5250/94.08.12
07.37 - ES0
MAN Diesel
Plate
60956-01 Converter Page 2 (2)
General
Item Item
021 1/E Coverter Converter
033 1/E Cable, length 1.8 m Kabel, længde 1.8 m
045 1/E Cable, length 10 m Kabel, længde 10 m
08028-0D/H5250/94.08.12
07.37 - ES0
Crankshaft
510/610
MAN Diesel
Description
Crankshaft and Main Bearings 610.01
Page 1 (1)
Edition 12H
L/V28/32H
Crankshaft Vibration Damper
The crankshaft, which is a one-piece forging with In special cases a vibration damper is mounted on
ground main bearing and crankpin journals, is sus- the crankshaft to limit torsional vibrations.The damper
pended in inderslung bearings. The main bearings consists essentially of a heavy flywheel totally en-
are equipped with insertion-type shells, which are closed in a light casing. A small clearance is allowed
coated with a wearing surface. To attain a suitable between the casing and the flywheel, and this space
bearing pressure the crankshaft is provided with is filled with a highly viscous fluid.The casing is rigidly
counterweights, which are attached to the crank- connected to the front end of the engine crankshaft
shaft by means of dovetail joints and secured with and the only connection between the crankshaft
a centrally placed screw. and the damper flywheel is through the fluid. Under
conditions of no vibration, the casing and damper
At the flywheel end the crankshaft is fitted with a gear flywheel tend to rotate as one unit, since the force
wheel which through an intermediate wheel drives required to shear the viscous film is consi-derable.
the camshaft. Also fitted here is the flywheel and a As the torsional vibration amplitudes increase, the
coupling flange for connection of a reduction gear or casing follows the movement of the crankshaft but
a alternator. At the opposite end there is a claw-type the flywheel tends to rotate uniformly by virtue of
coupling for the lub. oil pump or a flexible gear wheel its inertia, and relative motion occurs between the
connection for lub. oil and water pumps. flywheel and the casing. The viscous fluid film there-
fore undergoes a shearing action, and vibration
energy is absorbed and appears as heat.
08028-0D/H5250/94.08.12
91.45 - ES0U
MAN Diesel
Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00

(Hydraulic Tightened Connecting Rod)
L28/32H

Shut-off cooling oil 62010 35 Angle for
Stopped lub. oil circul. mounting on
crank web
Description:
Checking of main bearings alignment (deflec-

tion). Hand tools:
Starting position:
Turning gear in engagement. (If mounted).

Cover for crankshaft has been removed from
frame.
All indicator valves open.
Related procedure:
08028-0D/H5250/94.08.12
Working time : 1 1/2 hours Plate no. Item no. Qty. /

Capacity : 2 men
Data:

99.25 - ES0S
MAN Diesel
610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card

L28/32H
Alignment of Main Bearings.
The lower main bearing shells should be positioned

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 tening during the turning of the throw increases Fig. 1 Placing of dial gauge
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.
Checking The Deflection Measurement.
As the crankshafts of medium speed engines are very
stiff, any great deviations in the alignment will result The reading is entered in the table page 6, see
in clearance at the bottom shell of the bearings. example in fig. 2 - 6.
The cause of incorrect main bearing position may As "bottom" reading is used the mean value of the
be wear of the bearings or misalignmnet of the two "near bottom" readings X and Y, fig. 3.
engine.
The total deflection ("opening-closing") of the throw
during the turning from bottom to top position is
Effecting The Deflection Measurement. entered in fig. 4.
The deflection measurement is effected by placing a These figures are due to vertical misalignment of
springloaded dial gauge in the centre punch marks the main bearings.
provided for this purpose, see fig. 1.
Similarly, horizontal misalignment procedures the
"Closing" of the throw in top dead centre is regarded figures in the table fig. 5.
as negative, (compression of the gauge).
Besides misalignment of the bearings, the readings
In the example, page 3, the deflection reading is can be influenced by ovality or eccentricity of the
therefore negative. journals.
08028-0D/H5250/94.08.12
As during the turning of the throw, the gauge and the

connecting rod will meet near the bottom position of Engines Equipped with Turning Gear.
the throw, the measurement for the bottom position
is to be replaced by the average of the two near by When taking these deflection readings for the three
positions on either side. aftmost cylinders, the turning gear should at each
stoppage be turned a little backwards to ease off
The dial gauge is set to zero, when the crank throw the tangential pressure on the teeth of the turning
is in the near-bottom (x in fig. 8) and during the wheel as this pressure may otherwise falsify the
turning the throw is stopped in the position horizon- readings.
tal-top-horizontal-near bottom (P-T-S-Y in fig. 8) for
reading of the gauge.
99.25 - ES0S
MAN Diesel

Page 3 (6) (Hydraulic Tightened Connecting Rod) Edition 10H
L28/32H
Deflection of crankshaft in 1/100 mm. (0.01 mm).
Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig. 4.
Left side P 2 0 2 0 -1 2
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Bottom stop Y 2 -1 0 1 0 2 Right side - left side

or P - S = H -1 2 0 0 -1 1
Fig. 2. Fig. 5.
Bottom (0,5 x Y) = B 1 -0.5 0 -0.5 0 1 Check on T+B= C 4 -2.5 4 5.5 -2 4

gauge
readings P+S= D 5 -2 4 0 -1 3
Fig. 3.
Fig. 6.
C and D should be nearly the same, reading for cylinder 4 to be repeated.
S P
08028-0D/H5250/94.08.12
Y X
Front end view.

"Closing" of the crankthrow is considered Start in position X.
negative. Turn anti clockwise
Fig. 7. Fig. 8.
99.25 - ES0S
MAN Diesel

Pagee 4 (6)
Edition 10H (Hydraulic Tightened Connecting Rod)
L28/32H
Measurement of Crank Throw Deflections by Means of Dial Indicator (Autolog)
Crank throw deflection = Difference in dial indicator readings in two diametrically

opposite crank throw positions, i.e. two positions displa-
ced 180°.
Vertical deflection = Difference in top-bottom readings.
Horizontal deflection = Difference in side-side readings.
Vertical and Horizontal Deflections of Crank Throws
Unless otherwise stated the values refer to cold engine.
For new or realigned aggregate Aim for + or - 4/100 mm

Acceptable + or - 6/100 mm
For aggregate in service realignment

is recommended if deflections exceed + or -10/100 mm
Vertical Deflection 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
08028-0D/H5250/94.08.12
For new or realigned For new or realigned

aggregate 0 to + 4/100 mm aggregate Aim for - 7/100 mm
Acceptable - 10/100 mm
For aggregate in service realignment is For aggregate in service

recommended if deflection measured realignment recommendable
on warm engine exceeds - 10/100 mm if deflection exceeds - 14/100 mm
99.25 - ES0S
MAN Diesel

L28/32H
Process/Proces I.D. no.
Plant/Anlæg Page of/Side af
Engine Type/Motortype Engineer/Operatør Date/Dato
Instruction/Instruktion
Top
Right side Left side
Bottom end/ Bottom start/

1/100 mm Bund slut Bund start
Right side Right side
Cyl. no 1 2 3 Cyl. no 1 2 3
Left side Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
08028-0D/H5250/94.08.12
99.25 - ES0S
MAN Diesel

Edition 10H (Hydraulic Tightened Connecting Rod) Page 6 (6)
L28/32H
Component/Komponent Type I.D. no.
Process/Proces Page of/Side af
Test place/ Test bed/prøvehal Cold/Kold

Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal
Engine no.:
Motornr.:
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
Bottom
(0.5xY)=B
Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V
Deflection from
horizontal mis-
alignment.
08028-0D/H5250/94.08.12
Left side - Right

side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
99.25 - ES0S
MAN Diesel
Page 1 (3) Inspection of Main Bearing Shells Edition 05H
L+V28/32H

Shut-off cooling water 62010 10 2 pieces
Stopped lub. oil circul. 62010 15 2 pieces
62010 30 Extra tools
62021 40 Hydraulic tools
62021 50 2 pieces
Description: 62021 51
62021 20
Dismantling, inspection and/or replacement and
mounting of main bearing shells.
Hand tools:
Allen key, 12 mm.

Starting position: Lead hammer.
Silastene.
Copaslip.
Related procedure:
Inspection of guide bearing shell, 610-01.10

Criteria for replacement of bearings, 606-01.16
Manpower:
08028-0D/H5250/94.08.12
Working time : 2 hours Replacement and wearing parts:

Capacity : 2 men
Plate no Item no Qty/
Data:

96.30 - ES0S-G
MAN Diesel

Edition 05H Inspection of Main Bearing Shells Page 2 (3)
L+V28/32H
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 conveni-

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 620-01.05.
Fig 2. Mounting of Wire Straps.
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
Fig 1. Mounting of Hydraulic Tools.
hole in the crankshaft and turn out the upper bearing
shell by turning the crankshaft, see fig 3.
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
Dismantling of the Main Bearing Cap

08028-0D/H5250/94.08.12
6) Fit the eye screws, diagonally, in the threaded

holes in the main bearing cap, see fig 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. Tool for upper main
bearing
7) Work the main bearing cap loose from the

engine frame with a lead hammer or similar. Fig 3. Mounting of tool for upper main bearing.
96.30 - ES0S-G
MAN Diesel
Working Card 610.01-05
Page 3 (3) Inspection of Main Bearing Shells Edition 05H
L+V28/32H
Cleaning 17) Insert the lower bearing shell in the bearing
cap and mount the locking piece.
12) Clean all machined surfaces, on frame, bearing
cap, stud, nuts and bearing shells. Lubricate the bearing shell and journal with clean
lubricating oil.
Inspection of Main Bearing Shells

Mounting of the Main Bearing Cap
13) Inspect the main bearing shells according to
working card 606-01.16. 18) Raise the bearing cap into position, dismount
the guide tubes, coat the bearing studs with molycote
Note: The bearing is marked according to size and pasta or similar and fit the bearing stud nuts.
when replaced it must be by a new bearing of the
same size. Make sure that the bearing cap and bearing shell
are in their correct position.
Mounting of the Main Bearing Shells 19) Dismantle the wire straps.
14) Push the upper bearing shell as far into position 20) Mount the hydraulic tools, see working card
as possible. 620-01.05, and tighten the nuts as prescribed on
page 600-40.
15) Fit the tool for upper main bearing in the lub-
ricating hole in the crankshaft and turn in the upper 21) Coat the back side of the bracing screws' (side
bearing shell by turning the crankshaft. screws') hexagonal head with a thin coat of silastene
or similar.
Make sure that the shell enters its correct position
then remove the tool for upper main bearing. 22) Mount the screws and tighten with a torque
spanner as indicated on page 600.40.
16) Lubricate the end of the bearing shells with
molycote pasta or similar.
08028-0D/H5250/94.08.12
96.30 - ES0S-G
MAN Diesel
Page 1 (4) Inspection of Guide Bearing Shells Edition 08H
L+V28/32H

Shut-off cooling water 62006 28 140 - 760 Nm
Shut-off fuel oil 62010 10 2 pieces
62010 25
62010 15 2 pieces
Description 62021 40 Hydraulic tools
62021 50 2 pieces
Dismantling, inspection and/or replacement 62021 51
and mounting of guide bearing shells and thrust 62021 20
washer.
Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Molycote
Related procedure
Inspection of main bearing shells. 610-01.05

Criteria for replacement of bearing
shells. 606-01.16
08028-0D/H5250/94.08.12
Manpower
Working time : 2 hours

Capacity : 2 men Replacement and wearing parts
Data Plate no Item no Qty/

02.47 - ES0
MAN Diesel
Edition 08H Inspection of Guide Bearing Shells Page 2 (4)
L+V28/32H
Make Ready for Dismantling of the Guide

Bearing
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 fig 1, and

loosen the guide bearing stud nuts. For ope-
ration of the hydraulic tools, see working card
620-01.05. Fig 2 Mounting of Wire Straps
8) Lift the guide 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 Guide Bearing Shells
10) Remove the locking piece from the bearing

cap and take out the bearing shell.
To pump
Fig 1 Mounting of Hydraulic Tools Thrust washer
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
08028-0D/H5250/94.08.12
Dismantling of the Guide Bearing Cap
6) Fit the eye screws, diagonally, in the threaded

holes in the guide bearing cap, see fig 2.
Fig 3 Guide Bearing with Thrust Washer
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 The thrust washer of the guide bearing is partially
stud nuts are removed. countersunk into the engine frame and attached by
means of four screwed-on clamps which are visible
7) Work the guide bearing cap loose from the after lowering the bearing cap, see fig 3.
engine frame with a lead hammer or similar.
02.47 - ES0
MAN Diesel
Page 3 (4) Inspection of Guide Bearing Shells Edition 08H
L+V28/32H
In case the guide shell tool is locked between guide
bearing and bearing studs, use the bolt on the back
of the guide shell tool to dislodge it.
Cleaning of Components
14) Clean all machined surfaces, on frame, bearing

cap, stud, nuts and bearing shells.
Inspection of Guide Bearing Shells
15) Inspect the guide bearing shells according to

Guide for mounting of upper shell.
Fig 4 Dismounting of Upper Shell

Fig 5 Mounting of Upper Shell in Guide Bearing
11) Unscrew the clamns and push out the thrust Mounting of the Guide Bearing Shells
washers.
The bearing shells of the guide bearing, which are
12) Fit the tools for dismantling of upper guide identical to those of the main bearings, are narrower
bearing shell, see fig 4, in the bearing cap and than the bore for the guide bearing and it is therefore
raise the bearing cap into position, making sure essential that the shells are positioned perfectly cor-
that the guide shell is not being damaged. rect in the bore.
08028-0D/H5250/94.08.12
After that, dismount the guide tubes, fit and For this purpose a guide tool is supplied for positio-
tighten the nuts slightly. ning on the engine frame when the upper bearing
shell is to be fitted, see fig 5.
13) With the guide shell tool, which is guided by
the bearing cap, the upper bearing shell is 16) Push the bearing shell as far as possible into
carefully turned out into the bearing cap. Then position through this guide tool.
dismount the nuts and lower the bearing cap
on the collar of the guide tubes. Take out the 17) Insert the guide shell tool in the bearing cap,
bearing shell and the guide shell tool. which is resting on the collar of the guide tu-
bes.
02.47 - ES0
MAN Diesel

Edition 08H Inspection of Guide Bearing Shells Page 4 (4)
L+V28/32H
18) Raise the bearing cap with the guide shell tool Bearing Cap
into its correct position, dismount the guide
tubes, fit and tighten the bearing stud nuts Lubricate the bearing shell and journal with clean
slightly. lubricating oil.
19) Now push the bearing shell into its correct 24) Raise the bearing cap into position, dismount
position with the guide shell tool.Make sure the guide tubes, coat the bearing stud with
that the shell enters its correct position. molycote pasta or similar and fit the bearing
stud nuts.
20) Then unscrew the bearing stud nuts, fit the guide
tubes and lower the bearing cap again. Make sure that the thrust washers, bearing shell
and bearing cap are in their correct position.
21) Fit the thrust washers and clamps.
25) Dismantle the wire straps.
Note: Clearance in guide bearing axially, see page
600.35. 26) Mount the hydraulic tools, see working card
620-01.05, and tighten the nuts as prescribed
22) Lubricate the end of the bearing shells with on page 600-40.
molycote pasta or similar.
27) Coat the back side of the bracing screws' (side
23) Insert the lower bearing shell in the bearing screws') hexagonal head with a thin coat of
cap, and mount the locking piece. silastene or similar.
28) Mount the screws and tighten with a torque

spanner as indicated on page 600.40.
08028-0D/H5250/94.08.12
02.47 - ES0
MAN Diesel
Page 1 (3) Vibration Damper Edition 01H
General

Shut-off fuel oil
Description:
Taking a silicone oil sample

Hand tools:
Starting position:
Related procedure:
08028-0D/H5250/94.08.12
Working time : 2-4 hours Plate no. Item no. Qty. /

Capacity : 1 man
See plate 61004
Data:

10.15 - ES0
MAN Diesel
Edition 01H Vibration Damper Page 2 (3)
General
The vibration damper is equipped with extraction
plugs which provide the opportunity of testing the 3. Rotate the engine in order to bring the extraction
viscosity of the silicone oil inside the damper without plugs (6) of the damper in optimal position, see fig.
having to dismantle it. 2A.
Corresponding to the condition of the silicone oil an

approximate assessment of the damper efficiency
is possible. A
6
A silicone oil sample should be extracted as follows
by means of a special tube that can be required
from MAN Diesel & Turbo, PrimeServ Holeby, see
plate 61004.
1. After the engine is stopped let damper cool

down to approximately 40°C.
2. For access to the damper remove the blank 6

flange (A) on the front end cover (B) see fig. 1.
B
In some cases it is necessary to dismount the lub.
oil pump or the cooling water pump, for access to 5
the damper.
6
C
E
F
C
D
10 5 11
B
A
3
08028-0D/H5250/94.08.12
A. Blank flange or cooling water pump.

B. Front end cover.
C. Damper.
D. Gearwheel (if mounted) Fig. 2. Vibration Damper
E. Main bearing (Frame)
F. Crankshaft.
4. Prepare the sample container (10) by removing

Fig. 1. Mounting of Vibration Damper. one of its caps (11), see fig. 2 C.
10.15 - ES0
MAN Diesel

Page 3 (3) Vibration Damper Edition 01H
General
5. Unscrew and remove one of the extraction 9. Send the sample container to:
plugs (6) and replace it with the sample container
(10). MAN Diesel & Turbo
PrimeServ Holeby
If meeting the inertia ring (3) unscrew the container Østervej 2
one revolution. 4960 Holeby
Denmark
6. Remove the second cap from the sample
container and wait until silicone fluid (5) begins to The sample must be marked in such a way that we
flow out from the free end. Depending on the silicone can forward the result of the analysis correctly.
viscosity the process needs a certain amount of time.
If possible it, can be speeded up by means of: - Name of ship.
- Engine type.
A Turning the damper until the sample contai- - Engine no.
ner is underneath the crankshaft. - Running hours.
B Temporarily removing the second extraction - Data for vibration damper.
plug too.
10. For hours between taking new samples, see
7. As soon as the silicone fluid begins to flow, page 600.25.
close the sample container by the cap. Remove
the container from the damper casing, wipe off the The quantity of silicone oil removed its so small that
sealing jace round the extraction hole and screw in up to 10 such samples can be taken without risk.
the plugs together with new sealing washers (7).
Now close the second side of the container.
8. Tighten both extraction plugs with thumb and

forefinger then turn them further 45° (about 20 Nm).
Seal both plugs by caulking their grooves.
08028-0D/H5250/94.08.12
10.15 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 61001-15H
L28/32H
10
11
12
13
09
06
05
04
03
02+
15+
01
16
17
18
07-14
08-14
06.33 - ES0
MAN Diesel
Plate
61001-15H Crankshaft Page 2 (2)
L28/32H
Item Item
01 1/E Crankshaft Krumtapaksel

02+ /I Counterweight Kontravægt

6,7,9 cyl. engine 6,7,9 cyl. motor
03 1/W Locking plate Sikringsplade
05 2/W Screw Skrue
06 1/W Screw for Skrue for

counterweight kontravægt
09 12/E Screw Skrue
11 12/E Washer Skive
12 1/E Oil throw ring Olieafslyngningsring

(crankshaft) (krumtap)




+ Item No. 02 and 15 + Item nr. 02 og 15

require an indivi- kræver en individuel
dual matching tilpasning før
before mounting montering, kontakt
contact MAN Diesel, MAN Diesel, Holeby
Holeby
Qty./W = Qty./Counterweight Antal/W = Antal/Kontravægt
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
06.33 - ES0
MAN Diesel
Plate
Page 1 (2)
Crankshaft 61001-21H
5L28/32H
10
11
15+ 12
13
03 09
04
06
05
06
05
04
03
02+
01
07-14
08-14
06.33 - ES0
MAN Diesel
Plate
61001-21H Crankshaft Page 2 (2)
5L28/32H
Item Item
05 2/W Screw Skrue
06 1/W Screw for Skrue for

counterweight kontravægt
09 12/E Screw Skrue
11 12/E Washer Skive
12 1/E Oil throw ring Olieafslyngningsring

(crankshaft) (krumtap)
+ Item No. 02 and 15 + Item nr. 02 og 15

require an indivi- kræver en individuel
dual matching tilpasning før
before mounting montering, kontakt
Holeby
Qty./W = Qty./Counterweight Antal/W = Antal/Kontravægt
06.33 - ES0
MAN Diesel
Plate
Page 1 (2) Resilient Gear Wheel 61002-07H
L28/32H
01
Crankshaft 19+
(Plate 61001)
02
05 03
06
07
18
08
04
09
10 10
11
17 16
15
14
13
12
96.01 - ES0S
MAN Diesel
Plate
61002-07H Resilient Gear Wheel Page 2 (2)
L28/32H
Item Item
01 1/E Resilient gear Fjedrende tandhjul,

wheel, compl. komplet
03 4/E Screw Skrue
04 6/E Self locking nut, for Selvlåsende møtrik,

Item No. 03 and 19 for Item nr. 03 og 19
05 1/E Hub Nav
06 6/E Slide shoe Glidesko
07 3/E Distance piece Afstandsstykke
09 12/E Locking washer Låseblik for

for item No. 10 item nr. 10
10 12/E Nut Møtrik
11 4/E Cylindrical pin Cylindrisk stift
12 6/E Spring guide Fjederstyr
15 6/E Screw Skrue
16 6/E Locking washer, Låseblik for

for Item No. 15 Item nr. 15
17 1/E Side plate Sideplade
+ Item 19 require an + Item 19 kræver en

individual matching individuel tilpasning
during mounting, før montering, kontakt
Holeby
96.01 - ES0S
MAN Diesel
Plate
Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-11H
6-7-8-9L28/32H
Crankshaft
(Plate 61001)
01
02
03
07.02 - ES0
MAN Diesel
Plate
61002-11H Coupling for Central Driven Lub. Oil Pump Page 2 (2)
6-7-8-9L28/32H
Item Item
01 1/E Coupling flange Koblingsflange
02 3/E Locking plate Låseplade
03 6/E Screw Skrue
07.02 - ES0
MAN Diesel
Plate
5L28/32H
06
05
Crankshaft
(Plate 61001)
04
01
02
03
07.02 - ES0
MAN Diesel
Plate
5L28/32H
Item Item
03 6/E Screw Skrue
04 1/E Flyweight Svingklods
05 6/E Nut Møtrik
06 6/E Screw Skrue
07.02 - ES0
MAN Diesel
Plate
5L28/32H
06
05
Crankshaft
(Plate 61001)
04
01
07.03 - ES0
MAN Diesel
Plate
5L28/32H
Item Item
04 1/E Flyweight Svingklods
05 6/E Nut Møtrik
06 6/E Screw Skrue
07.03 - ES0
MAN Diesel
Plate
L28/32H
06
05
Crankshaft
(Plate 61001)
01
02
03
07.03 - ES0
MAN Diesel
Plate
L28/32H
Item Item
03 6/E Screw Skrue
05 6/E Nut Møtrik
06 6/E Screw Skrue
07.03 - ES0
MAN Diesel
Plate
L28/32H
01
Crankshaft
(Plate 61001)
02
05 03
06
07
18
08
09 04
10 10
11
17 16
15
14
13
12
07.03 - ES0
MAN Diesel
Plate
L28/32H
Item Item

03 6/E Stud Tap
04 12/E Self locking nut, Selvlåsende møtrik,

for Item No. 03 for Item nr. 03
05 1/E Hub Nav

10 12/E Nut Møtrik
15 6/E Screw Skrue

07.03 - ES0
MAN Diesel
Plate
L28/32H
01
Crankshaft 19+
(Plate 61001)
02
05 03
06
07
18
08
04
09
10 10
11
17 16
15
14
13
12
07.03 - ES0
MAN Diesel
Plate
L28/32H
Item Item

03 4/E Screw Skrue
04 6/E Self locking nut,for Selvlåsende møtrik,

05 1/E Hub Nav

10 12/E Nut Møtrik
15 6/E Screw Skrue


contact MAN diesel, MAN Diesel, Holeby
Holeby
07.03 - ES0
MAN Diesel
Plate
L28/32H
01
Crankshaft 19+
(Plate 61001)
02
05 03
06
07
18
08
04
09
10 10
11
17 16
15
14
13
12
07.03 - ES0
MAN Diesel
Plate
L28/32H
Item Item

03 4/E Screw Skrue
04 6/E Self locking nut,for Selvlåsende møtrik,

05 1/E Hub Nav

10 12/E Nut Møtrik
15 6/E Screw Skrue


Holeby
07.03 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 61003-02H
5L28/32H
10
04
11
05
01
Crankshaft
(plate 61001)
03 02
07.02 - ES0
MAN Diesel
Plate
61003-02H Flywheel with Gear Rim Page 2 (2)
5L28/32H
Item Item
01 1/E Gear rim 2/2 Tandkrans 2/2
02 18/E Screw Skrue
03 12/E Self locking nut, for Selvlående møtrik for

item no. 04 item nr. 04
04 12/E Screw Skrue
05 1/E Flywheel Svinghjul
10 2/E Screw Skrue
11 1/E Guide pin Styrestift
Qty./E = Qty./Engine Qty./E = Antal/Motor
07.02 - ES0
MAN Diesel
Plate
L28/32H
10
04
11
05
01
Crankshaft
(plate 61001)
03 02
07.02 - ES0
MAN Diesel
Plate
L28/32H
Item Item
02 18/E Screw Skrue

04 12/E Screw Skrue
10 2/E Screw Skrue
07.02 - ES0
MAN Diesel
Plate
L28/32H
10
04
11
05
01
Crankshaft
(plate 61001)
03 02
07.02 - ES0
MAN Diesel
Plate
L28/32H
Item Item
02 18/E Screw Skrue

04 12/E Screw Skrue
10 2/E Screw Skrue
07.02 - ES0
MAN Diesel
Plate
Page 1 (2) Torsional Vibration Damper 61004-05H
L28/32H
01
04*
05
02*
03*
10.14 - ES0
MAN Diesel
Plate
61004-05H Torsional Vibration Damper Page 2 (2)
L28/32H

Item Item
01 1/E Torsional vibration Svingningsdæmper

damper, with 30 mm med 30 mm monte-
mounting flange rings-flange
02* 1/E Plug screw Propskrue
03* 1/E Sample container Prøveudtagings-

beholder
04* 1/E O-ring O-ring
05+ Sampling kit for torsi- Prøvesæt for sving-

onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)
+ See also working + Se også arbejdskort

card 610-04.00 610-04.00
10.14 - ES0
MAN Diesel
Plate
L28/32H
01
04*
05
02*
03*
10.14 - ES0
MAN Diesel
Plate
L28/32H

Item Item


beholder


card 610-04.00 610-04.00
10.14 - ES0
MAN Diesel
Plate
L28/32H
01
04*
05
02*
03*
10.14 - ES0
MAN Diesel
Plate
L28/32H

Item Item


beholder


card 610-04.00 610-04.00
10.14 - ES0
MAN Diesel
Plate
L28/32H
01
04*
05
02*
03*
10.14 - ES0
MAN Diesel
Plate
L28/32H

Item Item


beholder


card 610-04.00 610-04.00
10.14 - ES0
MAN Diesel
Plate
L28/32H
01
04*
05
02*
03*
10.14 - ES0
MAN Diesel
Plate
L28/32H

Item Item


beholder


card 610-04.00 610-04.00
10.14 - ES0
MAN Diesel
Plate
L28/32H
01
04*
05
02*
03*
10.14 - ES0
MAN Diesel
Plate
L28/32H

Item Item


beholder


card 610-04.00 610-04.00
10.14 - ES0
MAN Diesel
Plate
Page 1 (2) Tuning Wheel 61004-06H
L28/32H
01
94.23 - ES0S
MAN Diesel
Plate
61004-06H Tuning Wheel Page 2 (2)
L28/32H
Item Item
01 1/E Tuning wheel with, Afstemningshjul med

30 mm mounting flan- 30 mm monterings-
ge flan-ge
94.23 - ES0S
Engine frame/Oil pan
511/611
MAN Diesel
Description
Engine Frame and Base Frame 611.01
Page 1 (1)
Edition 07H
L28/32H
Frame The crankshaft guide bearing is located at the fly-

wheel end of the engine.
The engine frame is made of cast iron, and is at-
tached to the top of the base frame by means of On the sides of the frame there are covers for acces
bolts. The cross girders of the frame are provided to the camshaft, the charge air receiver and crank-
with bores for the main bearings in which the crankcase. Some of the covers are fitted with relief valves
shaft is underslung, i.e. it is carried by the main which will act, should oil vapours in the crankcase be
bearing caps. ignited, for instance in the event of a hot bearing.
The main bearing caps are attached by means of

studs and nuts, which are loosened and tightened Base Frame
with the aid of hydraulic tools. After mounting, the
main bearing caps are further secured by means Engine and alternator (gear, pump) are mounted on
of bracing screws, which are screwed horizontally a common base frame which is in welded design.
into the sides of the caps and tightened against the
sides of the engine frame. The main bearings are The base frame is used as lubricating oil reservoir
equipped with replaceable shells which are fitted "wet sump".
without scraping.
08028-0D/H5250/94.08.12
91.13 - ES0U
MAN Diesel
Page 1 (2) Functional Test of Crankcase Safety Relief Valves Edition 04H
General

Shut-off fuel oil
Description:
Functional test of crankcase safety relief val-

ves. Hand tools:
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
61106 13 1/cyl.
Data: 61106 39 12/relief valve
61106 45 1/relief valve
06.46 - ES0
MAN Diesel
Edition 04H Functional Test of Crankcase Safety Relief Valves Page 2 (2)
General
Functional Testing
Functional testing of the crankcase safety relief Cover

valves cannot be performed during operation of the
engine, but it must be checked during overhauls that
the valve flap is movable. Relief
valve
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 floor with the pressure Fig 1 Cover with relief valve
area upwards.
3) Apply a weight at 18 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.
08028-0D/H5250/94.08.12
06.46 - ES0
MAN Diesel
Plate
Page 1 (2) Frame with Main Bearings 61101-11H
01
L28/32H
02
03 05
04 06
03
10 04
11
09
12
13
16 14
17 15
18
21+
19+
20 10
22
23
13 25
27
24
15
14
10
26+
23 22
21+
24
Cover
( Plate 61102)
06.49 - ES0
MAN Diesel
Plate
61101-11H Frame with Main Bearings Page 2 (2)
L28/32H
Item Item
01 1/C Wear ring Slidring 27 1/C Cylindrical pin Cylindrisk stift
02 3/C Protective cap, Beskyttelseshætte,

plastic plastik
+ Item No. 19, 21 and + Item nr. 19, 21 og 26
03 6/C Nut for Møtrik for 26 require an indi- kræver en individuel
cylinder cover cylinderdæksel vidual tilpasning før monte-
matching before ring,
04 6/C Cylinder cover Tap for mounting, contact kontakt MAN B&W,
stud cylinderdæksel MAN B&W, Holeby Holeby
05 3/C Protective cap, Beskyttelseshætte,

metal metal
09 6/C Sealing kit Tætningssæt for

for cap dæksel
10 Loctite 243 Loctite 243
11 Silicone oil Silikoneolie
12 1/E Frame Stativ
13 1/B Main bearing Hovedleje-

shell 2/2 skaller 2/2
14 1/B Locking piece Låsestykke
15 2/B Screw Skrue
16 4/E Safety sleeve Sikkerhedsbøsning
17 4/E Screw Skrue
19+ 1/E Guide bearing cap Styrelejedæksel
20 2/E Thrust bearing Trykleje
21+ 2/B Distance piece Afstandsstykke
22 6/B Screw Skrue
23 2/B Main bearing stud Hovedleje tap
24 2/B Nut for main Møtrik for

bearing stud hovedlejetap
25 2/B Bracing screw Sideskrue
26+ 1/C Main bearing cap Hovedlejedæksel
Qty./C = Qty/Cylinder Antal/C = Antal/Cylinder
Qty./B = Qty/Bearing Antal/B = Antal/Leje
06.49 - ES0
MAN Diesel
Plate Front Cover for

Page 1 (2)
Lubricating Oil Pump 61102-09H
L28/32H
01
02
For lubricating
oil pump, see
Plate 61501
05
03
06 04
07
91.45 - ES0S
MAN Diesel
61102-09H Front Cover for Plate

Page 2 (2)
Lubricating Oil Pump
L28/32H
Item Item
02 40/E Screw Skrue
04 2/E Nut Møtrik
07 6/E Screw Skrue
91.45 - ES0S
MAN Diesel

Page 1 (2)
Lubricating Oil Pump and Cooling Water Pump 61102-07H
L28/32H
Fresh water cooling pump

(Plate 61610)
13
01
14
02
03
12
04 11
10
09
08 04
05+
06
07
08
10
09
10 04
Lub. oil pump

(Plate 61501)
91.40 - ES0S
MAN Diesel

Page 2 (2)
Lubricating Oil Pump and Cooling Water Pump
L28/32H
Item Item
01 4/E Screw Skrue
02 4/E Locking plate Låseskive
04 52/E Screw Skrue
05+ 1/E Cover Dæksel
07 2/E Nut Møtrik
10 18/E Screw Skrue
14 2/E Nut Møtrik
+ Item No. 05 + Item nr. 05 kræver

require an individual en individuel til-
matching before pasning før montering,
mounting, contact kontakt MAN B&W,
91.40 - ES0S
MAN Diesel

Page 1 (2)
Lubricating Oil Pump and Cooling Water Pumps 61102-10H
L28/32H
Fresh water cooling pumps

(Plate 61610)
13
01
14
02
03
04
04
12
11 05+
10
06
07
08
09
10 04
Lub. oil pump

(Plate 61501)
92.38 - ES0S
MAN Diesel

Page 2 (2)
Lubricating Oil Pump and Cooling Water Pumps
L28/32H
Item Item
01 6/E Screw Skrue
02 6/E Locking plate Låseskive
04 58/E Screw Skrue
05+ 1/E Cover Dæksel
07 2/E Nut Møtrik
10 12/E Screw Skrue
14 4/E Nut Møtrik
+ Item No. 05 + Item nr. 05 kræver

require an individual en individuel til-
matching before pasning før montering,
mounting, contact kontakt MAN B&W,
92.38 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Covers on Frame 61106-20H
L28/32H
06.06 - ES0
MAN Diesel & Turbo
Plate
61106-20H Covers on Frame Page 2 (2)
L28/32H

Item Item
01 1/E Guard end aft Skærm, agter 27 /I Cover Dæksel
02 12/E Washer Skive 28 /I Gasket Pakning
03 12/E Screw Skrue 39 12/D Washer Skive
04 1/C Intermediate guard Mellemskærm 40 1/D Flange Flange
05 1/C Handle, upper Håndtag, øverst 45 1/D O-ring O-ring
06 1/C Handle, lower Håndtag, nederst
07 1/E Guard end fore Skærm, for + Item 14, 15 and 16 + Item 14, 15 og 16 er
are only mounted if kun monteret hvis mo-
08 1/C Intermediate gauge Mellemskærm, the engine is delive- toren er leveret uden
complete, Item 04, komplet, Item 04, red without fuel oil fuel olieforpumpe
05 and 06 05 and 06 feed pump
09 12/C Screw Skrue
10 1/C Cover for camshaft Dæksel for

housing Kamakselhus
12 Cover for Dæksel for

crankcase krumtaphus
+14 6/E Screw Skrue
+15 1/E Cover Dæksel
+16 1/E Gasket Pakning
17 6/D Self locking nut Selvlåsende møtrik
19 6/D Screw Skrue
24 Cover with safety Dæksel med sikker-

valve complete hedsventil komplet
25 1/D Safety valve Sikkerhedsventil,

complete komplet
26 /I Screw Skrue
Qty./D = Qty./Safety cover Antal/D = Antal/Sikkerhedsdæksel
06.06 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Covers on Frame 61106-14H
L28/32H
01 04
15 05
02
03
14
06 12
07
08
13
16
09
11
10
11
07.08 - ES0
MAN Diesel & Turbo
Plate
61106-14H Covers on Frame Page 2 (2)
L28/32H

Item Item
01 12/E Screw Skrue
02 1/E Sealing ring 2/2 Tætningsring 2/2
05 2/E Screw Skrue
06 6/E Screw Skrue
07 1/E Flange Flange
10 39/E Screw Skrue
11 1/E Cover 2/2 Dæksel 2/2
12 18/E Screw Skrue
15 2/E Nut Møtrik
16 4/E Nut Møtrik
07.08 - ES0
Turbocharger
512/612
MAN Diesel
Description
Turbocharger System 612.01
L28/32H
Fig. 1. Diagram for Turbocharger System
Turbocharger System The charging air cooler is of the compact tube-type

with a large cooling surface. The cooling water is pas-
The turbocharger system of the engine, which is a sed twice through the cooler, the end covers being
constant pressure system, consists of an exhaust designed with partitions which cause the cooling
gas receiver, a turbocharger, a charging air cooler water to turn.
and a charging air receiver, the latter being integrated
in the engine frame. The cooling water tubes are fixed to the tube plates
by expansion.
The turbine wheel of the turbocharger is driven by
the engine exhaust gas, and the turbine wheel drives From the exhaust valves, the exhaust is led through
the turbocharger compressor, which is mounted on water cooled intermediate pieces to the exhaust gas
the same shaft. receiver where the pulsatory pressure from the indi-
vidual exhaust valves is equalized and passed to the
Turbocharger, see separate manual. turbocharger as a constant pressure, and further to
the exhaust outlet and silencer arrangement.
The turbocharger pumps the air through the char-
ging air cooler to the charging air receiver. From the The exhaust gas receiver is made of pipe sections,
charging air receiver, the air flows to each cylinder one for each cylinder.The pipe sections are connected
through the inlet valves. to each other with compensators.This prevents exces-
sive stress in the pipes due to heat expansion.
03.26 - EO2S
MAN Diesel
612.01 Turbocharger System Description

Page 2 (2)
Edition 28H
L28/32H
In the cooled intermediate piece a thermometer for The purpose is to increase the compressor perfor-
reading the exhaust gas temperature is fitted. It is mance. With this system the engine can take up a
also possible to fit a sensor for remote reading. large momentary load increase.
To avoid excessive thermal loss and to ensure a The system is activated automatically and only when
reasonably low surface temperature, the exhaust the engine is exposed to a large momentary load
gas receiver is insulated. increase, see section 609.
The turbocharger is equipped with a jet system for

supply of extra driving torque to the compressor.
03.26 - EO2S
MAN Diesel
Description Cleaning the Turbocharger In Service 612.05
Page 1 (1)
Water Washing of Compressor Edition 07H
General
Compressor Chemical cleaning will not improve the cleaning
process as this primarily is based on the mechanical
Fouling of the airways depends primarily on the pu- effect from the impact of the water droplets.
rity of the inlet air and thus, in turn, on the general
maintenance condition of the machinery, i.e. mainly Certain types of fluid solvents can give formation
of the gas and oil tightness of the engines and on the of deposits on the compressor wheel, and should
fresh air ventilation system of the engine room. under no circumstances be used.
Fouling of air filter, compressor or charging air cooler The intervals between cleaning by injection of water
may be observed as changes in performance para- should be adjusted after assessing the degree and
meters: rate of fouling in the particular plant, i.e. based on
observations and experience.
- 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.
08028-0D/H5250/94.08.12
94.01 - ES0U
MAN Diesel
Description Cleaning the Turbocharger in Service 612.10

Page 1 (3)
Dry Cleaning - Turbine Edition 09H
L+V28/32H
Description Cleaning System
The tendency to fouling on the gas side of turbo- The cleaning system consists of a cleaning agent
chargers depends on the combustion conditions, container (2) with a capacity of approx. 0.5 liters and
which are a result of the load and the maintenance a removable cover. Furthermore the system consists
condition of the engine as well as the quality of the of an air valve (3), a closing valve (1) and two snap
fuel oil used. on connectors.
Fouling of the gas ways will cause higher exhaust The position numbers (2) and (3) indicate the system's
gas temperatures and higher wall temperatures of "blow-gun". Only one "blow-gun" is used for each
the combustion chamber components and will also engine plant. The blow-gun is working according to
lead to a higher fuel consumption rate. the ejector principle with pressure air (working air)
at 5-7 bar as driven medium. Injection time approx.
Tests and practical experience have shown that radi- 2 min. Air consumption approx. 5 Nm3/2 min.
al-flow 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 artifi-
cially shaped activated charcoal with a grain size of
1.0 mm to max. 1.5 mm should be used as cleaning
agents.
1 Closing valve 2 Container
The solid bodies have a mechanical cleaning effect 3 Air valve 4 working air inlet
which removes any deposits on nozzle vanes and 5 Exhaust pipe 6 Snap coupling
turbine blades.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine.
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 ex-cessive
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 - ES2S
MAN Diesel
612.10 Cleaning the Turbocharger in Service Description

Page 2 (3)
Edition 09H Dry Cleaning - Turbine
L+V28/32H
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.:(31) 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 - ES2S
MAN Diesel

Page 3 (3)
Dry Cleaning - Turbine Edition 09H
L+V28/32H
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

Teglholmsgade 41 2450 København SV, Danmark
Tel.: +45 33 851100 Fax.: +45 33 851030
The list is for guidance only and must not be considered complete. We under-
take no responsibility that might be caused by these or other products.
97.08 - ES2S
MAN Diesel
Page 1 (1)
Water Washing - Turbine Side Edition 02H
General
Description Heavily contaminated turbines, which where not
cleaned periodically from the very beginning or after
The tendency to fouling on the gas side of turbo- an overhaul, cannot be cleaned by this method.
chargers depends on the combustion conditions,
which are a result of the load on and the maintenance If vibration in the turbocharger occur after water-wa-
condition of the engine as well as the quality of the shing has been carried out, the washing should be
fuel oil used. repeated. If unbalance still exists, this is presumably
due to heavy fouling, and the engine must be stop-
Fouling of the gas ways will cause higher exhaust ped and the turbocharger dismantled and manually
gas temperatures and higher surface temperatures cleaned.
of the combustion chamber components and will
also lead to a lower performance. The washing water should be taken from the fresh
water system and not from the fresh cooling water
Tests and practical experience have shown that system or salt water system. No cleaning agents are
radial-flow turbines can be successfully cleaned solvents need to be added to the water.
by injection water into the inlet pipe of the turbine.
The cleaning effect is based on the water solubility To avoid corrosion during standstill, the engine must,
of the deposits and on the mechanical action of the upon completing of water washing run far at least 1
impinging water droplets and the water flow rate. hour before stop so that all parts are dry.
The necessary water flow is dependent on the gas

flow and the gas temperature. Enough water must be Water Washing System
injected per time unit so that, not the entire flow will
evaporate, but about 0.25 l/min. will flow off through The water washing system consists of a pipe system
the drainage opening in the gas outlet.Thus ensuring equipped with a regulating valve, a manoeuvring
that sufficient water has been injected. valve, a 3-way cock and a drain pipe with a drain
valve from the gas outlet, see illustration on work
Service experience has shown that the above card 612-15.00.
mentioned water flow gives the optimal reduced or
disappear. If the recommended water flow is exceed, The water for washing the turbine, is supplied from
there is a certain risk of a accumulation of water in the external fresh water system through a flexible
the turbine casing, which can result in damage on hose with couplings. The flexible hose must be
the turbocharger. disconnected after water washing.
The best cleaning effect is obtained by cleaning at By activating the manoeuvring valve and the regu-
low engine load approx. 20% MCR. Cleaning at low lating valve, water is led through the 3-way cock to
load will also reduce temperature shocks. the exhaust pipe intermediate flange, equipped with
a channel to lead the water to the gas inlet of the
Experience has shown, that washing at regular inter- turbocharger.
vals is essential to successful cleaning, as excessive
08028-0D/H5250/94.08.12
fouling is thus avoided. Washing at intervals of 100 The water which is not evaporated, is led out through
hours is therefore recommended. Depending on the the drain pipe in the gas outlet.
fuel quality these intervals can be shorter or longer.
However, the turbine must be washed at the latest
when the exhaust gas temperature upstream of the
turbine has risen about 20° C above the normal
temperature.
92.01 - ES0U
MAN Diesel
Page 1 (2) Overhaul of Charging Air Cooler Edition 02H
L+V28/32H

Shut-off fuel oil
Description:
Overhaul of charging air cooler.

Hand tools:

Starting position: Allen key, 10 mm.
Wire rope.
Tackle.
Related procedure:
08028-0D/H5250/94.08.12
Working time : 3-4 Hours Plate no. Item no. Qty. /

Capacity : 2 men
61203 14 8/cooler
Data: 61203 35 1/cooler
61203 37 1/cooler
Data for pressure and tolerance (Page 600.35) 61203 39 1/cooler
96.30 - ES0S-G
MAN Diesel

Edition 02H Overhaul of Charging Air Cooler Page 2 (2)
L+V28/32H
The charging air cooler is normally cleaned and 4) Clean the cooler element of the water and air
overhauled at the intervals indicated in the "Planned sides.
Maintenance Program", or if observations prove that
the cooler does not work satisfactory, see section After using cleaning agents the manufacting recom-
602. mendting must be followed.
The greatest care must be exercised when dismant-

Overhaul of Charging Air Cooler. ling cleaning and mounting the cooler element, as
the thin fins of the tubes cannot stand impacts and
1) Close the cooling water inlet and outlet valves pressure.
and disconnect the pipes.
If nevertheless, the metal is damaged, it should be
2) Remove the screw (1), fig. 1, which secure the carefully straightened, as bent fins will increase the
end cover of the cooler element to the cooler hous- pressure drop across the cooler considerably.
ing, and pull the cooler element half-way out.
Should one ore more cooler tubes become leaky
Place a wire rope round the cooler element and at- it/they must immediately be made tight, either by
tach a tackle hook, after which the elements are lifted expending the tube ends into the tube plates or by
and pulled out of the cooler housing and landed on blanking of the tube(s) concerned with plugs.
a couple of wooden planks on the floor.
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

5 with an anti-corrosion blocks agent. Inspect the anti-
corrosion (6) and renew if necessary.
4
Note: That paint or similar must not be applied to
6 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.
3 7) When mounting the air cooler, renew all gas-

kets.
2
08028-0D/H5250/94.08.12
1
Out of Service Periods.
At longer periods out of service the air cooler is

Fig. 1. drained if the coolant is sea water followed by flushing
with fresh water and left with drain and venting cocks
open.
3) Remove screws (2) and end cover (3) reversal
chamber (4) and side plates (5). At fresh water coolant systems recommendations
for the entire system is followed.
96.30 - ES0S-G
MAN Diesel
Page 1 (2) Charge Air Cooler Housing - Draining Edition 02H
L+V28/32H
Safety Precautions: Special Tools:

Shut-off fuel oil
Description:
Check of drain from charge air cooler housing.

Hand Tools:
Starting Position:
Related Procedure:
Replacement and Wearing Parts:
Plate No Item No Qty. /

08028-0D/H5250/94.08.12
Man Power:
Working time :
Capacity : 1 person
Data:

97.08 - ES0S
MAN Diesel

Edition 02H Charge Air Cooler Housing - Draining Page 2 (2)
L+V28/32H
In order to prevent water from collecting at the bottom
of the gas outlet of the turbocharger, the charge air
cooler and the charge air receiver, the charge air
cooler is equipped with a drain and an automatic
water discharger.
This installation will prevent water from the charge

air to be sucked into the engine, where it will destroy
the lubricating oil film on the cylinder walls, resulting
in increasing wear. Further, the water will cause
corrosion of the intake components.
Therefore, frequent control of the drain and the water

discharger has to take place to secure that these
components are free of foreign substances which
could foul them.
1) The drain screw at the bottom of the water

discharger has to be loosened and cleaned of im-
purities, if any.
Fig 1 Placement of Steam Trap
If, with the drain screw dismounted If, with the drain screw dismounted
- a constant air flow is present: - no constant air flow is present:
1. Everything is all right. 1. Dismount the drain pipe and blow-through the
pipe by means of compressed air.
2. Mount the drain screw at the bottom of the Clean the discharge hole in the charge air
water discharger. cooler in order to secure a clear passage of
water.
2. Mount the drain pipe and check with your hand

08028-0D/H5250/94.08.12
that a constant air flow is present.
3. Mount the drain screw at the bottom of the

water discharger.
97.08 - ES0S
MAN Diesel
Working Card Water Washing of Compressor Side 612-05.00
Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R.
L+V28/32H

Shut-off fuel oil
Description:
Water washing of compressor side.

Turbocharger cleaning with engine in service. Hand tools:
Starting position:
Related procedure:
Working time : 1/4 hour Plate no Item no Qty. /

Capacity : 1 man
See the special instructions for turbocharger.
Data:

96.30 - ES0S
MAN Diesel
612-05.00 Water Washing of Compressor Side Working Card

Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R
L+V28/32H
Before Cleaning
The cleaning process is only to be carried out when 3) Fill the container with 2 litres fresh water (see
the engine is at operating temperature (see Opera- the scale on the container).
ting Data 600.30) and when it is loaded as close as
possible to full load (see Main Data 600.00).
Warning: Do not use sea water or cooling water.
See also "Description for Water Washing of Com-
pressor side", 612.05.
4) Mount the top cover on the container.
Cleaning Procedure 5) Blow air into the container by means of a blow

gun, until an operation pressure of 3 bar is reached
1) Run the engine with as high a load as pos- (see fig 2).
sible.
2) Discharge the excesspressure in the container The safety valve will open at a pressure of 4 bar.
by drawing out the spindle in the safety valve (see
fig. 1) before loosening the top cover. Excesspressure will discharge through the safety
valve.
The spindle returns automatically by means of a
built-in spring.
Fig 1 Fig 2
96.30 - ES0S
MAN Diesel
Working Card Water Washing of Compressor Side 612-05.00

Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R.
L+V28/32H
6) Connect the plug-in coupling of the lance to
the snap coupling on the pipe (see fig 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

1 Injection tube 5 Hand valve with handle unaltered high load.
2 Pipe 6 Container
3 Snap coupling 7 Charge air line
4 Plug-in coupling 10) Compare the measurements of the operating
data (see fig 4) before and after the cleaning proce-
dure (see Operating Data 600.30).
Fig 3
IF THEN
the comparison indicates success of the the water washing of the compressor side
washing procedure is finished
the comparison indicates lack of the wa- carry out the washing procedure from step
shing procedure 1 with 10 minutes interval from the initial
washing
severe dirt is being deposited in the com- dismantling of the compressor components
pressor for manual cleaning is necessary (see spe-
cial turbocharger manual in section 612).
Fig 4
96.30 - ES0S
MAN Diesel
Page 1 (2) Dry Cleaning of Turbocharger - Turbine Side Edition 02H
L+V28/32H

Shut-off cooling water Blow gun with container.
Shut-off fuel oil
Description:
Dry cleaning of turbine side, cleaning with engine

in service. Hand tools:
Starting position:
Related procedure:

Capacity : 1 man
See the special instruction for turbocharger.
Data:

97.07 - ES0S
MAN Diesel

Edition 02H Dry Cleaning of Turbocharger - Turbine Side Page 2 (2)
L+V28/32H
Cleaning Procedure.
1) The cleaning is carried out during high engine 2) Before connecting the "blow-gun" open the
load minimum 75 % at full load. closing valve (1), see fig 1 and check whether there
is free passage.
3) Fill cleaning granulated substance into the

container (2) for turbocharger type:
NR20/R - NR20S: 0.2 - 0.3 liters.

NR24/R - NR26/R: 0.3 - 0.4 liters.
Connect to the working air system (4), 5 -7 bar.
4) Connect the "blow-gun" to valve (1). Open air

valve (3).
Then open valve (1) slowly until a whisling sound

indicates that blowing-in of granulated substance
takes place.
1 Closing valve 2 Container Injection time approx. 2 min.

3 Air valve 4 working air inlet
5 Exhaust pipe 6 Snap coupling For dry cleaning of turbine side, see also description
612.10 "Cleaning the Turbocharger in Service, Dry
Cleaning - Turbine Side.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine.
97.07 - ES0S
MAN Diesel
Page 1 (2) Water Washing of Turbine Side Edition 01H
General

Shut-off fuel oil
Description:
Water washing of turbine side, cleaning with

engine in service. Hand tools:
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
See the special instruction for turbocharger.
Data:

91.04 - ES0S
MAN Diesel
Edition 01H Water Washing of Turbine Side Page 2 (2)
General
Cleaning Procedure. 3) Turn the 3-way cock to position 2 "Open", see
fig. 2 and check for free passage. If ok turn to the
1) Adjust the engine load to approx. 20 % and let water wash position 3 "Wash".
the engine stabilize for 10 min.
4) Connect the water supply to the water wash
2) Open the drain cock at the turbocharger outlet system.
and check for free passage, see fig. 1.
5) Activate the manoeuvring valve, see fig. 1.
Then open the regulating valve and adjust the water

flow until the drain flow is approx. 0,25 l/min.
3-way cock
6) Continue the water washing 5 - 10 min. or until
the drain water is free of particles.
Plate with clean-
ing instruction 7) Release the manoeuvring valve and disconnect
the water supply.
Manoeuvering
valve
Turn the 3-way cock to position 1, "Closed" and check
Regulating valve that the water drain flow has stopped.
Cleaning water
inlet 8) Continue at this load at least 5 min. before
Drain cock increasing the load to the normal condition.
9) After the water washing, the engine should run

for at least 1 hour before stop.
Fig. 1. Arrangement for water washing. 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 descrip-

tion for water washing.
08028-0D/H5250/94.08.12
Fig. 2. 3-way cock.
91.04 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-12H
5-6L28/32H
08028-0D/H5250/94.08.12
97.06 - ES0S
MAN Diesel
Plate
61201-12H Charging Air Cooler - Freshwater Page 2 (2)
5-6L28/32H
Item Item
017 1/K Crossmember Travers
030 2/K Pipe Rør
042 1/K Cooler block Kølerblok
054 1/K Gasket end cover Pakning endedæksel
066 4/K Plug screw Propskrue
078 4/K Cu-washer Cu-skive
091 1/K End cover Endedæksel
101 4/K Nut Møtrik
113 8/K Screw Skrue
125 1/K Side plate right Sideplade højre
137 1/K Gasket reversing Pakning vendekam-

cover mer
149 1/K Reversing cover Vendekammer
150 32/K Screw Skrue
174 5/K Screw Skrue
198 5/K Screw Skrue
208 1/K Side plate left Sideplade venstre
221 4/K Screw Skrue
233 1/K O-ring O-ring
245 1/K Plug Prop
257 1/K Gasket Pakning
304 1/E Charging air cooler, Ladeluftkøler, komplet,

complete, incl. item inkl. item 017, 029, 030,
017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
08028-0D/H5250/94.08.12
125, 137, 149, 150, 162, 150, 162, 174, 186, 198,
174, 186, 198, 208, 221, 208, 221, 233 og 245
233 and 245
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler
97.06 - ES0S
MAN Diesel
Plate
7-8-9L28/32H
08028-0D/H5250/94.08.12
97.06 - ES0S
MAN Diesel
Plate
7-8-9L28/32H
Item Item
030 2/K Pipe Rør
101 4/K Nut Møtrik
113 8/K Screw Skrue

cover mer
174 5/K Screw Skrue
198 5/K Screw Skrue
221 4/K Screw Skrue
245 1/K Plug Prop

017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
08028-0D/H5250/94.08.12
125, 137, 149, 150, 162, 150, 162, 174, 186, 198,
174, 186, 198, 208, 221, 208, 221, 233 og 245
233 and 245
97.06 - ES0S
MAN Diesel
Plate
5-6L28/32H
08028-0D/H5250/94.08.12
97.06 - ES0S
MAN Diesel
Plate
5-6L28/32H
Item Item
030 2/K Pipe Rør
101 4/K Nut Møtrik
113 8/K Screw Skrue

cover mer
174 5/K Screw Skrue
198 5/K Screw Skrue
221 8/K Screw Skrue
269 1/K Ring Ring
270 1/K Drain pipe for WMC Drænrør for WMC
294 1/K Water mist catcher Vandudskiller

08028-0D/H5250/94.08.12
017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
125, 137, 149, 150, 174, 150, 174, 186, 198,
186, 198, 208, 221, 233, 208, 221, 233, 269, 270
269, 270 and 294 og 294
97.06 - ES0S
MAN Diesel
Plate
7-8-9L28/32H
08028-0D/H5250/94.08.12
97.06 - ES0S
MAN Diesel
Plate
7-8-9L28/32H
Item Item
030 2/K Pipe Rør
101 4/K Nut Møtrik
113 8/K Screw Skrue

cover mer
174 5/K Screw Skrue
198 5/K Screw Skrue
221 8/K Screw Skrue
269 1/K Ring Ring
270 1/K Drain pipe for WMC Drænrør for WMC

08028-0D/H5250/94.08.12
017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
125, 137, 149, 150, 174, 150, 174, 186, 198,
186, 198, 208, 221, 233, 208, 221, 233, 269, 270
269, 270 and 294 og 294
97.06 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Seawater 61201-16H
5-6L28/32H
08028-0D/H5250/94.08.12
97.45 - ES0S
MAN Diesel
Plate
61201-16H Charging Air Cooler - Seawater Page 2 (2)
5-6L28/32H
Item Item
017 1/K Crossmember Travers 304 1/E Charging air cooler, Ladeluftkøler, komplet,
029 1/K Crossmember Travers 017, 029, 030, 042, 042, 054, 066, 078, 091,
054, 066, 078, 091, 101, 101, 113, 125, 137, 149,
030 2/K Pipe Rør 113, 125, 137, 149, 150, 150, 174, 186, 198, 208,
174, 186, 198, 208, 221, 221, 233, 269, 270, 294,
042 1/K Cooler block Kølerblok 233, 269, 270, 294, 316, 316, 328, 341
328, 341
end cover endedæksel 316 12/K Nut Møtrik
066 4/K Plug screw Propskrue 328 6/K Anti-corrosion block Anode
078 4/K Cu-washer Cu-skive 341 12/K Stud Tapskrue
101 4/K Nut Møtrik
113 8/K Screw Skrue
125 1/K Top plate Topplade

reversing cover vendekammer
174 5/K Screw Skrue
198 5/K Screw Skrue
208 1/K Bottom plate Bundplade
221 8/K Screw Skrue
269 1/K Ring Ring
270 1/K Drain pipe for Drænrør for

water mist catcher vandudskiller

08028-0D/H5250/94.08.12
97.45 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Seawater 61201-17H
7-8-9L28/32H
08028-0D/H5250/94.08.12
97.45 - ES0S
MAN Diesel
Plate
61201-17H Charging Air Cooler - Seawater Page 2 (2)
7-8-9L28/32H
Item Item
017 1/K Crossmember Travers 304 1/E Charging air cooler, Ladeluftkøler, komplet,
029 1/K Crossmember Travers 017, 029, 030, 042, 042, 054, 066, 078, 091,
054, 066, 078, 091, 101, 101, 113, 125, 137, 149,
030 2/K Pipe Rør 113, 125, 137, 149, 150, 150, 174, 186, 198, 208,
174, 186, 198, 208, 221, 221, 233, 269, 270, 294,
042 1/K Cooler block Kølerblok 233, 269, 270, 294, 316, 316, 328, 341
328, 341
end cover endedæksel 316 12/K Nut Møtrik
066 4/K Plug screw Propskrue 328 6/K Anti-corrosion block Anode
078 4/K Cu-washer Cu-skive 341 12/K Stud Tapskrue
101 4/K Nut Møtrik
113 8/K Screw Skrue
125 1/K Top plate Topplade

reversing cover vendekammer
174 5/K Screw Skrue
198 5/K Screw Skrue
208 1/K Bottom plate Bundplade
221 8/K Screw Skrue
269 1/K Ring Ring


08028-0D/H5250/94.08.12
97.45 - ES0S
MAN Diesel
Plate
L28/32H
318
081 176 056

296
306 081
007
235
019
247
103
115 044
068
188 330
139
272
164
176
223 032
176
211
284
08028-0D/H5250/94.08.12
260
127
140
093
259 152 020
093
07.12 - ES0
MAN Diesel
Plate
L28/32H
Item Item
007 1/K End cover Endedæksel 306 4/K Gasket Pakning
019 1/K Gasket for Pakning for 318 1/E Charge air cooler, Ladeluftkøler,
end cover endedæksel complete komplet
020 2/K Reversing chamber Vendekammer 330 1/K Gasket Pakning
032 1/K Gasket for Pakning for

reversing chamber vendekammer
056 5/K Screw Skrue
068 5/K Gasket ring Pakningsring
081 5/K Screw Skrue
103 1/K Ring by drain pipe Ring ved drænrør
127 1/K Side cover- right Sidedæksel - højre
139 1/K Side cover- left Sidedæksel - venstre
152 2/K Distance pipe Afstandsrør
164 4/K Nut Møtrik
176 /I Locktite Locktite
188 8/K Screw Skrue
211 8/K Screw Skrue
223 8/K Washer Skive

259 8/K Spring, straight pin Spændestift

slotted
260 8/K Spring, side cover Fjeder, sideplade
272 4/K Lock, side cover Lås, sideplade

08028-0D/H5250/94.08.12
284 8/E Screw Skrue
Qty./I = Individual Antal/I = Individuelt
07.12 - ES0
MAN Diesel
Plate
Page 1 (2) Exhaust Pipe Arrangement 61202-23H
5,6L28/32H
11 08 05 05
06 10 08 10
11 07 05 10 04
09
11
16
14 13
15 12
23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34
91.18 - ES0S
MAN Diesel
Plate
61202-23H Exhaust Pipe Arrangement Page 2 (2)
5,6L28/32H
Item Item
04 1/E End cover, aft Endeplade, bag 30 1/C Gasket Pakning
05 Exhaust pipe Udstødsrør 31 1/C Gasket Pakning

5/E 6 cyl. engine 6 cyl. motor 32 1/C O-ring O-ring
06 1/E Exhaust pipe, Udstødsrør, tilgang 33 1/C Cooling water Kølevandsnippel

inlet TC. turbolader nipple
07 1/E Exhaust pipe for Udstødsrør for 34 1/C O-ring O-ring

cyl. 1 cyl. 1
08 Compensator Kompensator
09 1/E Compensator Kompensator
10 Gasket Pakning
12 Screw Skrue
13 Nut Møtrik
14 8/E Screw Skrue
15 8/E Nut Møtrik
16 16/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
26 1/C Intermediate piece Mellemstykke
28 4/C Screw Skrue
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder
91.18 - ES0S
MAN Diesel
Plate
Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-32H
5,6L28/32H
17
06
11 07 08 04
09 05
11
16
14
15
23 28
22
29
30
20 31
21
22
23
24
25
26 32
27 33
34
92.38 - ES0S
MAN Diesel
Plate
61202-32H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)
5,6L28/32H
Item Item
04 1/E End cover, aft Endeplade, bag
05 Exhaust pipe Udstødsrør

06 1/E Exhaust pipe, Udstødsrør, tilgang

inlet TC. turbolader
07 1/E Exhaust pipe for Udstødsrør for

cyl. 1 cyl. 1
14 8/E Screw Skrue
15 8/E Nut Møtrik
16 16/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
28 4/C Screw Skrue
33 1/C Cooling water Kølevandsnippel

nipple
92.38 - ES0S
MAN Diesel
Plate
7,8L28/32H
17 08 05 05
06 10 08 10
11 07 05 10 04
09
11
16
14 13
15 12
23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34
91.18 - ES0S
MAN Diesel
Plate
7,8L28/32H
Item Item
04 1/E End cover, aft Endeplade, bag 29 1/C Plug screw Propskrue
05 Exhaust pipe Udstødsrør 30 1/C Gasket Pakning

7/E 8 cyl. engine 8 cyl. motor 31 1/C Gasket Pakning
06 1/E Exhaust pipe, Udstødsrør, tilgang 32 1/C O-ring O-ring

07 1/E Exhaust pipe for Udstødsrør for nipple
cyl. 1 cyl. 1
10 Gasket Pakning
12 Screw Skrue
13 Nut Møtrik
14 8/E Screw Skrue
15 8/E Nut Møtrik
16 16/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
28 4/C Screw Skrue
91.18 - ES0S
MAN Diesel
Plate
7,8L28/32H
17
06
11 07 08 04
09 05
11
16
14
15
23 28
22
29
30
20 31
21
22
23
24
25
26 32
27 33
34
92.07 - ES0S
MAN Diesel
Plate
7,8L28/32H
Item Item
05 Exhaust pipe Udstødsrør



cyl. 1 cyl. 1
14 8/E Screw Skrue
15 8/E Nut Møtrik
16 16/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
28 4/C Screw Skrue

nipple
92.07 - ES0S
MAN Diesel
Plate
9L28/32H
16 08 05 05
06 10 08 10
11 07 05 10 04
09
11
15
14
12 13
13 12
23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34
91.18 - ES0S
MAN Diesel
Plate
9L28/32H
Item Item
05 8/E Exhaust pipe Udstødsrør


cyl. 1 cyl. 1
12 216/E Screw Skrue
13 216/E Nut Møtrik
14 12/E Screw Skrue
15 12/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
28 4/C Screw Skrue
33 1/C Cooling water nipple Kølevandsnippel
91.18 - ES0S
MAN Diesel
Plate
9L28/32H
17
06
11 07 08 04
09 05
11
16
14
15
23 28
22
29
30
20 31
21
22
23
24
25
26 32
27 33
34
97.08 - ES0S
MAN Diesel
Plate
9L28/32H
Item Item
05 8/E Exhaust pipe Udstødsrør


cyl. 1 cyl. 1
14 12/E Screw Skrue
15 12/E Nut Møtrik
16 24/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
28 4/C Screw Skrue

nipple
97.08 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Water Washing of Compressor Side 61205-02H
L+V28/32H
26*
23
25*
24*
27 01*
02*
03*
07
04*
08
05*
09
06*
10
22
21 11
20 12
19 13*
09
10
18
16
14*
17
15*
94.01 - ES0S
MAN Diesel & Turbo
Plate
61205-02H Water Washing of Compressor Side Page 2 (2)
L+V28/32H

Item Item
01* 1/E Top cover with non- Topdæksel med kon- 25* 1/E Straight male stud Ligeforskruning
return valve traventil coupling
02* 1/E O-ring for top cover O-ring for topdæksel 26* 1/E Plug in coupling Kobling
03* 1/E O-ring for non-return O-ring for kontraventil 27 1/E Lance complete, incl. Lanse komplet, inkl.
valve item 24-25 and 26 item 24-25 og 26
04* 1/E Valve seat Ventilsæde 28 1/E Container complete, Beholder komplet, som
as shown on plate vist på plate
05* 1/E Spring for non-return Fjeder for kontraventil
valve
06* 1/E Cap screw for non- Omløber til

return valve kontraventil
07 1/E Top cover with non- Topdæksel med kontra-

return valve complete, ventil komplet, inkl. item
incl. item 01-02-03-04- 01-02-03-04-05 og 06
05 and 06
08 1/E Safety valve Sikkerhedsventil
10 2/E Finger nut Fingermøtrik
11 1/E Cap Top
12 1/E Gasket for the cap Pakning for top
13* 1/E Cable binder Kabelbinder
14* 1/E Strap Gjord
15* 1/E Eye for strap Øje for gjord
16 1/E Strap complete, incl. Gjord komplet, inkl. item

item 13-14 and 15 13-14 og 15
17 1/E Container Beholder
18 1/E Flexible pipe Fleksibel slange
19 1/E Handle with flexible Håndtag med fleksibel

pipe and cap screw slange og omløber
20 1/E Filter insert Filterinsats
21 1/E Gasket for handle Pakning til håndtag
22 1/E Hand valve Håndventil
23 1/E Gasket for Pakning til

hand valve håndventil
24* 1/E Lance Lanse
94.01 - ES0S
MAN Diesel
Plate
Page 1 (2) Steam Trap 61208-01H
L+V28/32H
01
05
02
06
03
04
07
97.07 - ES0S
MAN Diesel
Plate
61208-01H Steam Trap Page 2 (2)
L+V28/32H
Item Item
01 1/E Steam trap, Vandudlader,

complete komplet
02 1/E Packing Pakning
03 1/E Clip Klemme
04 1/E House, bottom Hus, bund
05 1/E House, top Hus, top
06 1/E Swimmer Svømmer
07 1/E Valve Ventil
Qty./E = Qty./Engine Qty./E = Qty./Motor
97.07 - ES0S
MAN Diesel
Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 61210-02H
General
053
016 112 028 041 028 065 077
089 148
100
136
08028-0D/H5250/94.08.12
01.12 - ES0
MAN Diesel
Plate
61210-02H Blowgun for Dry Cleaning of Turbocharger Page 2 (2)
General
Item Item
016 1/E Snap coupling Snapkobling
028 2/E Nipple Nippel
041 1/E Tee T-stykke
053 1/E Ball valve Kugleventil
100 1/E Container, complete beholder, komplet
112 1/E Socket Muffe
136 1/E Blowgun, complete Rensepistol, complete
148 /I Granulate Granulat
08028-0D/H5250/94.08.12
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
01.12 - ES0
Compressed air system
513/613
MAN Diesel
Description
Compressed Air System 613.01
Page 1 (2)
Edition 20H
L28/32H
On-off valve
for jet-system
K1
Main
starting
valve
Overspeed
device
Starting
valve
Stop cylin- Emergency

der starting valve
Air starter
Cyl. 1
Fig. 1. Diagram for Compressed Air System
General Starting System
The compressed air system on the engine contains The engine is started by means of a built-on air
a starting system, starting control system and safety starter, which is of the turbine starter motor type
system. Further, the system supplies air to the jet with gear box, safety clutch and drive shaft with
system. pinion. Further, the starting system consists of a
main starting valve.
The compressed air is supplied from the starting air
receivers (30 bar) through a reduction station, where
from compressed air is supplied to the engine. Control System
To avoid dirt particles in the internal system, a dirt se- The air starter is activated electrically with a pneu-
08028-0D/H5250/94.08.12
parator is mounted in the inlet line to the engine. matic 3/2 way solenoid valve (starting valve).
The intervals between cleaning and draining will The valve can be activated manually from the star-
depend on the condition of the air in the main sup- ting box on the engine, and it can be arranged for
ply system, and has therefore to be determined remote control, manual or automatic.
according to service experience gained with the
particular plant. For remote activation, the starting spool must be
connected so that every starting signal to the starting
Note: Due to the safety system, the air supply to spool goes through the converter for engine RPM
the engine must not be interrupted during operation signal or via the engine control box if supplied.
of the engine.
94.23 - ES0S
MAN Diesel
613.01 Compressed Air System Description

Page 2 (2)
Edition 20H
L28/32H
Further, the system is equipped with an emergency Safety System
starting valve which makes it possible to activate the
air starter manually in case of a power failure. As standard the engine is equipped with a pneu-
matically/mechanically overspeed device, which
starts to operate if the maximum permissible RPM
Emergency Starting Valve is exceeded. This device is fitted to the end cover
of the engine driven lubricating pump and is driven
The emergency starting valve is activated by means from the pump through a resilient coupling, see
of a screw-driver or similar as illustrated in fig. 2. section 609.
When the maximum permissible RPM is exceeded,

the overspeed device will activate a pneumatically
controlled stop cylinder, which will bring the fuel
index to zero and stop the engine.
Pneumatic Start Sequence

Press down Emergency
start valve
⇓ When the starting valve is opened, air will be supplied
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 fly wheel.
When the pinion is fully engaged, the pilot air will

flow to, and open the main starting valve, whereby
air will be led to the air starter, which will start to
Fig. 2. Emergency start valve turn the engine.
Simultaneously with air supply for the air starter, air

will be supplied to the fuel limitating cylinder, thus
limiting the fuel supply during the start sequence.
When the RPM exceeds approx. 110, at which firing

has taken place, the starting valve is closed whereby
the air starter is disengaged.
08028-0D/H5250/94.08.12
94.23 - ES0S
MAN Diesel
Page 1 (2) Air Filter Edition 02H
General

Shut-off fuel oil
Cleaning and/or maintenance of air filter.
Starting position
Related procedure
08028-0D/H5250/94.08.12
Working time : hours Plate no Item no Qty/

Capacity : man
Data

02.46 - ES0
MAN Diesel
Edition 02H Air Filter Page 2 (2)
General
Cleaning Air Filter To replace filter element
1) Depressurize unit. 7) Depressurize unit.
2) Remove bowl and bowl guard assembly by 8) Remove bowl and bowl assembly by turning
turning counter-clockwise. counter-clockwise.
3) Inspect bowl for damage seals and replace, if 9) Unscrew baffle by turning counter-clockwise.
nessesary.
10) Remove filter element and discard.
4) If bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth or mild detergent. 11) Install new filter element and reassemble in
reverse order.
5) Before returning to service, insure that all seals
have been reinstalled or replaced. 12) 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 13) Reinstall bowl and bowl guard assembly and
place. Align arrow on bowl guard with arrow on filter rotate bowl guard clockwise to securely lock in
body. place. Align arrow on bowl guard with arrow on filter
body.
08028-0D/H5250/94.08.12
Fig 1 Air Filter
02.46 - ES0
MAN Diesel

Page 1 (9) Overhaul, Test and Inspection of Turbine Starter Edition 02H
L+V28/32H

Shut-off cooling water 62006 xx 20 - 120 Nm.
Shut-off fuel oil
Description:
Disassembly, overhaul and assembly of the air

starter. Hand tools:
Allen key, 4 mm.

Allen key (long), 8 mm.
Screwdriver.
Starting position: Big screwdriver.
Chisel.
All connection to the air starter have been re- Retaining ring pliers.
moved, and air starter is removed. Plastic hammer.
Lubricating oil.
Copaslip or similar.
Sleeve.
Bearing puller.
Related procedure: Impact Wrench
Bearing pressing tool.
08028-0D/H5250/94.08.12

Capacity : 1 man
See plate 61309.
Data:

03.47 - ES0-G
MAN Diesel

Edition 02H Overhaul, Test and Inspection of Turbine Starter Page 2 (9)
L+V28/32H
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
(38) 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 fit 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 Fig 1.
starter.
4. When grasping a part in a vise, always use 5. Remove the deflector retaining screw (5), de-
copper-covered vise jaws to protect the surface of the flector retai-ning spring (4) and the splash deflector
part and help prevent distortion. This is particularly (3) from the housing exhaust cover (1), See fig 2.
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 fine 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

08028-0D/H5250/94.08.12
cover (67) from the housing exhaust cover (1).

Fig 2.
3. Using an 8 mm hex-head wrench, unscrew

and remove the starter assembly cap screws (6) 6. Tap the motor housing with a plastic hammer
and washers (7), See fig 1. to dislodge it from the intermediate gear case (13).
4. Pull the housing exhaust cover (1) from the 7. Grasp the rear of the motor assembly (12) and
motor housing (8). To dislodge the housing exhaust pull it from the rear of the motor housing (8).
cover, rotate it until the ears clear the motor housing. If the motor assembly (12) is difficult to remove, lightly
Using a plastic hammer, tap the ears alternately until push the motor pinion which is on the front of the
the housing cover can be removed from the motor motor assembly toward the exhaust side of the motor
housing. housing in order to free the motor assembly.
03.47 - ES0-G
MAN Diesel

L+V28/32H
8. Tap the intermediate gear case (13) with a 13. Remove the planet gear frame assembly from
plastic hammer to dislodge it from the gear case the intermediate gear case. Using a sleeve that con-
(28). tacts the outer race of the front gear frame bearing
(17), press the planet gear frame shaft seal (16) and
9. Position the intermediate gear case (13) on a the front gear frame bearing (17) from the front end
bench in a copperfaced vise so that the intermediate and out of the rear of the intermediate gear case.
pinion (26) is secured in the jaws of the vise. Tighten
the vise only enough to hold the intermediate pinion 14. Remove the rear gear frame bearing (24) from
securely. the planet gear frame (18), using a bearing puller
and remove the gear shaft retaining washer (23),
10. Loosen the intermediate pinion retaining screw See fig. 4.
(27) 1-1/2 turns only. Do not remove. Remove the planet gear shafts (22), planet gears
(19), planet gear bearings (20) and bearing spac-
Warning: If the intermediate gear case is not sup- ers (21).
ported on a bench and if the intermediate pinion
retaining screw is completely removed, the interme- 15. Remove the front bearing spacer (25), using
diate gear case and compoments could fall causing a bearing puller and the gear shaft retaining washer
injury. (23) from the front of the planet gear frame by press-
ing on the front of the planet gear frame shaft.
11. Tap the intermediate pinion lightly to back the Remove the gear shaft retaining washer only if the
planet gear frame assembly out of the intermediate washer or front bearing spacer is damaged.
gear case.
12. Remove the intermediate gear case assembly

from the vise 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 fig 3.
08028-0D/H5250/94.08.12
Fig 4.
Drive Housing
1. Grasp the drive pinion (63) in a copper-faced

vise with the starter supported on the workbench.
Fig 3.
03.47 - ES0-G
MAN Diesel

L+V28/32H
2. Remove the drive pinion retaining screw (61) ment is necessary and new parts are available. The
which has a right-hand thread. bearing and/or the seal will always be damaged when
removed from the drive housing.
3. Remove the starter from the vise.
15. Remove the piston ring (55) from the piston
4. Remove the drive pinion washer (62) and the (54).
drive pinion (63).
16. Press the clutch spring cup (50) down and
5. Slide the pinion spring sleeve (64) and the remove the clutch spring cup retainer (49).
pinion spring (65) off the drive shaft (57).
17. Remove the clutch spring cup and clutch spring
6. Unscrew the drive gear screw (34). Using an (51).
impact wrench with a 5/16" (8 mm) x 8" (203 mm)
log hex inserted into the end of the drive shaft. 18. Remove the two clutch jaws (52).
7. Unscrew and remove the drive housing cap 19. Remove the front drive gear bearing (30), drive
screws (38) and lock washers (39). gear cup (36), drive gear lock washer (35), drive gear
screw ring (37) and drive gear screw (34).
8. Tap the drive housing (40) with a plastic ham-
mer to help dislodge it from the gear case (28). 20. Remove the large drive shaft bearing retainer
(53) using a screwdriver.
Warning: Failure to follow this procedure could result
in injury to personnel. 21. Press the rear drive shaft bearing and drive
shaft (57) out of the piston. If the rear drive shaft
9. Place the drive housing (40) in an arbor press, bearing needs to be replaced, proceed as follows:
piston end up. Apply a load to the piston (54) using
the arbor press to compress the piston return spring a. Cut and remove the small drive shaft bear-
(59) before removing the bulkhead retainer (45). Do ing retained in the drive shaft, using a small
not use compressed air to load the piston. chisel.
b. Press the rear drive shaft bearing (58) off
10. Remove the bulkhead retainer (45). Using a the drive shaft.
screwdriver and the arbor press.
22. Place the gear case (28) on a workbench.
Caution: Make sure the tension of the spring pushes
the bulkhead out of the drive housing before removing 23. Remove the drive gear bearing retainer (32),
the drive housing from the arbor press. using retaining ring pliers and working through the
access holes in the gear web, See fig 5.
11. Remove the bulkhead (46) from the piston
(54). 24. Pull the drive gear (29) out of the gear case.
08028-0D/H5250/94.08.12
12. Remove the outer bulkhead ring (47) and the Note: Do not disassemble the drive gear and clutch
inner bulkhead ring (48). parts of the turbine powered starters. If the drive shaft
is defective, install a new or factory-rebuilt unit.
13. Slide the drive shaft (57) from the drive housing
(40). 25. Remove the drive gear shaft bearing retainer
(33), using retaining ring pliers.
14. Pull the piston return spring (59) off the drive
shaft. 26. Remove the rear drive gear bearing (31) from
the drive gear.
Note: Do not remove the front drive shaft bearing
(42) or the drive housing seal (43) unless replace-
03.47 - ES0-G
MAN Diesel

L+V28/32H
5. Install the drive gear bearing retainer, using
retaining ring pliers and working through the access
holes in the gear web.
6. Lubricated 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

first, onto the drive shaft. Press it into position in
accordance with the in-structions packaged with the
new retainer.
9. Assemble the drive gear Schrew (34), drive

Fig 5. gear lock washer (35), drive gear cup (36) and drive
gear screw o-ring (37).
Assembly of the Starter 10. Grasp the drive shaft (57) in a vise, external
splined end down. Place assembled drive shaft screw
1. Always press on the inner ring of a ball bearing Unit into the drive shaft, screwhead down. Lubricate
when installing the bearing on a shaft. the inside diameter of the drive shaft with SHELL
ALVANIA EPO grease.
2. Always press on the outer ring of a ball bearing
when pressing the bearing in a bearing recess. 11. Slide the drive gear bearing (30) into the drive
shaft.
3. Whenever grasping a part in a vise, always use
leather-covered, copper-covered vise jaws to protect 12. Lubricate with SHELL ALVANIA EPO grease
the surface of the part and help prevent distortion. and install the driving clutch jaw teeth facing up and
This is particularly true of threaded members. driven clutch jaw teeth facing down into the drive
shaft.
4. Always clean every part, and wipe every part
with a thin film of oil before installation. 13. Insert the clutch spring (51) into the drive
shaft.
Gear Case 14. Insert the clutch spring cup (50) into the drive
shaft.
1. Place the drive gear bearing retainer over the
rear end of the drive gear. 15. Press the inserted parts into the drive shaft,
08028-0D/H5250/94.08.12
and install the clutch spring cup retainer (49).

2. Press the rear drive gear bearing (31) onto the
rear end of the drive gear, using an arbor press. Note: If it is necessary to replace the drive hous-
ing (40) and drive components, make sure that the
3. Seat the rear drive gear bearing into the gear piston seal has been removed from the rear of the
case by tap-ping the opposite end of the drive gear, new piston (54).The piston seal must be removed
using a plastic hammer. to prevent pressure build-up which will cause move-
ment of the planet gear frame shaft seal (16). If this
4. Install the drive gear shaft bearing retainer conditions occurs, the piston cannot retract and the
(33), using retaining ring pliers. drive pinion (63) will remain in engagement with the
03.47 - ES0-G
MAN Diesel

L+V28/32H
flywheel, causing damage to the starter drive train 26. Install the bulkhead retainer (45), using a
and/or starter motor. To remove the piston seal, in- screwdriver.
sert a screwdriver inside the lip of the seal and pry
it loose from the piston. Warning: Make sure the bulkhead retainer is properly
seated in the motor housing groove before easing off
16. Install the piston (54) onto the drive shaft until the arbor press. Failure to do so will allow improperly
the rear drive shaft bearing seats into the piston. retained parts to separate when removed from the
arbor press resulting in injury to personnel.
17. Coil the large drive shaft bearing retainer (53)
into the groove of the piston to retain the outer race 27. Remove the drive housing from the arbor
of the drive shaft bearing, using a thin flat blade press.
screwdriver to assist in this operation.
28. Lubricate and install the drive housing o-ring
18. Lubricate the piston o-ring (55) and install it in (41) in the groove of the drive housing.
the groove of the piston.
29. Position the assembled gear case on a work-
19. Position the drive housing in an arbor press, bench.The as-sembled unit must be upright to accept
pinion-end down and install the drive housing seal the drive housing.
(43) into the drive housing. Using a pressing sleeve of Carefully position the assembled drive housing (40)
the proper size, press the seal into the drive housing onto the gear case so as not to damage the piston
so that the lip of the seal faces away from the drive seal. Align the punch marks of the gear case and
pinion. drive housing.
20. Press the bearing into the drive housing until 30. Install the drive housing cap screw lock wash-
it seats, using a sleeve that contacts the outer race ers (39) and the drive housing cap screws (38) and
of the front drive shaft bearing (42). Drop the piston tighten to 28 Nm torque.
return spring seat (60) on top of front drive shaft
bearing. 31. Tighten the drive gear screw (34) 77.3 Nm
torque, using an impact wrench with a 8 mm x 203
21. Slide the piston return spring (59) onto the mm long hex inserted into the end of drive shaft.
drive shaft and snap it into the front of the piston so
that it is against the large drive shaft bearing retainer 32. Grease and slide the pinion spring (65) and
(53). the pinion spring sleeve (64) over the pinion end of
the drive shaft.
22. Lubricate and insert the assembled drive shaft
into the drive housing. 33. Grease the pinion end of the drive shaft and
install the drive pinion (63).
23. Lubricate and install the outer bulkhead o-
ring (47) and the Inner bulkhead o-ring (48) on the 34. Grasp the drive pinion in a copper-covered
bulkhead (46). vise with the starter supported on a workbench.
08028-0D/H5250/94.08.12
24. Slide the bulkhead onto the piston. 35. Place the drive pinion washer (62) onto drive
pinion retaining screw (61).
25. With the drive housing in the arbor press, press
down on the rear face of the piston. Note: The thread on the drive pinion retaining screw
is right-hand thread.
Note: Feel the underside of the drive housing to make
sure the drive shaft passes through the bearing. 36. Install the drive pinion retaining screw into
the end of the drive shaft and tighten it to 108.5 Nm
torque.
03.47 - ES0-G
MAN Diesel

L+V28/32H
Intermediate Gear Case, Motor Housing, Motor 6. Install the other planet gear shaft retaining
Assembly and Housing Exhaust Cover washer over the shaft at the rear of the planet
gear.
1. Press the front gear frame bearing (17) into
the rear of the intermediate gear case (13), using a 7. Press the rear gear frame bearing (24) on the
bearing pressing tool of the proper size. shaft at the rear of the planet gear frame, using the
proper size bearing inserting tool.
2. Press the planet gear frame shaft seal (16) into
the rear of the intermediate gear case over the front 8. Slide the planet gear frame assembly, coupling
gear frame bearing, using a sleeve which contacts end first, into the rear of the intermediate gear case
the outer ring of the seal. (13), making sure that the planet gears mesh with the
ring gear. Use care so as to not damage the seal.
Note: Make sure the flat side of the seal is installed
against the bearing. 9. Install the intermediate pinion (26), making
sure that the notches at the rear of the pinion align
3. Install the rear gear case o-ring (14) in the with the notches and tangs in the shaft of the planet
groove at the rear of the intermediated gear case gear frame.
and the front gear case o-ring (15) in the groove at
the front of the intermediate gear case. coat both 10. Clean the threads of the intermediate pinion
o-rings. retaining screw (27) and apply 2-3 drops of Perm-
abond HM 118 to the threads approximately 3 mm
4. Install one gear shaft retaining washer (23) on from the end of the screw. Install screw and tighten
the front of the planet gear frame (18). Press the front enough to hold assembly together.
bearing spacer (25) on the front shaft of the planet
gear frame to hold the gear shaft retaining washer 11. For final tightening, position the intermediate
snugly in position. gear case so the intermediate pinion is secured in
the jaws of the copperfaced vise. Tighten the inter-
Note: Coat the front bearing spacer with gear Lube mediate pinion retaining screw to 122 Nm torque.
before installing it. Be careful not to gouge or scratch
the front bearing spacer during installation as this 12. Remove the intermediate gear case from the
could result in leakage between the planet gear vise and set it on a bench.
frame and gear case.
Note: The intermediate gear case will work in only
5. Place planet gear frame on a bench, shaft side one orientation.
down. Place the planet gear bearing (20) inside of
planet gear (19). Place bearing spacers (21) on top Align the punch marks on the intermediate gear
and bottom of bearing and gear. Slide the components case and gear case and tap the intermediate gear
into the slots in the side of the planet gear frame. case with a plastic hammer until it seats in the rear
Align holes in spacers and bearing with holes in of the gear case. Make sure the intermediate pinion
planet gear frame and insert planet gear shaft (22), meshes with the drive gear.
08028-0D/H5250/94.08.12
integral keyed end down, through the spacers and

bearing so that the larger portion of the keyed end Coat the o-rings on the motor assembly and the
of the shaft contacts the planet gear shaft retain- inside of the cylinder before installing the motor
ing washer (23). Repeat the procedure for the two assembly.
remaining planet gears and components.
13. Install the motor assembly through the rear of
Note: Do not move or turn over the planet gear frame the motor housing with the geared end of the rotor
until step 6 and 7 have been completed. Movement toward the front.
of the planet gear frame assembly could dislodge
assembled components, making it necessary to
repeat step 5.
03.47 - ES0-G
MAN Diesel

L+V28/32H
Fig 6. Turbine Starter.
Note: Turn the intermediate pinion so that the gear 17. Align the punch marks on the housing exhaust
on the rotor meshes with the planet gears. Make cover with the punch marks on the motor housing
sure that the rear of the motor assembly is installed and tap the housing exhaust cover with a plastic
flush with the rear of the cylinder. hammer until it seats.
14. Align the punch marks on the motor housing 18. Install the housing exhaust cover on the rear
with the punch marks on the intermediate gear case of the motor housing using the starter assembly cap
and tap the motor housing with a plastic hammer until screws (6) and cap screw washers (7). Use an 8 mm
it seats on the rear of the intermediate gear case. hex-head wrench to tighten each a little at a time to
a final torque of 61 to 68 Nm increments.
15. Install the splash deflector (3), deflector retain-
08028-0D/H5250/94.08.12
ing spring (4) and deflector retaining screw (5) in the 19. Mount the exhaust cover (68) on the housing
rear of the housing exhaust cover. exhaust cover (1).
Note: Coat the threads of the deflector retaining Note: Use Intersoll-Rand SMB-441 pipe sealant on
screw with Ingersoll-Rand SMB-441 sealant. all plugs.
16. Coat the exhaust cover seal (2) and install it 20. Install the bottom housing plug (10) and the
in the groove on the housing exhaust cover. housing plug inlet boss (11). Put the starter on its
side with the side plug hole upward. Add 175 ml
automatic transmission fluid fulfilling DEXRON II D
specification, e.g. SHELL DONAX TA, through the
side plug hole.
03.47 - ES0-G
MAN Diesel

L+V28/32H
Caution: Do not overfill. Remove the pressure from the “IN” port. Measure
Install the side housing plug (10) and tighten all plugs the distance form the face of the drive shaft pinion
to 6.8 to 13.6 Nm torque. the the face of the mounting flange. It should be
45.0 +2.0 mm.
Test and Inspection Procedure 4. Motor Action: Secure starter in a vise and ap-
ply 90 psig (6.2 bar/620 kPa) pressure using a 3/8"
1. Clutch Ratcheting: Turn the drive shaft pinion (9 mm) supply line to the inlet of the motor. starter
(63) by hand in the direction of the starter rotation. should run smoothly.
The clutch should rachet smoothly with a slight click-
ing action. 5. Motor Seals: Plug the exhaust and slowly apply
20 psig (1.38 bar/138 kPa) pressure to the inlet of
2. Motor and Gearing Freeness: Turn the the motor. Immerse the starter for 30 seconds in o
drive shaft pinion (63) opposite the direction of the non-flammable, bubble-producing liquid. If the starter
starter rotation. The drive shaft pinion should turn by is properly sealed, no bobbles will appear.
hand.
6. Gear Case Seals: Plug the exhaust and slowly
Note: Inadvertent application of air pressure to the apply 20 psig (1.38 bar/138 kPa) pressure to the inlet
“OUT” port will result in drive malfunction (pinion will of the motor. Immerse the starter for 30 seconds in
fail to retract). If this condition occurs, loosen the drive o non-flammable, bubble-producing liquid.
housing cap screws (38) to vent gear case (28). Also,
loosen housing plugs (10) and (11) to vent motor. There should be no leakage in the housing joints
in the gear case area or in the shaft seal in the
3. Pinion Engagement: Apply 50 psig (3.4 intermediate gear system. If the starter is properly
bar/345 kPa) pressure to the engagement “IN” port. sealed, no bubbles will appear.
drive shaft pinion (63) should move outward and air
should escape from the “OUT” port. 7. Confirm Drive Rotation: Apply low pressure
to the motor and observe rotation. drive pinion (63)
Plug the “OUT” port and apply 150 psig (10.3 bar/1034 must rotate in the direction stamped on the nameplate.
kPa) pressure to the “IN” port. Check and make sure Chamfer on pinion teeth should be on the trailing
that no air is escaping. edge of the gear tooth.
Measure the dimension from the face of the drive

shaft pinion (63) to the face of the mounting flange.
It should be 69.0 +2.0 mm).
08028-0D/H5250/94.08.12
03.47 - ES0-G
MAN Diesel

Page 1 (2) Main Starting Valve Edition 01H
L+V28/32H

Shut-off fuel oil
Description:
Lubricating, disassembly and reassembly of main

starting valve in starting system. Hand tools:
Soft hammer.
Locking ring plier.
Allen key, 1/4".
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
61310 02 1/eng.
Data: 61310 03 1/eng.
61310 04 1/eng.
Data for pressure and tolerance (Page 600.35) 61310 07 1/eng.
91.08 - ES0S-G
MAN Diesel

Edition 01H Main Starting Valve Page 2 (2)
L+V28/32H
Warning: Disassembly:
Do not attempt any maintenance on the main start- 4) Clamp the main starting valve, in a vice with
ing valve before the starting air system has been the locking ring (9) end up.
bled off.
5) Carefully remove the locking ring (9). The end
plug (3) should spring out. If it does not, tap the valve
Important: housing (1) lightly with a soft hammer until it does.
The main starting valve should be periodically lub- 6) Remove the end plug (3), spring (8) and piston
ricated as follows: (2) assembly.
1) Blend off the air pressure. 7) Remove and discard all used o-rings, o-rings
retainer (5), bumper (7) and spring (8).
2) Remove the plug screw (A) , see fig. 1. and
squirt about 30 g of 10 w oil into the valve through 8) Wash all other parts in a clean, nonflammable
the plug opening. solvent.
3) Reinstall the plug.

Reassembly:
9) Using o-ring lubricant, lubricate and install the

new piston o-ring (4) and the new upper piston o-ring
B (6) on the piston (2).
6
Note: The upper piston o-ring (6) is slightly larger in
1
diameter than the end plug o-ring (11).
2 C
10) Turn the piston over and insert the new bumber
(7).
4
D 11)Using o-ring lubricant, lubricate and install the

7 5 new end plug seal o-ring (10) and the new end plug
8 o-ring (11) on the end plug (3).
11
A
12) Lubricate the lower small bore of the valve
9 housing (1) with o-ring lubricant.
10
3
13) Insert the piston assembly into the valve hou-
sing. Push on the piston until the piston o-ring seats
against the bevelied face.
08028-0D/H5250/94.08.12
A Plug screw B Pilot air

C Starting air outlet D Starting air inlet
14) Install the new o-ring retainer (5) with the large
1 Valve housing 2 Piston opening over the piston o-ring.
3 End plug 4 Piston o-ring
5 O-ring retainer 6 Piston o-ring
7 Bumper 8 Spring 15) Place the new piston spring (8) on the piston.
9 Retaining ring 10 O-ring
11 O-ring 16) Place the end plug assembly on the piston
spring.
17) Using a press to hold down the end plug as-

Fig. 1. Main starting valve.
sembly, install the end plug locking ring (9).
91.08 - ES0S-G
MAN Diesel

Page 1 (2) Check of Compressed Air Piping System Edition 02H
L+V28/32H

Shut-off fuel oil
Description:
Check of compressed oil piping system.

Hand tools:
Screwdriver.
Starting position:
Compressed air connected to the engine.
Related procedure:
08028-0D/H5250/94.08.12
Working time: ½ hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

94.21 - ES0U-G
MAN Diesel

Edition 02H Check of Compressed Air Piping System Page 2 (2)
L+V28/32H
With air connected. With air disconnected and stopped engine.
1) Examine the piping system for leaks. 6) Move all valves and cocks in the piping system.
2) Retighten all bolts and nuts in the piping system.
7) Connect the air supply and make a function test
3) Drain the system for condensed water. - This of the emergency valve. See description 613.01.
should be based on observations.
4) Check flexible connections for leaks and dama-

ges.
5) Check manometers.
08028-0D/H5250/94.08.12
94.21 - ES0U-G
MAN Diesel
Plate
Page 1 (3) Turbine Starter 61309-05H
L+V28/32H
96.26- ES0S-G
MAN Diesel
Plate
61309-05H Turbine Starter Page 2 (3)
L+V28/32H
Item Item
1 1/S Housing exhaust Hus for udstøds-dæk- 22 1/S Planet gear shaft. Planetgearaksel.
cover. sel.
23 2/S Gear shaft retainer Spænderingsskive for
2 1/S Exhaust cover seal. Tætningsring for ud- washer. gearaksel.
stødsdæksel.
24 1/S Rear gear frame Bagerste gearstelleje.
3 1/S Splash deflector. Stænk deflektor. bearing.
4 1/S Deflector return Returfjeder for de- 25 1/S Front bearing spa- Forreste gearstelleje.
spring. flektor. cer.
5 !/S Deflector retaining Spændeskive for 26 1/S Intermediate pinion. Mellemtandhjul.

screw. deflektor.
27 1/S Intermediate pinion Spændeskrue for mel-
6 4/S Starter assembly cap Dækselskrue for mon- retaining screw. lemtandhjul.
screw. tage af starter.
28 1/S Gear case. Gearkasse.
7 4/S Cap screw washer. Skive for dækselskrue.
29 1/S Drive gear. Drivgear.
8 1/S Motor housing. Motorhus.
30 1/S Front drive gear Forreste drivgearleje.
10 1/S Housing plug. Prop til motorhus. bearing.
11 1/S Housing plug inlet Tilgangsknast for prop 31 1/S Rear drive gear Bagerste drivgearleje.
boss. til motorhus. bearing.
12 1/S Motor assembly. Motor samling. 32 1/S Drive gear bearing Spændskrue for driv-
retainer. gearleje.
12A 2/S Cylinder o-ring seal. O-ringstætning for
cylinder. 33 1/S Drive gear shaft Spændskrue for driv-
bearing retainer. gearakselleje.
12B 2/S Housing o-ring seal. O-ringstætning for
motorhus. 34 1/S Drive gear screw. Drivgearskrue.
13 1/S Intermediate gear Mellem gearkasse. 35 1/S Drive gear lock Skive for drivgear.
case. washer.
14 1/S Rear gear case o- Bagerste gearkasse 36 1/S Drive gear cup. Dæksel for drivgear.
ring. o-ring.
37 1/S Drive gear screw O-ring for drivgear-
15 1/S Front gear case Forreste gearkasse o-ring. skrue.
o-ring. o-ring.
38 8/S Drive housing cap Dækselskrue for driv-
16 1/S Planet gear frame Tætningsring for pla- screw. gear.
shaft seal. netgearakselstel.
39 8/S Drive housing cap Skive for dækselskrue
16A 1/S Spacer ring. Afstandsring. screw lock washer. til drivgearhus.
17 1/S Front gear frame Forreste gearstelleje. 40 1/S Drive housing kit. Drivgearhus.
bearing.
41 1/S Drive housing o-ring O-ring for drivgearhus.
18 1/S Planet gear frame. Planetgearstel.
42 1/S Front shaft bearing. Forreste akselleje.
19 1/S Planet gear. Planetgear.
43 1/S Drive housing seal. Tætningsring for driv-
20 1/S Planet gear needle Nålevalse for planet- gearhus.
roller. gear.
44 1/S Drive housing vent Afluftningsprop for
21 1/S Bearing spacer. Ligemellemstykke. plug. drivgearhus.
Qty.//E = Qty./Engine Qty./E = Qty./Motor
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter
96.26 - ES0S-G
MAN Diesel
Plate
Page 3 (3) Turbine Starter 61309-05H
L+V28/32H
Item Item
45 1/S Bulkhead retainer. Skotholder 69A 2/E Turbine star- Turbinestar-

ter, complete. ter, komplet.
46 1/S Bulkhead kit. Skotsæt V28/32H. V28/32H.
47 1/S Outer bulkhead Ydre skot o-ring. 70 Spare parts Reservedels-

o-ring. kit, incl. item sæt incl. item
2, 12A, 12B, 2, 12A, 12B,
48 1/S Inner bulkhead o- Indre skot o-ring. 14, 15, 16, 14, 15, 16,
ring. 16A, 17, 21, 16A, 17, 21,
23, 24, 25, 41, 23, 24, 25, 41,
49 1/S Clutch spring cup Fjedertallerken holder. 45, 47, 48, 55, 45, 47, 48, 55,
retainer. 61 and 62 61 og 62.
50 1/S Clutch spring cup. Fjedertallerken.
51 1/S Clutch spring. Koblingsfjeder.
52 1/S Clutch jaw kit. Koblingssæt.
53 1/S Large drive shaft Stor lejespændering

bearing retainer. for drivaksel.
54 1/S Piston kit. Stempelsæt.
55 1/S Piston o-ring. Stempel o-ring.
57 1/S Drive shaft kit. Drivakselsæt.
58 1/S Rear drive shaft Bagerste drivakselleje.

bearing.
59 1/S Piston return spring. Stempel returfjeder.
60 1/S Seat. Sædering.
61 1/S Drive pinion retain- Tandhjulsspænde-

ing screw. skrue.
62 1/S Drive pinion washer. Tandhjulsskive.
63 1/S Drive pinion. Tandhjul. L28/32H.

L28/32H
63A 1/S Drive pinion. Tandhjul. V28/32H.

V28/32H
64 1/S Pinion spring sleeve. Tandhjulsbøsning.
65 1/S Pinion spring. Tandhjulsfjeder.
66 1/S Inlet flange kit. Tilgangsflangesæt.
67 3/S Cover Dæksel
68 1/S Self drilling screws Selvborende skruer
69 1/E Turbine starter, com- Turbinestarter, kom-

plete. L28/32H plet. L28/32H.
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter
96.26 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Main Starting Valve 61310-03H
L+V28/32H
03*
01*
04* 02*
05
07*
08
06*
08.03 - ES0-G
MAN Diesel
Plate
61310-03H Main Starting Valve Page 2 (2)
L+V28/32H
Item Item
01* 1/V O-ring O-ring
02* 1/V O-ring retainer O-ring holder
04* 1/V Bumper Stødfanger
05 1/V Spring Fjeder
08 1/E Main starting valve, Hovedstartventil,

complete komplet
09 1/V Spare part kit Reservedelssæt

Item No. 01, 02, 03, Item nr. 01, 02, 03,
04, 06 and 07 04, 06 og 07
Qty./V = Qty./Valve Antal/V = Antal/Ventil
08.03 - ES0-G
MAN Diesel
Plate
Page 1 (2) Muffler 61312-02H
L+V28/32H
01
91.20 - ES0S-G
MAN Diesel
Plate
61312-02H Muffler Page 2 (2)
L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty Designation Benævnelse
01 1/S Muffler Dæmper
Qty./S = Qty./Starting air motor Antal/S = Antal/Startemotor
91.20 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Emergency Starting Valve 61313-03H
L+V28/32H
11*
01
18* 20*
19*
04*
06*
16*
12*
20*
23
91.20 - ES0S-G
MAN Diesel
Plate
61313-03H Emergency Starting Valve Page 2 (2)
L+V28/32H
Item Item
01 1/E Emergency starting Nødstarteventil,

valve, complete komplet
04* 1/V Piston Stempel
06* 1/V Washer Skive
11* 4/V Screw Skrue
12* 1/V Nut Møtrik
16* 1/V Spring Fjeder
18* 1/V Gasket Pakning
21 1/V Repair kit, incl. item Reservedelssæt, inkl.

11, 18, 19, and 20 item 11, 18, 19 og 20
22 1/V Repair kit, incl. item Reservedelssæt, inkl.

4, 6, 12, 16, and 21 item 4, 6, 12, 16 og 21
23 1/V Silencer Lyddæmper
91.20 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Starting Valve 61314-03H
L+V28/32H
37
01
33*
34
30*
35
32*
31*
01.28 - ES0
MAN Diesel
Plate
61314-03H Starting Valve Page 2 (2)
L+V28/32H
Item Item
01 1/E Starting valve, Starteventil,

complete komplet
30* 1/V Armature, complete Anker, komplet
31* 1/V Spring Fjeder
33* 1/V Gude pipe, complete Styrerør, komplet
34 1/V Solenoid Spole
35 1/V Gasket Pakning
37 1/V Nut Møtrik
38* 1/V Repair kit, consisting Reservedelssæt, be-

of item 30, 31, and 32 stående af item 30, 31,
and 32
39 1/V Repair kit, consisting Reservedelssæt, be-

of item 33 and 38 stående af item 33
og 38
01.28 - ES0
MAN Diesel
Plate
Page 1 (2) Main Stop Valve 61315-03H
L+V28/32H
92.14 - ES0S-G
MAN Diesel
Plate
61315-03H Main Stop Valve Page 2 (2)
L+V28/32H
Item Item
05 1/V Gland flange Ters
10 1/V Stem with disc Spindel med skive
18 1/V Gasket Pakning
19 1/E Stop valve, complete Stopventil, komplet

(straight way) (ligeløb)
20 1/E Stop valve, complete Stopventil, komplet

(angel way) (vinkelløb)
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./C = Qty./Valve. Antal/V = Antal/Ventil.
92.14 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Air Strainer 61316-03H
L+V28/32H
08028-0D/H5250/94.08.12
94.20 - ES0S-G
MAN Diesel
Plate
61316-03H Air Strainer Page 2 (2)
L+V28/32H
Item Item
01 1/F Housing Hus
02 1/F Cover Dæksel
03 1/F Filter Filter indsats
04 4/F Stud Tap
05 4/F Nut Møtrik
06 1/E Air strainer, Filter, komplet

complete
08 1/F Gasket Pakning
09 1/F Plug screw Propskrue
08028-0D/H5250/94.08.12
Qty./F = Qty./Filter. Antal/F = Antal/Filter.
94.20 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Safety Valve 61319-01H
L28/32H
01
02
04
03
08028-0D/H5250/94.08.12
92.04 - ES0S
MAN Diesel
Plate
61319-01H Safety Valve Page 2 (2)
L28/32H
Item Item
01 1/E Safety valve, Sikkerhedsventil,

(10 bar) (10 bar)
02 1/E Safety valve, Sikkerhedsventil,

(15 bar) (15 bar)
03 1/E Protective device Beskyttelseshætte
04 3/E Screw Skrue
08028-0D/H5250/94.08.12
92.04 - ES0S
MAN Diesel
Plate
Page 1 (2) ON-OFF Valve for Jet System 61320-05H
L+V28/32H
01
05
06
07
08028-0D/H5250/94.08.12
07.13 - ES0S-G
MAN Diesel
Plate
61320-05H ON-OFF Valve for Jet System Page 2 (2)
L+V28/32H
Item Item
01 1/V Coil Spole
05 1/E Valve, complete 1 ¼" Ventil, komplet 1 ¼"

connecting branch tilslutningsstuds
06 1/E Valve, complete 1 ½" Ventil, komplet 1 ½"

07 1/E Valve, complete 2" Ventil, komplet 2"

08028-0D/H5250/94.08.12
Qty./V = Qty./Valve. Antal/V = Antal/Ventil.
07.13 - ES0SG
MAN Diesel
Plate
Page 1 (2) ON-OFF Valve for Jet System 61320-06H
L+V28/32H
08
09
10
11
08
12
08028-0D/H5250/94.08.12
07.13 - ES0S-G
MAN Diesel
Plate
61320-06H ON-OFF Valve for Jet System Page 2 (2)
L+V28/32H
Item Item
08 1/V Coil Spole
09 1/E Valve, complete ½" Ventil, komplet ½"

10 1/E Valve, complete ¾" Ventil, komplet ¾"



connecting branch, tilslutningsstuds,
with button for med knap for
manual override manuel overstyring
08028-0D/H5250/94.08.12
Qty./V = Qty./Valve. Antal/V = Antal/Ventil.
07.13 - ES0SG
MAN Diesel
Plate
Page 1 (2) Air Filter 61321-03H
General
02.46 - ES0
MAN Diesel
Plate
61321-03H Air Filter Page 2 (2)
General
Item Item
10 1/E Filter complete Filter komplet
11 1/F Repair kit Reparationssæt

(filter and O-ring) (filter og O-ring)
02.46 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Pressure Reduction Valve 61322-04H
L+V28/32H
03*
01 02
20
03*
21
16
22
17*
05*
06*
07*
08*
19
23
09*
10*
11*
12*
13*
PI 70 - Inlet to engine
09.37 - ES0-G
MAN Diesel & Turbo
Plate
61322-04H Pressure Reduction Valve Page 2 (2)
L+V28/32H

Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse
01 1/V Cover Dæksel
02 10/V Screw Skrue
03* 2/V Filter Filter
06* 1/V Diaphragh Membran
09* 1/V Valve, complete Ventil, komplet
11* 1/V Valve spring Ventilfjeder
16 2/V Pipe plug Rørprop
18 1/V Repair kit for item 19, Reparationssæt til item

incl. item 03, 05, 06, 19, inkl. item 03, 05, 06,
07, 08, 09, 10, 11, 12, 07, 08, 09, 10, 11, 12,
13, and 17 13 og 17
19 1/E Reduction valve, Reduktionsventil,

complete komplet
20 1/E Pilot valve, complete Styreventil, komplet
21 1/V Repair kit Reparationssæt

for item 20 for item 20
22 2/V Screw Skrue
23 1/V Manometer Manometer

0-25 bar - PI 70 0-25 bar - PI 70
24 1/E Pressure reduction Trykreduktionsventil,

valve, complete as komplet som plate
plate 61322 61322
25 1/V Gasket kit for item 19, Pakningssæt til item 19,
incl. item 03, 05, 07, 08, inkl. item 03, 05, 07, 08,
10, 12, 13 and 17 10, 12, 13 og 17
Qty/E = Qty/Engine Antal/E = Antal/Motor
Qty/V = Qty/Valve Antal/V = Antal/Ventil
09.37 - ES0-G
MAN Diesel
Plate
Page 1 (2) Turning Gear 61325-07H
L28/32H
08028-0D/H5250/94.08.12
02.12 - EO0
MAN Diesel
Plate
61325-07H Turning Gear Page 2 (2)
L28/32H
Item Item
011 1/E Steel pipe Stålrør 322 2/E Bulkhead coupling Forskruning
023 1/E Stud coupling Kobling 334 1/E Lubricator Smøreapparat
035 3/E Silencer Lyddæmper 346 1/E House for air motor Hus for luftmotor
047 1/E Reducing adaptor Reduktionsstykke 358 1/E Shaft Aksel
059 1/E Solenoid valve Magnetventil 371 2/E Retaining ring Låsering
060 2/E Stud coupling Forskruning 383 1/E Screwed connection Forskruning
072 1/E Steel pipe Stålrør 395 1/E Bracket Konsol
084 4/E Screw Skrue 405 1/E Handle Håndtag
096 4/E Washer Skive 417 1/E Shaft Aksel
106 1/E Cable Kabel 429 2/E Retaining ring Låsering
118 1/E Terminal box Klemkasse 430 1/E Flange Flange
131 2/E Cable union Kabelunion 442 1/E Gear wheel Tandhjul
143 4/E Screw Skrue 454 6/E Screw Skrue
155 2/E Screw Skrue 466 1/E Air motor Luftmotor
167 1/E Position switch Switch
179 2/E Nut Møtrik
180 2/E Screw Skrue
192 6/E Screw Skrue
202 1/E Handle Håndtag
214 2/E Pin Stift
226 1/E Screw Skrue
238 1/E Linkage Lænkeled
251 1/E Linkage Lænkeled
263 1/E Snap coupling Lynkobling
275 1/E Snap coupling Lynkobling
287 2/E Flexible hose Fleksibel slange
299 1/E Plate Plade

08028-0D/H5250/94.08.12
309 1/E Bulkhead coupling Forskruning
310 3/E Stud coupling Forskruning
02.12 - EO0
MAN Diesel
Plate
Page 1 (2) Pneumatic Turning Gear (Motor Power Unit) 61325-08H
L28/32H
08028-0D/H5250/94.08.12
05.05 - ES0
MAN Diesel
Plate
61325-08H Pneumatic Turning Gear (Motor Power Unit) Page 2 (2)
L28/32H
Item Item
01 1/G Motor housing Motorhus
02 1/G Plate retainer, Pladeholder,

rear end bagende
03 1/G Rotor bearing, rear Rotorleje, bagende
04 1/G Plate gasket, Pladepakning,

rear end bagende
05 1/G Plate, rear end Plade, bagende
06 1/G Rotor Rotor
07 1/G Vane packet Vingesæt

(set of 5 vanes) (bestående af 5 vin-
ger)
08 1/G Cylinder
Cylinder
09 1/G Cylinder dowel
Cylinderstyretap
10 1/G Rotor bearing
housing assembly Rotorlejehus
(samling)
10A 2/G Rotor bearing
housing seal Tætning for rotor-
lejehus
11 1/G Plate, front end
Plade, forende
12 1/G Rotor bearing, front
Rotorleje, forende
13 2/G Rotor spring washer,
front end Rotorlejepakning,
forende
14 1/G Rotor bearing
retainer, front end Rotorlejeholder,
forende
15 1/G Motor clamp washer
Motorspændeskive
58 2/G Flange key
Flangelås
60 1/E Turning gear (motor
power unit), com- Tørneapparat (motor-
plete enhed), komplet
63 1/E Motor power unit and Motorenhed og spindel,

spindle, gear case and gearboks og gearing,
gearing, complete as komplet som plate
plate 61325-08H + 61325-08H +
61325-09H 61325-09H
64 1/E Repair kit for Plate Reservedelssæt for

08028-0D/H5250/94.08.12
61325-08H and 61325- plate 61325-08H og

09H comprising item 61325-09H bestående
02, 03, 04, 07, 10A, 12, af item 02, 03, 04, 07,
14, 25, 26, 29, 34, 35, 10A, 12, 14, 25, 26, 29,
45, 52, 58 34, 35, 45, 52, 58
Qty./G = Qty./Turning gear Antal/G = Antal/Tørneapparat
05.05 - ES0S
MAN Diesel & Turbo
Plate Pneumatic Turning Gear

Page 1 (2) (Spindle, Gear case and Gearing) 61325-09H
L28/32H
05.05 - ES0
MAN Diesel & Turbo
Pneumatic Turning Gear Plate

61325-09H (Spindle, Gear case and Gearing) Page 2 (2)
L28/32H

Item Item
16 1/G Gear case Hus for drev 45 1/G Gear head bearing Drevhovedleje
17 1/G Spindle Spindel 46 1/G Gear head spacer Drevhoved afstandsrør
19 3/G Spindle planet gear Planethjulsakselsæt 50 1/G Gear case adapter Drevhusindsatsbøsning
assembly
51 1/G Seal, Gear case adap Tætning for drevhusind
20 3/G Planet gear bearing Planethjulleje ter sats
23 1/G Grease screw Smøreskrue 52 1/G Gasket, Aux. gear Pakning for hjælpedrev-
case front hus, forende
24 2/G Coupling nut Koblingsmøtrik
53 1/G Cap screw, Aux. gear Sætskrue for hjælpe-
25 2/G Coupling nut retai- Holder for koblings- case drevhus
ner møtrik
54 1/G Lock washer, Aux. Låseskive for hjælpe-
26 2/G Spindle bearing Spindelleje gear case drevhus
27 1/G Spindle bearing Spindellejebøsning 58 2/G Flange key Flangelås

spacer
59 1/G Spindle key Spindellås
28 1/G Gear case seal Tætning for drevhus
61 1/G Gear wheel Tandhjul
29 2/G Spindle and spindle Spindel og sikrings-
bearing retainer ring ring for spindelleje 62 1/E Turning gear (spindle, Tørneapparat (spindel,
gear case and gear gearboks og gearing),
30 1/G Gear case assembly Hus for drev (samling) ing), complete komplet
31 1/G Grease fitting wa- Fedtmonteringsskive 63 1/E Motor power unit and Motorenhed og spindel,
sher spindel, gear case and gearboks og gearing,
gearing, complete as komplet som plate
32 1/G Grease fitting Fedttilpasning plate 61325-08H + 61325-08H + 61325-
61325-09H 09H
33 1/G Spindle Spindel
64 1/E Repair kit for Plate Reservedelssæt for
34 1/G Spindle bearing, rear Spindelleje, bagende 61325-08H and 61325- plate 61325-08H og
09H comprising Item 61325-09H bestående
35 1/G Spindle bearing, Spindelleje, forende 02, 03, 04, 07, 10A, 12, af item 02, 03, 04, 07,
front 14, 25, 26, 29, 34, 35, 10A, 12, 14, 25, 26, 29,
45, 52, 58 34, 35, 45, 52, 58
36 3/G Planet gear shaft Planethjulsaksel
37 3/G Planet gear assem- Planethjul

bly
38 1/G Planet gear bearing Planethjulleje
39 1/G Spindle retainer Spindelholder
40 1/G Gear head Drevhoved
41 3/G Gear head planet Planethjul for drev-

gear assembly hoved
42 1/G Planet gear bearing Planethjulleje
44 2/G Planet gear shaft Planethjulsaksel
Qty./G = Qty./Turning gear Antal/G = Antal/Tørneapparat
05.05 - ES0
Fuel oil system
514/614
MAN Diesel & Turbo
Description 614.01
Page 1 (3) Internal fuel oil system
Edition 25H
L28/32H
Internal fuel oil system
Figure 1: Diagram for fuel oil system

Fuel oil system
Pipe description The fuel oil is delivered to the injection pumps
through a safety filter.
A3 Waste oil outlet DN15
The safety filter is a duplex filter of the split type with
A1 Fuel oil inlet DN25
a filter fineness of 50 my. The filter is equipped with
A2 Fuel oil outlet DN25 a common three-way cock for manual change of
A7 Nozzle cooling oil inlet DN15
both the inlet and outlet side.
A8 Nozzle cooling oil outlet DN15

Fuel injection equipment
Table 1: Flange connections are as standard according to DIN
2501 Each cylinder unit has its own set of injection equip-
ment, comprising injection pump, high-pressure
pipe and injection valve.
General
The injection equipment and the distribution supply
The internal built-on fuel oil system as shown in fig 1 pipes are housed in a fully enclosed compartment
consists of the following parts: thus minimizing heat losses from the preheated fuel.
▪ the high-pressure injection equipment This arrangement reduces external surface temper-
▪ a nozzle cooling system atures and the risk of fire caused by fuel leakage.
▪ a waste oil system
2011.08.15 - ES1
MAN Diesel & Turbo
614.01 Description
Internal fuel oil system Page 2 (3)
Edition 25H
L28/32H
The high-pressure pipe is led through a bore in the
Fuel oil injection pump cylinder head, in which it is surrounded by a shield-
ing tube, also acting as union nut for attachment of
The fuel oil injection pump is installed on the roller the pipe end to the fuel injector.
guide housing directly above the camshaft, and it is
The shielding tube has two holes in order to ensure
activated by the cam on the camshaft through roller
that any leakage will be drained off to the cylinder
guides fitted in the roller guide housing.
head bore. The bore is equipped with drain channel
The injection amount of the pump is regulated by and pipe.
transversal displacement of a toothed rack in the
The shielding tube is supported by a sleeve, moun-
side of the pump housing.
ted in the bore with screws.
By means of a gear ring, the pump plunger with the
The sleeve is equipped with O-rings in order to seal
two helical millings, the cutting-off edges, is turned.
the cylinder head bore.
Hereby the length of the pump stroke is specified
when the plunger closes the inlet holes until the cut-
ting-off edges again uncover the holes. Internal nozzle cooling system
The release of high pressure through the cutting-off The nozzles of the injection valves on HFO-engines
edges presses the oil with great force against the are temperature controlled by means of a separate
wall of the pump housing. At the spot, two circuit containing diesel oil or thermal oil as media.
exchangeable plug screws are mounted. The system maintains a nozzle surface temperature
The amount of fuel injected into each cylinder unit is low enough to prevent formation of carbon trum-
adjusted by means of the governor. pets on the nozzle tips during high load operation
It maintains the engine speed at the preset value by and high enough to avoid cold corrosion during
a continuous positioning of the fuel pump racks, via idling or low-load operation.
a common regulating shaft and spring-loaded link-
ages for each pump. Waste oil system
The injection valve is for "deep" building-in to the Waste and leak oil from the comparements, fuel
centre of the cylinder head. valves is led to a fuel leakage alarm unit.
The alarm unit consists of a box with a float switch
Fuel oil injection valve for level monitoring. In case of a larger than normal
The joint surface between the nozzle and holder is leakage, the float switch will initiate alarm. The sup-
machine-lapped to make it oil-tight. ply fuel oil to the engine is lead through the unit in
order to keep this heated up, thereby ensuring free
The fuel injector is mounted in the cylinder head by drainage passage even for high-viscous waste/leak
means of the integral flange in the holder and two oil.
studs with distance pieces and nuts.
A bore in the cylinder head vents the space below Optionals
the bottom rubber sealing ring on the injection
valve, thus preventing any pressure build-up due to Besides the standard components, the following
gas leakage, but also unveiling any malfunction of standard optionals can be built-on:
the bottom rubber sealing ring for leak oil. ▪ Pressure differential alarm high
– PDAH 43-40 Fuel oil, inlet and outlet filter
Fuel oil high pressure pipe ▪ Pressure differential transmitting
The high-pressure pipe between fuel injection pump – PDT 43-40 Fuel oil, inlet and outlet filter
and fuel injector is a shielded pipe with coned pipe
ends for attachment by means of a union nut, and a ▪ Pressure alarm low
nipple nut, respectively. – PAL 40 Fuel oil, inlet fuel oil pump
▪ Pressure transmitting
– PT40 Fuel oil, inlet fuel oil pump
2011.08.15 - ES1
MAN Diesel & Turbo
Description 614.01
Page 3 (3) Internal fuel oil system
Edition 25H
L28/32H
▪ Temperature element
– TE40 Fuel oil, inlet fuel oil pump
2011.08.15 - ES1
MAN Diesel & Turbo
Working Card
Fuel Injection Pump and Fuel Injection Pipe 614-01.05
L/V28/32H
Stopped engine Plate No. Item No. Note

62006 26 20-120 Nm
62006 28 140-760 Nm

Description:
Dismounting, inspection/overhaul and mounting

of fuel injection pump. Inspection of fuel injection
pipe.
Hand tools:
Starting position:
Cover in front of fuel injection pump has been Ring and open end spanner 14 mm
removed. Ring and open end spanner 17 mm
Allen key 8 mm, 10 mm
Plier for lock ring.
Tools for cleaning.
Related procedure: Clean kerosene or gas oil.
Clean lubricating oil.
Inspection of roller guide for fuel injection pump Anti seize product (Copaslip, Molykote GN Plus
608-01.05. or similar).
Man power:
Working time : 4 Hours Spare and wearing parts:

Capacity : 1 Man
Plate No. Item No. Qty./
61401 24 1/pump
Data: 61401 25 1/pump
61401 26 1/pump
Data for pressure and tolerance (Page 600.35) 61401 36 1/pump
Data for torque moment (Page 600.40) 61401 37 1/pump
Declaration of weight (Page 600.45) 61401 38 1/pump
92.25 - ES0S, L'Orange

MAN Diesel & Turbo
614-01.05 Fuel Injection Pump and Fuel Injection Pipe Working Card
L/V28/32H
Dismounting of fuel injection pump 7. Press the thrust cap (N) fig. 2 downwards and
remove the securing ring (P). Remove the thrust cap
1. Dismount the fuel injection pipe pos. 1 fig. 1 (N) with lower spring plate (O) and plunger (M). Be
and the fuel inlet pipe pos. 2. sure not to damage the plunger.
2. Separate the spring loaded lever from the

regulating rod on the fuel injection pump.
D
A
C
1 2
B
F
E
1
2
G
G
4
5
J 6
R
K
Fig. 1 View from Control Side I
H
3. Remove the pipe for lub.oil and drain. M
4. Remove the screws in the bottom flange (4 L

pieces) and take the fuel injection pump away. N
O
Separation of fuel injection pump.
P
5. If necessary, clean the exterior of the injection
pump. 1. Back-up ring (spirally coiled)
2. O-ring inside dia. 45.7 mm x 2.6
6. Mount the injection pump in the clamping 3. O-ring inside dia. 51 mm x 3
bracket PYO-W020 (see plate 62014 item 03), on 4. Back-up ring
the test pump. 5. O-ring inside dia. 43 mm x 3.5
6. O-ring inside dia. 37 mm x 3
Fig. 2 Cross Section of Fuel Injection Pump

MAN Diesel & Turbo
Working Card
L/V28/32H
8. Take out the plunger spring (L), upper spring 14. The axial clearance between lower spring plate
plate (K) and pinion (J). If necessary remove the lock and plunger foot must not exceed 0.25 mm. The
ring (R) and guide pin (I) and dismount the regulating clearance between lower spring plate and plunger
rod (H) as well as the cap screw in the opposite end foot is 0.05 to 0.1 mm when new. See fig. 3.
of the regulating rod (H).
15. Check the cavitation plugs (G) for wear and
9. Unscrew the four screws (A) and remove the renew if necessary.
connecting piece (B). Take out the valve spring (D)
and the non-return valve (F). 16. Barrel (E), plunger (M) and non-return valve
(F) are manufactured to very close tolerances.
10. Loosen and remove the four screws (C) and Any attempt to refinish these parts causes altera-
take out the barrel (E). tions of the tolerances and must therefore NOT be
carried out.
11. Remove all the O-rings and back-up rings from If during the visual inspection of the parts, heavy
the injection pump. abrasion symptoms or damage can be observed,
the part in question must be replaced.
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 Assembling of fuel injection pump:
houses and the barrel (E).
17. When assembling the injection pump, proceed
in the reverse order to disassembling. Pay attention
Inspection of fuel injection pump: to the following:
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.
Plunger (M)
Marking on
regulating rod
Tooth with chamfer
Max. 0.25 mm
Marking on pinion
Spring (L)
Lower spring
Plate (O)
Fig. 4 Mounting of Regulating Rod Mechanism
A. At initial tightening up of new parts the following

Fig. 3 Clearance between Lower Spring Plate and Plunger
(C) for barrel (E).
Tighten screws to 90 Nm, loosen and tighten again
to 90 Nm and then tighten to 90 Nm + 10 Nm.
Employ the same procedure when tightening the
other pump components for the first time.

MAN Diesel & Turbo
614-01.05 Fuel Injection Pump and Fuel Injection Pipe

Working Card
L/V28/32H
B. Renew all sealing and back-up rings. For placing Mounting of fuel injection pump:
of the rings, see fig. 1.
19. Before mounting the fuel injection pump, clean
C. Coat all the threads with an anti seize pro- the roller guide spring and washer for spring in the
duct. roller guide housing.
D. Wipe dry with paper plane sealing surface on 20. Reconnect the regulating rod (H) to the spring
barrel (E) and connecting piece (B). loaded lever and all the pipes to the fuel pump.
E. Before inserting the pinion (J), the easy mo-

tion of the plunger (M) in the barrel (E) must be Fuel injection pipe:
checked.
By normal working conditions the fuel injection pipe
F. When assembling the pinion (J), ascertain that require very little maintenance except replacement
the tooth (recognizable by the chamfer) will enter the of O-rings and gasket in connection with the normal
space of the regulating rod (H) marked by two sings, overhaul of fuel injection equipment. (See also de-
see fig. 4. scription of fuel injection pipe page 614.10).
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 fig. 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.

MAN Diesel & Turbo
Working Card
L/V28/32H
Stopped engine Plate No. Item No. Note

62006 26 20-120 Nm
62006 28 140-760 Nm

Description:
Dismounting, inspection/overhaul and mounting

of fuel injection pump. Inspection of fuel injection
pipe.
Cover in front of fuel injection pump has been Ring and open end spanner 13 mm
removed. Ring and open end spanner 14 mm
Allen key 8 mm, 10 mm
Related procedure: Tools for cleaning.
Clean kerosene or gas oil.
Inspection of roller guide for fuel injection pump Clean lubricating oil.
608-01.05. Anti seize product (Copaslip, Molykote GN Plus
or similar).
Man power: Spare and wearing parts:
Working time : 4 Hours Plate No. Item No. Qty./

Capacity : 1 Man
61401 05 1/pump
61401 06 1/pump
61401 07 1/pump
Data: 61401 08 1/pump
61401 09 1/pump
10.45 - ES0S, Nico

MAN Diesel & Turbo
614-01.05 Fuel Injection Pump and Fuel Injection Pipe

Working Card
L/V28/32H
Dismounting of fuel injection pump 7. Press the thrust cap (N) fig. 2 downwards and
remove the securing ring (P). Remove the thrust cap
1. Dismount the fuel injection pipe pos. 1 fig. 1 (N) with lower spring plate (O) and plunger (M). Be
and the fuel inlet pipe pos. 2. sure not to damage the plunger.
2. Separate the spring loaded lever from the

regulating rod on the fuel injection pump.
D
A
C
1 2
B
F
E
1
2
G
G
4
5
J 6
R
K
Fig. 1 View from Control Side I
H
3. Remove the pipe for lub.oil and drain. M
4. Remove the screws in the bottom flange (4 L

pieces) and take the fuel injection pump away. N
O
Separation of fuel injection pump.
P
5. If necessary, clean the exterior of the injection
pump. 1. Back-up ring (spirally coiled)
2. O-ring inside dia. 45.7 mm x 2.6
6. Mount the injection pump in the clamping 3. O-ring inside dia. 51.4 mm x 3.1
bracket PYO-W020 (see plate 62014 item 03), on 4. Back-up ring
the test pump. 5. O-ring inside dia. 41.7 mm x 3.5
6. O-ring inside dia. 37.2 mm x 3
Fig. 2 Cross Section of Fuel Injection Pump
10.45 - ES0S, Nico

MAN Diesel & Turbo
Working Card
L/V28/32H
8. Take out the plunger spring (L), upper spring 14. The axial clearance between lower spring plate
plate (K) and pinion (J). If necessary remove the lock and plunger foot must not exceed 0.25 mm. The
ring (R) and guide pin (I) and dismount the regulating clearance between lower spring plate and plunger
rod (H) as well as the cap screw in the opposite end foot is 0.05 to 0.1 mm when new. See fig. 3.
of the regulating rod (H).
15. Check the cavitation plugs (G) for wear and
9. Unscrew the four screws (A) and remove the renew if necessary.
connecting piece (B). Take out the valve spring (D)
and the non-return valve (F). 16. Barrel (E), plunger (M) and non-return valve
(F) are manufactured to very close tolerances.
10. Loosen and remove the four screws (C) and Any attempt to refinish these parts causes altera-
take out the barrel (E). tions of the tolerances and must therefore NOT be
carried out.
11. Remove all the O-rings and back-up rings from If during the visual inspection of the parts, heavy
the injection pump. abrasion symptoms or damage can be observed,
the part in question must be replaced.
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 Assembling of fuel injection pump:
houses and the barrel (E).
17. When assembling the injection pump, proceed
in the reverse order to disassembling. Pay attention
Inspection of fuel injection pump: to the following:
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.
Plunger (M)
Marking on
regulating rod
Tooth with chamfer
Max. 0.25 mm
Marking on pinion
Spring (L)
Lower spring
Plate (O)
Fig. 4 Mounting of Regulating Rod Mechanism
Fig. 3 Clearance between Lower Spring Plate and Plunger A. At initial tightening up of new parts the following
(C) for barrel (E).
Tighten screws to 90 Nm, loosen and tighten again
to 90 Nm and then tighten to 90 Nm + 10 Nm.
Employ the same procedure when tightening the
other pump components for the first time.
10.45 - ES0S, Nico

MAN Diesel & Turbo
614-01.05 Fuel Injection Pump and Fuel Injection Pipe Working Card
L/V28/32H
B. Renew all sealing and back-up rings. For placing Mounting of fuel injection pump:
of the rings, see fig. 1.
19. Before mounting the fuel injection pump, clean
C. Coat all the threads with an anti seize product. the roller guide spring and washer for spring in the
roller guide housing.
D. Wipe dry with paper plane sealing surface on
barrel (E) and connecting piece (B). 20. Reconnect the regulating rod (H) to the spring
loaded lever and all the pipes to the fuel pump.
E. Before inserting the pinion (J), the easy motion
of the plunger (M) in the barrel (E) must be checked.
Fuel injection pipe:
F. When assembling the pinion (J), ascertain that
the tooth (recognizable by the chamfer) will enter the By normal working conditions the fuel injection pipe
space of the regulating rod (H) marked by two sings, require very little maintenance except replacement
see fig. 4. of O-rings and gasket in connection with the normal
overhaul of fuel injection equipment. (See also de-
G. The marking on the guide cam of the plunger scription of fuel injection pipe page 614.10).
(M), must be in line with the marking in the slots of
the pinion (J). (Not shown on fig. 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.
10.45 - ES0S, Nico

MAN Diesel & Turbo

Page 1 (4) Fuel Injection Valve Edition 03H
L+V28/32H

Shut-off cooling water 62006 26 20-120 Nm
62014 35
62014 40
Description:
Dismounting, overhaul, pressure testing and

mounting of fuel injection valve.
Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump have been dismounted. Ring and open end spanner 24 mm
For dismounting of fuel injection pipe, see working Socket spanner 24 mm
card 614-01.05. Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseize product.
Related procedure: (Copaslip, Molykote GN Plus or similar).
Working time : 2 hours Plate no Item no Qty. /

Capacity : 1 man
61402 04 2/C
61402 05 1/C
61402 12 1/C
Data:

97.39 - ES3S
MAN Diesel & Turbo

Edition 03H Fuel Injection Valve Page 2 (4)
L+V28/32H
The fuel injection valve is the one component that 3. Clean the lower part of the nozzle (J) of car-
has the greatest influence on the diesel engine bonized oil deposits before dismantling the nozzle
condition. nut (H).
Various operation forms the fuel oil and quality af- Attention!
fect the overhaul intervals. In some cases it may Do not damage the lapped surfaces, when removing
be necessary to shorten the prescribed overhaul the nozzle nut (H) and the nozzle (J).
inter-vals.
Dismounting and cleaning:

D
1. Dismount the fuel injection valve from the cy-
linder head by means of the special tool as shown B
in fig 1.
B. Lock nut
C. Sealing ring
D. Adjusting screw F
E. Sealing ring
F. Nozzle spring
G. Spring spindle G
H. Nozzle nut
J. Nozzle H
J
Fig 2 Fuel injection valve.
4. The nozzle spring (F) and the spring spindle

(G) are to be taken out by unscrewing the adjusting
screw (D) completely.
Fig 1 Dismounting of fuel injection valve from cylinder head. 5. Clean all parts with kerosene or gas oil and
with a hard brush (not a steel brush).
2. Mount the fuel injection valve into the clamping 6. Clean the nozzle holes of charred coke by
bracket VTO-W022 (see plate 62014, item 02) on the means of the supplied special drill with holder.
pressure testing pump, and loosen the lock nut (B)
fig 2. 7. Clean the cooling chamber and the cooling
ducts in the nozzle guide and injector body.
Unstress the nozzle spring by turning the adjusting
screw (D). Place them in a cleaning liquid and then blow through
the parts with working air.
97.39 - ES3S
MAN Diesel & Turbo

Page 3 (4) Fuel Injection Valve Edition 03H
L+V28/32H
Inspection of the parts: 12. Lubricate the shoulder of the nozzle which
is in contact with the nozzle nut with an antiseize
The nozzle body and needle are matched by lapping product.
and are therefore only interchangeable as units.
13. Wipe the plane sealing surface of body and
8. Insert the nozzle needle with gas oil in the ne- nozzle dry with paper.
edle guide. It must be controlled whether the nozzle
needle slides down by its dead weight on its seat. 14. Renew the sealing rings (C) and (E).
9. Check if the holes in the nozzle are worn Tightening torque for nozzle nut, see page 600.40.
oval.
This is done by means of a magnifying glass. Pressure testing of fuel injection valve:
The most effective checking of the fuel valves is

WHEN the nozzle holes.. THEN obtained through pressure testing, preferably carried
out after each overhaul and also in case of irregu-
are worn oval Scrap the nozzles larities in operation.
are not worn oval Re-use the nozzles
The pressure testing is carried out in the following
way by means of the pressure testing apparatus
The best way, however, to check if the holes are worn supplied.
out is to control the flow rate of the nozzle which, in
general, only can be made by MAN B&W Holeby. 15. Mount the fuel injection valve in the bracket VTO-
W022. The bracket must be in such a position that
10. Replace parts with heavy abrasion symptoms, the nozzle of the injector is pointing downwards.
respectively damages, which were observed at the
visual inspection of the parts.
IF THEN
Every effort to refinish will result in alterations of
these values and malfunction of the nozzle. the engine is mount the test pipe
mounted with VWM-W007
If heavy abrasion symptoms, respectively damages cooling oil system (see plate 62014, item 05)
are observed at the visual inspection of the parts, on to the bracket for test
the parts in question must be replaced. of the cooling oil system.
Increase the pressure

Reassembling: by using the lever on
the test pump.
When all parts have been carefully cleaned, inspected
and overhauled and found in good order, then as- Apply pressure to the
semble the fuel injection valve. cooling oil system,
(see data page 600.35)
When assembling the injection valve, proceed in the after venting.
opposite order compared to the disassembly.
Check the sealing
Pay attention to the following: tightness of the O-rings.
11. Lubricate the threads on the adjusting screw

(D) with lub. oil, and the threads of the nozzle holder 16. Mount the test pipe VTO-W023 (see plate
for the nozzle nut. 62014, item 04) for test of the injection pressure and
atomizing.
97.39 - ES3S
MAN Diesel & Turbo

Edition 03H Fuel Injection Valve Page 4 (4)
L+V28/32H
17. Adjust the opening pressure to 320 bar by Mounting of the fuel injection valve in the cy-
means of the adjusting screw (D), see fig 2, then linder head:
tighten the lock nut (B).
20. Clean and inspect the valve bore in the cylinder
18. Check opening pressure again. head before mounting the fuel valve.
Do not expect chattering, but make sure that the 21. Grind the seating face, if necessary, with the
nozzle spray from all holes is in the same angle. The grinding tool (see fig 3).
nozzle might chatter if the lever is worked very fast,
actually by hitting it. 22. Coat the O-rings and the lower part of the valve
with an anti seize product and place the valve in the
Do not expect a nozzle tip with more than 1000 cylinder head, and press it down to the seat.
running hours to perform like a new nozzle in the
test pump. 23. Mount the high pressure pipe before tightening
the nuts. Then it is easier to fit the threads.
19. Increase the pressure to 300 bar and keep the
pressure by working the lever slowly downwards. 24. Put on the distance pieces, fit the nuts and
tighten up with a torque spanner (for torque moment,
When the pressure is kept at 300 bar, there should see page 600.40).
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 inflammations (blood poiso-
ning).
Fig 4 Grinding tools for fuel injection valve (extra tools).
Fig 3 Grinding tools for seat for fuel and liner i njection valve.
97.39 - ES3S
MAN Diesel & Turbo

Page 1 (2) Fuel Oil Split Filter Edition 01H
General

Shut-off fuel oil
Description:
Disassembly, cleaning and assembly of fuel oil

split filter. Hand tools:

Kerosene, gas oil or similar.
Starting position:
Related procedure:

Capacity : 1 man

Data:

91.08 - ES0S
MAN Diesel & Turbo

Edition 01H Fuel Oil Split Filter Page 2 (2)
General
1) During normal operation both filters should be 3) Position of three way cock, see fig. 2.
in operation, single operation only to be used when
dismantling one of the filters for manual cleaning or
inspection.
2) Normally the filters are cleaned during opera 4 5

tion by turning the handle, (1) see fig. 1, on the filter
housing top a couple of turns. (clockwise).
Simultaneously with turning of the handle, the drain

cock, (2) in bottom of the filter housing should be
opened in order to drain of the dirt being scraped of
the filter element, (3).
Left Filter Both filters in Right Filter

1 This position is operation. This position is
only for cleaning only for cleaning
of the right filter, of the left filter,
not for continu not for continu
ous operating. ous operating.
5
Fig. 2. Fuel oil split filter (top view).
3
Note: Shut-off fuel oil, before dismantling filter ele
ment.
4) If no drainage occurs when the drain cock is

opened, the filter housing should be dismantled for
manual cleaning. Remove the nuts (5), and take out
the filter element (3).
2
5) Clean the filter element in kerosene gas oil or
similar and blow it dry with working air.
Fig. 1. Fuel oil split filter 6) Mount the filter element again.
7) The filter element itself should never be dis

mantled, but has to be replaced if damage or mal
function is experienced.
91.08 - ES0S
MAN Diesel & Turbo

Page 1 (2) Check of Fuel Oil Piping System Edition 01H
General

Shut-off fuel oil
Description:
Check of fuel oil piping system.

Hand tools:
Starting position:
Engine is running.
Related procedure:

Capacity : 1 man

Data:

92.04 - ES0S
MAN Diesel & Turbo

Edition 01H Check of Fuel Oil Piping System Page 2 (2)
General
Fuel Oil System Lubricate valve spindles with graphite or si-
milar.
1) Dismount the covers to the injection pumps.
Blow-through drain pipes. 5) Check flexible connections for leaks and da-
mages.
2) Examine the piping system for leaks.
6) Check the condition of the lower O-ring for the
3) Retighten all bolts and nuts in the piping sy- fuel injecting valves by means of the venting
stem. pipe.
4) Move all valves and cocks in the piping sy- For fuel oil condition, see section 604.
stem.
Venting pipe
Fig. 1. Cross section of cylinder head
92.04 - ES0S
MAN Diesel & Turbo

Page 1 (3) Adjustment of The Maximum Combustion Pressure Edition 02H
General


Adjustment of the maximum combustion pressure Ring and open end spanner, 19 mm.
for the cylinders one by one and for all cylinders Socket spanner, 19 mm.
in total. Depth gauge.
Plastic hammer.
Starting position:
Camshaft mounted and adjusted in

relation to the crankshaft (lead), 607-01.20
Intermediate wheel mounted.
Related procedure:
Working time : 2-5 Hours Plate no. Item no. Qty. /

Capacity : 1 man
60801 23 1 set/cyl.
Data:

91.45 - ES0S
MAN Diesel & Turbo

Edition 02H Adjustment of The Maximum Combustion Pressure Page 2 (3)
General
If fuel oil valve, piston, inlet and exhaust valves as well Thinner and/or fewer shims (increase of the distance
as turbocharger and charge air cooler are working “X”) results in a delayed injection timing and a lower
correct and the compression pressure Pcomp is normal Pmax.
the maximum combustion pressure will indicate the
injection timing for the fuel oil pump. Thicker and/or more shims (reduction of the distance
“X”) results in an advanced injection timing and a
If Pmax is too low it indicates that the injection timing higher Pmax.
is delayed.
If the distance “X” is to be changed the trigger (1) is
If Pmax is too high it indicates that the injection timing used for dismantling of the thrust piece (2), where-
is advanced. after the thickness and/or the number of shims (3)
can be changed.
The injection timing can be altered by inserting or
removing shims under the thrust piece on the roller By changing “X” with 0.10 mm the maximum combu-
guide, thus changing the measure “X”, see fig. 1. stion pressure is changed with - see page 600.35.
After replacement of shims the thrust piece is re-

mounted in the roller guide (4) with a soft hammer
(5).
Measure "x"
1 5
1
2 2
3 2
Total height 3
3
4
4 4
1 Extractor 2 Thrust piece

3 Shims 4 Roller guide
5 Soft hammer
Fig. 1.
Fig. 3.
Action Results
Total height Distance Injection Max. combustion

on roller guide "x" timing pressure
increased ↑ Reduced ↓ Advanced ↑ increased ↑

Reduced ↓ increased ↑ Delayed ↓ Reduced ↓
Fig. 2.
91.45 - ES0S
MAN Diesel & Turbo

Page 3 (3) Adjustment of The Maximum Combustion Pressure Edition 02H
General
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 600.35.
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
Fig. 4.
to the hub.
The gear wheel is provided with an engraved scale,

see fig. 4, and the hub of the cam shaft is provided If the crankshaft is turned in the engines normal
with a mark. direction of rotation the maximum combustion pres-
sure P-max. is reduced.
When the screws, which fasten the gear wheel, are
loosened the gear wheel is turned (by turning the If the crankshaft is turned against the engines normal
crankshaft) in relation to the camshaft. By reading direction of rotation the maximum combustion pres-
the angle in which the gear wheel is displaced in sure P-max. is increased.
relation to the camshaft the altered Pmax can be
calculated. A line on the scale corresponds to: see After the adjustment the screws are fastened with a
page 600.35. torque wrench, see page 600.40, and secured.
91.45 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Fuel Injection Pump 61401-03H
L/V28/32H
43
35
14
48
16
09
05/06/ 17
56
05/06/56 33
18
37*
36* 23
24*
27
26*
51
38*
25* 49
30 50
07
03
44
04
45
28
11
29 04
08028-0D/H5250/94.08.12
03
39
52
40 10
13
41
54 01/02/57
55
12.23 - ES0, L'Orange

MAN Diesel & Turbo
Plate
61401-03H Fuel Injection Pump Page 2 (2)
L/V28/32H

Item Item
01 1/C Fuel injection pump, Fuel indsprøjtnings- 36* 1/P O-ring O-ring
complete (MDO) pumpe, komplet, MDO
37* 1/P Back-up ring Støttering
02 1/C Fuel injection pump, Fuel indsprøjtnings-
complete (HFO) pumpe, komplet, HFO 38* 1/P O-ring O-ring
03 2/P Shock screw Stødskrue 39 3/P Disc Skive
04 2/P Joint washer Pakning 40 1/P Pointer Viser
05 1/P Plunger and barrel, Stempel og cylinder 41 1/P Nut Møtrik

incl. non-return valve inkl. kontraventil
(MDO) (MDO) 43 4/P Screw Skrue
06 1/P Plunger and barrel, Stempel og cylinder 44 1/P Cap screw Hætteskrue
incl. non-return valve inkl. kontraventil
(HFO) (HFO) 45 1/P Joint washer Pakning
07 1/P Pump housing Pumpehus 48 1/P Ring Ring

witout IMO number uden IMO nummer og
and classification klassifikation 49 1/P Flange Flange
09 4/P Screw Skrue 50 1/P Gasket Pakning
10 1/P Lock washer Låseskive 51 4/P Screw Skrue
11 1/P Regulating rod Reguleringstandstang 52 4/P Screw f. mounting Skrue f. montering
13 1/P Locating bolt Styrebolt 53 1/P Kit comprising item Sæt bestående af item
24, 25, 26, 36, 37, 38 24, 25, 26, 36, 37, 38
14 1/P Pinion Tanddrev
54 1/P Plug screw Propskrue
16 1/P Upper spring plate Øverste fjederplade
55 1/P Gasket Pakning
17 1/P Spring Fjeder
56 1/P Plunger and barrel, Stempel og cylinder
18 1/P Lower spring plate Nederste fjederplade incl. non-return valve inkl. kontraventil (Svovl-
(Low sulphur fuel, fattig brændstof, WC/C)
23 1/P Thrust cap Trykhætte WC/C)
24* 1/P O-ring O-ring 57 1/C Fuel injection pump, Fuel indsprøjtnings-
complete (Low sul- pumpe, komplet (Svovl-
25* 1/P O-ring O-ring phur fuel, WC/C) fattig brændstof, WC/C)
26* 1/P Back-up ring Støttering
27 1/P Circlip Låsering
28 1/P Screw Skrue
29 1/P Joint washer Pakning

08028-0D/H5250/94.08.12
30 1/P Throttle screw Drosselskrue
33 1/P Non-return valve Kontraventilfjeder

spring
35 1/P Connecting piece Forbindelsesstykke
Qty./P = Qty./Pump Qty./P = Qty./Pump
Qty./C = Qty./Cylinder. Qty./C = Qty./Cylinder.
12.23 - ES0, L'Orange

MAN Diesel & Turbo
Plate
Page 1 (2) Fuel Injection Pump 61401-09H
L+V28/32H
19
01
24
02
25
03
26
04
20
04 27
05
28
06
07
29
08
09
10
11
12 21 30
13 31
14 32
15 13
12
16
17 22
23
18
33
06.28 - EO0, NICO

MAN Diesel & Turbo
Plate
61401-09H Fuel Injection Pump Page 2 (2)
L+V28/32H

Item Item
01 1/P Case : Delivery valve Hus for ventil 28 1/P Guide: Plunger Styr
02 1/P Ring Ring 29 1/P Snap ring Låsering
03 4/P Bolt Bolt 30 1/P Plug Prop
04 1/P Plunger, complete Stempel, komplet 31 1/P Gasket Pakning
05 1/P Back-up ring Støttering 32 1/P Control rack Reguleringstandstang
06 1/P O-ring O-ring 33 1/C Fuel injection pump, Brændselspumpe, komplete

complete
07 1/P O-ring O-ring
08 1/P Back-up ring Støttering
11 1/P Housing, complete Hus, komplet
12 2/P Deflector Deflektor
14 1/P Bolt Bolt
16 1/P Washer Skive
17 1/P Pointer Viser
18 1/P Nut Møtrik
19 4/P Bolt Bolt
20 1/P Spring: Delivery val- Fjeder

ve
21 1/P Plug Prop
22 1/P Snap ring Låsering
23 1/P Rack stopper Stop for tandstang
24 1/P Control sleeve Kontrolbøsning
25 4/P Spring seat Fjederplade (øverste)
26 1/P Spring: Plunger Fjeder
27 1/P Spring seat Fjederplade (neder-

ste)
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
06.28 - EO0, NICO

MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve 61402-04H
L/V28/32H
01
02
09
03
04
10
05
13 11
12
07
08028-0D/H5250/94.08.12
08
92.06 - ES0S
MAN Diesel
Plate
61402-04H Fuel Injection Valve Page 2 (2)
L/V28/32H
Item Item
01 1/V Lock nut Låsemøtrik
02 1/C Fuel injection valve, Brændselsventii,

complete komplet
03 1/V Injector housing Ventilhus
04 2/V O-ring O-ring
07 1/V Nozzle, complete Forstøver, komplet
08 1/V Screw cap Omløber
09 1/V Adjusting screw Justeringsskrue
11 1/V Thrust spindle Trykspindel
13 2/V Dowel pin Styrestift
08028-0D/H5250/94.08.12
Qty./V = Qty./Valve Qty./V = Qty./Ventil
92.06 - ES0S
MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve, Cooled - NICO 61402-07H
L+V28/32H
07
13
08
01
09
02
03
04
11
05
12
08028-0D/H5250/94.08.12
06
10
07.24 - EO0
MAN Diesel
Plate
61402-07H Fuel Injection Valve, Cooled - NICO Page 2 (2)
L+V28/32H
Item Item
01 1/V Injector body Brændstofsventil
04 2/V Dowel pin Styrestift
05 1/V Atomized, complete Forstøver, komplet
06 1/V Nozzle nut Forstøver
07 1/V Cap nut Omløber
08 1/V Nut Møtrik
09 1/V Adjusting screw Justeringsskrue
12 1/V Spindle Spindel
13 1/V Fuel injection valve, Brændstofsventil,

complete komplet
08028-0D/H5250/94.08.12
Qty./V = Qty./Valve Qty./V = Qty./Ventil
07.24 - EO0
MAN Diesel & Turbo
Plate
Page 1 (2) Fuel Oil Filter Duplex 61403-15H
L+V28/32H
25
26
A 24
23
27
28
22
29
21
30
01
20
19
09.28
MAN Diesel & Turbo
Plate
61403-15H Fuel Oil Filter Duplex Page 2 (2)
L+V28/32H

Item Item
01 1/E Fuel oil filter duplex, Brændselsoliespalte-

complete filter, komplet
19 2/F Lock screw Låseskrue
21 2/F O-ring O-ring
22 4/F Nut Møtrik
23 2/F Filter element Filterelement
26 1/F Fixing screw Fastspændingsskrue
27 2/F Lock screw Låseskrue
29 2/F Bushing Bøsning
Qty./E = Qty./Engine. Qty./E = Qty./Engine.
Qty./F = Qty./Filter Qty./F = Qty./Filter.
09.28
MAN Diesel & Turbo
Plate
Page 1 (2) Fuel Injection Pipe 61404-06H
L/V28/32H
01
02
03
04 07
05 03
06
08
09
10
11
05
06
91.40 - ES0S
MAN Diesel & Turbo
Plate
61404-06H Fuel Injection Pipe Page 2 (2)
L/V28/32H

Item Item
01 1/C Fuel oil high- Højtryksrør,

pressure pipe, komplet
complete
02 1/H Screwed socket Gevinmuffe
03 2/H O-ring O-ring
05 2/H Sleeve devided Bøsning 2-delt
06 2/H Round wire exp. Låsefjeder

ring
07 1/H Sleeve Styrebøsning
09 2/H Screw Skrue
10 1/H Flange Flange
11 1/H Sealing ring Tætningsring
Item Nos. marked with * are only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./H = Qty./High pressure pipe. Qty./H = Qty./Højtryksrør.
91.40 - ES0S
MAN Diesel & Turbo
Plate Pipes on Cylinder Section 61430-03H

Page 1 (3)
Forced Lubrication with Cooling Oil Pipes
L28/32H
95.28 - ES0S
MAN Diesel & Turbo
Pipes on Cylinder Section Plate

61430-03H Forced Lubrication with Cooling Oil Pipes Page 2 (3)
L28/32H
Item Item
014 1/C Drain pipe from fuel Drænrør fra 266 1/E Main pipe Stammerør
pump fuel pumpe
278 1/C Non-return valve Kontraventil
026 2/C Banjo coupling Banjoforskruning
291 1/C Lub. oil pipe for Smøreolierør for rulle-
038 1/C Branch pipe for fuel Stikrør for fuel olie, roller guide styr
oil, outlet afgang
301 1/C Straight male stud Ligeforskruning
051 1/C Banjo coupling Banjoforskruning coupling
063 1/C Straight male stud Ligeforskruning 313 1/C Lub. oil pipe Smøreolierør
coupling
087 1/C Branch pipe, Stikrør, coupling
lub. oil smøreolie
337 1/E Main pipe Stammerør
099 1/C Banjo coupling Banjoforskruning
coupling 350 1/E Steel pipe Stålrør
110 1/C Packing, square Pakning, firkantet 362 1/C Drain pipe from Drænrør fra cylinder
cylinder head dæksel
122 1/C Branch pipe, Stikrør, køleolie
cooling oil 374 1/C Male stud Vinkelforskruning
coupling
134 4/C Screw Skrue
386 1/E Equal elbow Vinkelforskruning
146 4/C Spring lock Fjederskive coupling
158 1/C Branch pipe, Stikrør, køleolie 398 1/E Screwed Vinkelforskruning
cooling oil connection
171 1/C Pipe for fuel oil Rør for fuel pumpe, 408 1/C Drain pipe from fuel Drænrør fra fuel pum-
pump, inlet tilgang pump pe
183 1/E Branch pipe Stikrør 421 1/C Pipe clamp Rørholder
195 1/E Elbow bulkhead Vinkelskotforskruning 433 1/C Screw Skrue

coupling
445 1/C Nut Møtrik
205 1/C Branch pipe, cylin- Stikrør,
der head cylinderdæksel 457 1/E Packing ring Pakningsring
217 1/E Straight coupling Ligeunion 469 1/E Restriction Restriktion
229 2/C Equal tee T-forskruning 470 1/C Gasket, oval Pakning, oval
coupling
482 2/C Screw Skrue
494 2/C Spring lock Fjederskive
504 Support Beslag
254 1/C Lub. oil pipe for Smøreolierør for vip- 4/E 5 cyl. 5 cyl.
rocker arm pearm 5/E 6 cyl. 6 cyl.
6/E 7 cyl. 7 cyl.
7/E 8 cyl. 8 cyl.
8/E 9 cyl. 9 cyl.
Qty./C = Qty./Cylinder. Antal/C = Antal/Cylinder.
95.28 - ES0S
MAN Diesel & Turbo
Plate Pipes on Cylinder Section

Page 3 (3)
Forced Lubrication with Cooling Oil Pipes 61430-03H
L28/32H
Item Item
516 Screw Skrue 612 4/E Pipe clamp Rørholder

4/E 5 cyl. 5 cyl. 5/E 5 cyl. 5 cyl.
8/E 9 cyl. 9 cyl. 9 cyl. 9 cyl.
528 Pipe clamp Rørholder 624 4/E Screw Skrue

541 Screw Skrue 636 4/E Pipe clamp Rørholder

10/E 6 cyl. 6 cyl. 6/E 6 cyl. 6 cyl.
12/E 7 cyl. 7 cyl. 7/E 7 cyl. 7 cyl.
14/E 8 cyl. 8 cyl. 8/E 8 cyl. 8 cyl.
553 1/E Fuel oil distributor Fuel oliefordelingsrør

pipe
565 Support Beslag

4/E 5 cyl. 5 cyl.
5/E 6 cyl. 6 cyl.
6/E 7 cyl. 7 cyl.
7/E 8 cyl. 8 cyl.
8/E 9 cyl. 9 cyl.
577 Screw Skrue

8/E 5 cyl. 5 cyl.
10/E 6 cyl. 6 cyl.
12/E 7 cyl. 7 cyl.
14/E 8 cyl. 8 cyl.
16/E 9 cyl. 9 cyl.
589 Spring lock Låsefjeder

8/E 5 cyl. 5 cyl.
10/E 6 cyl. 6 cyl.
12/E 7 cyl. 7 cyl.
14/E 8 cyl. 8 cyl.
16/E 9 cyl. 9 cyl.
590 Pipe clamp Rørholder

4/E 5 cyl. 5 cyl.
5/E 6 cyl. 6 cyl.
6/E 7 cyl. 7 cyl.
7/E 8 cyl. 8 cyl.
8/E 9 cyl. 9 cyl.
600 Screw Skrue

8/E 5 cyl. 5 cyl.
10/E 6 cyl. 6 cyl.
12/E 7 cyl. 7 cyl.
14/E 8 cyl. 8 cyl.
16/E 9 cyl. 9 cyl.
Qty./C = Qty./Cylinder. Antal/C = Antal/Cylinder.
95.28 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Nozzle Cooling Pump 61440-05H
L28/32H
02.12 - EO0
MAN Diesel & Turbo
Plate
61440-05H Nozzle Cooling Pump Page 2 (2)
L28/32H

Item Item
01 1/P Driving cover Medbringerdæksel
02 1/P Gear casing Gearhus
03 1/P End cover, complete, Endedæksel, komplet

incl. item 21 to 29 inkl. item 21 til 29
04 1/P Driving gear shaft Drivende gear aksel
05 1/P Gear shaft Gear aksel
09 4/P Screw Skrue
10 2/P Parallel pin Styrestift
11 1/P Retaining ring Sikringsring
12 1/P Parallel key Not
16 1/P Rotary shaft seal Roterende aksel tæt-

ning
20 1/E Pumpe, complete Pumpe, komplet uden

without El-motor el-motor
21 1/P End cover Endedæksel
22 1/P Piston Stempel
23 1/P Spindle Spindel
24 1/P Dome nut Lukkemøtrik
26 1/P Pipe nut Rørmøtrik
27 2/P Screwed plug Propskrue
28 2/P Sealing ring Tætningsring
30 1/P Coupling, complete Kobling, komplet
31 1/E El-motor, complete El-motor, komplet
32 1/E Pre.lub oil pump, Forsmørepumpe,

complete with el- komplet med el-motor
motor
33 1/E Ball bearing, rear Kugleleje, bagside
34 1/E Ball bearing, front Kugleleje, forside
02.12 - ES0
Lubricating oil system
515/615
MAN Diesel & Turbo
Description
Internal Lubricating Oil System 615.01
L28/32H
C3
C16 C15
PDT PT TE
21-22 22 22
PDAH PAL TAH PSL TI LAL
Hand wing pump 21-22 22 22 22 22 25
Filter
El. Driven pre- Centri-
Prelub. fugal
oil inlet lub. oil pump filter
TC Drain from
LAH LAL oil vapour
28 28 discharge
Filling plug
PI
23
To main bearing
TE TE TE TE TE C13
Lub. oil cooler 29 29 29 29 29
To rocker arms
To Cyl. 1
TI
To pump
20 drive piston To
A camshaft
drive Governor
drive
TE
20
TAH
20 Forced oil
Engine driven Boring in
lub. oil pump camshaft
PI
21-22
C4 C9
Separate full flow filter
A: When full flow filter Standard

Optionals
C7 C8
Fig 1 Diagram for internal lubricating oil system.
General
Pipe description for connection at the engine
C3 Lubricating oil from separator DN 25 As standard the lubricating oil system is based on
C4 Lubricating oil to separator DN 25 wet sump lubrication. All moving parts of the engine
C7 Lubricating oil from separate filter DN 80 are lubricated with oil circulating under pressure in
a closed built-on system.
C8 Lubricating oil to separate filter DN 80
C9 Back-flush from full-flow filter DN 20
The lubricating oil is furthermore used for the pur
C13 Oil vapour discharge* DN 50 pose of cooling the pistons.
C15 Lubricating oil overflow DN 50
C16 Lubricating oil supply DN 25 The standard engine is equipped with built-on:
Flange connections are as standard according to DIN 2501 – Engine driven lubricating oil pump
– Lubricating oil cooler
– Lubricating oil thermostatic valve
– Duplex full-flow depth filter
* For external pipe connection, please see section
– Pre-lubricating oil pump
for crankcase ventilation.
12.14 - ES0
MAN Diesel & Turbo
615.01 Internal Lubricating Oil System

Description
L28/32H
Oil Quantities 4 – Governor drive

5 – Rocker arms
The approximate quantities of oil necessary for a new
engine, before starting up are given in the table, see 6 – Camshaft
"B 12 01 1 / 604.06 Lubricating Oil in Base Frame"
(max. litre H3) 1) For priming and during operation, the tur
bocharger is connected to the lubricating oil
If there are connected external, full-flow filters etc., circuit of the engine, the oil serves for bearing
the quantity of oil in the external piping must also be lubrication.
taken into account.
The inlet line to the turbocharger is equipped
Max. velocity recommendations for external lubri with an orifice in order to adjust the oil flow and
cating oil pipes: a non-return valve to prevent draining during
stand-still.
– Pump suction side 1.0 - 1.5 m/s
– Pump discharge side 1.5 - 2.0 m/s The non-return valve has back-pressure func-
tion requiring a pressure slightly above the prim-
ing pressure to open in normal flow direction.
Lubricating Oil Consumption In this way overflooding of the turbocharger is
prevented during stand-still periods, where the
The lubricating oil consumption is 0.6 - 1.0 g/kWh, pre-lubricating pump is running.
see "Specific Lubricating Oil Consumption - SLOC,
B 12 15 0 / 604.07" 2) Lubricating oil for the main bearings is supplied
through holes drilled in the engine frame. From
It should, however, be observed that during the run- the main bearings it passes through bores in
ning in period the lubricating oil consumption may the crankshaft to the connecting rod big-end
exceed the values stated. bearings.
The connecting rods have bored channels for

Quality of Oil supply of oil from the big-end bearings to the
small-end bearings, which has an inner circum-
Only HD lubricating oil (Detergent Lubricating Oil) ferential groove, and a pocket for distribution
should be used, characteristic stated in "Lubricating of oil in the bush itself and for supply of oil to
Oil Specification B 12 15 0 / 604.01". the pin bosses and the piston cooling through
holes and channels in the piston pin.
System Flow From the front main bearings channels are

bored in the crankshaft for lubricating of the
The lubricating oil pump draws oil from the oil sump pump drive.
and presses the oil through the cooler and filter to
the main lubricating oil pipe, from where the oil is 3) The lubricating oil pipes, for the camshaft drive
distributed to the individual lubricating points. From gear wheels, are equipped with nozzles which
the lubricating points the oil returns by gravity to are adjusted to apply the oil at the points where
the oil sump. the gear wheels are in mesh.
The main groups of components to be lubricated are: 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
1 – Turbocharger
mesh.
2 – Main bearings, big-end bearing etc.
5) The lubricating oil to the rocker arms is led
3 – Camshaft drive
12.14 - ES0
MAN Diesel & Turbo
Description
Internal Lubricating Oil System 615.01
L28/32H
through pipes to each cylinder head. It continuos
through bores in the cylinder head and rocker A
arm to the movable parts to be lubricated at
rocker arms and valve bridge. Further, lubricat-
ing oil is led to the movable parts in need of
lubrication.
6) Through a bore in the frame lubricating oil is led

to the first camshaft bearing and through bores
in the camshaft from where it is distributed to
C B
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 Fig 2 Thermostatic Valve
is driven by means of the crankshaft through a cou-
pling. The oil pressure is controlled by an adjustable
spring- loaded relief valve built-on the oil pump. chamber without any interruption in lubricating oil
supply to the engine.
Thermostatic Valve Servicing is generally restricted to replacing of the

paper cartridges, cleaning of the radial mesh insert
The thermostatic valve is designed as a T-piece with and inspection of sealings, the latter to be replaced
the inlet in the cover (A) under which the thermostatic if damages observed.
elements are located.
Each filter chamber is equipped with 1 or 2 repla-
The outlet to the engine (by-passing cooler) is mar- ceable paper cartridges of fineness 10-15 microns.
ked (B) and outlet to the cooler is marked (C). In the
warming up period, the oil is by-passing the cooler. In the centre of each filter chamber a filter basket
When the oil from the engine reaches the normal (central element) is situated. This filter basket is
temperature see "Operation data & set points 600.30" acting as a safety filter, having a fineness of about
a controlled amount af oil passes through the cooler. 60 microns.
The thermostatic elements must be replaced if the During operation an increased pressure drop across
temperature during normal operation deviates es- the filter will be observed as dirt particles will deposit
sential from the one stated in the test report. on the filtration surfaces of the paper cartridges and
thus increase the flow resistance through the filter.
The valve cannot be set or adjusted, and it requires
no maintenance. If the pressure drop across the filter exceeds 2.0
bar, a release valve will open and by-pass the 10-15
microns filter element, and the engine will run with
Built-on Full-flow Depth Filter only the 60 microns safety filter.
The lubricating oil filter is a double filter which is To ensure safe filtering of the lubricating oil, none of
generally used with only one filter chamber being in the by-pass valves must open during normal service
operation, the other filter chamber being stand-by. and the elements should be replaced at a pressure
drop across the filter of 1.5 bar.
If the filter chamber in operation needs to be servi-
ced, the operation can be switched to the other filter
12.14 - ES0
MAN Diesel & Turbo
615.01 Internal Lubricating Oil System

Description
L28/32H
Servicing is essential the exchange of the paper Optionals
cartridges.
Besides the standard components, the following
When exchanging cartridges, it is advisable to release optionals can be built-on:
any old oil remaining in the filter housing by means
of the drain plug provided for this purpose, and to – Level switch for low/high level in oil sump
wipe out the housing with a cloth. (LAL/LAH 28)
– Centrifugal by-pass filter
The filter chambers can be serviced successively (standard for stationary engines)
during operation or when the engine is at standstill. – Hand wing pump
– Filling plug
It is essential to follow the instructions in work card
615-01.10 closely when replacing filter cartridges. Pressure differential transmitting
– PDT 21-22 Lubricating oil inlet across filter
Filter cartridges must under no circumstances be
cleaned and used again. Temperature alarm high
– TAH 20 Lubricating oil inlet before cooler
Pre-lubricating Pressure transmitting

– PT 22 Lubricating oil inlet after cooler
As standard the engine is equipped with an electric-
driven prelubricating pump mounted parallel to the Temperature element
main pump.The pump must be arranged for automatic – TE 20 Lubricating oil inlet before cooler
operation, ensuring stand-still of the pre-lubricating
pump when the engine is running, and running dur- Temperature element
ing engine stand-still in stand-by position. – TE 22 Lubricating oil inlet after cooler
Running period of the pre-lubricating pump is prefer- Temperature element

ably to be continuous. If intermittent running is requi- – TE 29 Lubricating oil inlet main bearings
red for energy saving purpose, the timing equipment
should be set for shortest possible intervals, say 2 Branches for:
minutes of running, 10 minures of stand-still, etc.
Further, it is recommended that the pre-lubricating – External fine filter
pump is connected to the emergency switch board – External full/flow filter
thus securing that the engine is not started without
pre-lubrication. Branches for separator is standard.
Draining of the Oil Sump
It is recommended to use the separator suction pipe

for draining of the lubricating oil sump.
12.14 - ES0
MAN Diesel
Description
Lubricating Oil Cooler 615.06
Page 1 (1)
Edition 02H
L+V28/32H
Principle of the Plate Heat Exchanger Plates
The built-on lubricating oil cooler is a plate heat After clamping of the plate pack, the plates - which
exchanger. are fitted gaskets - ensure an effective seal between
fluids and atmosphere. In addition, intermixing of the
The plate heat exchanger consist of a number of cold fluids is eliminated by a double gasket seal around
pressed plates which are compressed between a the inlet ports.
frame plate (head) and the pressure plate (follower)
by means of tie bolts. Every second plate is turned through 180°. This
means that the double gasket seal occurs around
The plates are made with special corrugations, every second inlet to the channels between the
which ensures turbolent flow and high heat transfer plates.
cofficients.
The plate pack now forms a series of parallel flow
channels in which the fluids flow in a counter cur-
rent regime.
08028-0E/H5250/94.08.12
96.26 - ES0U
MAN Diesel & Turbo
Description
Centrifugal By-Pass Filter 615.15
Page 1 (1)
Edition 05H
L+V28/32H
L32/40
Description
The centrifugal filter is a by-pass filter mounted directly For proper filtration, it is important that the rotor is
at the engine base frame. The centrifugal filter is a always correctly balanced.
supplement to the main filter.
An out-of-balance condition can occur as a result
During service, a part of the lubricating oil supplied of an uneven built-up of sludge or as a result of ex
from the engine driven lubricating oil pump enters cessive bearing or spindle wear.
the centrifugal filter and returns to the oil sump in
the base frame.
The centrifugal filter relies on the centrifugal force

and can therefore remove high density, sub-micron
particles.
Principle of Operation
D
Oil enters the base of the filter and depresses the
B
cut-off valve (A) which has a pre-set pressure valve.
The cut-off valve is fitted to ensure that at low pres- E
sure and flow conditions the entire oil pump output is
C
supplied to the engine working parts. Having depres-
sed 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 F
tube. The oil completely fills the cleaning chamber
(D) and travels through the strainer (E) into the drive
chamber (F), leaving under pressure via diametrically A
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
A Cut-off valve D Cleaning chamber
spindle at high speed. The oil leaving the nozzles is E
B Top Strainer
then allowed to drain back to the sump, by gravity C Rotor F Drive chamber
at atmospheric pressure.
The centrifugal force field within the spinning rotor Fig. 1. Diagram showing Principle of Operation.
forces the contaminants to travel to the inner wall of
the rotor, where they form a dense rubber-like sludge
which is easily removed.
96.26 - ES0S
MAN Diesel & Turbo
Description 615.31
Page 1 (2) Crankcase ventilation
Edition 03H
L32/40, L28/32H, V28/32H

Crankcase ventilation 1) The vent pipe from each engine is to run inde-
pendently to the manifold and be fitted with cor-
The crankcase ventilation is not to be directly con- rosion resistant flame screen within the mani-
nected with any other piping system. It is preferable fold.
that the crankcase ventilation pipe from each
engine is led independently to the open air. The out- 2) The manifold is to be located as high as practi-
let is to be fitted with corrosion resistant flame cable so as to allow a substantial length of pip-
screen separately for each engine. ing, which separates the crankcase on the indi-
vidual engines.
3) The manifold is to be vented to the open air, so
that the vent outlet is fitted with corrosion resist-
ant flame 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 must be designed to eliminate
the risk of water condensation in the pipe flowing
back into the engine and should end in the open air:
▪ The connection between engine (C13 / C30)
and the ventilation pipe must be flexible.
▪ The ventilation pipe must be made with continu-
ous upward slope of minimum 5°, even when
the ship heel or trim (static inclination).
▪ A continuous drain must be installed near the
engine. The drain must be led back to the
sludge tank.
Engine Nominal diameter ND (mm)
A B C
L16/24 50 65
L21/31 65 40 80
L23/30H 50 - 65
L27/38 100 - 100
L28/32H 50 - 65
V28/32H 100 - 125
L32/40 125 50 125
V28/32S 100 - 125
Table 1: Pipe diameters for crankcase ventilation
▪ Dimension of the flexible connection, see pipe
Figure 1: Crankcase ventilation diameters Fig 2.
▪ Dimension of the ventilation pipe after the flexi-
However, if a manifold arrangement is used, its ble connection, see pipe diameters Fig 2.
arrangements are to be as follows:
2012.01.16 - ES1
MAN Diesel & Turbo
615.31 Description
Crankcase ventilation Page 2 (2)
Edition 03H
L32/40, L28/32H, V28/32H

The crankcase ventilation flow rate varies over time,
from the engine is new/major overhauled, until it is
time to overhaul the engine again.
The crankcase ventilation flow rate is in the range of
3.5 – 5.0 ‰ of the combustion air flow rate [m³/h]
at 100 % engine load.
If the combustion air flow rate at 100 % engine load
is stated in [kg/h] this can be converted to [m³/h]
with the following formula (Tropic Reference Condi-
tion) :
Example :
Engine with a mechanical output of 880 kW and
combustion air consumption of 6000 [kg/h] corre-
sponds to :
The crankcase ventilation flow rate will then be in

the range of 19.2 – 27.4 [m³/h]
The maximum crankcase backpressure measured
right after the engine at 100 % engine load must not
exceed 3.0 [mbar] = 30 [mmWC].
2012.01.16 - ES1
MAN Diesel

Page 1 (3) Lubricating Oil Pump, Engine Driven Edition 01H
L+V28/32H

Shut-off fuel oil
Description:
Disassembly, overhaul and assembly of lubrica-

ting oil pump, engine driven.
Adjusment of lub. oil pressure. Hand tools:

Starting position: Ring and open end spanner, 46 mm.
(Socket spanner, 46 mm).
All pipe connections to the lub. oil pump have Allen key, 8 mm, 4 mm.
been disconnected, and the lub. oil pump is re- Plier for locking ring.
moved from the engine. Soft hammer.
Big screw driver.
Adjustable spanner.
Puller.
Related procedure: Silastene or similar.
Hard brush.
Man power:
08028-0D/H5250/94.08.12
Working time : 6-8 Hours Replacement and wearing parts:

Capacity : 1 man
Data: 61501 04 1/pump

61501 06 5/pump
96.26 - ES0S
MAN Diesel

Edition 01H Lubricating Oil Pump, Engine Driven Page 2 (3)
L+V28/32H
Disassembly: Before the gear wheels (7 and 8) can be mounted
the bearing bush must be adjusted with a reamer
1) Remove the coupling part or gear wheel (1), or a bearing scraper, so that the gear wheel can run
see fig. 2, by means of a puller or a soft hammer. easily when the pump is assembled.
2) Remove screws (2) and dismount the cover 8) Inspect all other parts for wear and damage,
(3). and renew, if necessary.
3) Dismount the locking ring (4), screws (5) and

remove the cover (6) with the overspeed device.
1
4) Remove the gear wheel (7 and 8).
15 14
5) Dismounting of the spring loaded adjustable 12
by-pass valve. 13
Remove the cap nut (9), nut (10), spring housing 11

(11), spring (12) and the cylinder (13). If the piston 7 10
(14) cannot be pulled out from the same side, the
plug screw (15) can be removed and the piston can 9
be pressed out from this side with a screw driver 8
or the like.
6
5
4
3
2
Fig. 2.
Assembly:
9) Mount the gear wheel (7 and 8).
Coat the sealing lip with silastene or similar and

Fig. 1. mount the cover (6) with gear wheel and locking
ring (4).
08028-0D/H5250/94.08.12
Overhaul. 10) Mount the cover (3) with gasket.
6) Clean all the parts with gas oil and a hard 11) Mount the gear wheel or coupling part (1).
brush, (never use a steel brush). The parts are blown
clean with working air. For tightening the nut for gear wheel, see page
600.40.
7) If the bearing bush is to be removed the
existing bearing bush is plugged out by means of 12) Mount the spring loaded by-pass valve, nut
a mandrel, the bores are cleaned and new bearing (10) with gasket, cap nut (9) and plug screw (15).
bush is mounted, see fig. 1.
96.26 - ES0S
MAN Diesel

Page 3 (3) Lubricating Oil Pump, Engine Driven Edition 01H
L+V28/32H
Adjusting of Lub. Oil Pressure. By turning the spring housing clockwise the pressure
is raised and reverse the pressure is lowered by
13) The outlet pressure of the lub. oil pump, can turning the spring housing (11) anti-clockwise. When
be adjusted by means of a adjusting screw in the the correct pressure is reached , see page 600.30,
by-pass valve. the spring housing (11) is locked with nut (10) and
finally the gasket and cap nut (9) are mounted.
Remove the cap nut (9) and loosen the nut (10).
08028-0D/H5250/94.08.12
96.26 - ESoS
MAN Diesel

Page 1 (3) Prelubricating Pump Edition 02H
General

Shut-off cooling water Wheel puller for bearing bush.
Shut-off fuel oil Compressed pin.
Shut-off cooling oil Protection cover for shaft seal.
Stopped lub. oil circul. Compressed pin for shaft seal.
(The special tools must be ordered separately

from MAN B&W Diesel A/S, Holeby)
Description:
Dismounting, replacement of the rotary shaft seal

and assembly of prelubricating pump.
Hand tools:
Bench vice.
Spanner.
Starting position: Torque spanner.
Soft hammer.
Related procedure:
08028-0D/H5250/94.08.12
Man power:
Working time : 2-3 Hours
Capacity : 1 man Plate no. Item no. Qty. /
Data: See plate 61504.

92.26 - ES0S
MAN Diesel
Edition 02H Prelubricating Pump Page 2 (3)
General
Overhauls. We advise not to change the bearing bushes. In
connectin with damages on the bearings it is normal
Overhauls for the purpose of avoiding functional that also the shafts and the parts in the gear box
trouble are not normally necessary for the prelubri- will be damaged.
cating pumps, when properly used, there is very
little wear on the pump gear shaft. When ordering spare parts, do not forget to state
the factory no. of the pump.
Spare Parts.
Replacement of mechanical seal.
Before any overhaul is done, please note the fol-
lowing: 1) Disconnect the cable and pipe connection to
the pump.
If a pump gets unusable by wear, it must be repla-
ced. Installation of spare parts cannot bring it back 2) Remove the pump from the engine base
to normal condition. frame.
It pays to keep extra pumps in stock or to have repairs 3) Separate the pump and the el-motor.
(overhauls) carried out at our repair shop.
4) Remove the coupling part and key (12), see
The shaft seal needs only to be replaced in case fig. 1, from the driving gear shaft (4).
of leakage or after dismounting of drive shaft. The
marks from the seal do not necessarily mean that 5) Tighten the pump to the flange. Pressure
the sealing is defective, but there is a risk of leakage control valve (3) upwards.
after replacement of sealing.
6) Loosen screws (9) and take off the pressure
control valve (3).
12 11 16 01 04 02 03 09
08028-0D/H5250/94.08.12
Fig. 1. Prelubricating Pump.
92.26 - ES0S
MAN Diesel
Page 3 (3) Prelubricating Pump Edition 02H
General
7) Take off the gear box (2), if necessary use a Mounting.
soft hammer for separation.
13) The mounting process follows in reverse order,
8) Remove the gear wheels from the cover (1). it is stressed that an exact cleaning works is neces-
Dismounting is only possible by disturbing the rotor sary.
shaft seal and by breaking the bearing bush.
Especially the sealing faces must be clean.
9) Remove the security ring (11) and take off the
rotary shaft seal (16). Tightening of screw pos. (9):
10) Press out the driving gear shaft bearing bush, R25 10 Nm
pull out the running bearing bush with the inner R35 50 Nm
wheel puller.
In connection with the bearing bush, attention must
11) Gear box (2). Dismounting is only possible be paid to the placement of the butt joint and the
by damaging the shaft bush. Press out the shaft mounting depth.
bushes.
The new shaft seal cannot be pressed into the pro-
12) Pressure control valve (3). The pressure control tection cover before exact mounting of the pump.
valve can be dismounted also without dismounting
the pump. O-ring must be changed.
08028-0D/H5250/94.08.12
92.26 - ES0S
MAN Diesel
Page 1 (3) Lubricating Oil Filter Edition 01H
General

Shut-off fuel oil
Description:
Replacement of paper filter element(s).

Cleaning of safety filter and filter housing. Hand tools:

Starting position: Adjustable spanner.
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
61502 01 See plate 61502
Data: 61502 28 1/Filter.

91.45 - ES0S
MAN Diesel
Edition 01H Lubricating Oil Filter Page 2 (3)
General
The lubricating oil filter is dimensioned so that each of 4) Filter housing cap is dismantled.
the two filter parts has sufficent capacity to treat the
amount of lubricating oil delivered by the pump. 5) Remove the inner safety element. Clean the
element with detergent. Check that it is intact.
The three-way valve positioned is determining
whether the left hand or the right hand filter chamber 6) Remove the outer element(s). Filter element is
is in operation, and also gives the possibility of having of disposable type. It change always to new original
both filter chambers in operation simultaneously. filter.
The three-way valve is marked with flow directions 7) Clean the filter housing and the cap. Be careful
and the figure indicates the operation modes accor- of not to let the oil from the dirty side to go into the
ding to valve positions. clean oil channel in the middle of bottom.
Three-way valve positions 5 6 5
Left hand filter cam- Right hand filter

ber in operation. camber in opera-
8 1 2 8
7
4
3
Both filter camber in
operation.
1 Left hand filter camber 2 Right hand filter chamber

Fig. 1. Three-way valve positions. 3 Inlet 4 Outlet
5 Vent screw 6 Three-way valve/
switch valve
7 Fill-up valve 8 Drain plug
Service Procedure.
08028-0D/H5250/94.08.12
1) Turn the three-way valve, see fig. 2, into the

position setting the stand-by filter chamber in ope- Fig. 2.
ration and the filter chamber requiring service out
of operation.
2) Open the vent screw (5) on the top of the filter 8) Check the seal on the bottom of the filter hou-
to get the pressure out of the filter half. sing and in the cap. Change if needed.
3) Open the drain plug (8) under the filter housing 9) Assemble the filter in opposite order.
and drain off oil.
91.45 - ES0S
MAN Diesel
Page 3 (3) Lubricating Oil Filter Edition 01H
General
10) Let the air valve be open and fill the filter
housing with oil by means of the slow fill-up valve
Fill-up valve positions (7) in position FILL, see fig. 3. This valve is inside
the three-way valve and by using it, the filling can
Operation Changing over
be made so slowly that the pressure on the other
part of the filter does not drop too much.
11) Close the vent screw (5) after the housing is

filled up with oil.
12) Open the three-way valve (6) and close the

Switch in normal Switch in fill fill-up valve (7) by turning it to position CLOSED,
operation position position see fig. 3.
13) The filter just serviced is now ready to be set

in operation.
Fig. 3. Fill-up valve position.
Inspect for oil leakages in order to ascertain all
sealings to be tight.
Check that pressure drop across filter is correct.
Clean the other side of the filter correspondingly.

08028-0D/H5250/94.08.12
91.45 - ES0S
MAN Diesel

Page 1 (2) Lubricating Oil, Thermostatic Valve Edition 01H
General
Stopped engine Plate No. Item No. Note.

Shut-off fuel oil
Description:
Inspection of thermostatic valve and replacement

of elements. Hand tools:

Copaslip
Tools and cleaning preparation for cleaning.
Starting position:
Lubricating oil drained from engine (if neces-

sary).
Related procedure:
08028-0D/H5250/94.08.12
Man power:
Working time : 2 Hour Replacement and wearing parts:

Capacity : 1 Man
Data:
61503 03 1/engine
Data for pressure and tolerance (Page 600.35) 61503 05 2 or 4/engine
Data for torque moment (Page 600.40) 61503 09 3/engine
92.05 - ES0S
MAN Diesel

Edition 01H Lubricating Oil, Thermostatic Valve Page 2 (2)
General
The thermostatic valve cannot be adjusted and un- Replacement of elements:

der normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements in the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part of the hou-

sing.
1
2 3) Remove the assembled elements (3) and the
3 elements O-ring sealing.
5 4) Remove the gaskets between the upper and
lower part of the housing.
4
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
1. Nut
mounted and tightened "cross-wise".
2. Washer
3. Element
Note:
4. O-rings sealing
5. Gasket
After inspection or replacement of the elements the
lub. oil temperature is checked to ensure that the
elements are working correctly.
Fig. 1 Thermostatic valve
08028-0D/H5250/94.08.12
92.05 - ES0S
MAN Diesel
Page 1 (2) Check of Lubricating Oil Piping System Edition 01H
General

Shut-off fuel oil
Description:
Check and examination of the lubricating oil

piping system. Hand tools:
Starting position:
Engine running.
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

92.04 - ES0U
MAN Diesel
Edition 01H Check of Lubricating Oil Piping System Page 2 (2)
General
4) Blow-through drain pipes.
Checks to be carried out.
5) Check flexible connections for leaks and dama-
1) Examine the piping system for leaks. ges.
2) Retighten all bolts and nuts in the piping system. 6) Check manometers and thermometers for pos-
sible damages.
3) Move all valves and cocks in the piping system. For lubricating oil condition, see section 604.
08028-0D/H5250/94.08.12
92.04 - ES0U
MAN Diesel

Page 1 (4) Lubricating Oil Cooler Edition 02H
L+V28/32H

Shut-off fuel oil
Description:
Separation, cleaning and assembling.

Replacement of plates and gaskets. Hand tools:

Starting position: Adjustable spanner
Cooling water and lub. oil have been drained from

cooler/engine. All pipes are disconnected.
Related procedure:
Manpower:
08028-0D/H5250/94.08.12
Working time : 4 hours Replacement and wearing parts:

Capacity : 1 man
Plate No Item No Qty./
Data:
61506 09 4/cooler
96.26 - ES0S
MAN Diesel

Edition 02H Lubricating Oil Cooler Page 2 (4)
L+V28/32H
Introduction Manual Cleaning
Cleaning of the cooler has to take place, when the Clean the plates with a soft brush and a suitable
pressure drop on the oil and water side is larger detergent. In case of dense coating of scale or
than allowable and/or if the oil cannot be sufficiently organic materials, the plates must be put in a bath
cooled. of detergent.
Note: Never use a steel brush, metal scraper or

Separation the like.
Cooling and Pressure Relief A high-pressure cleaner can be used with care, how-
ever, never with sand or other abrasives added.
Before opening the plate heat exchanger, it has
to be cooled down to below 40o C and be without
pressure! Detergents
The cooling must not exceed 10o C per minute. A detergent is suitable, if it will remove any coating
The pressure drop must not exceed 10 bar per on the plates without causing any damage to plates
minute. and gaskets.
Note: If these norms are exceeded, the guarantee Note: It is of great importance that decomposition
will cease to be valid. of the protective film on the stainless steel
does not take place - the film preserves the
corrosion resistancy of the steel.
Separation of Edge-clamped Frame
Do not use chlorine-containing agents such
Upon completion of the procedure “Cooling and as hydrochloricacid (HCI)!
Pressure Relief”, separate the frame by retaining
two or four diagonally placed bolts. Oil and fats are removed by using a water emulsify-
ing oil solvent, e.g. BP-system cleaner.
Note: Take care that the movable cover does not
tilt! Organic and greasy coatings are removed by using
sodium hydroxide (NaOH):
Loosen all bolts uniformly and diagonally (max. 10 mm
at a time), then push the movable cover towards the - max. concentration 1.5%
pillar. When the pressure plate is not tight anymore, (1.5% concentration corresponds to 3.75
the plates can be removed. l 30% NaOH per 100 l water).
- max. temperature 85o C.
Note: When using plate heat exchangers on board
ships, the movable covers have to be secured Stone and lime/calcareous deposits are removed by
08028-0D/H5250/94.08.12
in order to avoid danger due to the movements using nitric acid (HNO3):
of the ship.
- max. concentration 1.5%
(1.5% concentration corresponds to 1.75 l
Cleaning 62% HNO3 per 100 l water).
- max. temperature 65o C.
The capacity and corrosion resistance of the plate
heat exchangers depend on the purity of the plates. Note: The nitric acid has an important constructive ef-
Any coating on the plates can be removed manu- fect on the protective film of stainless steel.
ally.
96.26 - ES0S
MAN Diesel

Page 3 (4) Lubricating Oil Cooler Edition 02H
L+V28/32H
Control of Cleaning Fluid Concentrations Replacement of Glued Gaskets
Sodium hydroxide (NaOH) solution is tritrated with On Plate 61506 are stated gasket and glue quan-
0.1 n hydro-chloric acid (HCI) with methyl orange or tity.
methyl red as indicator.
Please use a degreasing agent on the new gas-
Nitric acid (HNO3) solution is titrated with 0.1 n sodium kets.
hydroxide (NaOH) with phenolphtalin as indicator.
The first plate after the end cover and the connector
The concentration of the cleaning fluid in % can be grid must have gaskets in all grooves. The gaskets
calculated from the titration result by means of the are to be cut according to the existing gaskets.
following formula:
Loosen the glued gaskets by heating the plate in
Concentration = bxnxm % water at 100o C. Clean the plates and remove the
a x 10 coatings, if any.
a : ml cleaning fluid taken out for titration

b : ml titration fluid used as cover Cleaning of New Gaskets and Plates
n : the molecular concentration of titration fluid
m : The molecular weight of the cleaning fluid New gaskets and gasket grooves of the plates are
(NaOH) molecular weight 40, HNO3 molecular cleaned with a cloth moistened with degreasing
weight 63) agent. The glue surfaces must be absolutely clean
- without finger prints etc.
Replacement of Plates and Gaskets Please use our cleaning fluid, which is according to
suppliers recommendations.
Marking
Alternatively, please use:
The plates are marked with material codes and refer-
ence numbers at each end, plus codes for non-glue - Trichloroethylene
gaskets, if any, and stamped with the letter V and H - Chlorothene VG
at either end (Fig 1). - Acetone
- Methyl ethyl ketone
Looking towards the gasket side, the plate is des- - Ethylacetat
ignated as a left plate, when the letter V is turning
upwards - and a right plate when the letter H is turn- It is important that all degreasing agent has evapo-
ing upwards. Inlets and outlets of the V-plates are rated, before the glue is applied. This will normally
taking place through the corner holes Nos 1 and 4. take approx. 15 min. at 20o C.
Inlets and outlets of the H-plates are taking place
through the corner holes Nos 2 and 3. Clean the new gaskets on the glue surfaces with
08028-0D/H5250/94.08.12
fine-grain sandpaper instead of the degreasing

agent supplied.
Replacement of Plates
Before mounting a spare plate in the plate stack, Gluing

please make sure that the spare plate is identical
with the defective plate. Pliobond 25, which is a nitrile rubber glue on solvent
basis (25% solids). The glue is applied with a brush
Note: The same corner holes must be open and the in a thin layer on the backs of the gaskets and the
letters V and H must be placed correctly. gaskets are to dry in a clean place free of dust.
96.26 - ES0S
MAN Diesel

Edition 02H Lubricating Oil Cooler Page 4 (4)
L+V28/32H
Apply a thin layer of glue on the gasket grooves The fixed cover has number 1 and the serial numbers
of the plates and press the gaskets down into the for the subsequent plates and intermediate frames,
gasket grooves. if any, have the numbers 2, 3, 4, 5 etc.
The insertion of gaskets starts at both ends of the The serial number are stamped in the right top corner
plate - and continues with the straight sections along of the plates. Further, please note that the gasket
the edges. side must face the fixed cover.
The gluing process is most easily effected by placing

the gaskets and the plates on a table. After having Fastening
pressed the gaskets into the grooves of a plate, it
is stacked. Fasten the plate heat exchanger until the movable
cover touches the duct spacers.
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 Serial number
mm per plate. (please state when
Material Code ordering single plates)
Heat up the plate heat exchanger to 90-100°C by
means of water or steam.
1 2
Please note:
- The temperature must be kept for 1½-2

hours.
- The liquid pressure must be kept as low as
possible. Four last digits Four last digits are the
H ref. number of the plate.
are the ref.
or (only on plates for non-
If there is no possibility of heating the plate heat number of plate
V glue gasket)
exchanger, it must be placed in a spot as warm as
possible with dismounted connections.
Fig. 1.
The drying time will at 20°C be approx. 48 hours.

At for instance 40°C, the drying time is reduced to
approx. 24 hours.
Assembling
08028-0D/H5250/94.08.12
If the plates have been dismounted, they have to

be correctly assembled according to the plate item
numbers.
96.26 - ES0S
MAN Diesel

Page 1 (3) Centrifugal Bypass Filter Edition 01H
L/V28/32H

Shut-off fuel oil
Description:
Cleaning procedure, cleaning intervals. Mainte-

nance intervals and procedures. Hand tools:
Big adjustable spanner.

Tools for cleaning.
Starting position:
Isolate the filter for lub. oil inlet
Related procedure:
Man power:

Capacity : 1 man
Data:
61515 39 1/Filter
Data for pressure and tolerance (Page 600.35) 61515 40 1/Filter
Data for torque moment (Page 600.40) 61515 41 1/Filter
Declaration of weight (Page 600.45) 61515 42 1/Filter
91.48 - ES0S
MAN Diesel

Edition 01H Centrifugal Bypass Filter Page 2 (3 )
L/V28/32H
6) Reassemble rotor body on to rotor base.
Cleaning procedure: Ensure that locating pins (8) and (9) in joint face of
body align with holes in cover and that standtube
1) Isolate the filter by closing the valve for lubri- fits correctly in the rotor base.
cating oil inlet to the filter.
7) Examine spindle in areas corresponding to
2) Slacken cover clamp ring (26), see fig. 1. top and bottom bushes. If damaged or worn replace
Unscrew cover nut (27) and lift off cover (31). with body assembly complete (25).
8) Replace rotor on to spindle ensuring rotor

revolves freely. Then replace body cover. Tighten
cover nut by hand only and refit safety cover clamp
21
27 ring. The clamp ring must be securely fitted at all
02 24 times when the filter is running. Do not run filter with
31 01 clamp ring loose.
08 9) Open for lubricating oil.

04
09 10) With filter running, check all joints for leakage.

Check for excessive vibration.
10
18
07
Cleaning intervals:
26
25
It is recommended to clean the centrifugal filter
every 100 hours maximum or when the dirt deposit
is 25 mm thick, whichever comes first. For cleaning
intervals, see also page 600.25.
Maintenance intervals and procedures:

Fig. 1 Centrifugal Bypass Filter
Recommended maintenance intervals for the filter
are as follows:
3) Lift off rotor assembly (01) having allowed the
oil to drain from the nozzles. Ensure that the rotor At 3000 hours change O-rings (23, 06 and 29). Chan-
assembly is removed from and replaced on to the ge these sooner if damaged. See Plate 61515.
spindle (24) with extreme care so as not to damage
the bushes (18) and (21). At 12000 hours change tube assembly (17). The
procedure for removing the tube assembly is to
4) Unscrew rotor cover jacking nut (2) and se- secure the rotor base in a tool, loosen circlip (19)
parate rotor cover (4) from rotor body (10). and with pressure applied via a fly press or hide
mallet extract tube assembly from rotor base. See
5) Remove sludge from inside the rotor by Plate 61515.
means of a spatula and wipe clean. Then remove
standtube (07). Ensure that all rotor components For inserting new tube assembly invert the rotor base
are thoroughly cleaned and free from deposits of and follow reverse of above procedure ensuring
dirt before reassembling the rotor. Failure to do so that pin (20) is correctly aligned with recess in rotor
could cause an out-of-balance condition which will base. See Plate 61515.
accelerate bearing and spindle wear.
At 24000 hours replace the filter complete.
91.48 - ES0S
MAN Diesel

Page 3 (3 ) Centrifugal Bypass Filter Edition 01H
L/V28/32H
Important note:
The maximum bush clearances when new are 0.10 All rotors are precision balanced before leaving
mm in the top bush (21) and 0.13 mm in the bottom the factory.
bush (18). See fig. 1.
Dependent on the conditions, wear will eventually Trouble shooting guide for centrifugal bypass filter,
take place both on the spindle and on the bushes see page 603.05
and if clearance is found to be in excess of 0.35
mm in top bush or 0.33 mm in bottom bush, then
replace with new bearing tube assembly.
The spindle/body assembly (25) and the rotor

bearing tube assembly (17) are factory assembled
items and should only be replaced with complete
assemblies.
91.48 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pump (Central driven) 61501-12H
L28/32H
01
02
03
04 35
05 15
16
17
06 18
19 21
06 20 04
07
23
06 04
24
25
09
06
10
11
12 26
11 20
13 28
29
08028-0D/H5250/94.08.12
30
31
32
33
34
91.41 - ES0S
MAN Diesel
Plate
61501-12H Lubricating Oil Pump (Central driven) Page 2 (2)
L28/32H
Item Item
01 1/P Dog Medbringer 34 6/P Screw Skrue
02 1/P Coupling Kobling 35 1/E Lub. oil pump, Smøreoliepumpe,

complete komplet
03 1/P Key Feder
06 5/P Bush Foring
07 1/P Gear wheel Tandhjul
09 1/P Sleeve Muffe
10 1/P Spring pin Fjederstift
11 2/P Ball bearing Kugleleje
12 1/P Circlip Sikringsring
13 1/P Cog wheel Konisk tandhjul
17 1/P Cylinder Cylinder
18 2/P Guide pin Styrestift
19 1/P Pump housing Pumpehus
20 20/P Screw Skrue
21 1/P Adjusting screw Juster skrue
23 1/P Nut Møtrik
24 1/P Cap nut Kapselmøtrik
28 2/P Cylindrical pin Cylindrisk stift
29 1/P Key Feder

08028-0D/H5250/94.08.12
33 1/P Cover Dæksel
91.41 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pump (Gear driven) 61501-22H
L28/32H
01
02
20 03
19
24
22
23
22
14
15
35
06
18
04
07 05
29
25
06
10
09
08028-0D/H5250/94.08.12
28
11
27
12
11
13 26
32 30
33 31
34
06.48 - ES0
MAN Diesel
Plate
61501-22H Lubricating Oil Pump (Gear driven) Page 2 (2)
L28/32H
Item Item
01 1/P Nut Møtrik 29 1/P Key Feder
02 1/P Gear wheel Tandhjul 30 1/P Cog wheel Konisk tandhjul
03 1/P Key Feder 31 1/P Circlip Sikringsring
04 1/P Gasket Pakning 32 1/P Gasket Pakning
05 1/P Plug screw Propskrue 33 1/P Cover Dæksel
06 5/P Bush Bøsning 34 6/P Screw Skrue
07 1/P Shaft with gear Aksel med tand- 35 1/E Lub. oil pump, Smøreoliepumpe,
wheel, short hjul, kort complete komplet
09 1/P Socket Muffe
10 1/P Pin Stift
14 1/P Piston, Trykregulering -

complete stempel, komplet
17 1/P Cylinder Cylinder
18 2/P Guide pin Styrestift
19 1/P Pump housing, Pumpehus,

incl. bushes inkl. bøsninger
20 6/P Screw Skrue
21 1/P Adjusting screw Justerskrue
23 1/P Nut Møtrik
24 1/P Cap nut Hættemøtrik
25 1/P Shaft with gear Aksel med tand-

08028-0D/H5250/94.08.12
wheel, long hjul, lang
26 1/P End cover, Endedæksel,

incl. bushes inkl. bøsninger
27 10/P Screw Skrue
28 2/P Cylindrical pin Cylindrisk stift
06.48 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Filter (Type A) 61502-11H
L28/32H
25
27
24
19 18
01 29 06
04 03 +
05 + 02
07
30 48
09 +
23 15
28 35
36
26 17
44
32
31
08028-0D/H5250/94.08.12
45
+ For detaljer se / for details see Plate 61502-15H
94.23 - ES0S
MAN Diesel
Plate
61502-11H Lubricating Oil Filter (Type A) Page 2 (2)
L28/32H
Item Item
01 2/F Paper element Papirelement 45 2/F Drain plug Drænskrue
02 2/F Safety element Sikkerhedselement 47 1/F Seal kit, not shown Pakningssæt, ikke vist
on the front side of på forsiden af platen
03 + 1/F Valve housing, incl. Ventilhus, inkl. the plate
item 07 and 30 item 07 og 30
48 1/E Lub. oil filter, Smøreoliefilter, kom-
04 2/F Housing, incl. O-ring Hus, inkl. O-ring complete plet
05 + 2/F Cap, complete, incl. Dæksel , komplet, inkl.

item 12, 13, 14, 19 item 12, 13, 14, 19
and 20 og 20
06 1/F Spindle, incl. item 8, Spindel, inkl. item 8,

18 and 37 18 og 37
07 2/F Thrust ring Trykring
09 + 2/F By-pass code, incl. By-passventil, inkl. item

item 10, 11, 16, 34 10, 11, 16, 34 og 49
and 49
15 1/F Plug to indicator hole, Propskrue til indikator

incl. O-rings hul, inkl. O-ringe
17 2/F Vent screw, incl. item Luftskrue, inkl. item 31

31 and 32 og 32
18 1/F Fill-up valve Opfyldningsventil
19 4/F Sealing ring Tætningsring
23 12/F Stud Støttetap
24 12/F Screw Skrue
25 4/F Screw Skrue
26 12/F Nut Møtrik
27 4/F Washer Skive
28 12/F Washer Skive
30 5/F Pin Tap
31 6/F Pin Tap

08028-0D/H5250/94.08.12
44 2/F Opening guard, incl. Åbningsbeskyttelses-

vent screw skærm, inkl. luftskrue
Qty./F = Qty./Filter Antal/F = Antal/Filter
94.23 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Filter (Type B) 61502-12H
L+V28/32H
25
27
24
18
29
01 19 06
04 48
05 + 01 46 03 +
19 02
23 07 09 +
28 30 15
35
26
36
17
44
32
31
08028-0D/H5250/94.08.12
45
+ For detaljer se / for details see Plate 61502-15H
94.23 - ES0S
MAN Diesel
Plate
61502-12H Lubricating Oil Filter (Type B) Page 2 (2)
L+V28/32H
Item Item
01 4/F Paper element Papirelement 45 2/F Drain plug Drænskrue
02 2/F Safety element Sikkerhedselement 46 2/F Spacer ring, complete Afstandsring, komplet
incl. seal inkl. tætning
03 + 1/F Valve housing, incl. Ventilhus, inkl.
item 07 and 30 item 07 og 30 47 1/F Seal kit, not shown Pakningssæt, ikke vist
on the front side of på forsiden af platen
04 2/F Housing, incl. O-ring Hus, inkl. O-ring the plate
05 + 2/F Cap, complete, incl. Dæksel , komplet, inkl. 48 1/E Lub. oil filter, Smøreoliefilter, kom-
item 12, 13, 14, 19 item 12, 13, 14, 19 complete plet
and 20 og 20
06 1/F Spindle, incl. item 8, Spindel, inkl. item 8,

18 and 37 18 og 37
07 2/F Thrust ring Trykring
09 + 2/F By-pass code, incl. By-passventil, inkl. item

item 10, 11, 16, 34 10, 11, 16, 34 og 49
and 49
15 2/F Plug to indicator hole, Propskrue til indikator

incl. O-rings hul, inkl. O-ringe
17 2/F Vent screw, incl. item Luftskrue, inkl. item 31

31 and 32 og 32
18 1/F Fill-up valve Opfyldningsventil
19 8/F Sealing ring Tætningsring
23 12/F Stud Støttetap
24 12/F Screw Skrue
25 4/F Screw Skrue
26 12/F Nut Møtrik
27 4/F Washer Skive
30 5/F Pin Tap
31 6/F Pin Tap

08028-0D/H5250/94.08.12
44 2/F Opening guard, incl. Åbningsbeskyttelses-

vent screw skærm, inkl. luftskrue
94.23 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Filter (Suppl. for Plate 61502-11H/12H) 61502-15H
L+V28/32H
08
37 61502/03 +
39
38
19
61502/05 +
12
13 16
21 10
31
14
11
20
61502/09 +
49 34
40
08028-0D/H5250/94.08.12
+ se/see Plate 61502-11H (Type A), Plate 61502-12H (Type B)
94.23 - ES0S
MAN Diesel
Plate
61502-15H Lubricating Oil Filter (Suppl. for Plate 61502-11H/12H) Page 2 (2)
L+V28/32H
Item Item
08 1/F Cap Dæksel
10 2/F By-pass valve seat By-passventilsæde
11 2/F By-pass valve spool By-passvnetilspindel
12 2/F Flange Flange
13 2/F Flange Flange
14 2/F Screw Skrue
16 2/F By-pass valve spring By-passventilfjeder
19 8/F Seal Tætningsring
20 2/F Spring Fjeder
21 2/F Spring Fjeder
31 6/F Pin Stift
08028-0D/H5250/94.08.12
94.23 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Thermostatic Valve 61503-08H
L28/32H
01
03
04
Note: When ordering new elements, state opening 05

temperature.
Husk! Ved bestilling af nye elementer at angive 06

åbningstemperaturen.
11
07
08
09
10
94.05 - ES0S
MAN Diesel
Plate
61503-08H Lubricating Oil Thermostatic Valve Page 2 (2)
L28/32H
Item Item
01 4/T Screw Skrue
03 2/T O-ring O-ring
04 2/T Thermostatic Følerelement

element
06 2/T Sleeve Bøsning
07 4/T Washer Skive
08 16/T Nut Møtrik
09 3/T Gasket Pakning
10 12/T Screw Skrue
11 1/E Thermostatic Termostatventil,

Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
94.05 - ES0S
MAN Diesel
Plate
Page 1 (2) Prelubricating Pump with El-Motor 61504-04H
L28/32H
12 11 16 01 10 05 04 02 20 15 03 09
24
29
26
29
23
30
25
31 21
22
27
28
34 33
94.23 - ES0S
MAN Diesel
Plate
61504-04H Prelubricating Pump with El-Motor Page 2 (2)
L28/32H
Item Item
01 1/P Driving cover Medbringerdæksel
02 1/P Gear casing Gearhus
03 1/P End cover, complete, Endedæksel, komplet

incl. item 21 to 29 inkl. item 21 til 29
04 1/P Driving gear shaft Drivende gear aksel
05 1/P Gear shaft Gear aksel
09 4/P Screw Skrue
10 2/P Parallel pin Styrestift
11 1/P Retaining ring Sikringsring
12 1/P Parallel key Not
16 1/P Rotary shaft seal Roterende aksel tæt-

ning
20 1/E Pumpe, complete Pumpe, komplet uden

without El-motor el-motor
23 1/P Spindle Spindel
24 1/P Dome nut Lukkemøtrik
26 1/P Pipe nut Rørmøtrik
27 2/P Screwed plug Propskrue
30 1/P Coupling, complete Kobling, komplet
31 1/E El-motor, complete El-motor, komplet
32 1/E Pre.lub oil pump, Forsmørepumpe,

complete with el- komplet med el-motor
motor
33 1/E Ball bearing, rear Kugleleje, bagside
34 1/E Ball bearing, front Kugleleje, forside
94.23 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Cooler 61506-10H
L+V28/32H
01
05
02 04
03
Note: When ordering

plates, please state the
serial number of the
plates. The serial
number of the plates
can be found in the
top right-hand corner
of the plates.
(See Working Card 06
615-06.00).
Husk: Ved bestilling af

plader angives serie- 07
nummeret på pladen. 17
Serienummeret er 18
stemplet i toppen af
19
pladen til højre.
(Se arbejdskort 20
615-06.00). 15
25 08
26
08028-0E/H5250/94.08.12
27 09
28 10
14 12
21
22 13
23 11
24
16
07.08 - ES0
MAN Diesel
Plate
61506-10H Lubricating Oil Cooler Page 2 (2)
L+V28/32H
Item Item
01 6/K Hexagon screw Bolt 23 1/E Lubricating oil Smøreoliekøler,

cooler, complete komplet
02 6/K Washer Skive 8 cyl. engine 8 cyl. motor
03 6/K Washer Skive 24 1/E Lubricating oil Smøreoliekøler,

04 1/K Pressure plate Trykplade 9 cyl. engine 9 cyl. motor
05 /I Gasket Pakning 25 /I Plates Plader

06 2/K Guide bar Styrepind
26 /I Plates Plader
07 6/K Distance piece Afstandsstykke 7 cyl. engine 7 cyl. motor
27 /I Plates Plader
08 1/K Frame plate Stativplade 8 cyl. engine 8 cyl. motor
09 4/K Gasket Pakning 28 /I Plates Plader

10 2/K Screw Skrue
11 1/K Glue Lim
12 2/K Guide bar Styrepind

(for dismantling) (for demontering)
13 32/K Screw Skrue
14 1/E Lubricating oil Smøreoliekøler,

15 /I Plates Plader
16 /I Cleaning fluid Rensevæske
17 6/K Distance piece Afstandsstykke





08028-0E/H5250/94.08.12

Qty./K = Qty./Cooler Antal/K = Antal/Køler
Qty./I = Qty./Individual Antal/I = Antal/Individuel
07.08 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Centrifugal By-Pass Filter 61515-09H
L+V28/32H
L32/40
23* 24 09*
07 31*
12
19
32*
11*
18* 22
10*
28
14 08
25
13
26
18*
06*
17
27
15
16
01
02*
30* 05*
04* 20
03*
07.37 - ES0
MAN Diesel & Turbo
Plate
61515-09H Centrifugal By-Pass Filter Page 2 (2)
L+V28/32H
L32/40

Item Item
01 1/F Body, assembly Sokkel, komplet 27 1/F Rotor base Rotor bund
02* 1/F Valve body Ventilsokkel 28 1/F Rotor tube Rotor rør
03* 1/F Valve adaptor Ventiladapter 30* 1/F Spring Fjeder
04* 1/F Valve seal Ventiltætning 31* 1/F Circlip Låsering
05* 1/F Flange gasket Flangepakning 32* 1/F Circlip Låsering
06* 1/F Filter body O-ring Filtersokkel O-ring
07 1/F Cover, complete Dæksel, komplet
09* 1/F Cover nut pin Stift for dækselmøtrik
10* 1/F Cover fixing nut Dækselmøtrik
11* 1/F Cover nut O-ring Dækselmøtrik O-ring
12 1/F Jacking nut kit, incl Møtrik kit, inkl 23 og

item 23 and 32 32
13 1/F Band clamp Spændering
14 1/F Rotor, complete Rotor, komplet inkl
15 1/F Nozzle Dyse
16 1/F Bearing tube Lejerør
17 1/F Circlip Låsering
18* 2/F Rotor O-ring Rotor O-ring
19 1/F Cover nut fixing kit, Dækselmøtrikskit, inkl

incl item 10, 11, 31 item 10, 11, 31 og 09
and 09
20 1/F Valve kit, incl item 02, Ventilkit, inkl item 02,
03, 04, 30 03, 04, 30
21 1/F Seals kit, incl item 05, Tætningskit, 05, 06,

06, 18 18
22 1/E Centrifugal by-pass Centrifugal by-pass fil

filter, complete ter, komplet
23* 1/F Nut Møtrik

08028-0E/H5250/94.08.12
24 1/F Rotor top Rotortop
25 1/F Paper insert Papir indsats
26 1/F Separation cone Afstandsbøsning
07.37 - ES0
MAN Diesel
Plate
Page 1 (2) Hand Wing Pump 61525-02H
L+V28/32H
01
08028-0E/H5250/94.08.12
94.20 - ES0S
MAN Diesel
Plate
61525-02H Hand Wing Pump Page 2 (2)
L+V28/32H
Item Item
01 1/E Hand wing pump, Håndvingepumpe,

complete komplet
08028-0E/H5250/94.08.12
94.20 - ES0S
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Separator 61530-07H
L28/32H
06
07
04
08
03 09
05 10
11
18
12
13
14
15
16
19
20
21
07.08 - ES0
MAN Diesel
Plate
61530-07H Lubricating Oil Separator Page 2 (2)
L28/32H
Item Item
03 1/F Breather with Ånderør med

flange flange
05 4/F Screw Skrue
06 8/F Screw Skrue
09 1/F Insert for oil Indsats for

separator olieudskiller
10 1/F Housing for Hus for

oil separator olieudskiller
11 4/F Screw Skrue
13 1/F Bend Bøjning
14 4/F Nut Møtrik
15 1/F Oil trap Olielås
16 1/F Union Forskruning
18 1/F Union Forskruning
19 4/F Screw Skrue
20 1/E Oil separator, com- Olieseparator, komplet

plete, consisting of bestående af item 06,
item 06, 07, 08, 09, 07, 08, 09 og 10
and 10
07.08 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pipes on Engine 61530-02H
L28/32H
01 08
02 15
03
04
05
10
08
03
08
12
Lub. oil filter 14
03
16
08 02
17 03
05
Thermostatic 03
valve 10
06 08
07 13 A 21
02
08 18 22
06 23
24
21
03
14 04
19 The piping design may vary from
04 08
06 the shown example, but it is of no
14 importance when ordering.
26
Lub. oil cooler 06 27
28
92.04 - ES0S
MAN Diesel
Plate
61530-02H Lubricating Oil Pipes on Engine Page 2 (2)
L28/32H
Item Item
01 /I Lub. oil distributing Sm. oliefordelingsrør

pipe
02 /I Stud Bolt
03 /I Pakning Pakning
04 /I Lub. oil pipe outlet Sm. olierør afgang fil-

filter ter
05 /I Nut Møtrik
06 /I Gasket Pakning
07 /I Lub. oil pipe inlet Sm. olierør tilgang kø-

cooler ler
08 /I Screw Sekskantskrue
12 /I Outlet pump/Inlet Sm. olierør afgang pum-

therm. valve pe/tilgang term. ventil
13 /I Lub. oil pipe inlet Sm. olierør tilgang fil-

filter ter
14 /I Stud Bolt
16 /I Lub. oil pipe inlet Sm. olierør tilg. pumpe

pump
17 /I Lub. oil suction pipe Sm. oliesugerør
18 /I Stud Bolt
19 /I Lub. oil pipe outlet Sm. olierør afgang kø-

cooler ler
22 /I Non-return valve Kontraventil
23 /I Pipe Rør
24 /I Stud Bolt
26 /I Ball valve Kugleventil
28 /I Plug screw Propskrue
92.04 - ES0S
516/616
MAN Diesel
Description
Cooling Water System 616.01
Page 1 (1)
Edition 17H
General
Description High Temperature Circuit
The cooling water system consists of two separate The high temperature circuit is used for cooling of
systems the low temperature (LT) and the high tem- the cylinder units.
perature (HT) circuits.
Cooling water is led through a distributing pipe to
the bottom of the cooling water space between the
Low Temperature Circuit liner and the frame of each cylinder unit. The water
is led out through bores in the top of the frame via
The low temperature circuit is used for cooling of the the cooling water guide jacket to the bore.
charge air and the lubricating oil, and the alternator
if the latter is water cooled.
08028-0D/H5250/94.08.12
90.47 - ES0U
MAN Diesel
Description
Cooling Water Thermostatic Valve 616.04
Page 1 (1)
Edition 15H
General
Thermostatic Valve The thermostatic valve cannot be set or adjusted,
and requires no maintenance.
The thermostatic valve in the high temperature cir-
cuit is mainly located imediately after the outlet of In some plants a corresponding thermostatic valve
the engine, but alternatively in the external cooling is installed in the low temperature circuit. The ther-
system near the fresh water cooler. mostatic elements of this valve have an other tem-
perature range.
The cooling water enters through the cover (A) under
which the thermostatic elements are located.
The number of elements depends on the size of

A
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 C B
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. Fig. 1. Thermostatic Valve
91.16 - ES0S
MAN Diesel
Page 1 (2) Check of Cooling Water System Edition 01H
General

Shut-off fuel oil
Description:
Check of cooling water system.

Hand tools:
Starting position:
Engine is running
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

92.04 - ES0U
MAN Diesel
Edition 01H Check of Cooling Water System Page 2 (2)
General
5) Check manometers and thermometers for pos-
Checks to be carried out. sible damages.
1) Examine the piping system for leaks. 6) Check the condition of the uppermost of the two
O-rings (which makes up the tightening between
2) Retighten all bolts and nuts in the piping system. the jacket cooling water space in the frame and the
crankcase) by means of the inspection holes in the
3) Move all valves and cocks in the piping system. engine frame - see also Working Card 606-01.40.
For check of the fresh water condition, see section
4) Check flexible connections for leaks. 604.
08028-0D/H5250/94.08.12
92.04 - ES0U
MAN Diesel

Page 1 (2) Cooling Water, Thermostatic Valve Edition 01H
L+V28/32H

Shut-off fuel oil
Description:
Inspection of thermostatic valve and replacement

of elements. Hand tools:

Copaslip
Tools and cleaning preparation for cleaning.
Starting position:
Cooling water drained from engine (if neces-

sary).
Related procedure:
Man power:

Capacity : 1 Man
Data:
61604 03 1/engine
Data for pressure and tolerance (Page 600.35) 61604 05 2 or 4/engine
Data for torque moment (Page 600.40) 61604 09 3/engine
94.29 - ES0S-G
MAN Diesel

Edition 01H Cooling Water, Thermostatic Valve Page 2 (2)
L+V28/32H
The thermostatic valve cannot be adjusted and un- Replacement of elements:
der normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements in the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part of the hou-

sing.
1
2 3) Remove the assembled elements (3) and the
3 elements O-ring sealing.
5 4) Remove the gaskets between the upper and
lower part of the housing.
4
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
1. Nut mounted and tightened "cross-wise".
2. Washer
3. Element Note:
4. O-rings sealing
5. Gasket After inspection or replacement of the elements the
cooling water temperature is checked to ensure that
the elements are working correctly.
Fig. 1 Thermostatic valve
94.29 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Fresh Water Thermostatic Valve 61604-07H
L28/32H
L32/40
01
03
04
05
Note: When ordering new elements, state opening
temperature.
06
Husk! Ved bestilling af nye elementer at angive
åbningstemperaturen.
11
07
08
09
10
94.06 - ES0S
MAN Diesel
Plate
61604-07H Fresh Water Thermostatic Valve Page 2 (2)
L28/32H
L32/40

Item Item
01 4/T Screw Skrue
04 4/T Thermostatic Følerelement

element
06 4/T Sleeve Bøsning
07 4/T Washer Skive
08 28/T Nut Møtrik
09 3/T Gasket Pakning
10 24/T Screw Skrue
11 1/E Thermostatic Termostatventil,

Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
94.06 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) High Temperature Fresh Water Pump 61610-05H
L28/32H
11
06
09
07
12
08
09 03
01 10
02
14
16
03
04
05
19
17 18
91.42 - ES0S
MAN Diesel & Turbo
Plate
61610-05H High Temperature Fresh Water Pump Page 2 (2)
L28/32H

Item Item
01 1/P Ball cock Kugleventil
03 2/P Key Feder
04 1/P Self locking nut Selvlåsende møtrik
05 1/P Impeller Løbehjul
06 8/P Screw Skrue
07 1/P Rotating sealing Roterende pakdåse
10 1/P Bearing housing Lejehus
11 1/P Shaft Aksel
19 1/E Fresh water pump, Ferskvandspumpe,

complete komplet
91.42 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Low Temperature Fresh Water Pump 61610-07H
L28/32H
11
06
09
07
12
08
09 03
01 10
02
14
16
03
04
05
19
17 18
91.42 - ES0S
MAN Diesel & Turbo
Plate
61610-07H Low Temperature Fresh Water Pump Page 2 (2)
L28/32H

Item Item
03 2/P Key Feder
06 8/P Screw Skrue
11 1/P Shaft Aksel

complete komplet
91.42 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (2) Low Temperature Fresh Water Pump 61610-10H
L28/32H
11
06
09
07
12
08
09 03
01 10
02
14
16
03
04
05
19
17 18
06.10 - ES0
MAN Diesel & Turbo
Plate
61610-10H Low Temperature Fresh Water Pump Page 2 (2)
L28/32H

Item Item
03 2/P Key Feder
06 8/P Screw Skrue
11 1/P Shaft Aksel

complete komplet
06.10 - ES0
MAN Diesel
Plate
Page 1 (2) Sea Water Pump 61615-04H
L28/32H
11
06
09
07
12
08
09 03
01 10
02
14
16
03
04
05
19
17 18
91.43 - ES0S
MAN Diesel
Plate
61615-04H Sea Water Pump Page 2 (2)
L28/32H
Item Item
03 2/P Key Feder
06 8/P Screw Skrue
11 1/P Shaft Aksel
19 1/E Sea water pump, Saltvandspumpe,

complete komplet
91.43 - ES0S
MAN Diesel
Plate
Page 1 (2) Pipes on Cylinder Head 61625-04H
L28/32H
01
06
04
12
08
13
14
15 09
10
02
11
03
01
05
08028-0D/H5250/94.08.12
Cylinder Head
Plate 60501, 60502,
60508, and 60510
06.44 - ES0
MAN Diesel
Plate
61625-04H Pipes on Cylinder Head Page 2 (2)
L28/32H
Item Item
02 2/C Nut Møtrik
03 3/C Screw Skrue
04 1/E Branch for cooling Grenrør for

water outlet pipe for kølevand for 5 cyl.
5 cyl.
06 1/C Thermometer, Termometer,

TI-11 TI-11
09 1/C Cooling water Forbindelsessrør

connecting pipe for kølevand
10 2/C Screw Skrue
11 2/C Screw Skrue

6 cyl.

7 cyl.

8 cyl.

9 cyl.
08028-0D/H5250/94.08.12
06.44 - ES0
MAN Diesel
Plate
Page 1 (2) Cooling Water Pipes on Engine 61630-01H
L28/32H
07
05
04 06
03 16 16
17 21 30
02 17
22
06 27
07
01
06
02 07
03
04 24
25 See plate 61625
15 02
03
04
T
IN 05
. OU26
HT. 06
07
HT
04
29
08
09
10
02
03
12
03
04 02
14 04
03 20
04 21 25
27
T 28
. OU 03 The piping design may vary from
LT 09 22 the shown example, but it is of no
importance when ordering.
23
04
IN
LT.
09
03
97.11 - ES0S
MAN Diesel
Plate
61630-01H Cooling Water Pipes on Engine Page 2 (2)
L28/32H
Item Item
01 /I HT water pipe inlet HT. tilgangsrør 30 /I HT water collecting HT. samlerør

GenSet GenSet pipe outlet engine
02 /I Stud Bolt
04 /I Nut Møtrik
05 /I Ball valve Kugleventil
10 /I LT pipe inlet/outlet LT. rør ind/ud ladeluft-

charge air cooler køler
12 /I Orifice Blænde
14 /I LT water pipe outlet LT. afgangsrør

lub. oil cooler sm.køler
15 /I HT water distributing HT. fordelingsrør tilgang

pipe inlet engine motor
20 /I LT water inlet LT. tilgang

GenSet GenSet
21 /I Nut Møtrik
23 /I Bracket Konsol
24 /I HT water outlet collec- HT. afgang samlerør

ting pipe
25 /I Clamp Bøjle
26 /I Bracket Konsol
28 /I LT water inlet lub. oil LT. tilgang sm.køler

cooler
97.11 - ES0S
MAN Diesel
Plate
Page 1 (2) Preheater - Fresh Water 61635-06H
L28/32H
03
04
06
07
02
07.46 - EO0
MAN Diesel
Plate
61635-06H Preheater - Fresh Water Page 2 (2)
L28/32H
Item Item
02 1/E Pipe for Preheater Rør for Forvarmer
03* 1/E Preheater Forvarmer

5, 6 L28/32H, 5, 6 L28/32H,
stationary stationær

7, 8, 9 L28/32H, 7, 8, 9 L28/32H,
stationary stationær

5, 6 L28/32H, 5, 6 L28/32H,
marine marine

7, 8, 9 L28/32H, 7, 8, 9 L28/32H,
marine marine
* At ordering please * Ved ordre oplyses

inform of voltage (V) spænding (V) og ef-
and output (W) fekt (W)
07.46 - EO0
Special equipment
517/617
MAN Diesel & Turbo
Kit
Page 1 (2) Kit for Cylinder Unit 61704-02H
L+V28/32H
125
01b
16a 149
04b
15 017
14
08c
01b
269
02
31
01a
08a 32
25
34
04a
07
08b
11a
16b
04d
08d 04c
11c 05
11b
12
12.21 - ES0
MAN Diesel & Turbo
Kit
61704-02H Kit for Cylinder Unit Page 2 (2)
L+V28/32H
Item
no Qty Designation Where to find in the engine instruction book
021 Kit per cylinder unit
4 O-ring Plate 60501 Item 017
1 Snap ring Plate 60501 Item 125
1 Gasket Plate 60508 Item 14
1 Gasket Plate 60508 Item 16a
2 O-ring Plate 60610 Item 01a
1 O-ring Plate 60610 Item 04a
1 Sealing ring Plate 60610 Item 08b
2 O-ring Plate 60610 Item 11b
1 Sealing ring Plate 60610 Item 16b
4 Gasket Plate 60801 Item 04b
2 Gasket Plate 60801 Item 08c
2 O-ring Plate 61402 Item 04c
1 O-ring Plate 61404 Item 04d
1 O-ring Plate 61404 Item 08d
1 Sealing ring Plate 61404 Item 11c
2 Gasket Plate 61625 Item 01b
Please Note that this is a kit supply, and that any exceeding number of parts are
not accepted as return goods.
12.21 - ES0
MAN Diesel & Turbo
Kit
Page 1 (2) Kit for Overspeed Device 61743-01H
L+V28/32H
See Working Card 609-01.05
19
24
25
27
39
40
41
*Please order item 004
47
11.49 - ES0
MAN Diesel & Turbo
Kit
61743-01H Kit for Overspeed Device Page 2 (2)
L+V28/32H
Item
004 Kit per overspeed device, complete consisting of:
1 Ball bearing Plate 60903 Item 19
1 Pin Plate 60903 Item 24
1 Lever Plate 60903 Item 25
1 Ball bearing Plate 60903 Item 39
1 Elastic coupling Plate 60903 Item 40
1 Spring (right) Plate 60903 Item 41
1 Spare parts kit for pneumatic valve Plate 60903 Item 47
11.49 - ES0
MAN Diesel & Turbo
Kit
Page 1 (2) Kit for Covers on Frame 61751-01H
L28/32H
11
13
Frame
Plate 61101
11.48 - ES0
MAN Diesel & Turbo
Kit
61751-01H Kit for Covers on Frame Page 2 (2)
L28/32H
Item
006 Kit per coves on frame
11.48 - ES0
Specific plant
information
519/619
MAN Diesel & Turbo
Description
Resilient Mounting of Generating Sets 619.03
L28/32H
Resilient Mounting of Generating Sets The support of the individual conical mounting can
be made in one of the following three ways:
On resilient mounted generating sets, the diesel
engine and the generator are placed on a common 1) The support between the bottom flange and
rigid base frame mounted on the ship's/erection the foundation of the conical mounting is made
hall's foundation by means of resilient supports, with a loose steel shim. This steel shim is ad-
type Conical. justed to an exact measurement (min. 40 mm)
for each conical mounting.
All connections from the generating set to the external
systems should be equipped with flexible connec
tions, and pipes, gangway etc. must not be welded
to the external part of the installation. Method 1
min 40 mm
Resilient Support
A resilient mounting of the generating set is made

with a number of conical mountings. The number Steel
Shim
and the distance between them depend on the size
of the plant. These conical mountings are bolted to
brackets on the base frame (see fig 1). Foundation
The setting from unloaded to loaded condition is

normally between 5-11 mm for the conical mounting. Method 2
The exact setting can be found in the calculation of
min 40 mm
the conical mountings for the plant in question.
min 10 mm
Supporting
Steel Shim
Steel Shim
CL - Engine
Foundation
175 mm*
60 mm**
260 mm
Method 3
Steel shim
min 40 mm
Foundation
min 10 mm
min 35 mm
Deck
* Unloaded Supporting
08028-0D/H5250/94.08.12
** Minimum distance Steel Shim

Steel Shim
Chockfast
Fig 1 Resilient mounting of generating sets.

Foundation
Fig 2 Support of conicals.
10.33 - ES1
MAN Diesel & Turbo
619.03 Description
Edition 10H Resilient Mounting of Generating Sets Page 2 (2)
L28/32H
2) The support can also be made by means of two Check of Crankshaft Deflection
steel shims, at the top a loose shim of at least
40 mm and below a shim of approx. 10 mm The resilient mounted generating set is normally
which are adjusted for each conical mounting delivered from the factory with engine and generator
and then welded to the foundation. mounted on the common base frame.
Eventhough engine and alternator have been ad-
3) Finally, the support can be made by means of justed by the engine builder, with the alternator rotor
chockfast. It is recommended to use two steel placed correctly in the stator and the crankshaft de-
shims, the top shim should be loose and have a flection of the engine (autolog) within the prescribed
minimum thickness of 40 mm, the bottom shim tolerances, it is recommended to check the crankshaft
should be cast in chockfast with a thickness of deflection ( autolog) before starting up the GenSet.
at least 10 mm.
Irrespective of the method of support, it is recommen

ded to use a loose steel shim to facilitate a possible
future replacement of the conical mountings.
08028-0D/H5250/94.08.12
10.33 - ES1
MAN Diesel
Working card 619-03.00

Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 21H
L28/32H

Shut-off fuel oil
Stopped lub. oil circulation
Description
Mounting and adjustment instruction for new

GenSets, and adjustment instruction for existing
plants.
Hand tools
Ring and open end spanner, 22 mm

Starting position Ring and open end spanner, 30 mm
Allen key, 6 mm
The foundation should be welded and milled off Feeler gauge, 1-2 mm
on shim surfaces. Measurement tool
Hydraulic jack (if necessary)
Related procedure
Check of main beraings alignment

(autolog)
610-01.00
Replacement of conicals 619-03.00
Man power
Working hours : 2 Hours

Capacity : 2 Men
08028-0D/H5250/94.08.12
Spare and wearing parts
Data Plate No. Item No. Qty./
Data for pressure and tolerance (Page 600.35) 61903 01 4/conical mount.
Data for torque moment (Page 600.40) 61903 02 4/conical mount.
Declaration of weight (Page 600.45) 61903 03 1/conical mount.
61903 04 4/conical mount.
03.50 - ES1
MAN Diesel
619-03.00 Working card
Edition 21H Fitting Instructions for Resilient Mounting of GenSets Page 2 (4)
L28/32H
Mounting and Adjustment Instructions for 7) Turn all the internal buffers (2), see fig 1, to
New Generating Sets (Method 1) check that they can move freely.
Make Ready for Adjustment of Conical Ele- If all internal buffers Then
ments
Can move freely Let conical elements
If the conical elements have not been mounted by settle for 48 hours.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have Cannot be moved Turn the four jacking
been mounted by the factory, please start with item in the base casting
number 2. clockwise or anticlock-
wise to release the inter-
1) Fit the conical elements to the bracket on the nal buffer.
base frame by means of four bolts screwed
into the tapped holes on the top casting (5),
see fig 1. Adjustment of Conical Elements after 48
Hours Settling
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see After the conical elements have been deflected un-
fig 1. der static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the
3) Position the four jacking bolts in the tapped recommended laden height.
holes (9) see fig 1, in the base casting (1).
4) Position the jacking bolts with a through-going

of minimum 40 mm, see fig 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.
08028-0D/H5250/94.08.12
Fig 2 Conical mounting.

Fig 1 Conical element
03.50 - ES1
MAN Diesel

L28/32H
8) Care must be taken, during levelling of the 12) Lift the generating set with crane or hydraulic
installation, to ensure that individual mountings jack.
are not overloaded.The variation in laden height
should not exceed 2 mm and should ideally 13) Remove all the jacking bolts.
be less. The laden height can be measured
between top and base casting at H, on two 14) Position each completed steel shim.
sides (see fig 1).
15) Lower the generating set until it rests completely
Example: in itself.
H1 + H2 + H3 ----- HN
Average = Number of conical elements 16) Number each steel shim together with each
conical element.
If Then
Adjustment of Internal Buffer
Difference exceeds Level the conical element
2 mm. by adjusting the jacking 17) Turn the internal buffer clockwise (downwards)
bolts - commencing with until it makes contact with the steel shim or
the conical element with foundation.
the largest deviation.
18) Turn the internal buffer anticlockwise (upwards)
Difference does not ex- The height of the steel until it obtains contact with the base casting.
ceed 2 mm shim can be measured.
This must be four full turns.
The difference between the two sides of a conical 19) Turn the internal buffer two full turns clockwise
mounting should not be more than 0.6 mm. (downwards) and check with a feeler gauge
between the base casting of the conical ele-
ment and the steel shim that the internal buffer
Measuring of Steel Shim (2), see fig 1, does not touch the steel shim or
foundation.
9) Measure the steel shim on several points to
obtain the highest possible accuracy during 20) Lock the internal buffer by remounting the top
preparation. lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
washer (8), see fig 1.
Fabricating Steel Shim
10) Make sure that the minimum height of the steel Mounting of Conical Elements on the Foun-
shim is 40 mm to secure a future replacement dation
08028-0D/H5250/94.08.12
of the conical element.

21) Drill four mounting holes in the foundation for
Drill the mounting holes in the steel shim according each conical element, either
to the conical base casting dimensions.
a) Mark the positions of the mounting holes on
the foundation through the conical element and
Mounting of the Completed Steel Shim the steel shim.
11) Turn the internal buffer anticlockwise until it (Re)move the set completely so that the mark-
contacts the base casting to secure the laden ings can be reached by drilling with conventional
height of each conical element. tools.
03.50 - ES1
MAN Diesel
L28/32H
Place the set on its former position by aligning The drilling has to be done on beforehand and
it with the drilled holes. the set must be aligned with the foundation
holes before the work starts to avoid further
or removal of the set.
b) Drill the mounting holes in the foundation by 22) Fix all the conical elements and the steel shims
means of the drilling pattern from the installa- to the foundation with four bolts per conical.
tion drawing.
Note! After completion of all works the buffer clear-
ance must be checked, see points 17, 18, 19 and
20.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
L28/32H

Shut-off fuel oil
Description

plants.
Hand tools

Allen key, 6 mm
Related procedure

(autolog)
610-01.00
Man power

Capacity : 2 Men
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
L28/32H
Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 2) of minimum 10 mm, see fig 2.
Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests completely
ments on the foundation.
If the conical elements have not been mounted by 7) Check that all jacking bolts have full contact
the factory, they must be mounted on the prepared with the foundation.
brackets on the base frame. In case they have
been mounted by the factory, please start with item 8) Turn the internal buffer (2), see fig 1 to check
number 2. that it can be moved freely.
1) Fit the conical elements to the bracket of the

base frame by means of four bolts screwed If all internal buffers Then
into the tapped holes on the top casting (5),
see fig 1. Can move freely Let conical elements set-
tle for 48 hours.
A supporting steel shim with a minimum height of 40
mm, to secure a future replacement of the conical Cannot be moved Turn the three jacking
element, complete with tapped holes for three jacking freely bolts in the supporting
bolts and mounting holes drilled according to conical steel shim clockwise, or
base casting dimensions, is required. anticlockwise to release
the internal buffer.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.
3) Position the supporting steel shim as per fig

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 fig
2.
08028-0D/H5250/94.08.12

03.50 - ES1
MAN Diesel
L28/32H
Adjustment of Conical Elements after 48 Drill the mounting holes in the steel shim according
Hours Settling to the mounting holes in the conical base casting and
the mounting holes in the supporting steel shim.
After the conical elements have been deflected un-
der static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the Mounting of the Completed Steel Shim
recommended laden height.
12) Lift the generating set 1 mm totally be means
9) Care must be taken, during levelling of the of the three jacking bolts.
installation, to ensure that individual mountings
are not overloaded.The variation in laden height 13) Position each completed steel shim.
should not exceed 2 mm and should ideally
be less. The laden height can be measured 14) Re-lower the generating set by means of the
between top and base casting at H, on two three jacking bolts until it rests completely in
sides (see fig 1). itself.
Example:
Adjustment of Internal Buffer
H1 + H2 + H3 ----- HN
Average = Number of conical elements 15) Turn the internal buffer clockwise (downwards)
until it makes contact with the steel shim or
foundation.
If Then
16) Turn the internal buffer anticlockwise (upwards)
Difference exceeds Level the conical element until it obtains contact with the base casting.
2 mm. by adjusting the jacking
bolts - commencing with This must be four full turns.
the conical element with
the largest deviation. 17) Turn the internal buffer two full turns clockwise
(downwards) and check with a feeler gauge
Difference does not ex- The height of the steel between the base casting of the conical ele-
ceed 2 mm shim can be measured. ment and the steel shim that the internal buffer
(2), see fig 1, does not touch the steel shim or
foundation.
The difference between the two sides of a conical
mounting should not be more than 0.6 mm. 18) Lock the internal buffer by remounting the top
lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
Measuring of Steel Shim washer (8), see fig 1.
08028-0D/H5250/94.08.12
10) Measure the steel shim on several points to

obtain the highest possible accuracy during Mounting of Conical Elements on the Foun-
preparation. dation
19) Remove the dowel pins.

11) Make sure that the minimum height of the steel each conical element, either
shim is 10 mm.
the foundation through the conical element and
the steel shims.
03.50 - ES1
MAN Diesel
L28/32H
(Re)move the set completely so that the mark- The drilling has to be done on beforehand and
ings can be reached by drilling with conventional the set must be aligned with the foundation
tools. holes before the work starts to avoid further
removal of the set.
Place the set on its former position by aligning
it with the drilled holes. 21) Fix all the conical elements and the supporting
steel shims/steel shims to the foundation with
or four bolts per conical.
b) Drill the mounting holes in the foundation by 22) Weld the lowest steel shim of approx. 10 mm
means of the drilling pattern from the installa- height to the foundation.
tion drawing.
Note! After completion of all works, the buffer clear-
ance must be checked, see points 15, 16, 17 and
18.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
L28/32H

Shut-off fuel oil
Description

plants.
Hand tools

Allen key, 6 mm
Related procedure

(autolog)
610-01.00
Man power

Capacity : 2 Men
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
L28/32H
Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 3) of minimum 10 mm plus permitted thickness,
as specified from the chockfast supplier, see
Make Ready for Adjustment of Conical Ele- fig 2.
ments
6) Lowed the generating set until it rests com-
If the conical elements have not been mounted by pletely on the foundation.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have 7) Check that all jacking bolts have full contact
been mounted by the factory, please start with item with the foundation.
number 2.
8) Turn the internal buffer (2), see fig 1, to check
1) Fit the conical elements to the bracket of the that it can be moved freely.
base frame by means of four bolts screwed
into the tapped holes on the top casting (5) If all internal buffers Then
see fig 1.
Can move freely Let conical elements set-
A supporting steel shim with a minimum height of tle for 48 hours.
40 mm, complete with tapped holes for three jacking
bolts, four mounting holes and four tapped holes, Cannot be moved Turn the three jacking
drilled according to the conical base casting dimen- freely bolts in the supporting
sion, is required see fig 2. steel shim clockwise, or
anticlockwise and slacken
2) Remove fixing bolt (7), spring washer (8) and the four hold-down
top lock ring (6) from the conical element, see bolts to release the inter-
fig 1. nal buffer.
3) Position the supporting steel shim as per fig

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 fig
2.
08028-0D/H5250/94.08.12

03.50 - ES1
MAN Diesel
L28/32H
Adjustment of Conical Element after 48 11) Drill the mounting holes in the steel shim accord-
Hours Settling ing to the mounting holes in the conical base
casting and in the supporting steel shim.
After the conical elements have been deflected un-
der static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the Adjustment of Internal Buffer
recommended laden height.
12) Turn the internal buffer clockwise (downwards)
9) Care must be taken, during levelling of the until it makes contact with the steel shim or
installation, to ensure that individual mountings foundation.
are not overloaded.The variation in laden height
should not exceed 2 mm and should ideally 13) Turn the internal buffer anticlockwise (upwards)
be less. The laden height can be measured until it obtains contact with the base casting.
between top and base casting at H, on two
sides (see fig 1). This must be four full turns.
Example: 14) Turn the internal buffer two full turns clockwise
H1 + H2 + H3 ----- HN (downwards) and check with a feeler gauge
Average = Number of conical elements between the base casting of the conical ele-
ment and the steel shim that the internal buffer
(2), see fig 1, does not touch the steel shim or
If Then foundation.
Difference exceeds Level the conical ele- 15) Lock the internal buffer by remounting the top
ment 2 mm. by adjusting the jacking lock ring (6) and turn it to the nearest thread
bolts - commencing with hole - then secure with fixing bolt (7) and spring
the conical element with washer (8), see fig 1.
the largest deviation.
Difference does not ex- The height of the steel Mounting of Conical Elements on the Foun-
ceed 2 mm shim and the chockfast dation
can be measured.
each conical element according to the sup-
The difference between the two sides of a conical porting steel shim/steel shim, either
mounting should not be more than 0.6 mm.
the foundation through the conical element
Measuring of Steel Shim and Chockfast and the shims.
08028-0D/H5250/94.08.12
10) The steel shim should be at least 10 mm (Re)move the set completely so that the mark-
high. ings can be reached by drilling with conventional
tools.
Check the minimum permitted thickness of chock-
fast for the load and surface of this application with Place the set on its former position by aligning
chockfast supplier. it with the drilled holes.
or
Make sure that the minimum height of the steel shim

is 10 mm.
03.50 - ES1
MAN Diesel
L28/32H
b) Drill the mounting holes in the foundation by Make sure that the mounting bolts are isolated from
means of the drilling pattern. the chockfast.
The drilling has to be done on beforehand and Note! After completion of all works, the buffer clear-
the set must be aligned with the foundation ance must be checked, see points 12, 13, 14 and
holes before the work starts to avoid further 15.
removal of the set.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel

Page 1 (2) Replacement of Conicals Edition 01H
L+V28/32H

Shut-off fuel oil
Description:
Replacement of conicals
Hand tools:
Starting position: Ring and open end spanner, 22 mm

Safety precautions Hydraulic jack
Related procedure:
Fitting instructions for resilient mounting
Man power:
Working hours : xxx Hours

Capacity : 2 Men
Data: Spare and wearing parts:
Data for pressure and tolerance (Page 600.35) Plate No. Item No. Qty./
Declaratiom of weight (Page 600.45)
94.29 - EO0S-G
MAN Diesel

Edition 01H Replacement of Conicals Page 2 (2)
L+V28/32H
Replacement of Conicals
1. Loosen all conicals in one side. 3. Lift the GenSet until the steel shim can be
removed. This will give enough space for removing
damaged conical.
2. Mount a jack under the base frame, see fig
1.
4. Mount the GenSet conical.
Note! Conicals should only be replaced in pairs, see

fig 2 and plate 61903.
5. Lower the GenSet again.
6. Repeat point 1-5 for the other side.
7. Adjust the conicals, see Working Card 619-

03.00 "Fitting Instructions for Resilient Mounting of
GenSet.
Fig 1 Removal of conicals
Fig 2 The conicals must be pairs
94.29 - ES0S-G
MAN Diesel

Page 1 (2) Maintenance of Conicals Edition 01H
L+V28/32H

Shut-off fuel oil
Description:
Control and adjustment of conicals.

Hand tools:
Ring and open end spanner.

Feeler gauge, 1-2 mm.
Hexagon socket key 6 mm.
Starting position:
Related procedure:
Check of crankshaft bend (autolog)

08028-0D/H5250/94.08.12
Manpower: Plate no Item no Qty/
Working time : 2 hours

Capacity : 1 man
Data:

97.25 - EO0S-G
MAN Diesel

Edition 01H Maintenance of Conicals Page 2 (2)
L+V28/32H
1. Visual Check 2.2. Result of clearance check.
If Then
1.1. What to check.
Everything is OK Check is completed
Check for oil deposits on the rubber element. Everything is not OK Adjust conicals which do not
Check for loose mounting bolts. comply with the clearance
Check for damage in the rubber element. demands acc. to item 2.3.
Re-check all conicals acc. to
item 2.1.
1.2. Result of visual check. Everything is still not OK Replace conical acc. to
If Then
Everything is OK Continue to next conical

2.3. Adjustment of conicals.
Oil deposits on rubber Clean rubber element
element a. Remove protective cap (no 10).
Loose mounting bolts Fasten mounting bolts
b. Remove fixing bolt (no 9) and top locking ring
Damage in conicals Replace conical according to (no 7).
c. Turn buffer clockwise until it has contact with
the steel shim (no 2).
2. Clearance Check
d. Turn buffer anticlockwise until it has contact
with the conical base casting (no 3). This must be
2.1. What to check. four full rotations.
Check clearance on all conicals between steel shim e. Turn buffer two full rotations clockwise. This
and internal buffer through the slot in the base ca- will ensure full vertical movement for the buffer.
sting of the conical (see fig 1) with a feeler gauge
of app. 2 mm. f. Check all conicals again.
g. Replace top locking ring, fixing bolt and protec-

tive cap etc.
08028-0D/H5250/94.08.12
Fig 1 Conical
97.25 - EO0S-G
MAN Diesel
Plate
Page 1 (2) Flexible External Connections 61902-03H
L28/32H
Item
Fig. Designation Connection
No.
Waste oil, outlet A3 01
Nozzle cooling oil, inlet A7 02
Nozzle cooling oil, outlet A8 03
Lubricating oil from separator, C3 04

inlet
Lubricating oil to separator, C4 05

outlet
Back flush from full-flow filter, C9 06

inlet
Lub. oil from by pass filter, C11 07

inlet
Lub. oil to by pass filter, outlet C12 08
Lub. oil supply, inlet C16 09
Venting to expansion tank F3 10
HT freshwater from preheater, F5 11

inlet
HT freshwater to preheater, F6 12
outlet
Fresh water for filling/draining F7 13
Compressed air, inlet K1 14
Control air, inlet K2 15
Drain from charge air cooler, M6 16

outlet
Fuel oil, inlet A1 17
Fuel oil, outlet A2 18
94.41 - ES0S
MAN Diesel
Plate
61902-03H Flexible External Connections Page 2 (2)
L28/32H
Item
Fig. Designation Connection
No.
Oil vapour discharge, outlet C13 19
Lubricating oil from full-flow C7 20

filter, inlet
Lubricating oil to full-flow filter, C8 21

outlet
HT freshwater, inlet F1 22
HT freshwater, outlet F2 23
LT freshwater/raw water, G1 24
inlet
LT freshwater/raw water, outlet G2 25
Sea water, Inlet G3 26
Sea water, outlet G4 27
94.41 - ES0S
MAN Diesel
Plate
Page 1 (2) Conical Element 61903-04H
L+V28/32H
05
06
07
01
02
03
04
08028-0D/H5250/94.08.12
Note! When ordering, be aware that conical elements Bemærk! Ved bestilling af conicals elementer.
always should be replaced in pairs, state manufac- Conicals elementer udskiftes parvis, opgiv fabrika-
turing no. of existing conical elements. tions nr. på eksisterende conicals elementer.
97.44 - EO0S-G
MAN Diesel
Plate
61903-04H Conical Element Page 2 (2)
L+V28/32H
Item Item
01 4/M Screw Skrue
02 4/M Washer Skive
03 1/M Conical element Konisk understøtning
04 4/M Adjusting screw Justerskrue
05 1/M Protecting cap Beskyttelseskapsel
06 1/M Fixing ring Fiksering ring
07 1/M O-ring O-ring
08028-0D/H5250/94.08.12
Qty./M = Qty./Conical mounting. Antal/M = Antal/Conical montering.
97.44 - EO0S-G
Tools
520/620
MAN Diesel
Description
Introduction to Spare Part Plates for Tools 620.01
General
The contents of these spare part plates with tools However, some tools, such as torque spanners, hy-
are a summary of STANDARD TOOLS for normal draulic tools etc., may also have other applications.
maintenance and EXTRA TOOLS for reconditioning, Information about the exact use of the tools appears
which can be supplied by MAN Diesel A/S, Holeby. from the relevant sections in the instruction book.
Thus, the list comprises the total extent of tools
available for this engine type. Note: The table on the spare part plates is marked
with an S or an E. An S means that the tools are
For each specific plant, the amount of tools delivered supplied when ordering Standard tools and an E
depends of the contractual specifications. means that the tools are supplied when ordering
Extra tools, i.e. Tools for Reconditioning. (Extra tools
The tools listed are assembled in sections corres- are not standard delivery)
ponding to the chapters of the instruction book.
08028-0D/H5250/94.08.12
93.50 - ES0U
MAN Diesel
Page 1 (7) Function of the Hydraulic Tools Edition 03H
General

Shut-off fuel oil
Press Blocking - Reset
Safety hints andd function of hydraulic tools.
Starting position
Application of hydraulic tools 620-01.06
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
MAN Diesel
Edition 03H Function of the Hydraulic Tools Page 2 (7)
General
Function of the Bolt Tensioning Device 8. The operation and handling of the device are
to be carried out by expert staff only.
In order to achieve an optimal result with one or
several devices, some rules have to be considered. 9. The given max. operation pressure is not to
We expressly point out that a conscientious handling be exceeded in any case and is to be watched
of the device as well as the accessories is of high- at the manometer of the pressure generator
est importance. To ignore these rules or separate during the complete tensioning or loosening
hints means danger to life or danger of injuries! See procedure. When having achieved the given
Safety Hints. pressure, stop the pressurization immedi-
ately.
Safety Hints 10. During the pressurization when tensioning or

loosening the bolt connection, always watch
Beside regarding the general accident-prevention the admissible stroke of the device. Exceed-
rules, the safe handling of the device and the hydraulic ing this stroke is connected with insufficient
accessories demand especially the consideration of generating of tensioning force because the
the following hints. When disregarding even single device is tensioned in itselve or the hydraulic
items, you can cause danger to life and/or danger pressure is bleeded automaticly.
of injuries!
11. On principle, when connecting high-pressure
1. When leakages occur during the pressuriza- hoses it has to be taken care that the connec-
tion, bleed pressure immediately and seal the tions are correct (see also separate hints).
leakage or replace defect parts.
12. The hydraulic hoses have to be installed in a
2. In case of repair, use exclusively original spare way that they are not run over by vehicles or
parts. Inexpert substitution of damaged parts unnecessarily walked over by people. Never lay
by non-original spare parts is prohibited. hoses across sharp objects (danger of cuts)
and never bend or jam them in.
3. All assembly parts are to be handled in corre-
spondence to the working cards only. A change 13. Never hold or transport the device by using the
in the procedure or another operation of the high-pressure hoses.
device is not allowed.
14. An incorrect working manometer that doesn´t
4. Make sure that the components to be tensioned show the right pressure leads to overstressing
do not exceed the admissible strain. of the parts and to an incorrect bolt connec-
tion. Apart from damaged parts an incorrect
5. In order to use the device, the thread has to bolt connection can also cause conditions that
be sufficiently exceeding in order to avoid that are danger to life. Therefore take care that
the turn of a thread cracks, see item 4. the manometer shows the right value or the
tensioning force is checked in an other way
08028-0D/H5250/94.08.12
6. During the pressurization the people involved (for example by using a master manometer).
have to remain in an appropriate distance. Tensioning forces can be checked for example
Staying in direction towards the bolt axis is by measuring the linear deformation. Damaged
forbidden. manometers have to be exchanged immedi-
ately.
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.
99.43 - ES0
MAN Diesel
General
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 squareness
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. Fig. 1. Turnable connection unit.
- After each pressurization, bring the device

back to zero, see also Piston Return Stroke. Exchange of the Seals
Should leakages show up at the connection unit, it

Turnable Connection Unit might be necessary to exchange the seals.
For doing so, loosen the securing ring and take the
In order to simplify the connection of the hydraulic disc off the bolt nipple. Having removed the seals,
hose, a turnable connection unit is mounted on clean the components with fluff-free cleaning material.
some devices. You can also apply compressed air. Having checked
The turnable connection unit consists of the follow- the components for damages and oiled them slightly,
ing components: apply new seals by help of the entry guide and reas-
semble the turnable connection unit.
- bolt nipple
- disc Hint: - For the cleaning, never use aggressive
- seal cleaning liquids.
- securing ring - For oiling the parts, use exclusively hydraulic
oil.
Furthermore, an entry guide is available or contained - For replacements, use exclusively new
08028-0D/H5250/94.08.12
in the scope of supply, see fig.1. 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
fit barring the connection.
99.43 - ES0
MAN Diesel
Edition 03H Function of the Hydraulic Tools Page 4 (7)
General
- By drawing the hose with a manual force of If necessary, turn back the device, but make sure
about 100 N make sure that the connection is that the max. admissible stroke of the device is not
correctly barred. exceeded. Beside that, it has to be ensured that the
cylinder and the support sleeve remain centrically
- For decoupling the high-pressure hose in towards each other (consider centering shoulder).
a pressureless condition, first pull back the
coupling socket and then take off the hose. Having made all hydraulic connections correctly,
see fig. 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
flange. Screw it back to the flange, see fig. 3. Check
by help of a feeler gauge leaf whether the main nut
really fits tight to the flange. After that, bleed hydraulic
pressure. Now the connection is tensioned.
Fig. 2. Coupling of the high-pressure hoses.
Having brought the piston to its zero position, see fig.
4, the hydraulic hoses can be decoupled. In order to
Hoses with fast-lock coupling sockets avoid, also prevent impurities, it is advisable to close coupling
when uncoupled, that oil runs out. When the hoses sockets and coupling nipples at once by protecting
get heated, there can be an inside pressure in the caps. The device can be unscrewed from the bolt.
uncoupled condition making a coupling impossible.
By loosening one screw connection (see fig. 2) the ● Always consider the safety and working
pressure can be bleeded hints!
- To avoid a contamination use protecting caps

for the sockets. Loosening Procedure
In order to loosen an existing bolt connection, screw

Tensioning Procedure the device onto the bolt. First put the support sleeve
on the bolt and align it centrically to the bolt axis.
Prior to the tensioning procedure make sure that When screwing on the device take care that the
the components to be tensioned are correctly posi- support sleeve at the cylinder is correctly centered
tioned towards each other. Then screw the device (consider centering shoulder).
onto the bolt.
The piston of the device must be at its zero position.
First put the support sleeve on the bolt and align it Having screwed the device down until the support
centrically to the bolt axis. When screwing on the de- sleeve or the support cylinder fits tight to the flange,
vice take care that the support sleeve at the cylinder
08028-0D/H5250/94.08.12
turn back the device by at least the value (slit meas-

is correctly centered (consider centering shoulder). ure) which the bolt and the components spring back
elastically during the loosening procedure.
Screw the device until the support sleeve or the sup-
port cylinder fits exactly to the flange. The piston of Hint: The adjusted slit measure may never exceed
the device must be at its zero position. Furthermore, the admissible stroke of the device! Furthermore,
take care that the hydraulic connector and the window take care that the window for the adjusting rod are
for the adjusting rod is well accessible. well accessible.
Having made all hydraulic connections correctly, see
fig. 2, start the pressurization.
99.43 - ES0
MAN Diesel
General
During the pressurization, a slight turn-back momen- Hint:
tum is applied to the main nut with the adjusting rod.
At the moment, when the main nut can be loosened, a) Should it be impossible to unscrew the device
interrupt the pressurization. Should it not be possible after the depressurization, it has been turned
to loosen the main nut when achieving the original back by a too low measure prior to the pres-
tensioning pressure, interrupt the pressurization im- surization. Pressurize again until the original
mediately. Find the cause with expert staff. tensioning pressure is reached, turn the main
nut and bleed the pressure again (tensioning
Having achieved the loosening pressure, turn back procedure). Now you can turn back the device
the main nut by the value that the bolt and the com- further. (Attention: consider the admissible
ponents spring back during the loosening procedure. stroke of the device!) Now repeat the loosening
The slit measure, however, must be lower than the procedure explained above.
slit measure adjusted at the device before, see also
hint b. b) Should it be impossible to loosen the main nut
after the depressurization, it has been turned
The main nut may never be turned back until it fits back by a too low measure prior to the pres-
to the piston or the cylinder since then the device surization. Pressurize again and turn the main
can be tensioned in itself. nut further back. Bleed the pressure again.
Having turned back the main nut, the pressure can Hint: Never screw the main nut back until it fits to
be bled. The bolt connection is loosened. Before the piston since the device can be tensioned
unscrewing the device, bring the piston back to its in itself.
zero position, see fig. 4. After that, the hydraulic hoses
can be decoupled. In order to prevent impurities, it
is advisable to close coupling sockets and coupling Adjustment and Turn Back of the Main Nut
nipples at once by protecting caps. The device can
be unscrewed from the bolt. During the pressurization of the device, the bolt
is being extended by the tensioning force and the
● Make sure that no operational forces (e.g. components are being edged. The result is that the
inner pressure) affect the components to be main nut does no longer fit to the flange.
loosened since only part of the bolts take over
these forces and thus the bolts, which are not Having achieved the necessary pressure, adjust the
yet loosened, might be overburdened. main nut - when tensioning - until it fits to the flange
again before bleeding the pressure, see Tensioning
● The pressure when the main nut can be loos- Procedure. When loosening the bolts, turn back the
ened may never exceed the tensioning pressure main nut after the pressurization according to the
by help of which the connection was tensioned! bolt and component deformations, (see Loosening
Should it not be possible to loosen the main nut Procedure.
when reaching the original tensioning pressure
08028-0D/H5250/94.08.12
interrupt the pressurization immediately. Find Hint: During the loosening procedure, never turn
the cause with expert staff. back the main nut until it fits to the piston or the
cylinder since the main nut sticks after the depres-
● Always consider the safety and working surization.
hints!
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.
99.43 - ES0
MAN Diesel
620-01.05 Function of the Hydraulic Tools Working Card
General
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 flow 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 fits to the cylinder again.
Exchange of the Seals

Fig. 3 Adjustment and turn back of the main nut.
Should leakages occur at the piston of the device,
an exchange of the seals might be necessary.
Piston Return Stroke Drive out the piston by carefully beating with a hammer
while using a plastic spacer in order to protect the
After each pressurization it must be ensured that device from unnecessary damages. After removing
the piston of the device is brought back to its zero the hydraulic connector, you can also carefully lead
position. On principle, it has to be considered that compressed air into the piston area.
hydraulic oil is being displaced from the piston area.
In order to enable the oil to flow back to the tank of Attention: Sudden input of compressed air can lead
the pressure generator, the corresponding hydraulic to the piston’s uncontrolled outlet.
connections must be done. After removal of the piston, the seals and the backup
rings can be removed from the piston and the cyl-
The piston return stroke is done by a screw-down at inder.
the bolt itself before the device is taken off.
Carefully clean the components with fluff-free mate-
Hint: When using fast lock coupling elements, the rial and check them for damages. If necessary, use
oil’s running out and thus a piston return stroke in compressed air for the cleaning, but never aggres-
an uncoupled condition is impossible! 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.
08028-0D/H5250/94.08.12
Fig. 4. Piston return stroke.
Fig. 5. Exchange of the seals.
99.43 - ES0
MAN Diesel
General
As shown in the picture, first 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 fits 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.
08028-0D/H5250/94.08.12
Check the components of the device and its acces-

sories for completion.
The operating manual has to be read by all users.
99.43 - ES0
MAN Diesel
Page 1 (2) Application of Hydraulic Tools Edition 01H
L/V28/32H

Shut-off cooling water See page 2
Shut-off fuel oil
Application of hydraulic tools.
Starting position
Function of hydraulic tools 620-01.05
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.50 - ES0
MAN Diesel

Edition 01H Application of Hydraulic Tools Page 2 (2)
L/V28/32H
This working card gives the information for applica-

tion of hydraulic tools, to be used in connection with
Please note:
The numbers refer to the
plate items in section 620.
Fig 1 Hydraulic tools.

08028-0D/H5250/94.08.12
99.50 - ES0
MAN Diesel
Page 1 (4) Hand Lever Pump Edition 01H
General

Shut-off fuel oil
Application of hydraulic tools.
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
MAN Diesel
Edition 01H Hand Lever Pump Page 2 (4)
General
Warning: The hand lever pump is not equipped with Initial Start-up and Venting
a pressure relief valve.
Never use the pump without a mounted manometer. In general and venting
Always pay attention to the given pressure of the
connected pressure consumers. Do never exceed Please make sure that all parts of the pump, espe-
this pressure or the max. pressure of the hand lever cially the manometer and the pressure port, are in a
pump. perfect condition. Defect parts are to be exchanged
against new ones immediately.
Important: Except for hydraulic oil, never use different
liquids such as petrol, water, diesel oil, alcohol or brake Turn the carrying handle with counter-clockwise
liquid, since these can lead to damages or even to rotation out of his fixing. Then turn it into the hand
destruction of the pump and/or the parts connected lever of the pump against the stopping face.
with it. Choose a place of assembling and operation
where the pump can always stand safe and firm on Attention: If the carrying handle is not srewed-in
a horizontal plain. There should always be sufficient into the hand lever, it can cause injuries while using
space for operating the pump. the pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the oil filler cap and check the oil level. If nec-
pump to great heat, fire or extreme coldness, since cessary, fill up the tank with hydraulic oil according
this leads to damages or even destruction. Protect to IS0 VG 32. Never overfill the tank. Close the oil
the pump from falling objects and avoid hard blows filler cap.
or pushes. Open the tank breather with the square wrench
(included in the scope of supply) by about one turn.
Attention - Danger to life Now loosen the breather screw at the pump on the
Check the manometer of the pump for the needed left side on the pump housing with an allen key SW
hydraulic pressure, given by an authorized person, 2,5 by about one turn. Close the depressurization
not to be exceeded. Make sure that the pressure valve tightly. Seal the nipple on the pump with a hose
you want to generate is also admissible for all con- and pump at the hand lever until oil flows out of the
nection parts. breather screw bladder-free. Only then are you al-
lowed to close the breather screw. The pump is now
All pressure connections and connecting elements vented and ready for operation.
have to be clean and undamaged. High-pressure
connections from the pump to the tools have to be After each operation and for the transport, close
established correctly prior to any pressurization. the tank breather in order to avoid the hydraulic oil’s
Disregard leads to danger to life. Please see working running out.
card 520-01.06.
Attention - Danger on injuries Pressurization

Loads being lifted by the pump may never be held
by the pump valves alone. Use additional non-return
08028-0D/H5250/94.08.12
- Open the tank breather with the square wrench

valves or safety relief valves and secure the load by approx. one turn.
sufficient support against falling.
Remark: The pump is only to be operated with open
tank breather.
- Close the depressurization valve at the pump

when turning clockwise by handoperation.
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.
99.43 - ES0
MAN Diesel
Page 3 (4) Hand Lever Pump Edition 01H
General
- Pump at the hand lever until the wanted pres- Attention: Inside of the adjusting screw is another
sure is achieved. Check the pressurization grub screw with inner hexagon (wrench size 4 mm) to
at the manometer and take care of possible limit the stroke of the change-over piston inside of
leakages. the pump block. It is absolutely necessary, to screw
out the grub screw approx. 2 times before turning
Remark: The pump works with two stages. The the adjusting screw!
change from the first stage to the second stage
happens automatical at a system pressure of about The regulation of the adjusting screw follows gra-
30 bar. dually in approx. 10° - steps. After everv adjusting
step the grub screw is to screw in until it fits closely
Attention: The pump is not equipped with an internal and approx. a l/4 turn to loosen.
pressure relief valve.The use of a manometer and the
control of the system pressure during pressurization Check by carefully pumping if the change-over pres-
is indispensable. sure wanted has been reached. If necessary, repeat
the procedure as described above.
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 hydraulic

On 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
08028-0D/H5250/94.08.12
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.
99.43 - ES0
MAN Diesel
Edition 01H Hand Lever Pump Page 4 (4)
General
Analysis and Correction of Malfunction Pressure Port
Correction of malfunctions The pressure port of the pump is produced accor-

ding to our customers’ wishes. In addition, there is a
In case of malfunctions at the pump, the following variety of possibilities to connect the pump with one
points are to help you with the analysis of the problem or more pressure consumers.
and correcting it yourself.
For this, uncouple or unscrew all consumer and Attention - Danger to life
high-pressure hoses from the pump. Prior 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
Malfunction Correction
and suitable for the necessary pressure.
No pressurization 1. Check the oil level and, if
necessary, fill it up as Attention - High-pressure hydraulic
described in chapter On principle, when leakages occur during the pressu-
maintenance and storage.
2. Close depressurization valve. rization, immediately release the hydraulic pressure
3. Visual inspection whether and seal the leakane or renew defect parts.
there are leakages. If so,
seal them.
4. Vent the pump as described
in chapter initial start-up and Maintenance and Storage
venting.
The pump should be lubricated frequently at the
Insufficient pressurization 1. Check the oil level and, if
necessary, fill it up, as
movable parts. Protect it from contamination because
described in chapter dirt in the oil or in the pressure port can lead to the
(prior to any corrections, mainteance and storage. pump’ s failure. A dry storage avoids the steel parts’
open de-pressurization 2. Close depressurization valve. getting rusty.
valve and release hydraulic 3. Visual inspection whether ther
pressure completely) are leakages. If so, seal them.
The storage and transport of the pump should always
4. Vent the pump as described be done in a horizontal position. Thus, you avoid a
in chapter initial start-up and possibly necessary venting of the pump during its
venting. start-up.
Pressure drop 1. Visual inspection whether
there are leakages. If so, For checking the oil level, please open the depres-
(prior to any corrections, seal them. surization valve and let the oil completely flow back
open de-pressurization 2. Close depressurization valve. into the tank. Open the oil filler cap and fill up hydraulic
valve and release hydraulic
pressure completely).
oil according to IS0 VG 32, if neccessary. Do not
overcharge the tank. Close the oil filler
If the problem cannot be solved, please contact MAN cap.
Diesel, Holeby.
08028-0D/H5250/94.08.12
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.
99.43 - ES0
MAN Diesel
Page 1 (2) Maintenance of Hydraulic Tools Edition 01H
General

Shut-off fuel oil
Description:
Maintenance of hydraulic tools and pressure

testing of hoses. Hand tools:
Allen key, 6 mm.

Clean lub. oil.
Starting position:
Related procedure:

08028-0D/H5250/94.08.12
Man power:
62021 43 Hydraulic tool.
Working time : 1/2 Hour 62021 44 Hydraulic tool.
Capacity : 1 man 62021 29 Hydraulic tool.
62021 30 Hydraulic tool.
Data:

91.46 - ES0S
MAN Diesel
Edition 01H Maintenance of Hydraulic Tools Page 2 (2)
General
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
fitted 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 with the help of working air.
Work.
air
Compression tool
Fig. 2.
Fit the sealing rings and lubricate with clean lub.

Fig. 1. 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.
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. Pressure Testing of Hoses.
2) The sealing rings are to be fitted with the o- To avoid working accidents caused by emission of
rings nearest to the pressure chamber and with the pressure oil from the hydraulic hoses, they should
back-up rings away from the pressure chamber. be pressure tested at 1200 bar once a year.
Note: During the pressure testing the hoses must

be covered carefully.
08028-0D/H5250/94.08.12
91.46 - ES0S
MAN Diesel
Page 1 (2) Tightening with Torque Spanner Edition 01H
General

Shut-off fuel oil
Description:
Hand tools:
Starting position:
Related procedure:

08028-0D/H5250/94.08.12
Working time Plate no. Item no. Qty. /

Capacity
Data:

91.16 - ES0S
MAN Diesel
Edition 01H Tightening with Torque Spanner Page 2 (2)
General
1) Before the nuts are screwed on, the threads 7) For setting the spanner at the torque required,
and the contact faces should be grease with copaslip there is a ball on a small arm at the end of the
or similar, the tightening torques being based on a handle.
coefficient of fiction in the threads.
8) When pulling the ball with the arm outwards,
2) The nuts should fit easily on the thread, and a small crank handle is formed.
it should be checked that they bear on the entire
contact face. A spring-loaded slide in the handle provided with a
mark which, when turning the crank handle, can be
3) In the case of new nuts and studs, tighten and set at the required torque on the scale.
loosen the nuts 2 or 3 times so that the thread may
assume its difinite shape, thus obviating the risk of The torque spanner functions as follows:
loose nuts.
9) The above-mentioned spring activates a pawl
4) Nuts secured with a split pin are tightened to the system in the handle, and when using the spanner,
stated torque and then to the next split-pin hole. this pawl system will be released when the pre-
set torque has been reached, at which moment a
5) The following instructions apply to the use and small jerk is felt in the spanner and a small click is
maintenance of torque spanner. heard.
10) The torque spanner must not be used for torque

Torque Spanner. higher than those stamped on it, and it must not be
damaged by hammering on it or the like.
6) The handle of the torque spanner is provided
with a scale indicating the torque at which the span-
ner can be set.
Scale for torque moment Key for adjusting

of torque moment
Fig. 1. Torque spanner.

08028-0D/H5250/94.08.12
91.16 - ES0S
MAN Diesel
Working Card Tool Combinations for Tightening 620-01.20
Page 1 (3) of Connecting Rod Screws Edition 01H
L28/32H

Shut-off fuel oil 62006 30 Ekstra tools.
Shut-off cooling oil 62006 32 Only for tightening
Stopped lub. oil circul. 62006 34 200 mm.
62006 37 32 mm.
62006 39 Ekstra tools.
62006 41 Ekstra tools.
Description:
Tool combinations for tightening and checking

connecting rod screws. Hand tools:
Starting position:
Related procedure:
Dismounting of piston and connecting

rod, 606-01.00
Tightening and check of connecting
rod screws, 606-01.25
In-situ inspection of connecting
rod big-end bearing, 606-01.30
08028-0D/H5250/94.08.12
Working time : Hours Plate no. Item no. Qty. /

Capacity : man
Data:

91.45 - ES0S
MAN Diesel
620-01.20 Tool Combinations for Tightening Working Card
Edition 01H of Connecting Rod Screws Page 2 (3)
L28/32H
The tightening procedure for connecting rod screws
can be executed with the tools originally delivered Tool combinations for tightening of lower screws,
with the GenSets. see fig. 2.
The enclosed pages illustrate different tool combi-

nations applicable to tightening of connecting rod
screws. 1. Torque spanner, 140 - 760 Nm.
2. Ratchet, (only for tightening).
The turning of the screws through a 60° angle, can 3. Socket, 32 mm.
be executed with less muscle power if a planet gear
spanner (extra tools) is used.
If tool combination with planet gear spanner is used

for check of the connecting rod screws tightening
condition, the gear ratio (1:4) has to be taken into
consideration when setting the torque spanner. For
prescribed test torque of 700 Nm, the torque spanner
should be set at 175 Nm. (4 x 175 = 700).
It is also acceptable to execute the turning of the 3 2 1

screws through a 60° angle, by means of a pneuma-
tic impact spanner, if available are adequate power
and dimensions.
Tightening with torque spanner ratchet, extension

piece (only for upper screws) and socket. Fig. 2. Tools combinations for tightening of lower screws.
Tool combinations for tightening of upper screws,

see fig. 1.
Tightening with torque spanner, ratchet, planet gear
spanner, extension piece (only for upper screws)
and socket.
1. Torque spanner, 140 - 760 Nm.
Tool combinations for tightening of upper screws,
3. Extension piece, (200 mm).
4. Socket, 32 mm. see fig. 3.
Tool combinations for tightening of lower screws,

see fig. 4.
Tightening with pneumatic spanner and special

08028-0D/H5250/94.08.12
socket. (extra tools).
The turning of the screws through a 60° angle, can

be executed with a pneumatic impact spanner.
4 3 2 1
The impact spanner must be of adequate dimensions
and capacity, with 1" quadrangular terminal shaft.
The 32 mm socket to be used must be a socalled

specially designed for use with mechanical or pneu-
matic impact tools.
Fig. 1. Tools combinations for tightening of upper screws.
91.45 - ES0S
MAN Diesel
Working Card Tool Combinations for Tightening 620-01.20

Page 3 (3) of Connecting Rod Screws Edition 01H
L28/32H
Compared to sockets for manually operated spanner, The connecting rod screws are situated very closely,
the power top has increased dimensions. leaving only minor space between collars and hexa-
gonals of the screw heads.
Dependent of the manufactures, it can be necessary

to adapt the power top to the limited space conditions
1. Torque spanner, 140 - 760 Nm. around the screws.
1
3. Planet gear spanner, (ratio 1:4). In such case only the absolutely necessary machin-
4. Extension piece, (200 mm). ing should be executed.
5. Socket, 32 mm.
An external diameter of 51 mm, see fig. 5 in a length

3
of 21 mm at the hexagonal end of the power top is
sufficient for access to the screws.
Connecting rod screws

5 4 2
Connecting rod
Fig. 3. Tools combination for tightening of upper screws with

planet gear.
ø51 21 mm
1. Torque spanner, 140 - 760 Nm. 1

2. Ratchet, (only for tightening). Special socket
(power top)
3. Planet gear spanner, (ratio 1:4).
4. Socket, 32 mm.
3
Fig. 5. Special socet.
08028-0D/H5250/94.08.12
Machining beyond these dimensions should not

take place as it could influence the rigidity of the
power top.
4 2
Fig. 4. Tools combination for tightening of lower screws with

planet gear.
91.45 - ES0S
MAN Diesel
Page 1 (2) Max Pressure Indicator Edition 02H
General

Shut-off cooling water 62005 10 Max pres. indicator
Shut-off fuel oil
Description:
Operation.
Overhaul intervals. Hand tools:
Dismantling, overhaul and assembly.
Allen key, 3 and 6 mm.
Copaslip or similar.
Starting position:
Related procedure:

08028-0D/H5250/94.08.12
Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man
See Plate 62005
Data:
Data for pressure and tolerance

Data for torque moment
Declaration of weight
94.12 - ES0S
MAN Diesel
Edition 02H Max. Pressure Indicator Page 2 (2)
General
Operation:
1) Open the indicator valve and blow through 1

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 2

the gauge. 5
Attention: The indicator valve has to be open while

reading the max pressure on the gauge. The measu- 4
ring period should not exceed 30 seconds.
3
4) Close the indicator valve and open the valve
screw (5), fig 1.
1 Housing 2 Allen screw
5) Disconnect the max pressure indicator and
3 Sealing 4 Screw
close the valve screw (5), fig 1.
5 Valve screw
6) Measure the remaining cylinders by following Fig 1 Pressure Indicator.

step 1 to 5.
3) Loosen the screws (2) (4 pieces) for separating

Overhaul Intervals. upper and lower part.
1) Dismount and clean the non-return valve after 4) After separation of the upper and lower part,
200 measuring periods. If the pressure drop is more take off the non-return valve assembly.
than 5 bar within 60 seconds (test pressure 100 bar)
it is recommended to relap the non-return valve. 5) Lap the valve and the valve seat.
2) Check the pressure gaugeafter 1.000 measu- 6) Renew the sealing ring (3) and screws (2), if
ring periods or after 12 month use. necessary.
7) When mounting the upper and lower part, use

Attention: Use only exhaust gas or nitrogen gas only original screws.
and never oil for testing the pressure drop and the
pressure gauge. By using oil carbon will deposit 8) Coat the screws (2) with copaslip or similar
08028-0D/H5250/94.08.12
inside the measuring instrument. and tighten to 10 Nm.
9) After assembly the instrument can be used

Dismantling and Assembly: without any new calibration.
1) Dismount the valve screw (5), fig 1.

Check of the Pressure Gauge:
2) Turn the screw (4) into the instrument to enable
dismounting of the housing (1). 10) Testing of the instrument should only be made
by skilled specialists, and it is recommended to send
the instrument to MAN Diesel A/S, Holeby for calibra-
tion.
94.12- ESOS
MAN Diesel
Plate
Page 1 (5) Tools for Cylinder Head 62005-03H
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Lifting tool for cylinder head

(complete). 380 400 230 S S 01
B
Mounting tool for valves (com-

06 B plete). 155 290 190 S S 05
07 C
Nut. 06
Thrust bearing. 07
Max. pressure indicator. S S 10
Spare Parts:
Valve screw. 11
08028-0D/H5250/94.08.12
Non return valve, complete incl.

seals and housing screws. 12
Connecting nut incl. wedge for

mounting. 13
Pressure gauge 0-180 bar. 14
06.06 - ES0
MAN Diesel
Plate
62005-03H Tools for Cylinder Head Page 2 (5)
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Grinding ring for cylinder head

A and cylinder liner. 376 30 S S 20
B Grinding table for cylinder head,

with bracket for wall mounting
(complete). 650 825 400 E E 25
C
Grinding table for cylinder head,

with frame for floor mounting
(complete). 715 805 1050 E E 30
C
08028-0D/H5250/94.08.12
A
B
06.06 - ES0
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Grinding machine for valve seat

ring (complete). E E 35
Spare parts:
Stone 36
Guide 37
40 Grinding machine for valve

spindle (complete). E E 40
Spare parts:
Stone 41
41
B Mounting tool for valve seat

rings (complete). 472 101 E E 45
08028-0D/H5250/94.08.12
06.06 - ES0
MAN Diesel
Plate
62005-03H Tools for Cylinder Head Page 4 (5)
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
B
Extractor for valve seat ring
(complete). 300 140 E E 50
A
Tools for grinding of valves. 110 95 ø90 S S 55
ø
Mandrel for dismounting of 400 17.5 ø25 E E 60
valve guide.
08028-0D/H5250/94.08.12
C B
A
06.06 - ES0
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Handwheel for indicator valve ø80 110 17 S S 65
Grinding machine for valve E E 70

seat ring incl. wooden box,
complete
Mandrel E E 71
Cutting tool E E 72
08028-0D/H5250/94.08.12
06.06 - ES0
MAN Diesel & Turbo
Plate Tools for Piston, Connecting Rod

Page 1 (6)
and Cylinder Liner 62006-11H
L+V28/32H
Dimensions
V28/32H
L28/32H
Item
Fig. Designation
A B C No.
Eye screw for lifting of piston. M16 35 27 S 01

C
B A
Shackle for lifting of piston. 28 50 S 03
Lifting tool for piston. 270 75 100 S 05
11.49 - ES0 - Stationary

MAN Diesel & Turbo
62006-11H Tools for Piston, Connecting Rod Plate

and Cylinder Liner Page 2 (6)
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Eye bolt for piston lift at check M16 65 611 S S 07

of connecting rod big-end
bearing.
B Back stop for cylinder liner (2 325 48 65 S S 09

pieces).
Guide ring for mounting of S S 11

piston.
ø296
65
ø280
60

MAN Diesel & Turbo
Plate Tools for Piston, Connecting Rod 62006-11H

Page 3 (6)
and Cylinder Liner
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Piston ring opener. S S 13
Testing mandrel for piston ring

and scraper ring grooves.
Grooves for piston ring. 5.43 S S 15
A
Grooves for scraper ring. 8.43 S S 16
Plier for piston pin lock ring. 550 25 ø3.5 S S 20
B
C

MAN Diesel & Turbo
62006-11H Tools for Piston, Connecting Rod Plate

and Cylinder Liner Page 4 (6)
L+V28/32H
Item
L28/32H
Dimensions
V28/32H
Fig. Designation
A B C No.
Guide fork for connecting rod 90 740 ø25 S 24
Torque spanner 20-120 Nm 463 1/2" S S 26

Torque spanner 50-300 Nm 618 1/2" S S 27
Pneumatic impact spanner. 1" E E 41

MAN Diesel & Turbo
Plate Tools for Piston, Connecting Rod 62006-11H

Page 5 (6)
and Cylinder Liner
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Lifting tool for cylinder liner. 1116 465 304 S S 45
B
A
Honing brush. ø280 900 S S 50
A Funnel for honing of cylinder ø323 1610 S S 51

liner.

MAN Diesel & Turbo
Tools for Piston, Connecting Rod Plate

62006-11H and Cylinder Liner Page 6 (6)
L+V28/32H
Dimensions
V28/32H
L28/32H
Item
Fig. Designation
A B C No.
Magnifier (30 x). 140 50 S S 55
Inside micrometer:
Measuring range:
275-300 mm (cylinder liner). E E 60
20
275 80
15
10
Measuring range:
225-250 mm (connecting rod). E E 61

MAN Diesel
Plate Tools for Operating Gear for Inlet Valves

Page 1 (1) Exhaust Valves and Fuel Injection Pumps 62008-03H
L+V28/32H
Dimensions Item
Fig. Designation
A B C No.
Feeler gauge for inlet valves. 0.5 0.4 13 S S 01
Feeler gauge for exhaust 1.0 0.9 13 S S 02

valves.
(2 sets of each).
Extractor for thrust piece, on

roller guide for fuel pump. 49 ø M24 S S 06
29.5 x 1.5
99.32 - ES0S
MAN Diesel
Plate Tools for Control and Safety Systems 62009-02H

Page 1 (1)
Automatics and Instruments
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Spanner for adjusting of over-

speed stop 125 ø20 100 S S 01
93.47 - ES0
MAN Diesel
Plate
Page 1 (3) Tools for Crankshaft and Main Bearing 62010-07H
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Turning rod. 1000 ø38 20 S S 01

B
Crankshaft alignment gauge

(autolog). 210 150 S S 05
Guide pipe for main bearing

C cap, 2 pieces. ø65 220 M48 S S 10
08028-0D/H5250/94.08.12
97.27 - ES0S
MAN Diesel
Plate
62010-07H Tools for Crankshaft and Main Bearings Page 2 (3)
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Lifting straps for main and guide

bearing cap, 2 pieces. 1000 M16 20 S S 15
C
B
Dismantling tool for guide bea-

ring shells. 250 32 S 18
250 32 S 19
Tool for upper main bearing ø50 51.5 S 20
O-ring ø7.9 ø2.6 S 21

08028-0D/H5250/94.08.12
O-ring ø9.9 ø2.6 S 23
97.27 - ES0S
MAN Diesel
Plate
Page 3 (3) Tools for Crankshaft and Main Bearings 62010-07H
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Guide tools for mounting of up-

A per guide bearing shell. 148 120 S S 25
B Lifting handle for main bearing

A 315 500 210 E E 30
cap.
C C
08028-0D/H5250/94.08.12
97.27 - ES0S
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.

(autolog). 210 150 S S 05

cap, 2 pieces. ø65 220 M48 S S 10
08028-0D/H5250/94.08.12
99.32 - ES0S
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.


250 32 S 19
O-ring ø7.9 ø2.6 S 21

08028-0D/H5250/94.08.12
O-ring ø9.9 ø2.6 S 23
99.32 - ES0S
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.

per guide bearing shell. 148 120 S S 25
Lifting handle for main bearing

cap. 315 500 210 E E 30
Magnetic tool for mounting

on crankweb without counter- 120 67 S S 35
weight
(for checking of main bear-
ings
08028-0D/H5250/94.08.12
alignment – autolog)
99.32 - ES0S
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.

(autolog). 210 150 S S 05

cap, 2 pieces. ø65 220 M48 S S 10
08028-0D/H5250/94.08.12
99.32 - ES0S
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.


250 32 S 19
O-ring ø7.9 ø2.6 S 21

08028-0D/H5250/94.08.12
O-ring ø9.9 ø2.6 S 23
99.32 - ES0S
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.

per guide bearing shell. 148 120 S S 25
Lifting handle for main bearing

cap. 315 500 210 E E 30
Angle for mounting on

crankweb without 84 60 25 S S 40
counterweight
(for checking of main bear-
ings
08028-0D/H5250/94.08.12
alignment – autolog)
99.32 - ES0S
MAN Diesel & Turbo
Plate
Page 1 (4) Tools for Fuel Oil System and Injection Equipment 62014-02H
L+V28/32H
V28/32H
Dimensions
L28/32H
Item
Fig. Designation
A B C No.
Pressure testing pump, compl.

01
03 GOU-G001 S S 01
02
Clamping bracket for fuel injec-

tor. VTO-W022 S S 02
04 Clamping bracket for fuel injec-

tion pump. PYO-W020 S S 03
05
Fuel pipe. VTO-W023 S S 04
Fuel pipe. VWM-W007 S S 05
Cleaning tool for fuel injector,

consist of: S S 10
1 pcs tool holder.
5 pcs needles.
C
Spanner for high pressure pipe. 30 270 19 S S 15
11.37 - ES0
MAN Diesel & Turbo
Plate
62014-02H Tools for Fuel Oil System and Injection Equipment Page 2 (4)
L+V28/32H
V28/32H
Dimensions
L28/32H
Item
Fig. Designation
A B C No.
Spanner for fuel injection pump

(left side). 270 88 24 S S 20
A B
C
Spanner for fuel injection pump
B
(right side). 270 88 24 S S 25
Spanner for fuel injection pump 270 88 24 S S 27

(right side)
11.37 - ES0
MAN Diesel & Turbo
Plate
Page 3 (4) Tools for Fuel Oil System and Injection Equipment 62014-02H
L+V28/32H
V28/32H
Dimensions
L28/32H
Item
Fig. Designation
A B C No.
Grinding tool for fuel injection 25 ø20 ø55 E E 30

valve.
Fuel Nozzle
Grinding tool for seat for fuel

injection valve. ø20 530 ø70 S S 35
Extractor for fuel injector valve 150 215 58 S S 40
A
C
11.37 - ES0
MAN Diesel & Turbo
Plate
62014-02H Tools for Fuel Oil System and Injection Equipment Page 4 (4)
L+V28/32H
V28/32H
Dimensions
L28/32H
Item
Fig. Designation
A B C No.
Measuring device for

plunger lift S S 42
11.37 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Lubricating Oil System 62015-02H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Guide bar for dismantling of

lubricating oil cooler, 2 pieces. 305 ø30 M20 S 02
01.11 - ES0
MAN Diesel
Plate
Page 1 (5) Hydraulic Tools 62021-08H
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Pressure pump, complete, with

wooden box S S 01
Manometer 02
Gasket for Item 07 06
Quick coupling 07
Distributor 08
Distributing piece for cylinder

head, complete. S S 15
Gasket 16
Quick coupling 17
Distributing piece for main bea-

ring, complete. S S 20
08028-0D/H5250/94.08.12
Gasket 16
Quick coupling 17
06.33 - ES0
MAN Diesel
Plate
62021-08H Hydraulic Tools Page 2 (5)
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Quick coupling 17
Allen key, 7 mm 26
Venting screw 27
Tommy bar 33
Ball 37
Adapter 38
Stroke indicator band 39
Hydraulic tools for connecting

rod with wooden box,
complete S S 70
Piston for hydraulic jack 71
O-ring with back-up ring 72
Cylinder for hydraulic jack 73
Spacer piece 75
Angle piece complete, incl. item

77, 78, 79, 81 76
O-ring 77
Adapter 78
08028-0D/H5250/94.08.12
Coupling socket 79
Hydraulic jack as item nos.

17, 27, 38, 39, 47, 71, 72, 73,
74, 75 80
Quick coupling 81
06.33 - ES0
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Quick coupling 17
Hydraulic tools for cylinder head

with wooden box, complete S S 25
Allen key, 7 mm 26
Venting screw 27
Spacer piece 32
Tommy bar 33
Tension screw 34
Hydraulic jack as Item Nos. 17, 35

27, 28, 29, 30, 31, 37, 38, 47
Tools for cylinder head with

wooden box, complete S S 36
Ball 37
08028-0D/H5250/94.08.12
Adapter 38
06.33 - ES0
MAN Diesel
Plate
62021-08H Hydraulic Tools Page 4 (5)
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Quick coupling 17
Allen key, 7 mm 26
Venting screw 27
Tommy bar 33
Ball 37
Adapter 38
Hydraulic tools for main

bearings with wooden box,
complete S S 40
Spacer piece 41
Hydraulic jack as Item 17, 27,

37, 38, 42, 43, 44, 45, 82 46

08028-0D/H5250/94.08.12
06.33 - ES0
MAN Diesel
Plate
L+V28/32H
V28/32H
L28/32H
Dimensions Item
Fig. Designation
A B C No.
Hose for hydraulic tools, 6 pie-

ces complete 600 ø27 S S 49
Hose for hydraulic tools, 1 pie-

ces complete 3000 ø27 S S 51
Hose 3000 53
Quick coupling with protecting

cap 54
Hose 600 56
Adapter 57
Air driven High pressure 367 256 326 E E 60

pump for hydraulic tools.
C
08028-0D/H5250/94.08.12
06.33 - ES0
MAN Diesel
Plate Tools for Low Overhaul Height,

Page 1 (2)
Piston, Cylinder Liner and Connecting Rod 62050-01H
L+V28/32H
1894 1894
1896
1895
1897
08028-0D/H5250/94.08.12
98.22 - ES0S-G
MAN Diesel
62050-01H Tools for Low Overhaul Height, Plate

Page 2 (2)
Piston, Cylinder Liner and Connecting Rod
L+V28/32H
Item Item
1894 2/E Pull-lift Pull-lift
1895 1/E Lifting tool for cylin- Løfteværktøj for cylin-

der liner, complete derforing, komplet
1896 1/E Collar for connecting Halsjern for plejlstang,

rod, complete komplet
1897 2/E Shackle Sjækel
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine. Qty./E = Qty./Motor.
98.22 - ES0S-G
Operating manual
Test rig GXO-G010a / GXO-G011a

Technical Operating manual
documentation for test rig
GXO-D001 GXO-G010a / GXO-G011a
Die Betriebsanleitung ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher
vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses
Verwendungszwecks darf die Betriebsanleitung ohne unsere vorherige Zustimmung nicht benutzt, vervielfältigt
oder Dritten sonstwie zugänglich gemacht werden.
Änderungen bleiben vorbehalten
The owner should make this operating manual available to maintenance and operating staff who should follow
the instructions it contains to prevent malfunctions or damage during operation. Other than for this purpose, the
operating manual may not be reproduced, used or disclosed to third parties by any other means without our
prior consent.
Subject to alterations and amendments
Änderungsdienst/Amendments service!
Falls Sie in den Änderungsdienst von L'Orange aufgenommen werden möchten, können Sie
uns das mit einer Postkarte an untenstehende Adresse mit folgenden Angaben mitteilen:
If you would like to be included in the L'Orange amendments service, send a postcard to the
address below including the following details:
Name / Name Betriebsanleitung für GXO-G010a / -G011a

Firma / Company
Straße / Street GXO-D001
Postfach / PO Box Operating manual for GXO-G010a / -G011a
PLZ / Postcode / Zip code
Ort / City GXO-D001/E
Land / Country
Betriebsanleitungs-Nr. / Operating manual No.
© 2007
L'Orange GmbH
Abteilung KVAM
Postfach 40 05 40
70405 Stuttgart
Germany
Contents
Section Page
1 Structure of the test rig (exterior) .....................................................................................................1
2 Structure of test rig (interior) ............................................................................................................2
3 Handling the test rig.........................................................................................................................5
4 Maintenance ....................................................................................................................................6
5 General safety instructions ..............................................................................................................7
5.1 Use in accordance with purpose.............................................................................................7
5.2 Handling the system ...............................................................................................................7
5.2.1 Hazards in handling the test rig ..........................................................................................7
5.2.2 Safety measures in normal operation .................................................................................7
5.2.3 Hazards from electrical energy ...........................................................................................7
5.2.4 Hazards from hydraulic energy...........................................................................................8
5.2.5 Servicing – Maintenance – Troubleshooting.......................................................................8
5.2.6 Organizational measures....................................................................................................8
5.3 Staff ........................................................................................................................................9
5.3.1 Notes relating to staff..........................................................................................................9
5.3.2 Outside normal operation ...................................................................................................9
5.4 General operating instructions................................................................................................9
5.4.1 How to behave....................................................................................................................9
5.4.2 Rules for operation .............................................................................................................9
6 Commissioning ..............................................................................................................................10
6.1 Transport ..............................................................................................................................10
6.2 Setting up .............................................................................................................................12
6.2.1 General information ..........................................................................................................12
6.2.2 Bench-top mounting (GXO-G011a) ..................................................................................12
6.2.3 Floor mounting (GXO-G010a) ..........................................................................................14
6.3 Commissioning the hydraulic system ...................................................................................16
6.4 Commissioning the electrical system....................................................................................17
6.5 Preparations for commissioning the test rig..........................................................................18
7 Technical data ...............................................................................................................................22
7.1 GXO-G010a (floor-mounted system)....................................................................................22
7.2 GXO-G011a (bench-top system) ..........................................................................................22
8 Parts list and exploded drawing.....................................................................................................23
1 Structure of the test rig (exterior)
Item Part Item Part Item Part

1.4 Selector switch for mode 5 Relief valve 17.3 Plexiglass tube
(sight glass)
3 Pressure gauge 15.1 Cover 17.6 Extraction
(pressure display bar/psi) (tray) (spray container)
4 Hand lever 15.2 Knurled screw 17.9 Oil collector
(hand pump) (to fix cover in position)
a Rotary receiver d Release lever f Oil sight glass

(pump/valve) (rotating mechanism)
b Height adjustment e Storage compartments g Switch
(extraction)
c Socket
(test line)
Editor Ruf (TEDO) Status as at: 00 Page 1

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2 Structure of test rig (interior)

1 Booster 4 Hand pump 15.4 Mesh filter
a Rotary receiver (pump/valve) b Test oil reservoir c Oil sight glass

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6 Tube 9 Tube 13b Hose
Pump – booster Booster – pressure gauge Oil container – pump
7 Tube 13a Hose 13c Hose
Booster – test line connection Relief valve – test oil reservoir Booster – test oil reservoir
8 Tube
Booster – relief valve

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The test rig was developed for checking leaks, pressure-testing injection, measuring the
pressure drop of injection valves and for assembling/dismantling all L'O devices for medium-
speed large diesel engines.
There are two versions: GXO-G010a has a base for mounting directly to the floor, whilst
GXO-G011a is intended to be fitted to a bench. Both devices have identical functions and
operation.
GXO-G010a GXO-G011a
The test rig has a safety valve (integrated in the booster) which opens at 900 bar!

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3 Handling the test rig
This operating manual applies primarily to the professional assembly/dismantling of L'O

devices, in particular injection pumps and injection valves. The instructions below must be
followed.
• In the event of malfunctions, the test rig must be professionally examined and repaired
with the utmost care by specialist staff. We therefore recommend that you make use of
the fitter service set up by L'Orange or take the test rig to a L'Orange customer service
center.
• L'Orange is unable to accept any liability for any damage caused by independent
assembly or repair work performed on the test rig.
• In the event of special circumstances requiring immediate work on the test rig, proceed in
accordance with the instructions in Assembly Instruction GXO-D002.
• The components of hand pump GCO-G005d are precision-engineered to match and can
consequently only be replaced as an entire unit (paired).
• Repair work may only be performed using the tools intended for the purpose.
• The test rig serves solely for testing, assembling and dismantling components up to a
maximum weight of 120 kg. All components are to be professionally attached to the
receiver and secured against rotation using the locator angle and screws.
• All locator angles for the preceding type (GUO, GXO) will fit the new test rigs without
modification.
• The function test (pressure drop time, opening pressure, leak test) of injection valves is
meaningful only up to a needle diameter of Ø 12 mm (e.g. VVO, VWM). The function test
on larger injection valves should be performed on test rig GXO-G004.

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4 Maintenance
The test rig is largely maintenance-free. Moving parts are subject to natural wear which
experience shows is very limited. However, the wear characteristics of the components
depend largely on the test rig being handled and cared for properly. To ensure smooth
operation of the test rig in the long term, please note and comply with the following care and
maintenance instructions.
• Clean the outside of the test rig after every use.
• Subject all components to a visual inspection once a month – damaged or worn

components should be replaced by specialist staff if required.
• All electrical components should be inspected for damage once a month. Likewise check
monthly that plug connections are tight – damaged components should be replaced by
specialist staff if required.
• Check all hydraulic lines and components once a month for pressure loss and damage.
The lines must be located firmly in their screwed connections to prevent them coming
loose – damaged components should be replaced by specialist staff if required.
• Check six-monthly that mechanical components have not come loose and are tight – if
required, components should be adjusted and tightened up.
• Check once a month that safety devices are working properly.
• All moving parts on the device should be greased. The locking bolt and sliding bar on the
spray container should also be oiled occasionally.
• Check the oil collector daily. Empty the collector if necessary. Used oil must be disposed
of properly and may not, under any circumstances, be reused.

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5 General safety instructions
5.1 Use in accordance with purpose
The test rig is solely for assembling/dismantling injection pumps which do not exceed a total
maximum weight of 120 kg (injection pump incl. valve) and for testing injection valves up to
size "VVO".
The owner of the system is responsible for those setting up, operating or maintaining the
device and for third parties following the safety precautions outlined in this operating manual.
L'Orange hereby refuses to accept any liability for damage to those operating or setting up
the device, to maintenance staff, to the company and/or to other third parties if the system is
used in any way not covered by "use in accordance with purpose", unless L'Orange causes
such damage deliberately or as a result of gross negligence.
5.2 Handling the system
5.2.1 Hazards in handling the test rig
The test rig is built in accordance with the state of the art and satisfies recognized safety
regulations. Nevertheless, its use can still present a hazard to the life and limb of the user or
of third parties, as well as damage to the system or to other material resources. The system
should therefore only be used in accordance with purpose and when it is in a perfectly safe
condition. Faults which may impair safety should be eliminated immediately and avoided
during operation.
5.2.2 Safety measures in normal operation
Operate the test rig only if all the safety devices are fully functional. Check the system for
externally visible damage and always check that the safety devices are working before
starting operation.
Before assembling, dismantling or modifying any circuit:

switch off the power supply and depressurize the test rig.
Follow the general safety instructions of DIN 58126 and VDE 0100.
5.2.3 Hazards from electrical energy
Once maintenance work is complete, check that the safety devices are working properly.
Only a professional trained electrician or electronics engineer may perform any work on the
electrical supply.

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5.2.4 Hazards from hydraulic energy
Keep away from the spray jet during the function test (pressure build-up) – risk of blood
poisoning!
Observed the permitted opening pressure for the injection valve in question (see catalogue
sheet).
5.2.5 Servicing – Maintenance – Troubleshooting
During the warranty period, servicing and maintenance work will be performed within the
scope of the maintenance contract. Make sure that the specified setting and servicing work is
performed at the prescribed intervals. Secure the hydraulic and electrical systems from being
switched on unintentionally.
The test rig must be disconnected from the power supply and depressurized for all
maintenance, servicing and repair work. Check that all screwed connections undone in the
course of maintenance, servicing and repair work are firm.
5.2.6 Organizational measures
All safety devices provided are to be checked regularly.

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5.3 Staff
5.3.1 Notes relating to staff
• The test rig may only be operated by persons who have received instruction. This applies
to both operation and the safety devices of the test rig.
• Wear safety footwear when working on the test rig.
• Wear oil-resistant clothing.
• Wear safety glasses.
• Wear oil-resistant gloves and clothing.
• Avoid several people working on maintenance and set-up tasks at the same time.
• Naked flames and smoking are forbidden within a radius of 5 m of the test rig!
5.3.2 Outside normal operation
Activities involved in maintaining, servicing or repairing the system may be performed only by
people with adequate specialist qualifications.
5.4 General operating instructions
The test rig demands some rules of operation which must be complied with. If these rules are
ignored, it is possible for faults to arise in the testing process and hazards to physical health
cannot be ruled out. You are strongly advised to follow the rules below.
5.4.1 How to behave
• Naked flames and smoking are absolutely prohibited at the test rig and within a radius of
5 m.
• It is prohibited to reach into the spray container (plexiglass tube) during the testing
process.
• Stations should be made safe by mechanical means in the event of relatively large groups
of spectators.
• It is prohibited to pull out any live cable connection.
• Water of any kind is to be kept away from the system.
• Test lines should be carefully examined for cracks or leaks before each use.
5.4.2 Rules for operation
• The test rig may only be operated by people who have received instruction.
• Operation should be in accordance with the operating manual.
• Prevent unsupervised operation of any equipment.

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6 Commissioning
6.1 Transport
When the test rig is delivered, ensure that it is only transported using suitable transportation
equipment. The GXO-G010a weighs approx. 150 kg and the GXO-G011a approx. 75 kg.
The routes to be taken should be cleared for transport and be accessible for the
transportation equipment. If appropriate, put up warning signs or barrier tape.
Take care when opening the transport box, preventing extra components like the test oil
supplied from falling out. Once the transport box is open and any additional components
have been removed, the test rig can be removed and taken to its final location.
Please check that all screwed connections are tight. Vibration during transport may have
caused them to come loose. The test rig may not be gripped by its feet and certainly not
under the feet – increased risk of crushing or trapping.

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State in which GXO-G010a delivered
Canister [b] containing the test oil is in the

base of the test rig.
The lever for the pump is enclosed with the

delivery and needs to be fitted for com-
missioning [a].
State in which GXO-G011a delivered
The lever for the pump is enclosed with the

delivery and needs to be fitted for com-
missioning [a].

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6.2 Setting up
6.2.1 General information
The test rig should be screwed to the floor (GXO-G010a) or bench (GXO-G011a) at its
intended location. In addition, the workbench should likewise be affixed to the floor to prevent
tipping over. A loadbearing/solid floor is a prerequisite for smooth assembly and operation.
An appropriate gap should be planned between the test rig and the wall.
Keep dust and dirt away from the test rig (cover).
6.2.2 Bench-top mounting (GXO-G011a)
• Remove screw [15.2].
• Remove cover [15.1].
• Fit dismantling aid [a] and hold the body

[15] steady using a crane.
• Undo and remove screws [b].
• Carefully lift body [15] using the crane

and place it aside.

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• The baseplate [a] is now in front of you

ready for assembly.
• Transfer the bores in the baseplate as

shown in the sketch to the workbench
and drill into the worktop using a
Ø 12 mm bit.
Line A represents the edge of the bench!
• Screw the baseplate firmly to the bench

using M10 screws (length depending on
the thickness of the workbench). The
screws must be pushed in from above
and tightened up from underneath with
washers and a nut.
• Put body [15] on the baseplate and

attach with screws [b].

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6.2.3 Floor mounting (GXO-G010a)
• Remove screw [15.2].
• Remove cover [15.1].
• Align the test rig and transfer the bore

positions for baseplate [1] to the floor.

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• Fit dismantling aid [a].
• Carefully lift subframe [20] using a crane

and place it aside.
• Drill holes in the floor.
• Use the crane to return subframe [20] to

its assembly position.
• Remove the dismantling aid [a].
• Depending on the substrate, attach the

baseplate of the test rig with four screws
[a].

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6.3 Commissioning the hydraulic system
The owner commissions the rig independently. The procedure required to do so is described
below. A prerequisite is that the test rig is already firmly screwed as described in the previous
section.
• Remove transport sealing plug [a].
• Fit filter [15.4].
• Pour Fuchs Renotest test oil into the test

oil reservoir to at least oil sight glass [a]
(capacity approx. 3.5 liters).

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• Fit cover [15.1] and fix in position with

screw [15.2].
• Pump lever [4] until test oil escapes from

connection [a] without bubbles.
6.4 Commissioning the electrical system
• Connect the cable for non-heating

appliances supplied to socket [a] and
supply with electrical power.
Extraction operates at a voltage of 230 V

and cannot be switched to 110 V!
The fitted plug can be changed if

required, but this should be done only by
a qualified specialist. The connection for
this must be fused at a rating to suit the
consumers. To prevent problems in oper-
ation, we strongly recommend separate
fuse protection for the test rig.

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6.5 Preparations for commissioning the test rig
If rotary receiver [1] needs to be swivelled, follow the instructions below.
• 360° rotation
The swivel restriction can be released

using release lever [b]. If the lever is
moved to the right and held there, rotary
receiver [a] can be turned through 360°.
Warning, risk of injury!

The valve can rotate in an uncontrolled
manner once the swivel restriction is
released.
• 12.5° rotation
If lever [b] is moved only briefly to the

right and then returned to the left-hand
position, rotary receiver [a] can be turned
through 12.5°.

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Make the following preparations every time you use the test rig.
• Follow the safety instructions!
• Only staff who have received instruction

may operate the test rig.
• The test rig must be depressurized com-

pletely using relief valve [5].

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• Use height adjuster [c] to move the spray

container right to the bottom and secure
the lever in the lowest latching position
[b].
• Fit valve receiver on rotary receiver [a].
• Fit valve in receiver.

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• Connect the injection valve to connector

[a] of the test rig using the corresponding
test line. Tighten screwed connections
firmly!
• Use height adjuster [b] to move the spray

container upwards until the injection
nozzle of the valve is inside the plexi-
glass tube. Secure the lever in one of the
latching positions!
• Switch on extraction.
• You can now select operating mode.

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7 Technical data
7.1 GXO-G010a (floor-mounted system)
Purpose: medium-speed diesel engines

Weight: GXO-G010a = 146 kg
Dimensions: height: 1130 mm
width: 440 mm excl. spray container
width: 670 mm incl. spray container
depth: 510 mm excl. spray container
depth: 560 mm incl. spray container
Piston diameter: 8 mm
Safety valve: opening pressure = 900 bar
Pressure gauge: display up to 1000 bar / 14400 psi
Test oil: Fuchs Renotest LO
Test oil viscosity: 4.5 cSt/40°C
Test oil reservoir: approx. 3.5 liters
Test oil line: connecting thread 24 x 1.5
Maximum load: 120 kg (receiver)
7.2 GXO-G011a (bench-top system)
Purpose: medium-speed diesel engines

Weight: GXO-G011a = 71 kg
Dimensions: height: 330 mm excl. spray container
height: 1120 mm incl. spray container
width: 440 mm excl. spray container
width: 670 mm incl. spray container
depth: 510 mm excl. spray container
depth: 560 mm incl. spray container
Piston diameter: 8 mm
Safety valve: opening pressure = 900 bar
Pressure gauge: display up to 1000 bar / 14400 psi
Test oil: Fuchs Renotest LO
Test oil viscosity: 4.5 cSt/40°C
Test oil reservoir: approx. 3.5 liters
Test oil line: connecting thread 24 x 1.5
Maximum load: 120 kg (receiver)

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8 Parts list and exploded drawing
GXO-G011a GXO-G010a
Weight Weight
Item Pcs. Part L'O-No. g
Item Pcs. Part L'O-No. g
Test rig GXO-G011a (replacement for all GUO-G...) 71000 15,2 Screw D464-M8x16 10
1 Booster, compl. GXO-U058 13500 15,3 Perforated plate GXO-T133 700
1,1 Booster GXO-U056 12000 15,4 Filter screw GCO-T065 60
1,2 4 Connection piece GXO-T173 30 15,5 Mesh filter FSH-1 5
1,3 2 Screw D912-M10x40-12.9 35 17 Spray container GXO-U065 7150
1,4 Valve actuator GXO-U057 1350 17,1 Cover GXO-U067 1100
3 Gauge FMA-160.1000AH 1100 17,2 Perforated plate GXO-T159 700

4 Hand pump Ø8 GCO-G005d 2700 17,3 Plexiglass tube GXO-T155 1350
5 Relief valve GXO-U059 350 17,5 3 Screw D7380-M8x25 15
6 Tube GXO-T126 110 17,6 Spray container GXO-U066 3900

7 Tube GXO-T127 130 17,8 Screw D7380-M8x20 12
8 Tube GXO-T128 130 17,9 Collector GUO-T041 75
9 Tube GXO-T129 125

10 9 Screw D7380-M6x20 7 Test rig GXO-G010a (replacement for all GXO-G003...) 146000
11 2 Screw D7380-M5x12 5 20 Lower section GXO-U055 57500
12 2 Screw D912-M8x60-12.9 30 20,1 4 Screw D912-M10x20-10.9 25

13 3 Hose GXO-T130 L = 1200 mm 50 20,2 Screw D7380-M8x25 15
15 Body GXO-U062 44150
15,1 Oil tray GXO-U063 2150 not specified items like GXO-G011a 06/07

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What are the main components of the test rig?

What are the main components of the test rig?

What technical specifications are provided for the test rig?

What technical specifications are provided for the test rig?

L28/32H

Instruction Manual - Marine

Text Index Drawing No.

Engine data 500/600

Preface Description A6000

Operation of engine 501/601

Operating Description 601.01 (21H)

Performance and condition 502/602

Engine performance and condition Description 602.01 (12H)

Trouble shooting 503/603

Starting failure Description 603.01 (08H)

Media specification 504/604

Text Index Drawing No.

Cylinder head 505/605

Cylinder head Description 605.01 (14H)

Piston/connecting rod 506/606

Piston, connecting rod and cylinder liner Description 606.01 (10H)

Text Index Drawing No.

Camshaft and camshaft drive Description 607.01 (05H)

Operating gear 508/608

Control and safety system Description 609.01 (20H)

Crankshaft and main bearings Description 610.01 (12H)

Text Index Drawing No.

Inspection of main bearing shells Working card 610-01.05 (05H)

Engine frame/Oil pan 511/611

Engine frame and base frame Description 611.01 (07H)

Turbocharger system Description 612.01 (28H)

Text Index Drawing No.

Exhaust pipe arrangement with welded compensator Plate 61202-28H

Compressed air system 513/613

Compressed air system Description 613.01 (20H)

Fuel oil system 514/614

Internal fuel oil system Description 614.01 (25H)

Lubricating oil system 515/615

Internal lubricating oil system Description 615.01 (29H)

Text Index Drawing No.

Lubricating oil, thermostatic valve Working card 615-01.20 (01H)

Cooling water system 516/616

Cooling water system Description 616.01 (17H)

Special equipment 517/617

Kit for cylinder unit Kit 61704-02H

Specific plant information 519/619

Resilient mounting of generating sets Description 619.03 (10H)

Introduction to spare part plates for tools Description 620.01 (01H)

Text Index Drawing No.

Instruction Manual for:

MAN Diesel & Turbo Identification No. for Instruction Manual.

Identification No. for Description: 000 . 00

Identification No. for Working Card: 000 - 00 . 00

Identification No. for Plates: 00000 - 00 H

Section No. and Function

For ordering of spare parts, see page 500.50 / 600.50

MAN Diesel & Turbo | PrimeServ

24-hour hotline number:

(Marine engines only)

Turbocharging principle : Constant pressure system and intercooling