MAN-BW L16-24 (ЧН 16 - 24) (Инстр. по экспл.) + PDF

Instruction book for:
L16/24
MAN B&W Diesel Identification No for Instruction Book
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
See page 500.50 concering order of spare parts
This book may not either wholly or in part be copied reproduced made public or in any other way made
available to any third party without the written consent to this effect of stx corporation.
HEAD OFFICE DIESEL ENGINE SALES AFTER SERVICE(A/S) PART SALES

641-315 641-315 641-050 641-315
80, Seongsan-Dong 80, Seongsan-Dong 80, Seongsan-Dong 80, Seongsan-Dong
Changwon Kyungnam Changwon Kyungnam Changwon Kungnam Changwon Kyungnam
Korea(ROK) Korea(ROK) Korea(ROK) Korea(ROK)
Tell 82-5 5-280-0114 Tell 82-55-280-0540 Tell 82-55-280-0590 Tell 82-55-280-0540-558

Fax 82-55-285-2030 Fax 82-55-285-0539 Fax 82-55-282-6907 Fax 82-55-282-1388
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Your Notes :
08031-0D/H5250/94.09.07
Engine Data
OPERATION Operation of Engine

DATA
Engine Performance and Conditio
Trouble Tracing
Specification and Treatment

Lubricating Oil, Fuel Oil and Cooling Water
Cylinder Head
Piston, Connecting Rod, and Cylinder Liner
Camshaft and Camshaft Drive
Operating Gear for Inlet Valves,

Exhaust Valves and Fuel Injection Pumps
Control and Safety Systems
Automatics and Instruments
DESCRIPIONS AND MAINTENANCE
Crankshaft and Main Bearings

SYSTEM AND COMPONENTS
Engine Frame and Base Frame
Turbocharger System
Compressed Air System
Fuel Oil System
Lubricating Oil System
Cooling Water System
Special Equipment
Alternator
Specific Plant Information
Tools
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Engine Data 500
L16/24
Description
Main data for engine .....................................................................................................500.00 (03H)

Introduction ..................................................................................................................... 500.01 (02)
Safety............................................................................................................................500.02 (02H)
Cross section ................................................................................................................500.05 (05H)
Key for engine designation ............................................................................................. 500.10 (02)
Designation of cylinders................................................................................................500.11 (03H)
Engine rotation clockwise .............................................................................................500.12 (02H)
Code identification for instruments ...............................................................................500.20 (02H)
Introduction to planned maintenance programme ........................................................500.24 (03H)
Planned maintenance programme, major overhaul/inspection ....................................500.25 (08H)
Planned maintenance programme, duties during operation.........................................500.26 (04H)
Operation data and set points.......................................................................................500.30 (34H)
Data for pressure and tolerance ...................................................................................500.35 (04H)
Data for tightening torque .............................................................................................500.40 (06H)
Declaration of weight ....................................................................................................500.45 (02H)
Ordering of spare parts.................................................................................................500.50 (01H)
Service letters ...............................................................................................................500.55 (01H)
Conversion table...........................................................................................................500.60 (01H)
Basic symbols for piping ...............................................................................................500.65 (01H)
Your Notes :
08031-0D/H5250/94.09.07
Description
Page 1 (1) Warning 000.00
General
Warning !
(Marine engines only)
It is important that all MAN B&W Diesel A/S engines

are operated within the given specifications and
performance tolerances specified in the engines'
Technical Files and are maintained according to the
MAN B&W Diesel A/S 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 diesel
engine shall be performed as specified in MAN B&W
Diesel A/S instructions including, but not limited to,
the instructions to that effect included in the
Technical File.
08028-0D/H5250/94.08.12
03.38 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Main Data for Engine 500.00
Page 1 (1) Edition 03H
L16/24
Cycle : 4-stroke
Configuration : In-line
Cyl. Nos. available : 5-6-7-8-9
Power range : 450-900 kW (610-1220 BHP)
Speed : 1000/1200 rpm
Bore : 160 mm
Stroke : 240 mm
Stroke/bore ratio : 1.5:1
Piston area per cyl. : 201 cm2
Swept volume per cyl. : 4.8 ltr.
Compression ratio : 15.2:1
Max. combustion pressure : 170 bar
Turbocharging principle : Constant pressure system and intercooling
Fuel quality acceptance : HFO up to 700 cSt/50° C (BSMA 100-M9)
Power lay-out MCR version
Speed rpm 1000 1200
Mean piston speed m/sec. 8 9.6
Mean effective pressure bar 22.4 20.7
Max. combustion pressure bar 170 170

08028-0D/H5250/94.08.12
Power per cylinder kW/cyl. 90 100

BHP/cyl. 122 136
Overload rating (up to 10%) allowable in 1 hour for every 12 hours
Power per cylinder kW/cyl. 99 110

BHP/cyl. 134 150
99.43 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description
Introduction 500.01
Page 1 (1) Edition 02
General
Description
This instruction book serves the purpose to provide Reliable and economical operation of the plant is
general information for operation and maintenance, conditional upon its correct operation and mainte-
and to describe the design. It can also be used as a nance in accordance with MAN B&W Diesel A/S'
reference when ordering spare parts. instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in
MAN B&W Diesel A/S' instructions and any addi-
tional instructions to that effect included in the Tech-
nical File. Consequently, it is essential that the
engine room personnel are fully acquainted with the
contents of this book and, in respect of instructions
on emissions related maintenance of the diesel
engine, also the additional instructions to that effect
Section 505-519
Spare parts plates set out in the Technical File.
The book is a basic instruction manual for the par-

Working card ticular engine supplied, with plant-adapted infor-
mation such as basic media-system drawings, elec-
trical wiring diagrams and test bed reports.
Description
The first five sections (500-504) of the book serve as

a guide to engine operation, and the next fifteen
sections (505-519) contain technical descriptions,
spare parts illustrations with appurtenant parts lists,
as well as working cards.
The last section (520) comprises tools.
The engine is divided into a number of main com-

Fig. 1 Structure of instruction book.
ponents/assemblies, each of which is described in
a section of this book (section 505-519).
Each of these sections starts with technical de-

scriptions of the systems/components, followed by
working cards and the spare parts illustration plates
and parts lists.
08028-0D/H5250/94.08.12
03.36 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Safety 500.02
Page 1 (2)
Edition 02H
General
General Spares
Proper maintenance, which is the aim of this book, is Large spare parts should, as far as possible, be
a crucial aspect of achieving optimum safety in the placed well strapped near the area of use and should
engine room. The general measures mentioned be accessible by crane. The spare parts should be
here should, therefore, be a natural routine for the well-preserved against corrosion and protected
entire engine room staff. against mechanical damage. 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 while 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 available everywhere.
In particular, welding or work which causes the

spreading of grit and chips must be avoided near the Freezing
engine, unless this is closed or covered, and the
turbocharger 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 Opening of cocks may cause discharge of hot liquids

or gases. Dismantling of parts may cause springs to
If the crankcase is opened before the engine is cold, be released.
welding and the use of naked light will involve the risk
of explosions and fire. The same applies to inspec- The removal of fuel valves (or other valves in the
tion of oil tanks and the space below the cooler. cylinder head) may cause oil to run down to the
Attention should furthermore be paid to the danger of piston crown, and if the piston is hot an explosion
fire when using paint and solvents with a low flash may then blow out the valve.
point. Porous insulating material drenched with oil
from leakages is easily inflammable and should be When testing fuel valves with the hand pump do not
renewed. See also: "Ignition in Crankcase" in sec- touch the spray holes, as the jet may pierce the skin.
tion 503. Consider beforehand which way the liquids, gases
or flames will move, and keep clear.
08028-0D/H5250/94.08.12
Order
Crankcase Work
Hand tools should be placed to be easily accessible
on tool boards. Special tools should be fastened to Check beforehand that the starting air supply to the
tool panels (if supplied) in the engine room close to engine is shut off.
the area of use. No major objects may be left
unfastened, and the floor and passages should be
kept clear.
01.32 - ES0
500.02 Safety Description
Edition 02H Page 2 (2)
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 it is ensured that there is no undue heating, oil- liquid in the combustion spaces, turning should
mist formation, blow-by, or failure of cooling water or always be effected through at least two complete
lubricating oil systems. revolutions.
Feel-over Sequence Check and Maintain
Feel over after 5-15 and 30 minutes' idle running and Lubricating oil condition, filter elements and measur-
finally when the engine is running at full load. See ing equipment, see "Planned Maintenance Pro-
also "Operation" in the section 501. gramme".
08028-0D/H5250/94.08.12
01.32 - ES0
Description
Cross Section 500.05
L16/24
08028-0D/H5250/94.08.12
99.40 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description 500.10
Page 1 (1) Key for Engine Designation Edition 02
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
08028-0D/H5250/94.08.12
Rating
MCR : Maximum continuous rating

ECR : Economy continuous rating
04.08 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description 500.11
Page 1 (1) Designation of Cylinders Edition 03H
General
08028-0D/H5250/94.08.12
98.19 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description 500.12
Page 1 (1) Engine Rotation Clockwise Edition 02H
General
08028-0D/H5250/94.08.12
98.18 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description
Code Identification for Instruments 500.20
General
Explanation of Symbols
Measuring device
TI
Local reading
40
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 *
* 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 H High
08028-0D/H5250/94.08.12
T Temperature I Indicating
U Voltage L Low
V Viscosity S Switching, Stop
X Sound T Transmitting
Z Position X Failure
98.33 - ES1
500.20 Code Identification for Instruments Description
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 19A inlet to prechamber
12 outlet from engine 15 outlet from HT system 19B outlet from prechamber
13 inlet to HT pump 16 outlet from turbocharger

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
Cooling Oil System

50 inlet to fuel valves 54 58
51 outlet from fuel valves 55 59
52 56
53 57
Exhaust Gas System

60 outlet from cylinder 64 68
61 outlet from turbocharger 65 69
62 inlet to turbocharger 66
63 67

70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system
08028-0D/H5250/94.08.12
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 84 88 index - fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocharger speed
82 86 90 engine speed
83 87
Miscellaneous
91 natural gas - inlet to engine 94 cylinder lubricating 97
92 oil mist detector 95 voltage 98
93 knocking sensor 96 switch for operating location 99
98.33 - ES1
Description
Introduction to Planned Maintenance Programme 500.24
General
General The front page indicates the following:
The overhaul intervals are based on operation on a 1) Safety regulations, which MUST be carried out
specified fuel oil quality at normal service output, before the maintenance work can start.
which means 70-100% of MCR.
2) A brief description of the work.
In the long run it is not possible to achieve safe and
optimum economical running without an effective 3) Reference to any work which must be carried
maintenance system. out before the maintenance work can start.
The structure and amount of information in the main- 4) Related procedures - indicates other works,
tenance programme mean that it can be integrated in depending on the present work - or works
the entire ship's/power station's maintenance sys- which it would be expedient to carry out.
tem or it can be used separately.
5) Indicates x number of men in x number of hours
The core of the maintenance system is the key to accomplish the work.
diagram, see pages 500.25 and 500.26, indicating
the inspection intervals for the components/systems, The stated consumption of hours is only intended as
so that the crew can make the necessary overhauls a guide.
based on the engines' condition and/or the time
criteria.
The maintenance system is divided into 2 main

groups:
a. Major overhaul / inspection (page 500.25):

These works are to be carried out during major
overhauls and inspections of the engine.
1
7
b. Duty during operation (page 500.26): indicated
the works to be carried out by the personnel
2
during the daily operation of the engine.
The stated recommended intervals are only for guid- 3

ance as different service conditions, the quality of the 8
fuel oil and the lubricating oil, treatment of the cooling
4
water, etc., will decisively influence the actual service
results and thus the intervals between necessary
overhauls.
5
9
Experience with the specific plant/personnel should
08028-0D/H5250/94.08.12
6
be used to adjust the time between overhauls. It
should also be used to adjust the timetable stated for
guidance in the working cards.
Working Cards Fig. 1 Instruction guide for working cards.
Each of the working cards can be divided into two: a

front page and one or several pages describing and
illustrating the maintenance work.
98.19 - ES0
500.24 Description
Edition 03H
Introduction to Planned Maintenance Programme Page 2 (2)
General
Experience with the specific station/personnel may 8) Various requisite hand tools.
lead to updating.
9) Indicates the components/parts which it is
6) Refers to data required to carry out the work. advisible to replace during the maintenance
work. Please note that this is a condition for the
7) Special tools which must be used. Please note intervals stated.
that not all tools are standard equipment.
08028-0D/H5250/94.08.12
98.19 - ES0
Description
Planned Maintenance Programme 500.25
L16/24
Major overhaul/inspection
Time Between Overhauls
overhauled parts
l
Working
Observations
3rd month
Description = Overhaul to be carried out
after - hours
n
Check new/
Card
Monthly
Weekly
200
6000
12000
24000
50
2000
Daily
= Check the condition
No
Cylinder Unit:
Dismantling of cylinder unit ............................................. l 505-01.55

Dismantling of cylinder head, water jacket and cyl. liner.
Cylinder Head and Water Jacket
Inspection of inlet, exhaust valves and valve guide ........ l 505-01.05
Valve rotator ................................................................... n 505-01.15

Lubricating of operating gear - Check ............................. n
Cylinder head cooling water space - Inspection .............. n 505-01.45
Cylinder head nut - Retightening .................................... 200 505-01.40
Piston, Connecting Rod and Cylinder Liner
Inspection of piston ......................................................... n 506-01.10

Piston ring and scraper ring ............................................ l 506-01.10
Piston pin and bush for connecting rod - Check of
clearance ........................................................................ n 506-01.15
Connecting rod - Measuring of big-end bore ................... n 506-01.15

Inspection of big-end bearing shells ............................... n 506-01.16
Connecting rod - Retightening ........................................ 200 n 506-01.25
Cylinder liner - Cleaning, honing and measuring ............ l 506-01.35
Camshaft and Camshaft Drive

08028-0D/H5250/94.08.12
Camshaft - Inspection of gear wheels, bolt, connections

etc. ................................................................................. 200 n 507-01.00
Camshaft bearing - Inspection of clearance ................... n 507-01.05
Camshaft adjustment - check the condition .................... n 507-01.20
Lubrication of camshaft bearing - Check ........................ n 507-01.00
00.41 - ES0
500.25 Planned Maintenance Programme Description
L16/24
overhauled parts
l Working
Observations
= Overhaul to be carried out
n
3rd month
Description
after - hours
Check new/
Monthly
Card
Weekly
200
6000
12000
24000
50
2000
Daily
No
Operating Gear for Inlet Valves and

Exhaust Valves
Roller guide for valve gear .............................................. n 508-01.00

Valve gear - Valve bridge, spring, push rod, etc ............. n 508-01.10
Lubricating of operating gear - Check ............................. n 508-01.00
Crankshaft and Main Bearing
Inspection of main bearing .............................................. n 510-01.05

Inspection of guide bearing ............................................. n 510-01.05
Vibration viscodamper - see Working Card .................... 510-04.00
Counterweight - Retightening, see page 500.40 ............. 200 n

Main and guide bearing cap - Retightening .................... 200 n 510-01.05
Engine Frame and Base Frame
Bolts between engine frame and base frame -

Retightening, see page 500.40 ....................................... 200 n
Turbocharger System
Charging air cooler - Cleaning and inspection ................ n 512-01.00

Retightening of all bolts and connections* ...................... 200
08028-0D/H5250/94.08.12
Cleaning of the compressor when dismounted* ..............

Cleaning of the silencer when dismounted* ....................
Basic check; all components, bearings, etc.* ..................
* see turbocharger manual
Air starter motor - Dismantling and inspection ................ n 513-01.30
00.41 - ES0
Description
Planned Maintenance Programme 500.25
L16/24
overhauled parts
l Working
Observations
n
3rd month
Description
after - hours
Check new/
Card
Monthly
Weekly
200
6000
12000
24000
50
2000
Daily
No
Fuel Oil System and Injection Equipment
Fuel oil injection pump - Check of condition .................... l 514-01.06
Fuel injection valve - Adjustment of opening pressure .... 200* n 514-01.10
* After major overhaul
Lubricating oil pump - Engine driven ............................... n 515-01.00

Lubricating oil cooler ....................................................... l 515-06.00
Prelubricating pump - El. driven ...................................... n 515-01.05

Thermostatic valve ......................................................... n 515-01.20
Cooling water pump - Engine driven (HT / LT water) ...... n 516-10.00

Thermostatic valve ......................................................... n 516-04.00
Alternator - see special instruction book
Planned maintenance programme during operation,

see 500.26.
08028-0D/H5250/94.08.12
00.41 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description 500.26
Page 1 (2) Planned Maintenance Programme Edition 04H
L16/24
Duties during Operation
overhauled parts
l Working
Observations
3rd month
Description
n
after - hours
Check new/
Monthly
200
6000
12000
24000
Weekly
50
2000
Card
Daily
No
Operating of Engine
Readings of data for Engine and Generator, with refer-

ence to "Engine Performance Data", section 502-1 ........ n 502-01.00
Check for leakages ......................................................... n 502-05.00
Specification - Cooling water
Cooling water system - Water samples, see section 504 n 505-01.15
Cylinder Head
Inlet and exhaust valve - check and adjustment of valve

clearance ........................................................................ n 508-01.10
Check of valve rotators' rotation during engine rotation .. n 505-01.15
Control and Safety System, Automatics and

Instruments
Safety, alarm and monitoring equipment ........................ n 509-01.00

Lambda controller - Adjustment ...................................... n 509-10.00
Governor - Check oil level, see governor instruction
book, section 509 ........................................................... n section 509
Turbocharger System
08028-0D/H5250/94.08.12
Cleaning the turbine, dry cleaning .................................. l 512-10.00

Water washing of compressor side ................................. see TC
manual
Exhaust pipe compensator ............................................. n 512-01.10
Cleaning the turbine, wet cleaning .................................. l 512-15.00
00.19 - ES1
500.26 Planned Maintenance Programme Description
L16/24
Duties during Operation

Time Between Overhaul
Overhauled parts
l Working
Observations
3th month
Description
n
Check new/
after -hours
50
2000
6000
200
24000
Weekly
12000
Card
Montly
Daily
No
Function test - Main and emergency starting valve ......... n 513-01.40

Air filter, draining of bowl (filter element to be replaced
when pressure drop exceeds 0,7 bar) ............................ l 513-01.21
Compressed air system - Check of the system .............. n 513-01.90
Fuel Oil System and Injection Equipment
Fuel oil system - Check the system ................................ n 514-01.90

Fuel oil - Oil samples after every bunkering, see sec.504 section 504
Fuel injection valve - Adjustment of opening pressure .... n 514-01.10
Lubricating oil filter - Cleaning and replacement ............. l 515-01.10

Centrifugal filter - Cleaning and replacement paper filter l 515-15.00
Lubricating oil - Oil samples ............................................ n

Lubricating oil system - Check the system ...................... n 515-01.90
Cooling water system - Water samples .......................... n

Cooling water system - Check the system ...................... n 516-01.90
08028-0D/H5250/94.08.12
Engine Frame and Bedplate
Flexible mounting - Check anti-vibration mountings ........ n 519-03.00

Safety cover - Function test ............................................ n
Alternator - see special instruction book
Major overhaul/inspection, see 500.25
00.19 - ES1
Description
Operation Data & Set Points 500.30
L16/24
Normal value at full load Alarm set point and Delay Cut-off
shutdown (autostop) set point standstill
Temp. after cooler

(inlet filter) SAE 40 TI 21 73-78° C TAH 21 82° C 3 sec No
Pressure after filter(inlet engine) PI 22 4.2-5.0 bar PAL 22 3.5 bar 3 sec Yes
PSL 22 3.0 bar 0 sec Yes
(PSL 22) (D) (2.5 bar) 1.5 sec Yes
Pressure drop across filter PDAH 21-22 0.1-1 bar PDAH 21-22 1.5 bar 3 sec No
Prelubricating pressure (PI 22) 0.3-1.5 bar PAL 25 0.1 bar (H) 60 sec No
Pressure inlet turbocharger
5 and 6 cyl. engine PI 23 1.5 ±0.2 bar (C) PAL 23 0.25 bar 3 sec Yes
7, 8 and 9 cyl. engine 1.5 ±0.2 bar
Lub. oil level in base frame LAL 28/LAH 28 low/high level 30 sec No
Pressure before filter PI 21 4.5-5.5 bar
Fuel Oil System
Pressure after filter MDO PI 40 3-6 bar PAL 40 2 bar 5 sec No

HFO PI 40 6-16 bar (A) PAL 40 4-6 bar (E) 5 sec No
Leaking oil LAH 42 High leakage 5 sec No

level
Temperature inlet engine MDO TI 40 30-40°C
HFO TI 40 110-140°C
Press. LT system, inlet engine PI 01 1.5-4.5 bar PAL 01 0.4 + (B) bar 3 sec Yes
Press. HT system, inlet engine PI 10 1.5-4.0 bar PAL 10 0.4 + (B) bar 3 sec Yes
Temp. HT system, outlet engine TI 12 76-80°C TAH 12 90° C 3 sec No
TAH 12-2 93° C 3 sec No
TSH 12 95° C 0 sec No
(TSH 12) (D) (100° C) 1.5 sec No
Temp. LT system, inlet engine TI 01 10-45°C
Exhaust Gas and Charge Air

Exh. gas temp. before TC TI 62 500-530° C TAH 62 600° C 10 sec No
TAH 62-2 650° C 3 sec No
Exh. gas temp. outlet cyl. TI 60 425-475° C TAH 60 525° C 3 sec No
Diff. between individual cyl. TAD 60 average ± 50° C 60 sec Yes

Exh. gas temp. after TC TI 61 325-375° C TAH 61 450° C 3 sec No
Ch. air press. after cooler PI 31 2-2.5 bar

08028-0D/H5250/94.08.12
Ch. air temp. after cooler TI 31 35-55° C

Press. inlet engine (start/stop) PI 70 7-10 bar PAL 70 6.5 bar 15 sec No
Speed Control System

Engine speed elec. SI 90 1200 rpm SAH 81 1380 rpm
SSH 81 1356 rpm 0 sec Yes
(SSH 81) (D) (1380 rpm) 100 msec Yes
SI 90 1000 rpm SAH 81 1150 rpm

SSH 81 1130 rpm 0 sec Yes
(SSH 81) (D) (1150 rpm) 100 msec Yes
03.50 - ES1
500.30 Operation Data & Set Points Description
L16/24
Normal value at full load Alarm set point and Delay Cut-off
shutdown (autostop) set point standstill
Turbocharger speed SI 89 53000-69000 rpm SAH 89 (J) 3 sec No
Alternator
Winding temperature TI 98 100° C TAH 98 130° C 3 sec No

Miscellaneous
Jet system failure SX32 switch 10 sec Yes
Monitoring system failure 24 VDC± 15% UX 95-1 switch 120 sec No

Safety system failure 24 VDC± 15% UX 95-2 switch 120 sec No
Turning engaged ZS75 Engaged (F) 0 sec No
Local indication ZS 96 switch

Remote indication ZS 97 switch
Common shutdown SS 86 switch (F) 0 sec Yes
Monitoring sensor cable failure SX 86-1 switch 120 sec No

Safety sensor cable failure SX 86-2 switch 120 sec No
Start failure SX 83 switch (G) 10 sec No
Stop signal SS 84 switch (F)

Stop failure SX 84 switch 30 sec Yes
Engine run SI 90 1000/1200 rpm SS 90 910/1130 rpm (I)
Ready to start SS 87 switch
Remarks to Individual Parameters
A. Fuel Oil Pressure, HFO-operation. C. Lub. Oil Pressure, Offset Adjustment.
When operating on HFO, the system pressure must At charge air pressure below 1.0 bar the lub. oil
be sufficient to depress any tendency to gasification pressure to turbocharger is normal at 0.6 ±0.1 bar.
of the hot fuel.
The read outs of lub. oil pressure has an offset
The system pressure has to be adjusted according adjustment because of the transmitter placement.
08028-0D/H5250/94.08.12
to the fuel oil preheating temperature. This has to be taken into account in case of test and
calibration of the transmitter.
B. Cooling Water Pressure, Alarm Set Points.
D. Software Created Signal.
As the system pressure in case of pump failure will
depend on the height of the expansion tank above Software created signal from PI 22, TI 12, SI 90.
the engine, the alarm set point has to be adjusted to
0.4 bar plus the static pressure. The static pressure
set point can be adjusted on the base module SW3.
03.50 - ES1
Description
Operation Data & Set Points 500.30
L16/24
E. Set Points depending on Fuel Temperature. G. Start Failure.
If remote start is activated and the engine is in

blocking or local mode or turning is engaged
the alarm time delay is 2 sec.
Start failure will be activated if revulutions are
below 50 rpm within 5 sec. from start or
revulutions are below 210 rpm 10 sec. from
start.
Start failure alarm will automatically be re-
leased after 30 sec. of activation.
H. Alarm Hysterese.
On all alarm points (except prelub. oil pressure) a

hysterese of 0.5% of full scale are present. On
prelub. oil pressure alarm the hysterese is 0.2%.
Fig 1 Set point curve.
I. Engine Run Signal.
F. Start Interlock. The engine run signal is activated when engine

rpm >1130 or lube oil pressure >3.0 bar or TC
The following signals are used for start interlock/ rpm >5000 rpm.
blocking: If engine rpm is above 210 rpm but below 1130
rpm within 30 sec. the engine run signal will be
1) Turning must not be engaged activated.
2) Engine must not be running
3) "Remote" must be activated J. Limits for Turbocharger Overspeed Alarm
4) No shutdowns must be activated. (SAH 89)
5) The prelub. oil pressure must be OK, 20 min.
after stop. Engine type 1000 rpm 1200 rpm
6) "Stop" signal must not be activated 5L16/24 75,000 75,000
6L16/24 75,000 75,000
7L16/24 75,000 62,200
8L16/24 62,200 62,200
9L16/24 62,200 62,200
08028-0D/H5250/94.08.12
03.50 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description
Data for Pressure and Tolerance 500.35
L16/24
Section Description mm. / bar
505 a) Maximum inner diameter, valve guide 12.2 mm

b) For grinding of valve spindle and valve seat ring (see also working card 505-01.10)
c) Minimum height of valve head, inlet valve and exhaust valve, "H" 1 5.0 mm
d) Maximum height of spindle above cylinder head, "H" 2 66.5 mm
506 a) Piston and piston ring grooves (see working card 506-01.10)
b) Clearance between connecting rod bush and piston pin 0.15-0.20 mm

c) Maximum ovalness in big-end bore (without bearing) 0.06 mm
d) Maximum inside diameter cylinder liner, max. ovalness 0.1 mm 160.5 mm
507 a) Clearance between camshaft and camshaft bearing
b) Maximum clearance between camshaft and camshaft bearing 0.25 mm

c) Clearance between teeth on intermediate wheel 0.2-0.3 mm
508 a) Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm

b) Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.50 mm
c) Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm
509 a) Free spand between pick-up and band steel (Lambda controller) 1 mm
08028-0D/H5250/94.08.12
98.18 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Data for Torque Moment 500.40
L16/24
Lubricant
Note: For tightening bolts to a specified torqe, only

M Lubricating paste up to 200°C Coefficient of
friction 0.08 - 0.12 use the specified lubricants. For component tem-
peratures p to 200°C, e.g. Molykote Pasta d or
MH High temperature lubricating Coefficient of Optiuoly Paste White-T. For component tempera-
paste above 200°C friction 0.08 - 0.12 tures above 200°C, e.g. Molykote Paste HSC or
Copa Slip.
O Oil
XX Screw in with Loctite 243 until it

sits squarely
° Angle when slackening
L Number of holes by which the

nut must be turned back
Tab. 1.
Oil Screw-in Tightening Working

Screw Connection pressure moment torques Card Figure
Bar torsions angle
012 Cylinder Crankcase
012-1
Cap main bearing / 1200 HAND/hand-M M 510-01.05
Cylinder crankcase Loctite 243
012-2
Cap main bearing / 200 HAND/hand-M MH 510-01.05
Cylinder crankcase 1200 HAND/hand-M MH 510-01.05
012-3
Crankcase / 1200 MH 505-01-55
Cylinder head
020 Crankshaft
020-1
08028-0D/H5250/94.08.12
Crankshaft / Counter 1200 45-M

weight
020-2
Gear wheel 100-M
(two parts)
020-3
Gear wheel / 100-M
Crankshaft
01.08 - ES0
500.40 Data for Torque Moment Description
L16/24
Oil Screw-in Tightening Please see

Screw Connection pressure moment torques Working Figure
Bar torsions angle Card
027 Vibration Damper
027-1
Gear wheel / Damper 1. step 450-M 510-04.00
2. step +60
027-2
Side / Disc 45-M
030 Connecting Rod
030-1
Connecting rod shaft / Con- 1200 M 506-01.25
necting rod cover 506-01.15
506-01.30
034 Piston
034-1
Piston 506-01.10
08028-0D/H5250/94.08.12
034-2
Piston 506-01.10
01.08 - ES0
Description
L16/24

056 Mounting of Fuel Injection Valve
056-1
Clamp / Cylinder head 5-M 9-M 514-01.10
Note: See also working

card 514-01.10
073 Crankcase Casing with Relief Valve
073-1
Crankcase covers / 8-M 511-01.00
Cylinder crankcase
100 Control Drive
100-1
Cylinder crankcase / 1200 HAND/hand-M 507-01.20
Stepped spur gear
101 Camshaft (Valve camshaft)
101-1
Camshaft part piece / 55-M 507-01.00
08028-0D/H5250/94.08.12
Bearing disk
101-2
Bearing plate / Housing 55-M 507-01.00
507-01.05
101-3
Damper (9 cyl.) / Gear wheel 55-M 507-01.00
507-01.05
101-4
Spur gear / Bearing disk 55-M 507-01.05
01.08 - ES0
500.40 Description
Edition 06H
Data for Torque Moment Page 4 (8)
L16/24

101 Camshaft (injection camshaft)
101-5
Camshaft part piece / 55-M 507-01.00
Bearing disk
Spur wheel / Bearing disk 507-01.05
101-6
Bearing plate / Housing 55-M 507-01.00
507-01.05
101-7
Damper (9L) / Gear wheel 55-M 507-01.00
507-01.05
111 Valve Bridge
111-1
Valve bridge / Settting screws 40-M
111 Rocker arm
111-2
Rocker arm / Setting screws 40-M
112 Tappet
112-1
Housing / Axle 8-M 505-01.05
200 Fuel Injection Pump
200-1
Connection socket / 4-MH 39-MH 514-01.06
Front-end box Loctite 638
08028-0D/H5250/94.08.12

card 514-01.06
01.08 - ES0
Description
L16/24

200 Fuel Injection Pump - Cont.
200-2
Plugs on the side of the fuel
injection pump:
Woodward 45 M
L'Orange 100-120 M 514-01.90
Dismounting of pump 514-01.05
289 Exhaust Pipe
289-1
Pipe piece / Compensator 80-MH
289-2
Clamping strap 34-MH 505-01.55
289-3
Cover / Pipe piece 80-MH
289-4
Pipe piece / Turbocharger 34-MH
289-5
Pipe piece 80-MH
311 Casing
311-1
Oil separator (closing cover)
/ Housing 7-MH 68-MH
08028-0D/H5250/94.08.12
01.08 - ES0
L16/24

350 Water pump
350-1
Water pump shaft/spur gear 80-O

350-2
Water pump shaft/impeller 40-O
434 Fuel Injection Pipe
434-1
2 clamps / Cylinder head 4-MH 28-MH 514-01.05
434-2
3 clamps / Cylinder head

447 Cooling Water Pipe
447-1
Flange / Bearing 4-MH 39-MH 505-01.55
08028-0D/H5250/94.08.12
01.08 - ES0
Description
L16/24

701 Assembly Flywheel
701-2
Crankshaft / Flywheel 1.step 150-MH
2. step +90°
Lub. Oil Cooler
Lub. oil cooler 515-06.00

card 515-06.00
08028-0D/H5250/94.08.12
01.08 - ES0 98.08 - ES0

L16/24
Tightening of Screwed Connections by the
Strength class 5.6 6.8 10.9 12.9
Torque
Conversion factor x 0.47 0.75 1.40 1.7
If screwed connections other than those listed are to
be tightened using a torque wrench, see tab. 3,
Tab. 2. Conversion factors for tightening torques as a function of
should be looked up for approximate tightening
the bolt strength class.
torques. The following should be observed:
- The load acting on a screwed connection

depends on the tightening torque applied, on Approximate coefficient of friction:
the lubricant used, the finished condition of the
surfaces and threads, and on the materials µ = 0.08 for lubricants containing molib-
paired. It is, therefore, of great importance that denum disulphid (MoS2)-(Molycote
all these conditions are met. paste type G-n or HSC and Optimoly
paste White T),
- Tab. 3 lists the tightening torques for various
threads as a function of the coefficient of µ = 0.14 for surfaces that are not finish-
friction µ, i.e. of the lubricant used. The torques treated, with a thin film of oil or
are based on bolt material of the strength class grease using Loctite.
8.8 with the bolts stressed up to approximately
7% of the elastic limit. For other strength
classes, the tightening torques listed in the
table have to be multiplied by the corresponding
conversion factors. the strength class is
stamped on the bolt head.
Tightening torque in Nm Tightening torque in Nm

Thread Coefficient of friction µ Thread Coefficient of friction µ
nominal size nominal size
0.08 0.14 0.08 0.14
M5 4 6 M 24 475 690
M6 7 10 M 24 x2 500 750
m8 17 25 M 27 700 1020
M 10 34 50 M 27x2 730 1100
M 12 60 85 M 30 950 1380
M 14 95 135 M 30x2 1015 1540
M 14x1.5 100 145 M33 1270 1870
M 16 140 205 M 33x2 1350 2060
M 16x1.5 150 220 M 36 1640 2400
08028-0D/H5250/94.08.12
M 18 200 280 M 36x3 1710 2550

M 18x1.5 215 320 M 39 2115 3120
M 18x2 205 300 M 39x3 2190 3300
M 20 275 400 M 42 2630 3860
M 20x1.5 295 450 M 42x3 2760 4170
M 20x2 285 425 M 45 3260 4820
M 22 370 540 M 45x3 3415 5180
M 22x1.5 395 595 M 48 3950 5820
M 22x2 380 565 M 48x3 4185 6370
Tab. 3. Tightening torques for bolts of the strength class 8.8.
01.08 - ES0
Description
Declaration of Weight 500.45
L16/24
Section Component Plate No Item No Weight in Kg
505 Cylinder head 50501 027 35

Cooling water jacket 50501 218 20
Cylinder unit 203
506 Piston, complete 50601 081 14

Connecting rod, complete without bearing 50601 068 17.5
Cylinder liner, complete 50601 018 45
509 Governor, complete 50901 021/104/

116 30
511 Main bearing cap 51101 157 20

Main bearing cap, axial 51101 169 21
Front-end box 51102 019 539
512 Turbocharger, complete 132

Air cooler 51201 162 450
513 Air starter 51309 242 30
514 Fuel injection pump 51401 565 15

Fuel injection valve 51402 116 5
515 Lubricating oil pump 51501 031/043 45

Prelubricating oil pump, incl. el-motor 51504 122 20
Centrifugal filter 51515 337 24
516 HT- and LT-cooling water pump 51610 105 10

08028-0D/H5250/94.08.12
01.08 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Ordering of Spare Parts 500.50
Page 1 (2)
Edition 01H
General
Whenever spare parts are ordered (or referred to in These data are used by us to ensure supply of the
correspondence, etc.) the following data must be correct spare parts for a particular engine, even
indicated for the engine concerned: though the spare part illustrations contained in this
book may not always be in complete accordance with
1) Name of Plant the individual components of a specific engine.
2) Engine Type and Engine no ----, built by Note: For ordering of spare parts for governor, turbo-
charger and alternator, please see the special in-
3) Illustration Plate number struction book for these components.
(complete with ed. figures)
4) Item no
5) Quantity Required (and description)
Information found on page 500.15 or on the nameplate of the engine(s)
Example: Name of plant Eng. type Eng. no Built by

DANYARD 5L28/32H 20433 MAN B&W Holeby
Information found on each plate:
Plate no Edition Item no Qty. (and description)

50601 13H 10 10 pcs (Piston ring)
Pla
Page te
1 (2)
Piston
and Conn
ecting
Rod
60601-
13H
L/V28/
08
32H
09
10
11
12
01
02
03
08028-0D/H5250/94.08.12
04
05
607
608
609
06
610
611
13
612
07
3
61
4
91.4
61
6 - ES
0S
14
5
61
6
61
7
61
8
61
9
61
0
62
98.18 - ES2
Description
Ordering of Spare Parts 500.50
General
Name of Plant
Engine type Engine number Built by
Plate no Ed. no Item no Description Qty.

08028-0D/H5250/94.08.12
98.18 - ES2
Description
Service Letters 500.55
Page 1 (1)
Edition 01H
L16/24
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 tance to the operation of the plant, we recommend
send out "Service Letters" containing first-hand infor- that engine staff file them as supplements to the
mation 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
98.18 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description 500.60
Page 1 (3) Conversion Table Edition 01H
General
Basic Sl Units Length (m)
Quantity Name Symbol 1 in (inch) 25.40 mm = 0.0254 m
1 ft (foot) = 12 inches 0.3048 m
length metre m 1 yd (yard) = 3 ft = 36 inches 0.9144 m
mass kilogram kg 1 statute mile = 1760 yds 1609 m
time second s 1 n mile (international nautical mile) 1852 m
electric current ampere A
absolute temperature* kelvin K
amount of substance mole mol SI Prefixes

luminous intensity candela cd
Factor Prefix Symbol Factor Prefix Symbol
* Also named "thermodynamic temperature"
1018 exa E 10-1 deci d

15
10 peta P 10-2 centi c
Supplementary SI Units
1012 tera T 10-3 milli m
Quantity Name Symbol 109
giga G 10-6 micro µ
106 mega M 10-9 nano n

plane angle radian rad 103
kilo k 10-12 pico p
solid angle steradian sr 102 hecto h 10-15 femto f
10 deca da 10-18 atto a
Derived Si Units with Special Names

Quantity Name Symbol Expressed in basic, Area (m2)
supplementary or
derived SI units 1 sq. in (square inch) 0.6452 x 10-3 m2
1 sq. ft (square foot) 92.90 x 10-3 m2

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* Volume (1 m3 = 1000 l)

energy, working quantity of heat joule J 1J = 1 Nm
1 cub. in (cubic inch) 16.39 x 10-6 m3
power watt W 1W = 1 J/s
1 cub. ft (cubic foot) 28.32 x 10-3 m3 = 28.32 l
electric potential (DC) volt V 1V = 1 W/A
1 gallon* (imperial, UK) 4.546 x 10-3 m3 = 4.546 l
temperature Celsius °C 1°C = 1 k**
1 gallon* (US) 3.785 x 10-3 m3 = 3.785 l
* For mechanical stresses N/mm2 is widely used. 1 N/mm2 = 106 N/m2
1 barrel (US petroleum barrel) =
** t (°C) = T(K) - T0(K), where T0 = 273.15 K
42 gallon (US) 0.1590 m3
1 bbl (dry barrel, US) 0.1156 m3
Additional SI Units 1 register ton = 100 cub. ft 2.832 m3
* 1 gallon = 4 quarts = 8 pints

Quantity Name Symbol Definition
time minute min 1 min = 60 s Velocity, Speed (m/s) (3.6 km/h = 1 m/s)
08028-0D/H5250/94.08.12
time hour h 1h = 60 min

1 kn (knot) = 1 nautical mile/h 1.852 km/h = 05144 m/s
plane angle degree ° 1° = (π/180) rad
Cincerning other conversions, see table for length
volume litre l 1l = 1 dm3
pressure bar bar 1 bar = 105 Pa
98.19 - ES0
500.60 Conversion Table Description
General
Mass (kg) Dynamic viscosity (N s/m2)
1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)
1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg 1 poundal s/sq.ft 1.488 N s/m2
1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg 1 lbf/sq.ft 47.88 N s/m2
1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg poise is a special name taken from the CGS system. 1 P = 0.1 Pa s
1 slug* 14.59 kg 1 cP = 1 mPa s = 10-3 Pa s
* Unit and mass in the ft-lb-s system
Kinematic viscosity (m2/s)

Density
1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *
1 lb/cub. ft 16.02 kg/m3 * 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name taken from the
CGS system. 1 St = 10-4 m2/s
Force (1 kg m/s2 = 1 N)
Energy, Work (1 Nm = 1 J, Wh)
1 kp (kilopound)* 9.807 N
1 poundal** 138.3 x 10-3 N 1 cal I.T* 4.187 J*

1 lbf (pound force) 4.448 N 1 kpm 9.807 J
* Can occasionally be found stated as kgf (kilogram force). 1 hph (metric) 2.648 x 106 J = 0.7355 kWh
Standard acceleration of free fall gn = 9.80665 m/s 2 1 ft. lbf 1.356 J
** Unit of force in the ft-lb-s system 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
* Exact value: 4.1868 J

Pressure I.T. = International Steam Table
(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) Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W)

750 mm Hg* 105 Pa = 1 bar
1 kpm/s 9.807 W
1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar
1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW
1 mm H2O** (T = 277 K) 10-4 at = 9.807 Pa = 98.07 x 10-3 mbar
1 kcalI.T./h 1.163 W
1 in Hg* (T = 273 K) 3386 Pa = 33.86 mbar
1 ft lbf/s 1.356 W
1 in H2O** (T = 277 K) 249.1 Pa = 2.491 mbar
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 atm (standard atmosphere) = 760 mm Hg, 1.013 x 105 Pa = 1013 mbar
1 BTU/h 0.2931 W
1 atm = 1.033 at
1 lbf/sq.in (psi) 6895 Pa = 68.95 mbar
* Mercury. 1 mm Hg = 1 Torr
Moment of Force, Torque (kg m2/s2 = Nm)
Values in table provided gn = 9.80665 m/s2
** Water column (WC) Can easily be derived from the above tables.
08028-0D/H5250/94.08.12
Stress ( 1 N/m2 = 10 -6 N/mm2) Moment of Inertia (kg m2)
1 kp/mm2 = 100 kp/cm2 9.807 N/mm2 1 GD2 (old notation) = 4 x I* kg m2
1 lbf/sq. in (psi) = 0.07031 at 6.895 x 10-3 N/mm2 1 WR2 (old notation)* = 1 x I* kg m2
*I = ∫ dmr x r2 mr = mass at the radius r

G = W = mass in kg D = Diameter of gyration
R = Radius of gyration
98.19 - ES0
Description 500.60
Page 3 (3) Conversion Table Edition 01H
General
Specific fuel consumption* (g/kWh) Some physical data in SI units

1 g/hph (metric) 1.360 g/kWh
Nomenclature
* See also table for specific fuel oil consumption values t = temp. in °C ∆K = temperature difference
ρ = density in kg/m3 Cp = heat capacity in J/(kg ∆K)
Temperature difference (K) t ρ Cp t Cp

range
1 °C (Celsius) 1K
1 °F (Fahrenheit) 5/9 K 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
Temperature levels (K) (see "Derived SI Units with special
Names) * Viscosity: 100-140 cSt at 40°C
750 mm Hg = 1 bar = 105 Pa
t °C (Celsius) tc + 273.15 = K 1 atm (standard pressure at sea level) = 760 mm Hg = 1013 mbar
t°F (Fahrenheit) 5/9(tf - 32) + 273.15 = K Gas constant for air and exhaust gas = 287 J/(kg x K)
Celsius from Fahrenheit: tc = 5/9(tf - 32) Water, heat of evaporation 100°C 1.013 bar 2.256 x 106 J/kg
Fahrenheit from Celcius: tf = 9/5 x tc + 32 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)
Specific heat capacity (J/(kg K))

1 kcalI.T./(kg x °C) 4.187 x 103 J/(kg K)
1 BTU*/(lb x °F) = 1 kcalI.T. /(kg °C) 4.187 x 103 J/(kg K) Specific fuel oil consumption (SFOC)
* British Thermal Unit (see table for energy conversions)
Reference conditions
Specific fuel oil consumption values refer to brake power, and the following
Heat conductance (W/(m K)) reference conditions:
1 calI.T./(cm x s x °C) 418.7 W/(m K) Reference conditions (ISO)

1 kcalI.T./(m x h x °C) 1.163 W/(m K)
1 BTU*/(ft x h x °F) 1.731 W/(m K) Blower inlet temperature 25°C 298 K
* British Thermal Unit (see table for energy conversions) Blower inlet pressure 1000 mbar
Charge air coolant temperature 25°C 298 K
Fuel oil lower calorific value (10200 kcal/kg) 42707 kJ/kgk
Heat transmission (W/(m2 K))

1 calI.T./(cm x s x °C) 41.87 x 103 W/(m2 K)
1 kcalI.T./(m" x h x °C) 1.163 W/(m2 K)
1 BTU*/(ft2 x h x °F 5.678 W/(m2 K)
08028-0D/H5250/94.08.12
98.19 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Basic Symbols for Piping 500.65
General
No Symbol Symbol designation No Symbol Symbol designation
1. GENERAL CONVENTIONAL SYMBOLS 2.14 Spectacle flange
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 3.1 Valve, straight through
Enclosure for several components as-

1.8 sembled in one unit 3.2 Valve, angle
2. PIPES AND PIPE JOINTS 3.3 Valve, three-way
2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight
2.2 Crossing pipes, connected 3.5 Non-return valve (flap), angle
Non-return valve (flap), straight screw

2.3 Tee pipe 3.6 down
2.4 Flexible pipe 3.7 Non-return valve (flap), angle, screw down
2.5 Expansion pipe (corrugated) general 3.8 Safety valve
2.6 Joint, screwed 3.9 Angle safety valve
2.7 Joint, flanged 3.10 Self-closing valve

08028-0D/H5250/94.08.12
2.8 Joint, sleeve 3.11 Quick-opening valve
2.9 Joint, quick-releasing 3.12 Quick-closing valve
2.10 Expansion joint with gland 3.13 Regulating valve
2.11 Expansion pipe 3.14 Ball valve (cock)
2.12 Cap nut 3.15 Butterfly valve
2.13 Blank flange 3.16 Gate valve
97.40 - ES0
500.65 Basic Symbols for Piping Description
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

08028-0D/H5250/94.08.12
3.34 Non-return valve (air) 5.1 Mudbox
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
On/off valve controlled by solenoid and pilot

3.39 directional valve and with spring return 5.6 Centrifugal pump
97.40 - ES0
Description
Basic Symbols for Piping 500.65
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
Fixed capacity pneumatic motor with

5.20 7.3 Level indicator
direction 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
97.40 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Operation of Engine 501
L16/24
Description
Operating ......................................................................................................................501.01 (03H)

Out of service................................................................................................................501.05 (05H)
Starting-up after repair..................................................................................................501.10 (03H)
Guidelines for longterm low-load operation on HFO ....................................................501.15 (02H)
Your Notes :
08031-0D/H5250/94.09.07
Description
Operation 501.01
Page 1 (3)
Edition 03H
L16/24
Preparations for Starting 4) Check pre. lub. oil pressure at inlet to filter, inlet
of the engine and inlet turbocharger on the
The following describes what to do before starting monitoring box display according to the data
when the engine has been out of service for a period and setpoints sheet.
of time.

5) Open the cooling water supply.
1) Check the oil level in the base frame with the
dipstick. 6) Check the cooling water pressure.
2) Check the oil level in the governor, see Fig. 2, Note: To avoid shock effects owing to large tempera-
with the level indicator on the governor. ture fluctuations just after start, it is recommended:
3) Start up the prelubricating pump. a) to preheat the engine. Cooling water at least
60°C should be circulated through the frame
Note: The engine must be prelubricated for at least and cylinder head for at least 2 hours before
30 minutes prior to start-up (at the first starting-up, or start:
if the engine is cold, the engine must be prelubricated
for at least 60 minutes) - by means of cooling water from engines which
or are running or by means of a preheater (if
check that there is oil coming out at bearings, pistons installed).
and rocker arms.
08028-0D/H5250/94.08.12
Fig. 1 Monitoring of temperature/pressure (MTP). Fig. 2 Governor.
98.47 - ES0
501.01 Description
Edition 03H
Operation Page 2 (3)
L16/24
b) When starting without preheated cooling

water, the engine may only be started on MDO
(Marine Diesel Oil).
Note: When starting on HFO (Heavy Fuel Oil), only

item a) applies.
HFO System
7) Open the fuel oil supply.
Starting on HFO: circulate preheated fuel through the

pumps until correct working temperatures have been
achieved. This normally takes 30-60 minutes.
8) Regulating gear - please check:
- that all fuel injection pumps are set at index "0"

when the regulating shaft is in STOP position.
- that each fuel injection pump can be pressed

by hand to full index when the regulating shaft
are in STOP position, and that the pumps
return automatically to the "0" index when the
hand is removed.
Fig. 3 Operation box (OB).
Starting Air System

Check the following on the monitoring box according
9) Check the pressure in the starting air receiver(s). to the data and setpoints sheet.
10) Drain the starting air system. 14) Check the lubricating oil pressure.
11) Open the starting air supply. 15) Check the cooling water pressure.
12) Check the air pressure on the operating box 16) Check the fuel oil feed pressure.
according to the data and setpoints sheet.
17) Check that the turbocharger is running.
08028-0D/H5250/94.08.12
Starting 18) Check that the prelubricating oil pump stops

automatically.
13) Start the engine by activating the start button
on the operation box; push the button until the 19) Check that all cylinders are firing, see exhaust
engine ignites, see Fig. 3. gas temperatures.
Note: Check the stop cylinder (Lambda controller)

Testing during Running for regulating the shaft works properly, both when
stopping normally and at overspeed and shut down.
See Description 509.05 before operating the control
panel.
98.47 - ES0
Description
Operation 501.01
L16/24
Check that all shutdowns are connected and function 29) To ensure full operational reliability, the condi-
satisfactory. tion of the engine should be continuously ob-
served so that order for preventive mainte-
20) Test the overspeed, see Working Card nance work can be carried out before serious
509-01.05. breakdowns occur, see also section 502.
21) Check that all alarms are connected.

Stopping
Operation 30) Before stopping, it is recommended to run the

engine at reduced load, max. 2 min.
The engine should not be run up to more than 50%
load to begin with, and the increase to 100% should 31) The engine is stopped by activating the stop
take place gradually over 5 to 10 minutes. button on the operating box. Only one push is
needed.
Note: When the engine is running the planned mainte-
nance programme and the following should be
checked: Starting and Stopping on HFO
22) The lubricating oil pressure must be within the Starting and stopping of the engine should take place
stated limits and may not fall below the stated on HFO in order to prevent any incompatibility prob-
minimum pressure. The paper filter cartridges lems on changeover to MDO.
must be replaced before the pressure drop
across the filter reaches the stated maximum MDO should only be used in connection with mainte-
value, or the pressure after the filter has fallen nance work on the engine or before a longer period
below the stated minimum value. Dirty filter of engine standstill.
cartridges cannot be cleaned for re-use.
Before starting on HFO the engine must be properly
23) The lubricating oil temperature must be kept preheated as described in "Preparations for Starting"
within the stated limits indicated on the data and as described below.
and setpoints sheet.
Stopping the engine on HFO is no problem, but it
24) The fuel oil pressure must be kept at the stated should be ensured that the temperature of fuel pipes
value. is not reduced to a level below the pour point of the
fuel. Otherwise reestablishing the circulation might
25) The cylinder cooling water temperature must cause problems.
be kept within the limits indicated on the data
and setpoints sheet.
Starting on MDO
08028-0D/H5250/94.08.12
26) The exhaust gases should be free of visible

smoke at all loads. For normal exhaust tem- For starting on MDO there are no restrictions except
peratures, see the test report from shop and that lubricating oil viscosity may not be higher than
sea trials. 1500 cSt (10°C SAE 40).
27) Keep the charging air pressure and tempera- Initial ignition may be difficult if the engine and ambi-
ture under control. For normal values, see the ent temperatures are lower than 5°C and 15°C cool-
test report from shop and sea trials. ing water temperature.
28) Recharge the starting air receivers to the de-

scribed value. A starting air pressure above 10
bar is sufficient for the L16/24 engine.
98.47 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Out of Service 501.05
L16/24 L27/38
V28/32S L21/31
Stand-by Mode 3) A lubricating oil sample should be sent to a
laboratory for immediate analysis.
During engine standstill in stand-by position the
media cooling water and fuel oil should be conti- 4) The installed drain fasilities in the exhaust gas
nuously circulated at temperatures similar to the system must be open.
operating conditions.
The prelubricating pump must always run in stand- Work during Repairs
by mode.
The following should be carried out during major
repairs.
Maintenance during Standstill
5) Retighten all bolts and nuts in the crankcase.
In periods during standstill of the engine (not in
stand-by position) it is recommended to start the 6) Check the various gearwheel drives for the
prelubricating oil pump for minimum 20 minutes camshafts.
once every week and to turn the engine during the
prelubricating period by 2-3 revolutions. 7) Remedy leakages of water and oil in the en-
gine, and blow through blocked-up drain pipes.
Laid-up Vessels 8) Drain starting air pipes of water.
During the lay-up period we recommend that our 9) Empty the oil sump of lubricating oil and check
special instructions for preservation of the engines the bottom of the oil sump for fragments of
are followed. babbitt from bearings. Remove the sludge, if
not done within a period of one year. Clean the
sump very thoroughly and subsequently coat
Work before Major Repairs with clean lubricating oil.
Follow all Working Cards carefully. Carry out all the

measuring and inspection stated on these Working Work after Repairs
Cards.
Cleaning of Lubricating Oil System
1) After stopping the engine, while the oil is still
warm, start the el-driven prelub. pump, open 10) If opening-up the engine or lubricating oil sys-
up the crankcase and camshaft housings and tem has caused the ingress of impurities, clean-
check that the oil is flowing freely from all ing should be carried out very carefully before
bearings. starting the engine.
08028-0D/H5250/94.08.12
After overhaul of pistons, bearings, etc. this check The differential pressure across the lubricating oil
should be repeated before starting the engine. filter must be watched very carefully after cleaning
and starting-up the engine. Be sure to replace filter
2) Open up all filters to check that filter elements cartridges in due time.
are intact. Filter cartridges in the lub. oil filter
are to be replaced before start, after repair, or 11) After restoring normal prelubricating oil circula-
after excessive differential pressure. After re- tion, turn the engine at least two revolutions by
moval, dirty elements can be examined for means of the turning device to check the
particles of bearing metal at the bottom of the movability of the relevant parts of the engine.
paper lamella (the elements cannot be used
again). 12) Close drain cocks in the exhaust gas system if
mounted.
02.47 - ES0
501.05 Description
Edition 05H
Out of Service Page 2 (2)
L16/24 L27/38
V28/32S L21/31
Lubrication of Manoeuvering Gear b) Adjustment speed: switch in the alternator on
the switchboard and set the load to about 40%.
13) Lubricate the bearings and rod connections in On reaching normal oil temperatures in gover-
the manoeuvering gear. Move the rod connec- nor and engine increase the load instantly to
tions by hand to check that the friction in about 80% (by starting a major pump or com-
bearings and fuel injection pumps is suffi- pressor). This must not cause the frequency to
ciently low. fall by more than some 8%, and the engine
must return to a constant no. rpm after about 3
14) Checks to be made just before starting the seconds (although this rpm will be a little lower
engine are described under 501.01. than before owing to the speed drop of the
governor). If the engine is operated in parallel
with other engines, an even sharing of the load
Check of Governor must be established within about 3 seconds. If
the governor reacts too slowly, compensating
Note: At starting-up after an overhaul the overspeed adjustment is effected as indicated in the
shutdown must be testet at correct setpoint after the governor's instruction manual (Compensating
following has been done: Adjustment).
a) Start the engine and keep it at no load. Note: It is a condition for this test that the engine and
turbocharger are in perfect operating condition, so
b) Turn the speed setting on governor until the that possible sources of error can be eliminated
overspeed is released. Check that it is re- immediately.
leased at correct rpm according to "Operation
data & set points", 500.30 and working card c) Hunting: run the engine at synchronous rpm,
509-01.05. and without load. Provided that the governor
oil is warm, the regulating lever must not
Note: If both overspeed shutdown (SSH 81) are perform any major periodical movements, and
activated, nuts and bolts have to be retightened neither must there be any variation in the
before the engine is started, (Nuts and bolts accord- engine speed. If that is the case, repeat the
ing to the colomn "Check new/overhauled parts after compensating adjustment according to the
- hours" in the planned maintenance program). governor's instruction manual.
15) Check the governor as follows: start up the d) Speed drop: in case of unsatisfactory load
engine and run it at the synchronous number of sharing between two or more engines this can
revolutions. be rectified by increasing the speed drop of the
engine that is subject to the greatest load (or
a) Speed-setting: before switching-in the alterna- by reducing the setting of the other engines).
tor on the switchboard please check that the
servomotor adjusts the rpm with a suitable
08028-0D/H5250/94.08.12
The setting should normally not be increased be-

quickness after actuation of the synchronizer yond the "max" value (stated below) on the scale,
knob on the switchboard. The range from - 5% and satisfactory parallel operation can generally be
to + 5% from the synchronous rpm should be obtained at settings "normal range" (stated below).
tested. Setting "Default" stated below can be used in most
cases.
Woodward Europa
Max. 70 100
Normal range 45-60 70-90
Default 52 80
02.47 - ES0
Description
Starting-up after Repair 501.10
Page 1 (1)
Edition 03H
General
The following enumerated checks are to be made After 5-15 and 30 minutes' idle running, open the
immediately after starting and during load increase. crankcase and the camshaft housing and perform
feel-over on the surfaces of all moving parts where
Note: In the following it is assumed that the engine friction may arise and cause undue heating.
has been out of service for some time due to repairs
and that checks during out of service periods have Feel: main bearings, big-end bearings, alternator
been carried out as described in the previous chap- bearings, and camshaft bearings, cylinder liners,
ter. roller guides and gear wheels.
When starting up after repair, the following checks After the last feel-over, repeat check 4.1. on page
must be made, in the order stated in addition to 501.05, see also "Ignition in Crankcase" on page
normal surveillance and recording. 503.04 in section 503.
After repair or renewal of cylinder liners, piston rings

To be Checked Immediately after Starting or bearings, allowance must be made for a running-
in period, i.e. the engine load should be increased
1) Check that the turbocharger is running. gradually as indicated in the tables below. The en-
gine output is determined on the basis of the fuel
2) Check that the lubricating oil pressure is in index and the load on the electric switchboard. The
order. turbocharger speed gives some indication of the
engine output, but is not directly proportional to the
3) Check that all cylinders are firing (see exhaust output throughout the service period.
temperatures).
Begin the starting-up sequence at a reduced engine
4) Check that everyting is normal for the engine speed, e.g. 400 rpm, until it can be known for certain
speed, fuel oil, cooling water and system oil. that there are no hot spots in the engine. Then
increase the speed to the normal rpm and connect to
5) Check by simulation of the overspeed shut- the switchboard and put on load.
down device that the engine stops, see work-
ing card 509-01.05. The load increase during the starting-up sequence
may, for instance, be:
Note: The overspeed setting should be according to
"Operation data & set points", 500.30. 25 % load for 2 hours
50 % load for 2 hours
75 % load for 2 hours
To be Checked during Starting-up, but only 100 % load may be put on
if Required after Repairs or Alterations
For loads: see the fuel pump index on the testbed
6) If the condition of the machinery is not well- figures in section 502.
08028-0D/H5250/94.08.12
known, especially after repairs or alterations,

the "feel-over sequence" should always be After completing the starting-up sequence, make
followed, i.e.: sure that all fuel injection pumps are set at the same
index and that the governor can cause all fuel pumps
to move to "0" index.
98.19 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Guidelines for Longterm Low-Load Operation on HFO 501.15
General
Part load/low load operation HFO-operation at loads lower than 20% MCR should
therefore only take place within certain time limita-
In certain ship operation situations the diesel-gen- tions according to the curves.
erator sets are sometimes exposed to part load/low
load operation. After a certain period of HFO-operation at a load
lower than 20% MCR, a change to MDO should take
During manoeuvring all diesel-generator sets are place in order to prevent further retardation of the
often started up for safety reasons, resulting in low engine performance condition, or the engine load
load conditions for all sets. should over a period of 15 minutes be raised to 70%
MCR and maintained here for a certain period of time
During harbour stay even one diesel-generator run- in order to burn off the carbon deposits, thus reestab-
ning could be lowloaded when hotel purposes are lishing adequate performance condition. After such
the only electricity consumers. "cleanburning period" low-load operation on HFO
can be continued.
At part load/low load it is important to maintain
constant media temperatures, i.e. for cooling water, However the operator must be aware of the fact that
lubricating oil and fuel oil, in order to ensure ad- fouwling in the air inlet channels, if any, will not be
equate combustion chamber temperature and thus cleaned with high load running. Extensive low-load
complete combustion. running can therefore result in necessity off manual
cleaning of the inlet channels.
At loads lower than 20% MCR there is risk of timede-
pendant retardation of the engine performance con- If special application conditions demand continuous
dition due to fouling of gas- and air channels, com- HFO-operation at loads lower than 20% MCR. and
bustion chambers and the turbocharger. occasionally performed "clean-burning" periods are
inconvenient or impossible, special equipment and
arrangements must be established.
Load %
20
Admissible low-load operation 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
08028-0D\H5250\94.08.12
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.
00.11 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Engine Performance and Condition 502
L16/24
Description
Engine performance and condition...............................................................................502.01 (04H)

Evaluation of readings regarding combustion condition...............................................502.02 (02H)
Condensate amount .....................................................................................................502.05 (03H)
Working card
Engine performance data ....................................................................................... 502-01.00 (03H)

Check of leakages from inspection holes ............................................................... 502-05.00 (01H)
Your Notes :
08031-0D/H5250/94.09.07
Description Engine Performance and Condition 502.01
L16/24
Performance Data and Engine Condition An increase in charge air temperature involves a
corresponding increase in the exhaust gas tempera-
During operation small changes in the engine condi- ture level by a ratio of about 1:1.5, i.e. 1°C higher
tion take place continuously as a result of combus- charge air temperature causes about 1.5°C higher
tion, including fouling of airways and gasways, for- exhaust gas temperature.
mation of deposits, wear, corrosion, etc. If continu-
ously recorded, these changes in the condition can Reduction of the charge air pressure results in a
give valuable information about the operational and corresponding reduction of the compression
maintenance condition of the engine. Continuous pressure and max. combustion pressure.
observation can contribute to forming a precise and
valuable basis for evaluation of the optimum opera-
tion and maintenance programmes for the individual Fuel Injection Pump
plant.
The amount of fuel injected is equivalent to the
supplied energy and is thus an expression of the load
Engine Performance Data and mean effective pressure of the engine. The fuel
pump index can therefore be assumed to be propor-
If abnormal or incomprehensible deviations in operational to the mean pressure. Consequently, it can be
tion are recorded, expert assistance in the evaluation assumed that the connected values of the pump
thereof should be obtained. index are proportional to the load.
We recommend taking weekly records of the most The specific fuel consumption, SFOC (measured by
important performance data of the engine plant. weight) will, on the whole, remain unchanged whether
During recording (working card 502-01.00 can be the engine is operating on HFO or on MDO, when
used) the observations are to be compared continu- considering the difference in calorimetric heat value.
ously in order to ascertain alterations at an early However, when operating on HFO, the combination
stage and before these exert any appreciable influ- of density and calorific value may result in a change
ence on the operation of the plant. of up to 6% in the volumetric consumption at a given
load. This will result in a corresponding change in the
As a reference condition for the performance data, fuel pump index, and attention should be paid to this
the testbed measurements of the engine or possibly when adjusting the overload preventive device of the
the measurements taken during the sea trial on the engine.
delivery of the ship can be used. If considerable
deviations from the normal conditions are observed, Abrasive particles in the fuel oil result in wear of fuel
it will be possible, in a majority of cases, to diagnose injection pumps and fuel valve nozzles. Effective
the cause of such deviations by means of a total treatment of the fuel oil in the purifier can keep the
evaluation and a set of measurements, after which content of abrasive particles to a minimum. Worn fuel
possible adjustment/overhauls can be decided on injection pumps will result in an increase of the index
and planned. on account of an increased loss in the pumps due to
leakage.
08028-0D/H5250/94.08.12
Evaluation of Performance Data When evaluating operational results, a distinction is

to be made between changes which affect the whole
Air Cooler engine (all cylinder units) and changes which occur
in only one or a few cylinders. Deviations occuring for
Fouling of the air side of the air cooler will manifest a few cylinders are, as a rule, caused by malfunction-
itself as an increasing pressure drop, lower charge ing of individual components, for example a fuel
air pressure and an increased exhaust/charge air valve with a too low opening pressure, blocked
temperature level (with consequential influence on nozzle holes, wear or other defects, an inlet or
the overhaul intervals for the exhaust valves). exhaust valve with wrongly adjusted clearance,
burned valve seat, etc.
98.48 - ES0
502.01 Engine Performance and Condition Description
L16/24
Turbochargers Exhaust Valves
Fouling of the turbine side of the turbocharger will, in The overhaul intervals for exhaust valves is one of
its first phase, manifest itself in increasing turbo- the key parameters when the reliability of the entire
charger revolutions on account of increased gas engine is to be judged. The performance of the
velocity through the narrowed nozzle ring area. In the exhaust valves is therefore extremely informative.
long run, the charging air quantity will decrease on
account of the greater flow resistance through the Especially under unfavourable conditions, fuel quali-
nozzle ring, resulting in higher wall temperatures in ties with a high vanadium and sodium content will
the combustion chambers. promote burning of the valve seats. Combinations of
vanadium and sodium oxides with a corrosive effect
Service experience has shown that the turbine side will be formed during combustion. This adhesive ash
is exposed to increased fouling when operating on may, especially in the event of increased valve tem-
HFO. peratures, form deposits on the seats. An increasing
sodium content will reduce the melting point and
The rate of fouling and thereby the influence on the thereby the adhesive temperature of the ash, which
operation of the engine is greatest for small turbo- will involve a greater risk of deposits. This condition
chargers where the flow openings between the guide will be especially unfavourable when the na weight
va
vanes of the nozzle ring are relatively small. Deposits ratio increases beyond 1:3.
occur especially on the guide vanes of the nozzle ring
and on the rotor blades. In the long run, fouling will The exhaust valve temperature depends on the
reduce the efficiency of the turbocharger and thereby actual maintenance condition and the load of the
also the quantity of air supplied for the combustion of engine. With correct maintenance, the valve tem-
the engine. A reduced quantity of air will result in perature is kept at a satisfactory low level at all loads.
higher wall temperatures in the combustion spaces The air supply to the engine (turbocharger/air cooler)
of the engine. and the maximum pressure adjustment are key pa-
rameters in this connection.
Fuel Valves It is important for the functioning of the valves that the
valve seats are overhauled correctly in accordance
Assuming that the fuel oil is purified effectively and with our instructions.
that the engine is well-maintained, the operational
conditions for the fuel valves and the overhaul inter- The use of rotocaps ensures a uniform distribution of
vals will not normally be altered essentially when temperature on the valves.
operating on HFO.
If, for any reason, the surface temperature of the fuel Air Inlet Valves
valve nozzle is lower than the condensation tem-
perature of sulphuric acid, sulphuric acid condensate The operational conditions of the air inlet valves are
can form and corrosion take place (cold corrosion). not altered substantially when using residual fuel.
The formation of sulphuric acid also depends on the
08028-0D/H5250/94.08.12
sulphur content in the fuel oil.

Fuel Injection Pumps
Normally, the fuel nozzle temperature will be higher
than the approx. 180°C at which cold corrosion starts Assuming effective purification of the fuel oil, the
to occur. operation of the fuel injection pumps will not be very
much affected.
Abrasive particles in the fuel oil involve heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
Therefore, abrasive particles are to the greatest
possible extent to be removed at the purification.
98.48 - ES0
Description
Engine Performance and Condition 502.01
L16/24
The occurrence of increasing abrasive wear of plunger The fresh air supply (ventilation) to the engine room
and barrel can be a consequence of insufficient should correspond to approximately 1.5 times the air
purification of the fuel oil, especially if a fuel which consumption of the engines and possible boilers in
contains residues from catalytic cracking is used. operation. Sub-pressure in the engine room will
Water in the fuel oil increases the risk of cavitation in involve an increased exhaust temperature level.
connection with pressure impulses occurring at the
fuel injection pump cut-off. A fuel with a high asphalt The exhaust back-pressure measured after the tur-
content has deteriorating lubricating properties and bochargers at full load must not exceed 250-300 mm
can, in extreme cases, result in sticking of the fuel water column. An increase in the exhaust back-
injection pump plungers. pressure will also cause an increased exhaust valve
temperature level, and increased fuel comsumption.
Engine Room Ventilation, Exhaust System
Good ventilation of the engine room and suitable

location 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 exhaust valves.
08028-0D/H5250/94.08.12
98.48 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description Evaluation of Readings Regarding 502.02
Page 1 (1) Combustion Condition Edition 02H
L16/24
PRESSURE DROP
INCREASING
(limit 50%)
Air filters
fouled.
PRESSURE DROP
INCREASING
(limit 50%)
Air side of
cooler fouled.
ALL CYLINDERS
Exhaust temp. increasing:
TEMP. DIFFERENCE
Air system fouled
TOO LARGE
(Air filter-blower-cooler).
Water flow too small
Exhaust system fouled
(nozzle ring, turbine wheel).
TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.
ONE CYLINDER DECREASING CHARGE AIR

Exhaust temp. in- PRESSURE:
creasing: Fuel valve Decreasing air amount.
needs overhaul. Fouled turbocharger,
08028-0D/H5250/94.08.12
Compression too low air filter or charge

owing to leakage of air cooler (air side).
exhaust valve or piston
ring blow-by.
See also:
Engine Performance
and Condition 502.01
98.19 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Condensate Amount 502.05
General
Fig. 1 Nomogram for calculation of condensate amount.
General Then normally, the air cannot absorb the same

amount of water as before.
There is always a certain amount of water in air.
When the air is saturated with aqueous vapour, the Condensation of water in the engine's charge air
humidity is said to be 100% and there is as much receiver is consequently dependent on the humidity
water in the air as it can absorb without condensing. and the temperature of the ambient air. To find out if
The amount of water in kg/kg air can be found from condensation in the charge air receiver will occur the
08028-0D/H5250/94.08.12
the diagram. The ability to absorb water depends on diagram can be used.
the pressure and temperature of the air.
Example:
Amount of Condensation Water in the Charge Diesel engine1000 kW

Air Receiver Ambient air condition:
air temperature 35 C
Both higher pressure and lower temperature reduce relative air humidity 90 %
the ability to absorb water. A turbocharged diesel Charge air temperature 50 C
engine takes air from outside, compresses and cools Charge air pressure 2.6 bar
the air.
98.21 - ES2
502.05 Condensate Amount Description
General
As a guidance, an air consumption of 8.2 kg/kWh (Le) Amount of Condensate Water in Air Tanks
at full load can be used for MAN B&W, Holeby
engines. The volume of condensate in the air tank is determined
by means of the curve at the bottom to the right of the
Solution according to diagram: diagram, representing an operating pressure of 30
bar.
Water content of air (I) 0.033 kg/kg
Max. water cont. of air (II) 0.021 kg/kg Example:
Amount of condensate in charge air receiver. Amount of condensate in air tank.
= (I-II) x le x P Volumetric capacity of tank (V) 4000 dm³

= (0.033 - 0.021) x 8.2 x 1000 = 123 kg/h Temperature in tank (T) 40 °C=313K
Internal press. of tank (p) 30 bar
= 31 x 105 N/m²(abs.)
Draining of Condensation Water Gas constant for air (R) 287 Nm/kg.K
Ambient air temperature 35 °C
This phenomenon will occur on all turbocharged Relative air humidity 90 %
engines. For MAN B&W, Holeby 4-stroke engine, Weight of air in tank
there is no risk with a small amount of water in the
charge air receiver. But if the charge air receiver is pxV 31 x 105 x 4
filled with water, there is a risk of getting water into the m= = = 138 kg
RxT 287 x 313
cylinder. This water have to be drained away. As
standard a valve is mounted on the charge air receiver/
cooler on the engine. This valve is to be used for Solution acc. to above diagram:
draining of the water. If there is a great amount, the
valve can be left half-open. If the amount is small, the Water content of air (l) 0.033 kg/kg
charge air receiver can be drained periodically. 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
98.21 - ES2
Working Card 502-01.00
Page 1 (1) Engine Performance Data Edition 03H
L16/24
Safety precautions Special tools
Stopped engine Plate No Item No Note

Shut-off starting air
Shut-off cooling water
Shut-off fuel oil
Stopped lub. oil circul.
Description Hand tools
Measuring of engine performance data.

According to scheme "Performance L16/24".
Starting position
Engine is running.
Related procedure
Manpower Replacement and wearing parts

08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty. /

Capacity : 1 man
Data
Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
99.03 - ES0
Performance L16/24
M/V
Eng. type: Eng. No:
T/C type: Serial No:
Fuel type: Viscosity:
Density:
Load
Air temp °C
Date
Time
Run hours
RPM 1/min
T/C rpm 1/min
HT temp. °C
HT press. bar
LT temp. °C
LT press. bar
LO temp. °C
LO press. b. filt. bar
LO press. a. filt. bar
LO press. T/C bar
FO temp. °C
FO press. bar
CA temp. °C
CA press. bar
Exh. cyl. 1 °C
Exh. cyl. 2 °C
Exh. cyl. 3 °C
Exh. cyl. 4 °C
Exh. cyl. 5 °C
Exh. cyl. 6 °C
Exh. cyl. 7 °C
Exh. cyl. 8 °C
Exh. cyl. 9 °C
Exh. b. T/C °C
Exh. a. T/C °C
L1 °C
L2 °C
L3 °C
Gov. IDX
IDX 1 mm
IDX 2 mm
IDX 3 mm
IDX 4 mm
IDX 5 mm
IDX 6 mm
IDX 7 mm
IDX 8 mm
IDX 9 mm
Power kW
Voltage V
Current A
Cos phi / kvAr
Crankcase press. mmWc
Signature:
10029-0EX/H5810/98.07.03
Working Card
Check of Leakages from Inspection Holes 502-05.00
L16/24

Shut-off fuel oil
Description
Check of leakages from inspection holes.
Hand tools
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : ¼ hour Plate No Item No Qty./

Capacity : 1 man
Data

98.22 - ES0
502-05.00 Check of Leakages from Inspection Holes Working Card
L16/24
Description
1) Leakages from cylinder head, see fig. 1.
If Then
Water leaks from the inspection hole The O-ring on the top of the liner has to be
replaced
Gas leaks from the inspection hole The sealing ring cylinder head/liner has to be
replaced
Inspection hole for

cooling water or
gas leakage
Fig 1 Inspection holes in the cylinder unit

08028-0D/H5250/94.08.12
98.22 - ES0
Working Card
Check of Leakages from Inspection Holes 502-05.00
L16/24
2) Leakages from HT cooling water pump, see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing
3) Leakages from LT cooling water pump, see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing
4) Leakages from charge air cooler, see fig. 2.
If Then
Air leaks from the inspection holes The inner O-ring on the charge air cooler has to
be replaced
Water leaks from the inspection hole The O-rings on the cooling water connecting has
to be replaced
08028-0D/H5250/94.08.12
Fig. 2 Inspection holes in the front-end box
98.22 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Trouble Tracing 503
L16/24
Description
Starting failures .............................................................................................................503.01 (02H)

Faults in fuel oil system ................................................................................................503.02 (05H)
Disturbances during running.........................................................................................503.03 (03H)
Ignition in crankcase .....................................................................................................503.04 (03H)
Trouble shooting guide for centrifugal by-pass filter.....................................................503.05 (02H)
Trouble shooting for cooling water system ...................................................................503.09 (03H)
Trouble shooting for lubricating oil cooler.....................................................................503.10 (01H)
Trouble shooting/electrical failures ...............................................................................503.20 (01H)
Your Notes :
08031-0D/H5250/94.09.07
Description
Starting Failures 503.01
General
Trouble Possible cause Troubleshooting
Engine turns as soon as shut- Faults in electrical system. Check electrical parts.
off valve is opened, without
start button being activated.
Engine does not turn when start Air pressure in starting air re- Start compressors, re-charge
button is activated. ceiver too low. air receiver.
Main valve(s) closed. Open valve at receiver and

stop valve interposed in line
between receiver and engine.
Pinion does not engage with Check the air starter.

the flywheel.
Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing or clutch jaws,
see Working Card 513-01.30.
Faults in electrical system. Check electrical parts.
Engine turns too slowly or Worn air motor parts. Remove and disassemble the
irregularly when start button is air motor. Examine all parts
depressed. and replace any that are worn
or damaged. Use the guide-
lines for determining unserv-
iceable parts, see Working
Card 513-01.30.
Start valve is sticking in closed Check start valve.

position.
Low air pressure. Raise the air receiver pres-

sure.
Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.
08028-0D/H5250/94.08.12
00.12 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Faults in Fuel Oil System 503.02
L16/24 L27/38
V28/32S L21/31
Engine turns, but ignition fails. Fuel Sluggish movement of manoeuvering Lubricate and mobilize rod connections
pumps are not actuated. gear. in manoeuvering gear.
Incorrect adjustment of manoeuvering Check rod connec. Check that fuel pump
gear. index corresponds to "Adjustments after
trials" in testbed chart.
Safety system stop activated. Reset safety system stop.
Piston in Lambda controller is actuated. Check that piston is not sticking. Check
that pressure in cylinder is relieved.
Check that the shutdown trip is not
actuated.
Piston in Lambda controller cylinder is Check pressures and temperatures.

actuated due to stop function or fuel Check for faults in shut-down devices:
limitation. Check for faults in fuel limitation devices.
Check adjustment according to
Working Card 509-10.00.
Incorrect adjustment of Lambda con- Adjust setting of adjustment screw, see

troller's adjustment screw. Working card 509-10.00.
Governor setting incorrect. Adjust governor, see special instruction

manual.
Failures in governor. Check that governor is working properly.

For further fault location, see special
instruction manual in section 509.
Sticking fuel pumps. Dismantle and clean.
Engine turns, but no fuel is injected Fuel oil service tank empty. Pump oil into the tank.
owing to failure in fuel system.
If Then
Air in fuel pumps. Loosen hexagon
socket screw on
fuel pumps until air
disappears.
Engine runs, but does not ignite on all Air in fuel valves. Ignition fails on Vent the respective
08028-0D/H5250/94.08.12
cylinders. one or more fuel valves.

cylinders due to
air in the fuel
valves.
Ignition fails on Change the fuel

one or more valves and check
cylinders and them for sticking
no air bubbles spindle or broken
appear. spring. Check for
collecting oil on
piston top.
Air appears in Check stuffing box

the entire system. and sealing in the
fuel system.
Cont.
02.40 - ES0
503.02 Faults in Fuel Oil System Description
L16/24 L27/38
V28/32S L21/31
Worn-out fuel pump. Change fuel pumps.
If Then
Pressure before Clean fuel filter.
pumps is too low. Check that by-pass
valve for feed pump
is not open.
Pressure is still Increase the fuel

too low. oil feed pump
pressure.
Engine turns, fuel is injected, but Water in the fuel. Drain off water and repeat venting of fuel
ignition fails. pumps by loosening the hexagonal socket
screw until air disappears.
Fuel valves or nozzles defective. Change defective fuel valves, see working
card 514-01.10.
If Then
Compression Check intake and
during start too exhaust valve for
low. tight closing.
Check piston rings.
Timing of fuel Check fuel cam-

camshaft is shaft adjustment,
incorrrect. see Working card
507-01.20.
Major alteration Adjust camshaft,

of the fuel de- see Working card
mand adjustment 507-01.20.
of the fuel pump
timing.
Oil has collected Slow turning to

on piston crown. remove oil. Locate
and change defec-
tive fuel valve.
08028-0D/H5250/94.08.12
First ignitions are too violent. Engine Sluggish movement of manoeuvering Lubricate and mobilize rod connections
runs erratically. gear. and bearings in manoeuvring gear.
Fuel pump index to high. Check rod connection in manoeuvring

gear. Check that governor is working
properly.
02.40 - ES0
Description
Disturbances During Running 503.03
Page 1 (3)
Edition 03H
General
Exhaust gas temperatures Increased charging air temperature due Clean air coolers, see working card 512-01.00.
increased on all cylinders. to ineffective air coolers.
Fouling of air and gas passages. Clean air and gas passages, see working cards in section
512.
Insufficient cleaning of fuel oil or Check separator and fuel filters.

changed combustion characteristics.
Wrong maximum combustion pres- Check camshaft adjustment, see working card
sure. 507-01.20.
Exhaust gas temperature Fuel valve or valve nozzle defective. Overhaul fuel valve, see working card 514-01.10.
increased on one cylinder.
Leaky exhaust valves. Check the valve clearance, see working card 514-01.10
or
change the leaky valve and recondition the exhaust valve,
see working card 505-01.05.
Note: This manifests itself by a rise If Then

in the exhaust temperature and failling Stopping of the The fuel pump of the cylinder con-
of the compression and maximum com- engine is not cerned should be put out of opera-
bustion pressure of the respective cyl- possible or tion by moving the index to stop
inder. convenient. and locking it in this position.
Blow-by = leaky combustion chamber. Check piston rings, see working card 506-01.35.
Blow-by means a serious danger of piston seizure, and

the engine must if possible be stopped and the piston in
question pulled. Leaky piston rings will normally result in
heavy excess pressure in the crankcase.
If Then
Stopping of the The fuel pump of the cylinder con-
engine is not cerned should be put out of opera-
possible or tion by moving the index to stop
convenient. and locking it in this position.
Damaged fuel pump cam. Replace camshaft section, working card 507-01.05.
08028-0D/H5250/94.08.12
Exhaust gas temperature Decreased charging air temperature. Check the thermostatic valve in the cooling water system,
decreases on all cylinders. see working card 516-04.00.
Exhaust gas temperature Spindle in fuel valve is sticking. Change and overhaul defective fuel valve, see working
decrease on one cylinder. card 514-10.00.
Fuel pump plunger is sticking or leak- Change fuel pump plunger/barrel assembly, see working
ing. card 514-10.00.
Cont.
98.19 - ES0
503.03 Disturbances During Running Description
Page 2 (3)
Edition 03H
General
Engine speed decreases. Pressure before fuel pumps too low. Raise fuel oil feed pump pressure to normal.
or
check filter, see working card 514-01.15.
Fuel valve defective. Change defective valve, see working card 514-01.10.
Fuel injection pump defective. Change or overhaul.
Water in the fuel. Drain off water from service and setting tanks. Check fuel
oil centrifuge.
Governor defective. See governor manual.
Engine stops. Shut-down for overspeed. Check fuel pumps, see working card 514-10.00.
Check governor, see governor manual.
Check movement of regulating mechanism.
Shut-down for low lubricating Check pressostat, see working card 509-05.00.
oil pressure. Check lubricating oil filter, see working card 515-01.10.
Check lubricating oil pump, see working card 515-01.00.
Shut-down for high lubricating Check lub. oil flow and pressure,
oil pressure. see working card 515-01.20.
Clean lubricating oil cooler, see working card 515-06.00.
Smoky exhaust. Turbine speed lagging behind engine Clean turbine(s), see working card 512-15.00.
speed.
Air supply too low. Clean air cooler, see working card 512-01.00.
Clean air filter, see working card 512-35.00.
Clean compressor, see working card 512-05.05.
Clean turbine, see working card 512-15.00.
Fuel valves or nozzles defective. Check fuel valves, see working card 514-01.10.
Exhaust valve knocking. Adjusting screw for valve setting loose. Inspect and replace defective parts, see working card
Push rod thrust disc damaged. 508-01.00.
08028-0D/H5250/94.08.12
Rising cooling water Thermostatic function Check thermostat.

temperature.
Pump defective Stop the engine and repair the pump.
Decreased flow Check valves.
If Then
The cooling water Open the test cocks (if fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-100°C.
Cont.
98.19 - ES0
Description
Disturbances During Running 503.03
General
Check whether steam has

developed.
Steam has developed. Stop the engine.

Leave the engine to cool while the
discharge valve is closed.
After 15 minutes open the dis-

charge valve a little to allow the
water to rise slowly in the cooling
jackets.
Check filling at test cocks.
Lubricating oil pressure Lubricating oil pump defective. Check lubricating oil pump, see working card 515-01.00.
fails.
Filters fouled. Clean filter, see working card 515-01.10.
Cooler fouled. Clean cooler, see working card 515-06.00.
If Then
The lubricating oil Stop the engine: find the
pressure drops below cause of the pressure drop
the minimum stated and remedy the defect before
in the Data sheet. restarting the engine.
Note: Feel over 5-15-30 minutes after starting, and again

when full load is achieved.
See section 502.

08028-0D/H5250/94.08.12
98.19 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description 503.04
Page 1 (1) Ignition in Crankcase Edition 03H
General
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 oil drops is slung around everywhere. If
undue friction, and thus heating, arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is otherwise transmitted to after stopping the engine. When opening up, keep
the crankcase, the heated surface will cause eva- clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed onto it. When do not smoke.
the oil vapours condense they form milky white oil
mist which can ignite. Such ignition may be caused 3) Cut off starting air.
by the same "hot spot" that produced the oil mist. If Set the control panel in "Blocking Mode" see
a large quantity of oil mist has developed before description 501.01.
ignition, the burning may cause considerable pres- Take off all doors on one side of the crankcase.
sure rise in the crankcase, forcing the relief valves to
open. In a few cases, presumably when the whole 4) Locate the hot spot. Powerful lamps should be
crankcase has been filled with oil mist, a subsequent employed at once (in explosion-proof fittings).
explosion has thrown off the crankcase doors and Feel over all sliding surfaces (bearings, liners,
caused fire in the engine room. pistons, roller guides, etc.).
Every precaution should therefore be taken to (A) Look for squeezed-out bearing metal and discolora-
avoid "hot spots" and (B) discover oil mist in time. tion by heat (blistered paint, burnt oil, heated steel).
5) Prevent further heating, preferably by making

"Hot spots" in Crankcase a permanent repair. Special attention should
be paid to ensuring lubricating oil supply and
Overheating of bearings is a result of inadequate or the satisfactory condition of the frictional sur-
failing lubrication, possibly caused by pollution of the faces involved. It is equally important to re-
lubricating oil. place filter elements in time.
It is therefore important that the lubricating oil filtra- 6) Start electrically driven lubricating oil pump
tion equipment is in perfect condition. Filter cartrid- and check oil flow from all bearings and spray
ges may not be used again if they have been pipes in crankcase while turning the engine
removed from the filter. Checking of the oil condition through at least two revolutions.
by analysis is recommended.
7) Stop and feel over. Look out for oil mist.
Oil Mist in Crankcase Especially the frictional surfaces that caused the
08028-0D/H5250/94.08.12
heating should be felt over (5-15-30 minutes after

The presence of oil mist may be noted at the vent starting, and again when full load is obtained). Sec-
pipe which is usually fitted to the top of the engine tion 501.10.
frame.
8) If it has not been possible to locate the hot spot,
Measures (in case of white oil mist). step 7 should be intensified and repeated until
the cause of the oil mist has been found and
Warning: Keep away from doors and relief valves on remedied. In very rare cases oil mist could be
crankcase. Do not stay unnecessarily in doorways due to "atomization" of lubricating oil by the
near the doors of the engine room casing. action of an air jet (for instance blow-by, or
blow-by through cracked piston).
00.12 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
General
Tabulated below are the remedial actions to be taken

if the following faults are observed:
Trouble Possible cause Trouble shooting
Oil leakage through cover nut. Missing or damaged O-ring Replace O ring.
(see Item 158, Plate 51515).
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 (see Item Replace O ring.

109, Plate 51515), allowing leakage.
O-ring seat on rotor joint faces Replace rotor assembly.

damaged.
Rotor assembly inadequately tight- Tighten and bring to notice of maintenance

ened. staff.
Standtube incorrectly seated or Refit or replace if damaged.

damaged.
Dirt deposit not completely removed. Clean and bring to notice of maintenance
staff.
Rotor castings distorted through Replace rotor assembly.

maltreatment.
Rotor assembly components fitted in Follow sequence in Working card 515-15.00

wrong sequence. in section 515.
Bushes loose or worn in tube assembly. Fit new bearing tube assembly.
08028-0D/H5250/94.08.12
98.20 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1)
Edition 03H
General
Description The pump bearings are lubricated automatically with

oil from the lubricating oil system of the engine.
The built-on fresh water pumps in the high and low
temperature circuits are of the centrifugal type. They If the pump leaks and the shaft sealing rings are
are mounted in the front end box and are driven worn, it is recommended to replace the shaft seal,
through the gearing. see Working card 516-02.00.
Oil or water flows out of the inspec- Worn rotating sealing. See working card 502-05.00.
tion holes.
The pump does not work after start. Pump draws in air at suction side. Check packings and pipes for 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 normal Air leakages from shaft seal. Overhaul the shaft seal.
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 trouble with the pump, apart from

mechanical faults, is most often due to leaks in the
08028-0D/H5250/94.08.12
suction line. It is therefore essential that all packings

and gaskets are in order and that they are renewed
when necessary. Even a tiny hole in the suction line
will reduce the pump capacity.
98.20 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01H
General
Trouble Shooting Fatigue fracture will normally necessitate replacement
of all plates and gaskets as there may be a risk of
It is necessary to replace damaged plates or gaskets. fatigue fracture in all the material.
In case of corrosion, all plates must be examined
First examine the external conditions around the carefully!
plate heat exchanger in order to localize the cause of Concerning the work to be carried out see Working
the damage. Do this very carefully. card 515-06.00.
Visible Leakage
Leakage. Too high pressure. Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operating
Data & Set Points".
Leakage. Insufficient tightening. Tighten up the plate heat exchanger, but

(Phase 1) not below the minimum dimension and
never when the plate heat exchanger is
under pressure or over 40°C.
If the plate heat exchanger is still leaky,

proceed to phase 2.
Leakage. Fouled or deformed plates. Separate the plate heat exchanger and
(Phase 2) Inelastic or deformed gaskets. check if the plates are deformed or fouled.
Check that the gaskets are elastic and
non-deformed, and that the faces of the
joints are clean.
Replace deformed plates and gaskets, if
any.
Before assembling clean all plates and
gaskets very carefully.
Assemble the plate heat exchanger and
start it up again.
Note: Even tiny impurities such as sand
grains may cause leakage.
Leakage. Gaskets. Separate the plate heat exchanger.

(Even after tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension.) Replace the gaskets.
08028-0D/H5250/94.08.12

start it up again.
Leakage. Defective gasket or badly corroded plate. Separate the plate heat exchanger.
(Through the drain holes of the gas- Replace defective plates and gaskets, if
kets.) any.
start it up again.
98.20 - ESO
503.10 Troubleshooting for Lubricating Oil Cooler Description
General
Non-Visible Leakage
Reduced heat transmission and/or in- Fouled plates or choked plate Separate the plate heat exchanger and
creasing pressure drop. channels. check if the plates are fouled.
Clean the plates very carefully.
start it up again.
Leakage. Holes in plates. A suspected leakage can be localized in

(The fluids get mixed.) Corrosion or fatigue fracture. the following way:
(Phase 1) Remove one of the lower pipe connec-
tions.
Then put the opposite side under pres-
sure.
If the medium continues to run out of the
lower pipe connections after the pressure
has stabilized one or several plates are
leaking.
Close down the plate heat exchanger.
Separate the plate heat exchanger and
check the plates very carefully.
Check suspected plates with a dye pen-
etrant.
Check defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
check to find more defective plates, if any,
by putting one side under press.
Start up again.
Leakage. Holes in plates. Close down the plate heat exchanger.

(The fluids get mixed.) Corrosion or fatigue fracture. 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 unpressu-
rised and free from liquid!
Stop the circulation after a few minutes of
operation and open the plate heat ex-
changer again. Take care to avoid water
spraying onto the dry plate side!
By a careful study of the plates it will be
08028-0D/H5250/94.08.12
possible to find moist areas, if any, on the

otherwise dry plate sides.
Check these areas with a dye penetrant!
Replace defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
check to find more defective plates, if any,
by putting one side under press.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!
98.20 - ES0
Description
Trouble Shooting / Electrical Failures 503.20
L16/24
L27/38
Trouble Shooting Further, please remember to inform the software no
when ordering a new module.
This description is a trouble shooting guide for the
automation system on the diesel engine type L16/
24 and L27/38. Safety System
The safety system is an independent system and

General consists of maker ABB PLC hardware modules and
MAN B&W software. Fig 1 describes the hardware
The following trouble shooting guide is an aid in iso- modules.
lating troubles to the engine built-on safety system
and monitoring system incl. the sensors connected For wiring of the modules and sensors a reference
to these systems. is made to the scheme which can be found in the
operation manual, section 509.
CAUTION! The control system can be damaged
with the wrong voltage. When replacing a control The safety system consists of two ABB PLC mod-
unit, check that the power supply is switched off ules. The modules named 3P1 is the CPU module
during replacement and check the power supply for and the module named 4P1 is an I/O-module. Indi-
the correct voltage before switching-on. cation of individual input and output can be found
on the modules by yellow diodes. The reference
Table 1.1 for the safety system and table 1.2 for the number for each input and output can be found in
monitoring system are general guides for isolating the scheme.
system problems. Each system check assumes that
the prior checks have been done properly. Table 1.3 On the operation box individual indication of the shut-
and 1.4 are system error messages which can be a downs (low lub. oil pressure, high cool. water temp.,
guideline to the problem. overspeed and emergency stop) can be found.
If the conclusion of a trouble shooting indicates that If a replacement module is needed, the software ver-
an exchange of a module is needed, please fill-in sion must be informed at ordering. Software version
the enclosed inspection report, and return the mod- number is written on the module.
ule together with the inspection report to the engine
maker.
08028-0D/H5250/94.08.12
Fig 1 Hardware module.
01.38 - ES0-ny
503.20 Trouble Shooting / Electrical Failures Description
L16/24
L27/38
Table 1.1
Engine will not start. Supply voltage polarity, or no sup- Check the supply voltage on the green diode on
Start motor is not engaged. ply voltage. 3P1. If it is alight the power supply for the PLC
modules are OK.
RUN/STOP change-over switch on Put the RUN/STOP change-over switch in RUN

3P1 in wrong position. position. Check RUN LED on 3P1.
No software in the module. If all diodes on 3P1 and 4P1 are alight after having
switched on the power supply, the module is without
software. The module must be replaced with a
module incl. software.
Note! After switch-on of the power supply the initiali-
zation takes app. 3 sec. Please wait these seconds
before observation.
Output relay on A10.04 is in failure Check that diode A10.04 is alight.

or loose connections. If A10.04 is not alight check that A62.01 is alight and
A62.07 is stable (continuous on or continuous off)
Check for loose wires on terminals 27 + 28 on 4P1.
One or several shutdown signals Reset the shutdowns.

are activated on the monitoring box If one is still activated on the operation box, check
that input A62.00, A62.01, A62.02 and A62.03 are
not alight. If one is alight, check the sensor and
wiring for short circuit.
All shutdown LED are alight on the Connector is not correctly connected Check the connector J29 on the base module. No
monitoring box. on internal failure in 3P1 or failure in red LED must be alight on 3P1 or 4P1. Activate the
CPU socket. change-over switch RUN/STOP. Exchange the 3P1
module.
Low lub. oil shutdown occurs when Damaged or wrong adjustment of Check the pick-up for correct adjustment.
normal stop is activated. the rpm pick-up. Sensing distance = app. 1 mm, (for Honeywell pick-
up the latern must be placed at 3 or 9 o‘clock)
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly. Replace the pick-up.
Note! Diode A62.07 will be alight if actual speed is
above nominal speed. If actual speed is below, it will
be dark.
08028-0D/H5250/94.08.12
The alarm „System & Power failure“ The internal bus connection is dis- Check that the bus connection on terminals 1 + 2 is
is activated. connected or internal component OK. Check that the resistance (120R) is installed
Diode A10.01 is not alight or diode failure. correctly and OK. Check that power supply is OK.
A10.02 is not alight. (Green diode must be alight). Switch on the RUN/
STOP change-over switch. The problem could be
related to an internal component failure and the
module must be replaced. Observe that no red
diode is alight on 3P1 or 4P1.
The shutdown functions are not Wiring or sensor problem. Check the wiring for shutdown sensors.
working. Internal component failure. Replace the module.
Overspeed set point is not correct. Missing jumper or wrong software. Check that E62.10 is alight for 720 rpm engines,
and OFF for 750 rpm engines. Check the software
label on the front of the module or in the scheme.
01.38 - ES0-ny
Description
L16/24
L27/38
The Monitoring System Interface to the alarm and monitoring system in the
control room is made by MODBUS or Interlink to
The monitoring system monitors shows all relevant the output module.
pressures, temperatures and rpm on the engine.
The software can be read on the label attached on
The monitoring system consists of four hardware the Base Module or by pushing the lamp test button
modules as standard and a module as option for for 3 seconds. The software version number will be
bearing temp. monitoring. The monitoring system displayed in the operation box display.
hardware and software is developed by MAN B&W.
Fig 2 describes the hardware. The software for engine type L16/24 will start with
2.xx, and the software for engine type L27/38 will
All sensors are connected to the base module and start with 3.xx, f.ex. 3.11. Please make sure that the
the Operation Box (OB), Monitor for Temp. and Pres- dip switches SW1, SW2, SW5 and SW3 are in cor-
sure Module (MTP) and Monitor for Exh. Gas Temp. rect position acc. to the plant related scheme. See
Module (MEG) are connected via interlink bus con- section 509.
nection.
08028-0D/H5250/94.08.12
Fig 2 Hardware modules.
01.38 - ES0-ny
L16/24
L27/38
Table 1.2
Engine will not start. Power supply is not correct, inter- Check that the power supply is correct 24 V ± 20%
Start motor is not engaged. lock activated or internal compo- on terminals J3; 132, 133.
nent failure Check that no interlocks are activated
– Turning gear not engaged
– No start failure activated
– No engine run signal
– Remote mode is activated
– No shutdown activated
– Stop valve not activated
– No lub. oil pressure
– Prelub. oil pressure is OK
Check that LED on base module is steadily green
alight. See also table 1.3
Check that wirings from terminals J20; 98, 99 are
correct.
Check the safety system (see table 1.1)
Check that the ON/OFF switch on the base module
is working properly.
Note! After having switched on the power supply,
the system initializes app. 3 seconds. Please wait
with observations until initializing is finished.
Replace the base module.
Data communication failure. EMC problem or loose connections. Check that the green LED on the base module is
alight. See also table 1.3
Check that all cable screens are connected cor-
rectly in the EMC cable glands.
Check that the data communiation cable (MODBUS)
is the twisted pair type.
No RPM indication Defect pick-up or incorrect adjust- Check the pick-up for correct adjustment.
ment. Sensing distance = app. 1 mm, (for Honeywell pick-
up the latern must be placed at 3 or 9 o‘clock)
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly.
Replace the pick-up. For the Dr. Horn pick-up the
sensing distance must be 1-1.8 mm (the thread on
the pick-up is 1 mm)
08028-0D/H5250/94.08.12
the engine suddenly starts or stops. Two or more earth failures on the Check for earth failures on all sensors.
engine and yard installation. Special attention should be made to the exh. gas sen-
sors. Check for earth failures in the yard system. Re-
place the base module.
LED flashing green, yellow or red. Internal component failure or EMC See table 1.3. Switch the power ON/OFF.
problem. Exchange the base module.
All red diodes on the operation box No power supply or software in the Check the safety system accoding to table 1.1.
are alight. safety system.
Jet system activated under no load The band steel on the lambda arm is Adjust the band steel to app. 2-3 mm above the jet
condition and/or jet alarm activated. adjusted incorrectly. pick-up.
Cont.
01.38 - ES0-ny
Description
L16/24
L27/38
Cont. Table 1.2
„Frozen“ operation box, MTP and Internal software failure. See table 1.3. Switch the power supply on/off.
MEG box. Exchange the base module.
Instable behaviour of the output sig- Too high voltage on the output cir- Check that the voltage is below 48 VDC.
nals for start/stop of prelubricating cuit terminals J20, 108, 109 120 VAC or 220 VAC is not allowed.
pump. Note! The voltage must be checked in the
prelubricating pump starter panel.
Temp. indication is too high acc. to Internal component failure. Replace the base module.
calibrated values, or values are ab-
normal.
Change-over switch between LO- Internal failure in the operation box. See table 1.3 and 1.4. Replace the operation box.
CAL - REMOTE - BLOCKING is not Damaged flat cable between print
working. card and front panel.
The alarm „System & Power failure“ This alarm consists of different alarm 1) Check diode A10.01 on the safety system
is activated. possibilities module 4P1. If it is alight, it is OK. No red LED must
1) Power & system failure in the be alight on 3P1or 4P1. See also table 1.1. SUPPLY
safety system. LED and RUN LED must be alight.
2) Power supply failure to the pres- 2) Check green diode J29/J30 and fuse 2.5 AT. If
sure sensors. green diode is alight, it is OK.
3) Cable/wire failure for monitor 3) Check if any analog signals are missing. If all
sensors. signals are present, it is OK. Remember to check
4) Cable/wire failure for safety sys- also the spare exh. gas input channels. A jumper
tem sensors. must be present. See also table 1.4
5) Communication link failure. 4) Check diode A10.02. If it is alight, it is OK. If it is
6) Tacho failure. not alight, check the safety system for cable break
or loose connections.
5) Check if rpm pick-up is OK, and/or lub. oil pres-
sure is OK. If lub. oil pressure is normal, but no rpm
signal is present, the tacho alarm will be activated.
6) Check the diode on the base module to table 1.3
and table 1.4.
OB display indicates OFFLN or Cable break on data communica- See table 1.3. Check cable installation for sensor(s)
ERR-1 or fault. tion or sensor(s). and/or data communication
08028-0D/H5250/94.08.12
01.38 - ES0-ny
L16/24
L27/38
Table 1.3
Base Module LED indications
On the Base Module printed circuit board a two-coloured lamp (light diode, LED) is located , which indicates the current state of the
Base Module central processor.
The following failure LED indications are possible:
Observations Description
GREEN permanent light OK, all Interlink modules are online
GREEN flash One or more Interlink modules are offline (disconnected) or incorrect setup on SW2.
RED permanent light BM internal hardware error (or lockup caused by EMC disturbances).
YELLOW permanent light BM internal hardware error (or lockup caused by EMC disturbances).
RED flash BM software or hardware fault. The number of flashes indicates an internal error code which must be
reported when returning the module. (It may also be caused by EMC disturbances)
Yellow 4x flash MODBUS address error (SW1): Incorrectly set to an illegal address (0 or 255, all switched ON or OFF).
Other yellow flashes BM internal software fault. The number of flashes indicates an internal error code which must be re-
ported when returning the module. (It may also be caused by EMC disturbances)
Table 1.4
Display indications on the Operation Box (OB)
Observations Description
Ready Shown for a few seconds when the OB module is powered on, indicating that the internal selftest of the module
was successfully passed.
OFFLN The OB module is OFFLINE. There is no communication from the base module to the OB module. This message
will appear shortly when powering on the system, indicating that the base module has been reset.
– Defective link between BM and OB module.

– No power on BM
– BM fatal hardware or software error. Indicated be red or yellow light or flashes on the BM two-coloured LED.
08028-0D/H5250/94.08.12
ERR-1 Indicates cable break or sensor failure on the corresponding input.
FAULT Indicates that the BM module has entered failsafe mode either because of a fatal software or hardware fault.
Shown if the exhaust temperature is selected for an invalid cylinder number.
01.38 - ES0-ny
08028-0D/H5250/94.08.12
Your Notes :
08031-0D/H5250/94.09.07
Index Specification and Treament, Lubricating Oil, Fuel
Page 1 (1) 504
Oil and Cooling Water
L16/24
Description
Lubricating oil specification...........................................................................................504.01 (05H)

Maintenance of lubricating oil condition........................................................................504.03 (04H)
Criteria for cleaning/exchange of lubricating oil............................................................504.04 (03H)
Lubricating points..........................................................................................................504.05 (03H)
Lubricating oil in base frame.........................................................................................504.06 (08H)
Specific lube oil consumption - SLOC ..........................................................................504.07 (01H)
Fuel oil specification .....................................................................................................504.20 (04H)
Fuel oil quality ...............................................................................................................504.25 (02H)
Nomogram for determination of CCAI ..........................................................................504.26 (02H)
Analysis data.................................................................................................................504.27 (02H)
Fuel oil cleaning ............................................................................................................504.30 (01H)
Fresh water system treatment ......................................................................................504.40 (02H)
Your Notes :
08031-0D/H5250/94.09.07
Description
Lubricating Oil Specification 504.01
General
Requirement Guiding Values
This document is valid for the following engine types: Based on typical load profile for marine GenSet (50-
L16/24, L21/31, L23/30H, L27/38, L28/32H, V28/ 60% of rated power)
32H, V28/32S
Oil type TBN TBN TBN
For the engines, a HD-lub. oil (heavy duty) corre- (initial) (equilibrium) (min. level)
sponding to at least type CD Comercial Class D after
API service system (meets MIL-L-2104 C and D) has Gas oil 8-12 6-8 6
to be used.
Marine diesel 10-15 8-10 8
The oil should be rust and oxidation inhibited. Heavy fuel (S<1.5) 10-15 8-10 8
When selecting a lubricating oil, attention must be Heavy fuel (1.5<S<2.5) 15-20 10-14 8
paid to the fuel oil sulphur content.
Heavy fuel (2.5<S<3.5) 20-25 10-14 8
Due to generating running mode for HOLEBY's Heavy fuel (3.5<S<4.5) 20-25 10-14 8
engines, where the lub. oil consumption depends on
running time and the fuel oil consumption and follow-
ing the sulphur input to the lub. oil depends on the Based on typical load profile for stationary GenSets
load, a lower TBN-value (Total Base Number) than (50-100% of rated power)
normal for main engines is needed.
(initial) (equilibrium) (min. level)
Viscosity
Gas oil 8-12 6-8 6
Marine
Engine SAE class Heavy fuel (S<1.5) 15-20 8-10 8

L23/30H, L+V28/32H
30* 105 mm2/sec at 40° C Heavy fuel (1.5<S<2.5) 20-25 10-14 8
L16/24, L21/31, L27/38
Heavy fuel (2.5<S<3.5) 20-30 10-14 8
40 145 mm2/sec at 40° C
Heavy fuel (3.5<S<4.5) 20-30 10-14 8
Stationary
L16/24, L21/31, L27/38 Based on typical load profile for variable speed
L23/30H, L+V28/32H, V28/32S engine, pumps (10-100% of rated power)
08028-0D/H5250/94.08.12
40 145 mm2/sec at 40° C

* At cooling water temperatures above 32° C SAE 40 (initial) (equilibrium) (min. level)
oil can be used. In this case, please contact MAN
B&W, Holeby. Gas oil 10-14 6-8 6

If load profile is different, this should be taken in
consideration. Heavy fuel (S<1.5) 15-20 8-10 8
In the long run though, the operation results are the Heavy fuel (1.5<S<2.5) 20-30 10-14 8
criteria that prove which TBN is the most economical
Heavy fuel (2.5<S<3.5) 20-30 10-14 8
one for efficient engine operation.
Heavy fuel (3.5<S<4.5) 25-30 10-14 8
01.24 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description
Maintenance of Lubricating Oil Condition 504.03
Page 1 (2)
Edition 04H
General
General A more economical solution is to maintain the condi-
tion by continuous treatment. Experience has proved
During operation of trunk engines the lubricating oil that centrifuging is superior to other methods of
will be contaminated slowly by small particles origi- cleaning lubricating oils.
nating from the combustion.
The optimum cleaning effect is achieved by keeping
The burning of heavy fuels will normally increase this the lubricating oil in a state of low viscosity for a long
contamination due to the increased content of car- period in the centrifuge bowl.
bon residues and other impurities.
Low viscosity is obtained by preheating the lubricat-
Contamination of lubricating oil with water, fresh or ing oil to a temperature of 85°C - 95°C.
salt, can also take place.
Slow passage of the lubricating oil through the
A certain amount of contaminants can be kept sus- centrifugal separator is obtained by using a reduced
pended in the lubricating oil without affecting the flow rate and by operating the separator 24 hours a
lubricating properties. day, stopping only when cleaning of the bowl is
necessary.
But the condition of the lubricating oil should be kept
under observation by analyzing oil samples. See When treating detergent type lubricating oil, the flow
also 504.04 "Criteria for Cleaning/Exchange of rate is usually recommended to be reduced to 15-
Lubricating Oil". 25% of the rated flow of the separator.
The engine bearings are protected by the full-flow In order to keep the amount of lubricating oil in the
lubricating oil filter built onto the engine, the filter engine in good condition, it is necessary to treat 0.3-
cartridges having a fineness of 15 micron and the 0.4 l/kw per hour.
safety filter a fineness of 60 micron.
A centrifuge for treating this amount of lubricating oil
The condition of the lubricating oil can be main- under the aforementioned derated flow conditions
tained/reestablished by exchanging the oil at fixed should have a rated capacity of 1.5-2.5 l/kw per hour,
intervals or based on analysis results. but in each case the separator manufacturer's rec-
ommendations for capacity and operating in-
structions should be followed.
Operation on Marine Diesel Oil (MDO)
For engines with cartridge-type oil filters (depth
The built-on full-flow dept filter cleans the oil thor- filters), continuous and efficient purification of the oil
oughly. For operation on MDO we recommend to in the separator is essential to ensure a long service
install a built-on centrifugal by-pass filter too. life for the cartridge filters.
08028-0D/H5250/94.08.12
For cleaning of the lubricating oil system after over-

Operation on Heavy Fuel Oil (HFO) hauls and inspection of the lubricating oil piping
system, see section 515.
For engines operating on HFO a lub. oil centrifugal
unit is required.
Deterioration of Oil
Continuous lub. oil centrifugation plus a built-on full-
flow depth filter clean the oil in a sufficient and safe Oil seldom loses its ability to lubricate, i.e. to form a
way. Any other filter system is not necessary, but not friction-decreasing oil film, but it may become cor-
wasted. 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.
02.16 - ES0 - G
504.03 Maintenance of Lubricating Oil Condition Description
General
In that case not only must the bearings be renewed, These may be some or all of the following:
but the journals must also be polished. The corro-
siveness of the lubricating oil is either due to far - Sludge precipitation in purifier multiplies.
advanced oxidation of the oil itself (TAN) or to the
presence of inorganic acids (SAN). In both cases the - Smell of oil becomes acrid or pungent.
presence of water will multiply the effect, especially
an influx of sea water as the chloride ions act as an - Machined surfaces in crankcase become cof-
inorganic acid. fee brown with a thin layer of lacquer.
- Paint in crankcase peels off or blisters.

Oxidation of Oils
- Excessive carbon is formed in the piston cool-
At normal service temperature the rate of oxidation ing chamber.
is insignificant, but the following factors will accele-
rate the process: In a grave case of oil deterioration, the system
should be cleaned thoroughly and refilled with new
oil.
High Temperature
If the coolers are ineffective the temperature level Water Washing

will generally rise.
Water washing of HD oils must not be carried out.
A high temperature will also arise in electrical preheat-
ers if circulation is not continued for 5 minutes after
the heating has been stopped, or if the heater is only Water in the Oil
partly filled with oil.
If the TAN is low, a minor increase in the fresh water
content of the oil is not immediately detrimental while
Catalytic Action the engine is running. Naturally, it should be brought
down again as quickly as possible (below 0.2%
Oxidation of the oil will be accelerated considerably water content, which is permissible). If the engine is
if catalytic particles are present in the oil. Wear stopped while corrosion conditions are unsatisfac-
particles of copper are especially harmful, but also tory it should be turned just over 1/2 revolution once
ferrous particles and rust are active. Furthermore, every hour (i.e. stop in different positions) while the
the lacquer and varnish-like oxidation products of oil circulation and purifying at a high preheating
the oil itself have an accelerating effect. Continuous temperature continue to remove water. Water in the
cleaning of the oil is therefore important to keep the oil may be noted by steam formation on the sight
sludge content low. glasses, by appearance, or ascertained by immers-
08028-0D/H5250/94.08.12
ing a piece of glass or a soldering iron heated to 200-

300°C in an oil sample. If there is a hissing sound,
Signs of Deterioration water is present. If a large quantity of water has
entered the oil system, it may be profitable to suck up
If circulating oil of inferior quality is used and the sedimented water from the bottom of the tank. Taste
oxidative influence becomes grave, prompt action is the water for salt. If salty, an oil sample should be
necessary as the last stages in the deterioration may analysed immediately for chloride ions.
develop surprisingly quickly, i.e. within one or two
weeks. Even if this seldom happens, it is wise to be
acquainted with the signs of deterioration.
02.16 - ES0 - G
Description
Criteria for Cleaning/Exchange of Lubricating Oil 504.04
General
Replacement of Lubricating Oil 3. Water Content
It is not possible to predict the expected life time for Limit value : < 0.5
lubricating oil, as it is not possible for the engine preferred < 0.2 (higher value is
manufacturer to know which fuel and lubricating oil permissible in a shorter period)
qualities will be used and under which operation
conditions the engine will be operated. Possible test
method : Patable test unit or gas chrom-
A replacement of lubricating oil is required when the atography (or infra red distil).
oil's identification values have changed no that the If the limit value is exceeded, a
lubricating cleaning and neutralization properties no supplementary test for chlorides
longer are sufficient. (ASTM D-878) can be made.
Exchange of the lub. oil has to be based on the oil

suppliers evaluation of samples of oil in service. 4. Total Base Number (TBN-Number)
Samples should be forwarded at appropriate inter-
vals at least once every three months depending of Limit value : Ref. to fresh-oil TBN% : > 70%
running-mode and results of last analysis.
Unit : mg KOH/g
The oil sample should be taken after the filter and, if
possible, while the engine is running as this will Possible test
ensure that the test will be representative for the method : ASTM D-2896
whole change in the engine.
Due to the generating running mode for HOLE-
BY's engines, where the lub. oil consumption
Evaluation of the Lubricating Oil Condition depends on running time and the fuel oil con-
sumption and following the sulphur input to the
For evaluating the conditions of a used oil, the lub. oil depends on the load, a lower TBN-value
following guidance conditions are normally suffi- than normal for main engines is needed.
cient. Anyway, all parameters have to be evaluated
as a whole, and no single can be taken as a criterion Following guiding values can be given:
for changing oil.
Oil type TBN TBN (equi-
(initial) librium)
1. Viscosity
Gas oil 10 7
Limit value : < ±1 viscosity grade
Marine diesel 15 10
Heavy fuel (S>2.5) 15 10
Units : SAE-units
Heavy fuel (S>4) 20 14
08028-0D/H5250/94.08.12
Possible test
method : ASTM D-445 (modified) The TBN is normally reduced gradually with the
time of operation. The influential elements are the
sulphur content in the fuel oil, the lubricating oil
2. Flash Point amount and the amount of re-filling due to normal
consumption. After a certain time of ope-ration,
Limit value : > 185° C the TBN will stabilize at a lower value, the TBN
equilibrium.
Possible test
method : Setaflash tests (cut of point cor
relates with 204° C i ASTM D-92
(coc)
96.44 - ES1
504.04 Criteria for Cleaning/Exchange of Lubricating Oil Description
General
Re-filling should be carried out with lubricating oil of Unit : Weight %

the initial TBN.
Possible test
method : ASTM D-893 procedure B in n-
5. Neutralization Number Heptane.
Limit value : 0.4-1.0 above typical level Additionally

test : If the level in n-Heptane insolub-
Unit : mg KOH/g les is considered high for the ty-
pe of oil and application, the test
Possible test could be followed by a supple-
method : ASTM D-974 mentary determination in Tolu-
ene.
6. The Total Contamination (insolubles Con- Also infra red test can be used.
tent) Heptane insolubles
Limit value : < 1.5 generally, depending upon

actual dispersant value and the
increase in viscosity.
08028-0D/H5250/94.08.12
96.44 - ES1
Description 504.05
Page 1 (1) Lubricating Points Edition 03H
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 504.01.
Turbocharger Engine system lubricating oil.
Governor See governor instructions in section 509.
Alternator See special instructions in section 518 or separate instructions.
Hydraulic tools Hydraulic oil or turbine oil (with a viscosity of about SAE 20).
08028-0D/H5250/94.08.12
97.40 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Lubricating Oil in Base Frame 504.06
L16/24
Type L16/24 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.
Min. level alarm H1 (mm) 285 285 285 285 285
Min. level H2 (mm) 295 295 295 295 295

08028-0D/H5250/94.08.12
Max. level H3 (mm) 370 370 370 370 370
Max. level alarm H4 (mm) 385 385 385 385 385
Min. litre (H2) 342 389 436 483 530
Max. litre (H3) 429 488 547 606 665
99.27 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description
Specific Lube Oil Consumption SLOC 504.07
General
In order to determine the engine condition, the lube In order to evaluate the correct engine SLOC, the
oil consumption needs to be recorded. To secure a following circumstances must be noticed and
uniform method to evaluate the SLOC, the following subtracted from the engine SLOC:
method should be used as guidance:
A1) Desludging interval and sludge amount from
During the routinely engine inspections the lube oil the lube oil separator (or automatic lube oil filters).
level in the base frame must be observed. The The expected lube oil content of the sludge amount
engine must be in operation or the pre-lubricating is 30%.
pump must be running during this inspection!
The following does also have an influence on the
The lube oil volume between maximum and minimum SLOC and must be considered in the SLOC
level at the dipstick is described in the Instruction evaluation:
Manual or in the Product Manual. If the lube oil level
is at the minimum, lube oil is added until the max level A2)
is reached at the dipstick. Lube oil evaporation
Lube oil leakages
The lube oil volume added, the lube oil temperature Lube oil losses at lube oil filter exchange
and the engine running hours are recorded and the
readings could be filled in the attached data sheet.
The engine maximum continuous rating (PMCR) must
The lube oil density, ρ @ 15°C must be known in always be used in order to be able to compare the
order to convert ρ to the present lube oil temperature individual measurements, and the running hours
in the base frame. The following formula is used to since the last lube oil adding must be used in the
calculate ρ: calculation. Due to inaccuracy *) at adding lube oil,
the SLOC can only be evaluated after 1,000 running
ρlube oil [kg/m3] = hours or more, where only the average values of a
number of lube oil addings are representative.
ρlube oil @15°C [kg/m3] – 0,64 * (tlube oil [°C] – 15)
If the SLOC deviates from the nominal value stated
in the Instruction Manual or in the Product Manual,
The following formula is used to calculate the SLOC: the engine cylinder condition should be inspected.
SLOC [g/kWh] =
(lube oil added – A1 – A2 [dm3]) * ρlube oil [kg/m3] Note *)

run.hrs period * PMCR [kW] A deviation of ± 1 mm with the dipstick measurement
must be expected, witch corresponds ± 5 dm3,
depending on the engine type.
08028-0D/H5250/94.08.12
03.14 - ES0
Description
Specific Lube Oil Consumption SLOC 504.07
General
Plant / Ship
Lube oil consumption
Engine type:___________________ Engine # :__________________
Lube oil brand/type:__________________________________________
Density @15°C:_____________ [kg/m3]

Date Run. hrs Add. Lube oil A1 + A2 L.O.Temperature SLOC Remarks
[h] [dm³] [dm³] [°C] [g/kWh]
08028-0D/H5250/94.08.12
03.14 - ES0
Description
Fuel Oil Specification 504.20
General
Commercially available fuel oils with a viscosity up to The data refer to the fuel as supplied, i.e. before
700 cSt at 50° C corresponding to 55 cSt at 100° C any on-board cleaning.
can be used for MAN B&W Holeby 4-stroke medium
speed diesel engines.
For guidance on purchase, reference is made to ISO Property Units Value

8216/17, BS 6843 and to CIMAC recommendations
regarding requirements for heavy fuel for diesel Density at 15°C kg/m3 ≤ 991*
engines, third edition 1990. From these maximum
accepted grades are RMH 55 and K55. The mention- Kinematic
ed ISO and BS standards supersedes BS MA 100 in viscosity
which the limit is M9. at100°C cSt ≤ 55
at 50 °C cSt ≤ 700
It means that engines can be operated on the same
fuel oils as MAN B&W 2-stroke low-speed diesel Flash point °C > 60
engines.
Pour point °C ≤ 30
The data in the above HFO standards and specifica-
tions refer to the same fuel type as delivered to the Carbon residue % (m/m) ≤ 22
ship, i.e. before on-board cleaning.
Ash % (m/m) ≤ 0.15
In order to ensure effective and sufficient cleaning of
the HFO, i.e. removal of water and solid contaminants, Total sediment
the fuel oil specific gravity at 15° C (60° F) should be after ageing % (m/m) ≤ 0.10
below 0.991. Higher densities can be allowed if
special treatment systems are installed. Water % (v/v) ≤ 1.0
Current analysis information is not sufficient for Sulphur % (m/m) ≤ 5.0

estimating the combustion properties of the oil.
This means that service results depend on oil pro- Vanadium mg/kg ≤ 600
perties which cannot be known beforehand. This
especially applies to the tendency of the oil to form Aluminium +
deposits in combustion chambers, gas passages Silicium mg/kg ≤ 80
and turbines. It may, therefore, be necessary to rule
out some oils that cause difficulties.
m/m = mass V/V = volume
Guiding Heavy Fuel Oil Specification *) May be increased to 1.010 provided adequate
cleaning equipment is installed, and modern
Based on our general service experience we have, type of centrifuges.
08028-0D/H5250/94.08.12
as a supplement to the above-mentioned standards,

drawn up the guiding HFO-specification shown below.
If heavy fuel oils, with analysis data exceeding the
Heavy fuel oils limited by this specification have, to above figures, are to be used, especially with regard
the extent of the commercial availability, been used to viscosity and specific gravity, the engine builder
with satisfactory results on MAN B&W GenSets. should be contacted for advice regarding possible
changes in the fuel oil system.
01.34 - ES1
504.20 Fuel Oil Specification Description
General
Fuel Oil Condition, when Entering the Engine
As practically all fuel oil specifications including the For fuels above 180 cSt/50° C a pressurerized fuel
above standards refer to the same fuel type as oil system is necessary to avoid boiling and foaming
supplied, the fuel supplied to a ship has to be treated of the fuel.
on board before use. For running on the oil quality
mentioned above it is necessary that equipment The viscosity leaving the heaters should be 10-15
exists on board, which can treat, viz clean and cSt and approx. 12-18 cSt entering the engine. The
preheat, the fuel oil with optimum efficiency. maximum temperature of oil after preheater should
be 150° C to avoid to rapid fouling of preheater.
In B 11 00 0 "Cleaning Recommendations" our
recommendations are outlined. The preheating chart on page 3 illustrates the expect-
ed preheating temperature as function of the specific
For economical HFO operation the fuel oil condition fuel oil viscosity.
at engine inlet should be as recommended below.
Property Units Max. value
Water % by volume max. 0.2
Solid
particles ppm (mg/kg) max. 20
Particle size Micron max. 5
Viscosity cSt Range 12-18
08028-0D/H5250/94.08.12
01.34 - ES1
Description
Fuel Oil Specification 504.20
General
Fuel oil - preheating chart
Approx. viscosity
after preheater
Temperature sec.
cSt
after preheater °C Rw.
7 43
170
160 10 52
Normal preheating limit 12 59

150
15 69
140
20 87
130
120
30 125
110
100
90
80
70
60
Approx. pumping limit
50
40
30
Log scales 10 15 25 35 45 55 cSt/100° C
30 60 100 180 380 700 cSt/50° C

200 400 800 1500 3500 7000 sec. Rw/100° F
08028-0D/H5250/94.08.12
Viscosity of fuel
This chart is based on information from oil suppliers regarding typical marine fuels with viscosity index 70-80.
Since the viscosity after the preheater is the controlling parameter, the preheating temperature may vary,
dependent on the viscosity and viscosity index of the fuel.
01.34 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Description
Fuel Oil Quality 504.25
General
General Considerations Combustion Quality
The quality of a fuel oil is stated, in analysis data, in Combustion quality is the ability of the fuel oil to ignite
terms of physical and chemical properties, which are and burn in a proper way. The ignition quality,
decisive to the suitability of the fuel oil for different combustion intensity, and length and completeness
applications. For diesel engine fuels the combustion of combustion are properties influenced by the
quality, the content of impurities and the handling chemical combustion and structure of the fuel oil.
properties are the main quality criteria.
Ignition quality relates to ignition delay, i.e. the time
Since residual fuels are traded and designated elapsed between the start of injection and the start of
according to viscosity, it has become common combustion.
practice to associate viscosity with quality. This
practice can be very misleading, especially with Ignition quality is expressed by the cetane number,
modern residual fuels, as a fuel oil of low viscosity diesel index or cetane index. In all cases the higher
can often be just as bad, or even worse, than other the value, the better the ignition quality. For diesel oil
fuel oils of very high viscosity. the ignition quality is expressed by the cetane number
determined by a specified method in a standard
The quality of refinery residues is dependent on the engine running under standard conditions.
origin of the crude oil, the grade of utilization when
refining the crude oil, and the refinery technique For residual fuels the ignition quality can be expressed
used. by the diesel index or cetane index, both to be
calculated from physical properties such as the
Some of the residues used in fuel oil production are aniline point, specific gravity and mid-distillation
of a viscosity requiring visbreaking, a process which temperature. The cetane number, diesel index or
will reduce the viscosity without improving the quality cetane index of a certain fuel oil will show reasonable
at all. correlation between the numerical values.
When producing residual fuels from visbreaked, A FIA cetane number test is also good for evaluation
cracked residues and from "straight run" residues, of the combustion quality.
the final adjustment of viscosity to fulfil the
requirements of the different grades of intermediate The combustion condition of the fuel oils is normally
fuels is achieved by adding gas oil. evaluated from Conradson Carbon residue and the
asphaltene contents.
However, it must be noted that considerable reduction
of the viscosity is achieved by adding a relatively
small amount of gas oil, which will give only a minor Content of Impurities
improvement of the quality of the blend. This means
that the quality to a major extent depends on residues The content of impurities of diesel engine fuels
present in the blend. Therefore the quality also should be kept as low as possible, and harmful and
depends on the density, see 504.26. unwanted impurities should, to the greatest possible
08028-0D/H5250/94.08.12
extent, be removed in the pre-treatment system in

As a consequence of the possible variations in the order to minimize wear and corrosion of engine
quality of residues and the influence of adding gas components. Impurities derive from the crude oil
oil, the quality of blended fuels can vary, even for fuel itself, from refinery processes and from handling and
oils of equal nominal viscosity. storage of oils. Some impurities, such as sulphur and
vanadium, are oil soluble and therefore impossible
to remove in a conventional mechanical fuel oil
treatment system, while the amount of water and
solid impurities can be reduced by centrifuging and
filtration.
02.16 - ESO - G
504.25 Fuel Oil Quality Description
General
Sand, rust, metal oxides and catalyst particles can The flash point is related to the volatility of the
be found as solid particles in fuel oil. amount and nature of lighter fractions in the fuel oil,
and might thus be used to estimate the propensity of
Fuel-related wear and corrosion in diesel engines gasification in non-pressurized parts of the fuel
take the form of mechanical wear and chemically system.
induced corrosion, the latter in the form of high and
low temperature corrosion. The pour point defines the temperature at which wax
crystallization will take place and prevent the fuel oil
The solid impurities and particles produced during from flowing and from being pumped.
combustion, collectively known as ash, cause
mechanical wear of engine components. Therefore, the pour point must be taken into account
when deciding the presence and capacity of heating
Especially catalyst particles, silicone and aluminium coils in bunker tanks.
oxides and silicates in the form of sand are very
abrasive. From vanadium and sodium corrosive ash
in the form of oxides, carbonates and sulphates, is Quality Fuel Oil Main Effects
created during combustion. Criteria Characteristics
Combustion Conradson carbon Ignition ability.

The sulphur content of a fuel oil may lead to low quality asphaltenes + Combustion condition.
temperature corrosion of combustion chamber FIA test Fouling of gasways.
components and the formation of deposits on these.
The corrosive effect is due to the formation of sulphuric Sulphur Corrosive wear. Cold
acid. corrosion.
Vanadium Formation of deposits on

Water in the fuel oil may lead to several detrimental Sodium exhaust valves and turbo-
effects to the fuel system and to the diesel engine in chargers.
general by giving rise to mechanical and corrosive High temperature corrosion.
wear, as well as fouling.
Water Disturbance of combustion
process.
Increased heat-load of com-
Handling Properties Content of bustion chamber compo-
impurities nents, fouling of gas ways,
mechanical wear and cavita-
Handling of the fuel, i.e. storage, pumping and
tion of fuel injection system.
treatment, is affected mainly by physical properties
such as viscosity, density, flash point and pour point, Ash Mechanical and corrosive
but other fuel oil properties such as stability, emul- wear of combustion
sification tendency, viscosity index and the nature chamber components.
Formation of deposits.
and amount of water and solid impurities will also
Catalyst fines Mechanical wear of fuel in-
influence the handling system. jection system, cylinder
liners and piston rings.
08028-0D/H5250/94.08.12
The nominal viscosity is decisive for the preheating

temperature necessary to achieve adequate viscosity Viscosity Temperatures, pressures,
Density and capacities of fuel oil
for pumping, settling, centrifuging and injection.
Handling Pour point systems for storage,
properties pumping and pre-treatment.
The density influences the gravitational settling of
water and solid contaminants in settling tanks. Flash point Safety requirements.
Specific gravity is also an important parameter in the
centrifuging process. The flash point is, for safety Table 1. Fuel properties affecting diesel engine and fuel systems.
reasons, limited to a minimum of 60°C (140°F) by
classification societies and other authorities.
02.16 - ES0 - G
Description
Nomogram for Determination of CCAI 504.26
General
08028-0D/H5250/94.08.12
Fig 1 Nomogram for determination of CCAI.
01.34 - ES1
504.26 Nomogram for Determination of CCAI Description
General
Example: Ignition quality is an important fuel parameter. The

reason why it does not appear in the international
Viscosity: 180 cSt at 50°C specifications is that there are no standardized testing
Density: 990 kg/m³ at 15°C method is non-existent. Therefore, parameters such
as the Calculated Carbon Aromaticity Index (CCAI)
The combining straight line across density (990 kg/ are resorted to as an aid which is derived from
m³) and viscosity (180 cSt) of a heavy fuel oil results determinable fuel parameters. According to our
in CCAI (859). From CCAI, conclusions may be experience, only a rough assessment of the ignition
derived with regard to the ignition qualities. quality of the heavy fuel oil is possible with the help
of this method.
CCAI may be calculated with the aid of the following
formula: However, the CCAI has become so well-known in
widespread publications that, in spite of the
CCAI = D - 141 log (log (v + 0.85)) - 81 reservations mentioned above. We were compelled
to classify the respective MAN B&W Diesel A/S,
Holeby engines according to CCAI-rating, too.
08028-0D/H5250/94.08.12
01.34 - ES1
Description
Analysis Data 504.27
General
Comments on Analysis Data for Fuel Oils Asphaltenes also influences the lubricating proper-
ties of the fuel oil and, in extreme cases, high
Carbon Residue asphalteness content may lead to fuel injection
pump sticking.
The carbon residue of a fuel oil indicates its coke-
forming tendency and can be used to determine the Fuel oils with a high asphalteness content will have
tendency to form deposits in the combustion cham- a tendency to form sludge, especially if the water
ber and gasways. The higher the carbon residue content is also high. The asphaltenes content of a
value, the higher the fouling tendency. fuel oil is influenced by pre-treatment. The heaviest
semi-solid asphaltenes, and asphaltenes bound to
Some changes in the combustion process, requiring water as sludge, can be separated by centrifuging.
adjustment of the maximum pressure, may also be
attributed to a high carbon residue content. The
value is measured by standardized tests, such as Diesel Index
the Conradson or Ramsbottom tests which give
similar results. Diesel index is a calculated value to determine the
ignition quality of a fuel oil. The ignition quality is
The non-vaporized residue from the carbonizing test related to the hydrocarbon composition, paraffin
consists of carbonaceous material and inorganic being of high quality, n-heptanes of moderate quality
impurities and is expressed as percentage weight of and aromatics of low quality.
the fuel sample tested. Carbon residue and
asphaltenes content generally move in parallel, both With certain exceptions the properties of the aniline
in relation to the carbon-to-hydrogen ratio, with in- point and the specific gravity reflect the hydrocarbon
creasing values for a higher ratio. composition of a fuel oil, and are therefore used in
the following simple formula as an expression of
The carbon-to-hydrogen ratio and thus also the ignition quality:
carbon residue depends on the source of the crude
oil and the type of refinery processing used. Diesel index = (aniline point °F x API gravity) x 0.01.
The effect of carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment of the fuel oil, as centrifuging equal volumes of the fuel and aniline become just
only influences solid inorganic contaminants and miscible. The test relies on the fact that aromatic
hard asphalts, which are only small amounts of the hydrocarbons mix completely with aniline at com-
percentage weight called carbon residue. paratively low temperatures, whereas paraffins re-
quire considerably higher temperatures before they
are completely miscible.
Asphaltenes
A high aniline point thus indicates a highly paraffinic
Asphaltenes is defined as the part of a fuel oil sample fuel, and consequently a fuel oil of good ignition
which is insoluble in heptane. The content of quality. Similarly, a high API gravity number denotes
08028-0D/H5250/94.08.12
asphalteness is expressed as percentage weight of a low specific gravity and high paraffinicity, and
the fuel oil sample tested. again a good ignition quality.
Asphaltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea of the
solid hydrocarbon compounds dispersed in the fuel ignition quality, but generally gives figures slightly
oil, has a similar effect on the combustion process to above the cetane number.
the carbon residue, the main impact being fouling of
gasways. The stability of the fuel oil is related to the Fuel oils with poor ignition quality and a low diesel
asphaltenes content. index might in particular cause problems in starting
diesel engines and running at low load.
02.16 - ES0 - G
504.27 Analysis Data Description
General
In addition to starting difficulties, a prolonged ignition Especially if the weight ratio of sodium to vanadium
delay may give rise to alternations in the maximum exceeds 1:3, ash with a very low melting point and
pressure, leading to increased mechanical or ther- stiction temperature is formed, giving rise to high
mal load. temperature corrosion of exhaust valves and de-
posit formation in turbochargers.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling It is possible to reduce the tendency for formation of
of gasways. detrimental vanadium-sodium ash by effective cen-
trifuging, which will remove sodium salts together
with water. If a very low content of sodium is ensured,
Sulphur a relatively high vanadium content might be accept-
able.
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free Water
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low The water content of fuel oil is measured by a
temperature corrosion. During combustion, sulphur standardized distillation test and is expressed as
oxides are produced in the form of gases. Since percentage volume of the sample tested. Water in
humidity is also present sulphur and sulphuric acid the fuel oil may lead to several detrimental effects on
may be formed on components in the combustion the fuel oil system, and corrosion and cavitation of
chamber and in the gasways, where the temperature fuel injection pumps and fuel valves, and cause
is below that of the dew point for sulphuric acid. fouling of exhaust systems and turbochargers.
The detrimental effect of sulphur in fuel oil is counter- Due to its content of sodium, salt water in combina-
acted by maintaining an adequate temperature of tion with vanadium contributes to the formation of
the combustion chamber components and by using low-melting corrosive ash, which attacks exhaust
alkaline lubricating oil to neutralize the sulphuric acid valves and turbochargers. When it disturbs the fuel
produced during combustion. atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
It is possible to reduce the water content of a fuel oil
Vanadium and sodium are constituents of the ash primarily by centrifuging, and this should be done to
content. The amounts of these are measured by the widest possible extent in order to avoid the
analyzing the residue from the combustion test used detrimental effects of water in the fuel oil.
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil Ash
sample being tested for ash content. Vanadium
08028-0D/H5250/94.08.12
derives from the crude oil itself and, being oil soluble, Ash content is a measure of the non-combustible
cannot be removed from the fuel oil by conventional material present in the fuel oil. The ash content is
pre-treatment. Sodium derives from the crude oil, determined by a combustion test and it is expressed
and also from contamination with salt water during as a percentage weight residue from complete com-
storage and transport of the fuel oil. Sodium is water- bustion of the oil sample tested.
soluble and, regardless of derivation, tends to com-
bine with the water present in the fuel oil. Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
Owing to its water solubility, it is possible to remove contamination of the fuel oil.
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.
02.16 - ES0 - G
Description
Analysis Data 504.27
General
Ash-forming materials exist both as solid contami- Viscosity of Marine Gas Oil (MGO) and Marine
nants and in soluble compounds. The solid contami- Diesel Oil (MDO) are expressed in centistokes (cSt)
nants may lead to abrasive wear in the fuel injection at 40° C.
system. Ash formed during combustion may lead to
abrasive as well as corrosive wear of combustion Viscosity is an important parameter in connection
chamber components and give rise to formation of with pumping, pre-treatment and injection of fuel oil,
detrimental deposits. It is therefore essential, to the since the possibility and efficiency of these processes
greatest possible extent, to reduce the amount of to a large extent depend on adequate viscosity.
ash-forming materials by centrifuging.
Adjustment of viscosity to adequate values is possible
Solid contaminants such as sand, rust, certain metal by taking advantage of the interdependence between
oxides and catalyst fines can be removed by centri- the temperature and viscosity index of the fuel oil.
fuging, and the same goes for water-soluble salts
such as sodium. The nominal viscosity of a fuel oil is the factor
determining the preheating temperatures necessary
Some of the components included in the ash content to obtain adequate viscosity for pumping, centrifug-
have been found to be particularly harmful and are ing and injection of the fuel oil, and thus also the
therefore stated individually in the analysis data. factor determining the capacity of the preheating
equipment in the fuel oil system.
Silicium and Aluminium Oxides

Density
Residual fuels produced by refineries using fluid
catalytic cracking may be contaminated by catalyst Density is defined as the mass of a unit volume and
particles in the form of silicium and aluminium ox- is expressed in g/cm³ at a temperature of 15°C
ides. Any catalyst particles are shown by the ash (59°F).
content value. Separate values for silicium oxide
content and aluminium oxide content are measured Specific gravity is the ratio of the mass of a given
by analyzing the ash content. volume of liquid at 60°F (15.6°C) and the mass of an
equal volume of water at the same temperature. For
The amount of silicium and aluminium oxides is a given liquid, the specific gravity will generally give
expressed in ppm in relation to the weight of the the same numerical value as the density.
original fuel oil sample being tested for ash content.
API gravity is an arbitrary scale calibrated in degrees
As catalyst particles are very hard and abrasive, they and related to specific gravity by the following for-
can cause extreme mechanical wear of the fuel mula:
injection system, cylinder liners and piston rings. 141.5
° API gravity = specific gravity/50°F + 131.5
Catalyst particles, being solid and insoluble, can be
removed from the fuel oil. The guidelines for
08028-0D/H5250/94.08.12
dimensioning the centrifuge size are based on the As the formula indicates, the API gravity is in inverse
fact that approx. 1/3 of the catalyst particles in terms proportion to density and specific gravity.
of weight is removed.
Density is an important parameter in the centrifuging
process, where separating water and water-dis-
Viscosity solved impurities from the fuel oil is based on the
difference in densities. If the density of the fuel oil
Basically viscosity is a measure of the internal fric- approaches that of water, centrifuging thus becomes
tion or resistance of a liquid to flow. less effective, necessitating a reduced flow rate and
therefore increased centrifuge capacity.
02.16 - ES0 - G
504.27 Analysis Data Description
General
The water separation ability of fuel oil is increased by Pour Point

preheating the fuel oil prior to centrifuging since the
densities of fuel oil and water change with the The pour point is the lowest temperature at which an
temperature at different rates, thus making it possi- oil will flow or can be poured. The pour point is
ble to optimize density differences. measured under specific test conditions. Fuel oil
must be stored, handled and pumped at tempera-
To some extent the quality of a fuel oil can be judged tures above the pour point to avoid wax crystalliza-
by the density, since this is directly proportional to tion, which may result in precipitation in storage
the carbon-to-hydrogen ratio, which again is in direct tanks, blocking of filters and pipe lines and preven-
proportion to aromativity, carbon residue and tion of pumpability. Normally, the pour point of re-
asphaltene content, but in reverse ratio to calorific sidual fuel oil does not create any problems, since
value. the temperature needed to reduce the viscosity to
pumpable levels will be adequately in excess of the
pour point.
Analysis Data for Fuel Oils
Carbon Residue % weight Flash Point

Asphaltenes % weight
Diesel Index The flash point of an oil is defined as the temperature
Engine- FIA
at which it gives off sufficient vapour to create an
Relevant Ash % weight
Properties Sulphur % weight inflammable mixture with air. This mixture will ignite
Water % volume or flash under the influence of an open flame, but will
Vanadium ppm not support combustion itself. The flash point of fuel
Sodium ppm oil is normally tested by the Pensky-Martens closed-
Silicium Oxide ppm
up method.
Aluminium Oxide ppm
Viscosity cSt/50°C In order to provide a sufficient margin of safety from

Installation- Density g/ml fire risk during storage, handling and transportation,
Relevant Flash Point °C fuel oils for shipboard use must meet the classifica-
Properties Pour Point °C
tion societies' requirements of flash point, limited to
a minimum of 60°C (140°F).
Table 2 Analysis data for fuels.
08028-0D/H5250/94.08.12
02.16- ES0 - G
Description
Fuel Oil Cleaning 504.30
General
Purification Recommendations Especially for fuels above 180 cST/50°C (1500 sec.
RW/100°F) the highest possible temperature of 98°C
Fuel oils are always contaminated and should (208°F) should be maintained in the centrifuge oil
therefore be cleaned thoroughly of solid as well as preheater.
liquid contaminants before use. The solid contami-
nants in the fuel are mainly rust, sand, dust and re- The fuel is kept in the centrifuge for as long as
finery catalysts. Liquid contaminants are mainly water, possible by adjusting the flow rate through the
i.e. either fresh water or sea water. centrifuge so that it corresponds to the amount of fuel
required by the engine without excessive re-
The impurities can cause damage to fuel injection circulating. Consequently, the centrifuge should
pumps and fuel valves, result in increased cylinder operate for 24 hours a day except during necessary
liner wear and cause the exhaust valve seats to cleaning.
deteriorate. Increased fouling of gasways and
turbocharger blends may also result from the use of Taking today's fuel qualities into consideration the
inadequately cleaned fuel oils. need to clean centrifuges ("shooting frequency")
should not be underestimated. Correct choice and
Effective cleaning can only be ensured by means of adjustment of the regulating screws and/or the gravity
a centrifuge. We recommend that the capacity of the discs are of special importance for efficient water
centrifuges installed be at least according to the removal. The centrifuge manual states the disc or
centrifuge maker's recommendations. To obtain screw adjustment which should be chosen on the
optimum cleaning it is of the utmost importance to basis of the specific gravity of the fuel.
operate the centrifuge with as low a viscosity of the
fuel oil as possible and to allow the fuel oil to remain Normal practice is to have at least two centrifuges
in the centrifuge bowl for as long as possible. available for fuel cleaning. Results from experimental
work on centrifuges, treating today's qualities of
residual fuel, have shown that the best cleaning
effect, especially as regards removal of catalyst
Cleaning of HFO by Centrifuging
fines, is achieved when the centrifuges are operated
in series, in purifier/clarifier mode.
Operating Single centrifuge as purifier.
options Two centrifuges in parallel.
Therefore series operation of centrifuges to ensure
Two centrifuges in series.
maximum safety is a fully accepted alternative to the
Optimum Operating Configurations previously recommended parallel operation, provided
the operating capacity of each individual centrifuge
Water content Parallel operation can handle the total amount of fuel required by the
below 1 % Purifier / Purifier engine, without exceeding the flow rate recommended
Normal by the centrifuge maker for the operating mode in
conditions or
Density at 15°C Series operation question.
below 0.991 Purifier + Clarifier
If the centrifuge capacity installed is on the low side,
08028-0D/H5250/94.08.12
Water content corresponding to the specific viscosity of the fuel oil

below 1 % Parallel operation used, and if more than one centrifuge is available,
parallel operation may be considered in order to
Extreme Density at 15°C Purifier / Purifier obtain an even lower flow rate. However, in view of
conditions below 0.991 the above results and recommendations serious
consideration should be given to installing new
High content Series operation equipment in accordance with today's fuel qualities
of catalyst fines Purifier + Clarifier and flow recommendations.
Table 1. Cleaning of HFO.
97.40 - ES0
504.30 Fuel Oil Cleaning Description
General
To determine centrifuging capacity we generally

advise to follow the recommendations of the Flow Rate
centrifuge maker, but the curves in fig. 1, can be Related to Rated Capacity of Centrifuge
%
used as a guideline.
100
A homogenizer may be installed in the fuel oil system 80

as a supplement to the centrifuges in order to 60
homogenize possible water and sludge still present 40
in the fuel 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 Flow rate through centrifuge related to nominal capa-

city of centrifuge.
08028-0D/H5250/94.08.12
97.40 - ES0
Description
Freshwater System Treatment 504.40
General
Protection against Corrosion in Freshwater Cleaning agents emulsified in water as well as
Cooling System slightly alkaline cleaning agents can be used for the
degreasing process, whereas ready-mixed cleaning
The engine fresh water must be carefully treated, agents which involve the risk of fire must obviously
maintained and monitored so as to avoid corrosion not be used. For descaling with acid, especially
or the formation of deposits which can result in products based on amino-sulphonic acid, citric acid,
insufficient heat transfer, it is necessary to treat the and tartaric acid are recommendable, as these acids
cooling water. MAN B&W recommend that this treat- are usually obtainable as solid substances, easily
ment is carried out according to the following proce- soluble in water, and do not emit poisonous vapours.
dure:
The cleaning agents should not be directly admixed,
but should be dissolved in water and then added to
– Clean the cooling water system. the cooling water system.
– Fill up with deionized or distilled cooling water Normally, cleaning can be executed without any
(for example from the freshwater generator) dismantling of the engine. We point out that the water
with corrosion inhibitor added. should be circulated in the engine to achieve the best
possible result.
– Carry out regular checks of the cooling water
system and the condition of the cooling water. As cleaning can cause leaks to become apparent in
poorly assembled joints or partly defective gaskets,
inspection should be carried out during the cleaning
Observance of these precautions, and correct ven- process. The acid content of the system oil should
ting of the system, will reduce service difficulties also be checked immediately after cleaning, and 24
caused by the cooling water to a minimum. hours afterwards.
Cleaning of the Cooling Water System Cooling Water - Inhibitors
Before starting the inhibition process, any existing The filling-up with cooling water and the admixture of
deposits of lime or rust, or any oil sludge, should be the inhibitor is to be carried out directly after the
removed in order to improve the heat transfer and to cleaning in order to prevent formation of rust on the
ensure uniform protection of the surface by means of cleaned surfaces.
the inhibitor.
Raw Water
The cleaning should comprise degreasing to remove
oil sludge, and descaling with acid afterwards to The formation of lime stone on cylinder liners and in
remove rust and lime deposits. cylinder heads may reduce the heat transfer, which
will result in unacceptably high temperatures in the
Ready-mixed cleaning agents, specially made for material.
08028-0D/H5250/94.08.12
cleaning the cooling water system, can be obtained

from companies specializing in cooling water treat- Therefore, it is recommended that deionized or
ment. These companies offer assistance and control distilled water (for example from the freshwater
of the treatment in all major ports. A number of these generator) is used as cooling water. However, on
companies are mentioned on the enclosed list. We account of its lack of hardness, this water will be
point out that the directions given by them should be relatively corrosive, and a corrosion inhibitor should
closely followed. It is of particular importance to flush therefore always be added.
the system completely after cleaning.
00.11- ES1
504.40 Freshwater System Treatment Description
General
If deionized or distilled water cannot be obtained, Checking of the Cooling Water System and
normal drinking water can be used in exceptional the Sooling Water during Service
cases. If so, the total hardness of the water must not
exceed 9° dH (German hardness degrees). The If the cooling water is contaminated during service,
chloride, chlorine, sulphate, and silicate contents are sludge or deposits may form. The condition of the
also to be checked. These contents should not cooling water system should therefore be regularly
exceed the following values: checked, especially if deionized or distilled water is
not used. If deposits are found in the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces or, if necessary, the entire system
Chlorine 10 ppm (10 mg/litre) should be cleaned.
Sulphate 100 ppm (100 mg/litre)
Silicate 150 ppm (150 mg/litre) According to experience, a zinc galvanized coating
in the freshwater cooling system is often very sus-
There should be no sulphide and ammonia content. ceptible to corrosion, which results in heavy for-
Rain water must not be used, as it may be heavily mation of sludge, even if the cooling water is cor-
contaminated. rectly inhibited. The initial descaling with acid will, to
a great extent, remove the galvanized coating. Gen-
It should be noted that softening of water does not erally, therefore, we advise against the use of galva-
reduce its sulphate and chloride contents. nized piping in the freshwater cooling system.
Corrosion Inhibitors The quality of the cooling water is to be checked

regularly, if possible once a week. Basically the
To protect freshwater cooling systems in marine inhibitor concentration, the pH value and the chloride
diesel engines against corrosion, various types of concentration should be in accordance with limits
inhibitors are available. stated by inhibitor manufacturer. For this purpose
the inhibitor manifactures normally supply simple
Generally, only nitrite-borate based inhibitors test kits.
are recommended.
As a general guidance values the pH value should be
A number of the products marketed by major compa- 7-10 measured at 20° C and the chloride concentra-
nies are specified on the enclosed list, together with tion should not exceed 50 ppm (50 mg/litre).
the necessary dosages and admixing procedures.
We recommend that these directions are strictly The water sample for these tests is to be taken from
observed. the circulating system, and not from the expansion
tank or the pipe leading to it.
Treatment of the cooling water with inhibting oils is
not recommended, as such treatment involves the The concentration of inhibitor must under no
risk of oil adhering to the heat transmitting surfaces. circumstances be allowed to fall below that re-
commended by the producer, as this would in-
Chromate inhibitors must not be used in plants crease the risk of corrosion.
08028-0D/H5250/94.08.12
connected to a freshwater generator.

A clear record of all measuring results should be
Evaporated cooling water is to be replaced with kept, so that the actual condition and trend of the
noninhibited water, whereas a loss of water through system may be currently ascertained and evaluated.
leakage must be replaced with inhibited water.
A sudden or gradual increase in the chloride content
When overhauling individual cylinders, a new dos- of the cooling water may be indicative of salt water
age of inhibitor must, if necessary, be added im- leakages. Such leakages are to be traced and repai-
mediately after completing the job. red at the first opportunity.
00.11- ES1
Description
General
A chloride content in the cooling water higher than The cooling water system must not be kept
the 50 ppm specified might, in exceptional cases be under pressure.
tolerated. However, in that case the upper limit
specified by the individual inhibitor supplier must not Check, and repair any leaks.
be exceed.
Drain the system and fill up completely with clean tap
A clear record of all measuring results should be water, in order to flush out any oil or grease from the
kept, so that the actual condition and trend of the tank.
system may be currently ascertained and evaluated.
Circulate the water for 2 hours, and drain again.
A sudden or gradual degrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased Descaling with Acid Solution
by adding inhibtor; however, if major quantities are
necessary, the water should be replaced. Fill up with clean tap water and heat to 70-75° C.
Every third month a cooling water sample should be Dissolve the necessary dosage of acid compound in
sent ashore for laboratory analysis, in particular to a clean iron drum with hot water.
ascertain the contents of inhibtor, sulphate, and iron,
as well as the total salinity of the water. Fill the drum half up with water and slowly add the
acid compound, while stirring vigorously. Then fill
the drum up completely with hot water while conti-
Cleaning and Inhibiting Procedure nuing to stir (e.g. using a steam hose).
The engine must not be running during the cleaning Be careful - use protective spectacles and gloves.
procedure, as this may involve the risk of overhea-
ting when draining. For engines which have been treated before the trial
trip, the lowest concentration recommended by the
supplier will normally be sufficient.
Degreasing
For untreated engines, a higher concentration -
Use clean tap water for filling-up. The cooling water depending on the condition of the cooling system -
in the system can be used, if it does not contain will normally be necessary.
inhibitors.
Drain some water from the system and add the acid
Heat the water to 60° C and circulate the water solution via the expansion tank.
continuously.
The cooling water system must not be put under
Drain to lowest water level in expansion tank. pressure.
08028-0D/H5250/94.08.12
Add the amount of degreasing chemical specified by Keep the temperature of the water between 70° C
the supplier, preferably from the suction side of the and 75° C, and circulate it constantly. The duration
freshwater pump. of the treatment will depend on the degree of fouling.
Normally, the shortest time recommended by the
Drain to lowest water level in the expansion tank supplier will be sufficient for engines which are
directly afterwards. treated before the trial trip. For untreated engines, a
longer time must be reckoned with. Check every
Circulate the cleaning chemical for the period speci- hour, for example with pH-paper, that the acid in the
fied by the supplier. solution has not been used up.
00.11- ES1
504.40 Freshwater System Treatment Description
General
A number of descaling preparations contain colour Adding of Inhibitors

indicators which show the state of the acid solution.
If the acid content is exhausted, a new acid solution Fill up the cooling water system with water from the
can be added, in which case, the weakest recom- evaporator to the lowest water level in the expansion
mended concentration should be used. tank.
The solubility of acids in water is often limited. Weight out the quantity of inhibitors specified by the
Therefore if, in exceptional cases, a large amount is supplier and dissolve in a clean iron drum with hot
required, descaling can be carried out in two stages water from the evaporator.
with a new solution of compound and clean water.
Normally the supplier will specify the maximum Add the solution via the expansion tank to the
solubility. system. Then fill up to normal water level with water
from the evaporator.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized Allow the engine to run for not less than 24 hours to
with clean tap water containing 10 kg soda per ton of ensure that a stable protection of the cooling surfa-
water. Circulate the mixture for 30 minutes, then ces is formed.
drain and flush the system.
Subsequently, test the cooling water with a test kit
The cooling water system must not be put under (available from the inhibitor supplier) to ensure that
pressure. an adequate inhibitor concentration has been obtai-
ned.
Continue to flush until water used is neutral (pH
approx. 7). This should be checked every week.
The acid content of the system oil is to be checked

directly after the descaling with acid, and again 24
hours afterwards.
08028-0D/H5250/94.08.12
00.11- ES1
Description
General
Nitrite-borate corrosion inhibitors

for cooling water treatment
Maker's minimum
Company Name of Inhibitor Delivery Form Recommended
Dosage*
Castrol Limited Castrol Powder 3 kg/1000 l

Swindon Solvex WT4
Wiltshire, England Castrol Liquid 20 l/1000 l
Solvex WT2
Drew Ameriod DEWT-NC Powder 3.2 kg/1000 l

Marine Liquidewt Liquid 8 l/1000 l
Boonton, N.J./U.S.A Maxiguard Liquid 16 l/1000 l
Houseman Scandinavia Cooltreat 651 Liquid 5 l/1000 l

3660 Stenløse
Denmark Cooltreat 652 Liquid 5 l/1000 l
Nalfleet Marine Chemicals Nalfleet EWT Liq

Northwich, (9-108) Liquid 3 l/1000 l
Cheshire CW8DX, England Nalfleet EWT 9-131C Liquid 10 l/1000 l
Nalfleet EWT 9-111 Liquid 10 l/1000 l
Nalcool 2000 Liquid 10 l/1000 l
Rohm & Haas RD11 DIA PROSIM Powder 3 kg/1000 l

(ex Duolite) RD25 DIA PROSIM Liquid 50 l/1000 l
Paris, France
Unitor Rochem Dieselguard NB Powder 3 kg/1000 l

Marine Chemicals Rocor NB Liquid Liquid 10 l/1000 l
Oslo, Norway
* Initial dosage may be larger
The list is for guidance only and must not be The suppliers are listed in alpabetical order.
08028-0D/H5250/94.08.12
considered complete. We undertake no responsi-

bility for difficulties that might be caused by these or Suitable cleaners can normally be supplied by
other water inhibitos/chemicals. these firms.
00.11- ES1
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Cylinder Head 505
L16/24
Description
Cylinder head and water jacket ....................................................................................505.01 (02H)
Working card
Dismantling of cylinder unit from engine................................................................. 505-01.00 (01H)

Disassembly of cylinder unit ................................................................................... 505-01.01 (02H)
Inspection of inlet valve, exhaust valve and valve guide........................................ 505-01.05 (07H)
Reconditioning of valve spindle seat and valve seat ring....................................... 505-01.10 (02H)
Valve rotator............................................................................................................ 505-01.15 (02H)
Replacement of valve guide ................................................................................... 505-01.20 (05H)
Replacement of valve seat ring .............................................................................. 505-01.35 (05H)
Inspection of cylinder head cooling water space .................................................... 505-01.45 (02H)
Assembly of cylinder unit ........................................................................................ 505-01.50 (02H)
Mounting of cylinder unit in engine ......................................................................... 505-01.55 (02H)
Plates
Kit for cylinder unit ...........................................................................................................50500-04H

Kit for complete cylinder unit exchange...........................................................................50500-05H
Cylinder head...................................................................................................................50501-03H
Valve spindles and valve gear .........................................................................................50502-03H
Cylinder head, top cover..................................................................................................50510-02H
Cylinder unit .....................................................................................................................50515-02H
Your Notes :
08031-0D/H5250/94.09.07
Description 505.01
Page 1 (1) Cylinder Head and Water Jacket Edition 02H
L16/24
Cylinder Head distribution gallery and tappet housing. The water

jacket is bolted to the cylinder head by five bolts. The
The cylinder head is of cast iron with an integrated five connection bolts to the cylinder head are free
charge air receiver, made in one piece. It has a bore- accessible from the top side and permit also a
cooled thick walled bottom. It has a central bore for dismantling of the cylinder head itself.
the fuel injection valve and 4 valve cross flow design,
with high flow coefficient. Intensive water cooling of
the nozzle tip area made it possible to omit direct Air Inlet and Exhaust Valves
nozzle cooling. The valve pattern is turned about 20°
to the axis and achieves a certain intake swirl. The valve spindles are made of heat-resistant ma-
terial and the spindle seats are armoured with
The cylinder head is tightened by means of 4 nuts welded-on hard metal.
and 4 studs which are screwed into the engine
frame. The nuts are tightened by means of hydraulic All valve spindles are fitted with valve rotators which
jacks. turn the spindles each time the valves are activated.
The turning of the spindles ensures even tem-
The cylinder head has a screwed-on top cover. It has perature levels on the valve discs and prevents
two basic functions: oil sealing of the rocker chamber deposits on the seating surfaces.
and covering of the complete head top face.
The cylinder head is equipped with replaceable
The valve guides are identical and therefor inter- valve seat rings. The exhaust valve seat rings are
changeable. water cooled in order to assure low valve tempera-
tures.
Water Jacket The seat rings are made of heat-resistant steel. The
seating surfaces are hardened in order to minimize
The main function of this part is as liner water jacket, wear and prevent dent marks.
08028-0D/H5250/94.08.12
Fig 1. Cylinder Head
98.38 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Dismantling of Cylinder Unit from Engine 505-01.00
L16/24

Shut-off cooling water 52005 038
Shut-off fuel oil 52006 212
Stopped lub. oil circul. 52006 109
52021 011
52021 059
52021 118
Description 52021 143
52021 180
Dismantling of cylinder unit from engine for 52021 202
inspection and/or overhaul. 52021 275
52021 334
Starting position Hand tools
Engine stopped and cooled down. Unbraco top

Ratchet
Extension
Related procedure
Valve rotator 505-01.15

Disassembly of cyl.head - water
jacket, cyl. liner and piston 505-01.01
Fuel injection valve 514-01.10

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

Capacity : 2 men
Data

99.03 - ES0
505-01.00 Dismantling of Cylinder Unit from Engine Working Card
L16/24
Preparing before dismantling 9) Disconnect the 2 clamps for locking the charge
air connections by removing the locking bolts
1) Drain off the water from the engine. for the clamps.
2) Take off the top cover. 10) Push the charge air connections, inside the
cylinder head which to be removed.
3) Take off the side covers on both sides of the
engine. 11) Turn the piston to top position.
4) Remove the exhaust gas cover.

Removal of bearing cap
Disassembling of connecting 12) Loosen the connecting rod nuts by means of

the hydraulic jacks, see working card 506-
5) Disconnect the clamp for connecting cylinder 01.25.
head and exhaust gas receiver.
13) Remove the connecting rod nuts and bearing
6) Disconnect the fuel oil high pressure pipe. cap by hand.
7) Disconnect the 4 clamps for locking the FW

connection between the cylinder heads by
removing the locking bolts for the clamps.
Lifting tool
8) Push the FW connections inside the cylinder
heads, which are be removed.
Cylinder unit
Fixing tool
08028-0D/H5250/94.08.12
Fig 1. Push the F.W. and charge air connections inside the
cylinder heads, which are be removed.
Fig 2. Mounting of lifting and fixing tool.
99.03 - ES0
Working Card
Dismantling of Cylinder Unit from Engine 505-01.00
L16/24
Mounting of support tools
14) Mount the fixing part, see plate 52006 item 212
Cylinder unit
for locking the connecting rod to the cylinder
liner.
15) Remove the cylinder head nuts by means of

the hydraulic jacks, see working card 520-
01.05.
Work table
Fig. 4 Cylinder unit placed in work table.
16) Mount the lifting tool on the cylinder head, see

plate 52005 item 038.
Removal of cylinder unit from engine
17) Lift the cylinder unit just enough for removing

the upper connecting rod bearing shell by
hand
18) Lift carefully the cylinder unit out of the engine

after the upper connecting rod bearing shell is
removed.
19) Land and fasten the cylinder unit upon the

special work table, or on the floor upon wooden
supports and remove the lifting tool.
08028-0D/H5250/94.08.12
Fig. 3. Hydraulic tools for dismounting of cylinder head nuts.
99.03 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Disassembly of Cylinder Unit 505-01.01
L16/24

52006 021
52006 082
Dismounting of cylinder head, water jacket, cylin- Measuring tools.

der linder and piston for inspection/overhaul. Unbraco top, 8 mm.
Ratchet.
Extension.
Serrated fork.
Starting position
Dismantling of cylinder unit 505-01.00
Related procedure
Inlet and exhaust valve - overhaul and

regrinding of spindel and valve seat, 505-01.10
Valve rotator, 505-01.15
Replacement of valve guide, 505-01.20
Replacement of valve seat ring, 505-01.35
Inspection of piston, 506-01.10
Cylinder liner 506-01.35
Separation of piston and
connecting rod 506-01.06

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

99.03 - ES0
505-01.01 Disassembly of Cylinder Unit
Working Card
L16/24
Before starting to dismantle the cylinder unit it must Removal of Cylinder Head
be placed on the grinding table.
4) Remove five allen screws pins in the cylinder
head.
Removal of Piston and Connecting Rod
5) Remove the cylinder head by means of the
1) Remove the fixing part (please see plate 52006, lifting tool .
item 212) from the cylinder liner and connecting
rod.
2) Turn the unit 180° in the table.
3) Pull out the piston and connecting rod with the

aid of the tool as shown in fig. 1.
Fig 2 Removal of cylinder head
08028-0D/H5250/94.08.12
Fig 1 Removal of piston and connecting rod
99.03 - ES0
Page 3 (3) Disassembly of Cylinder Unit Edition 02H
L16/24
Removal of Water Jacket and Cylinder Liner
6) Loosen two register pins in the water jacket

and remove two roller guides.
7) Lift the cylinder liner out of the water jacket by

means of the lifting tool as shown in fig. 3.
8) Remove the flame ring from the cylinder liner

by means of the tool as shown in fig. 4. Use an
used/scrapped piston ring.
Fig 4 Removal of flame ring

08028-0D/H5250/94.08.12
Fig 3 Removal of water jacket and cylinder liner
99.03 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Page 1 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 07H
L16/24
Stopped engine Plate no Item no Note.

Shut-off fuel oil
Press Blocking - Reset
Dismounting of inlet and exhaust valve, inspec-

tion of valve guide and mounting of inlet and
exhaust valve.
Starting position
Disassembly of cylinder unit 505-01.01
Related procedure
Reconditioning of valve spindle seat

and valve seat ring 505-01.10
Valve rotator 505-01.15
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35

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

Capacity : 1 man
Data

03.42 - ES0
505-01.05 Inspection of Inlet Valve, Exhaust Valve and Valve Guide Working Card
L16/24
Dismantling of Inlet and Exhaust Valve

Spindles
1) Land and fasten the cylinder head upon a

special work table and remove the lifting tool.
Or as an Alternative:
Land the cylinder head on the floor upon

wooden supports and remove the lifting tool.
2) Turn back the rocker arm and remove the

valve bridge over the valve spindles.
3) Install the tool for mounting of valves (B), see

fig 1.
4) Compress valve springs by tightening nut A,

see fig 2.
Fig 2 Mounting of compression tool
Fig 1 Mounting of compression tool.

08028-0D/H5250/94.08.12
5) Press valve up to access cone ring, see fig 3 *)
6) Remove cone rings, see fig 3.
7) Release springs again. Fig 3 Removal of cone rings.
8) Loosen nut A and extractor plate B, see fig 1.
9) Remove a valve rotator and springs.
10) Repeat point 4 - 9 to remove other valve

spindles.
03.42 - ES0
Working Card
Page 3 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide 505-01.05
Edition 07H
L16/24
Inspection of Valves/Valve Seats
If the valve seat is burnt or scarred, it should be

ground using a valve seat grinder, please see working
card 505-01.10.
Inspection of Valve Guide
Too much clearance between the valve spindle and

the spindle guide may cause:
- increased lub. oil consumption.

- fouling up of the spindle guide and thus give
the risk of the sticking of the valve spindle.
11) Clean the valve spindle guide.
12) Inspect and measure for wear.
If the inner diameter of the valve spindle guide

Fig 4 Measurement of valve spindle guide for wear.
exceeds the tolerance, please see page 500.35,
the valve spindle guide must be replaced.
Please see working card 505-01.20.
Too much clearance also means insufficient

guidance of the valve spindle, and thus bad
alignment between the spindle head and the
valve seat ring.
Mounting of Valve Spindle
13) For mounting the valve spindle follow the

instructions in point 3-9 in reverse order.
Note:
Please be aware of the different valve disk diameter
at inlet and exhaust valves.
Inlet valve : Ø57 mm
Exhaust valve : Ø54 mm
08028-0D/H5250/94.08.12
03.42 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card Reconditioning of Valve Spindle Seat 505-01.10
Page 1 (3)
and Valve Seat Ring Edition 02H
L16/24

Shut-off cooling water 52005 408 Grinding machine
Shut-off fuel oil for valve spindle.
Stopped lub. oil circul. (extra tools).
52005 350 Grinding machine
for valve seat ring
(extra tools).
Description
Reconditioning of valve spindle seat and valve

seat ring, with special grinding machine.
Valve spindle has been removed 505-01.05 All the hand tools and new stones are included in
the tools box for grinding machine.
Related procedure
Mounting of valve spindle 505-01.05

08028-0D/H5250/94.08.12
Capacity : 1 man
Data

98.40 - ES0
505-01.10 Reconditioning of Valve Spindle Seat Working Card
Edition 02H and Valve Seat Ring Page 2 (3)
L16/24
Reconditioning of Valve Seat Ring However, when seat "S" is ground to such an extent
that recess "R" disappears, see fig 1, the valve seat
Reconditioning of valve seat rings by machining is ring must be scrapped and a new one must be
carried out by means of a grinding machine, the pilot installed, please see working card 505-01.35
spindle of which must be mounted in the valve
spindle guide. For operation of the grinding machine, This is only valid for the exhaust valve seat, the inlet
see separate instructions. valve seat has no recess due to less wear of the inlet
valve seat.
Grinding of Valve Seats

Reconditioning of Valve Spindle
Grinding of valve seat rings should be carried out in
the following order: Reconditioning by machining is carried out with the
valve spindle being rotated in a turning lathe and a
1) Grind the seating surface with a feed at an special grinding machine mounted on the tool post of
angle "A" of 30° ± 0,05° the turning latch.
0
2) Continue grinding until a clean and uniform Grinding of Valve Spindle

surface is obtained.
For operation of the grinding machine, see separate
3) Carry out final grinding with a feed in an in and instructions.
out direction. Normally, the best surface quality
is obtained this way. 1) Grind the seating surface with a feed at an
angel "A" of 30° ± 0.0,4°.
2) Continue grinding until a clean and uniform

"A" 30 ± 0,05°0
surface is obtained.
"R"
3) Check height "H"1 upon completion the
"S"
grinding, see fig 2.
"H"1 must be no less than indicated on page

500.35.
If less, the spindle must be scrapped.
08028-0D/H5250/94.08.12
Fig 1. Valve Seat Ring
"H"1
Scraping of Valve Seat Rings "A" 30° ± 0 0,1°
Normally, the valve seat ring can be reconditioned

several times.
Fig 2. Valve Spindle
98.40 - ES0
Working Card Reconditioning of Valve Spindle Seat 505-01.10
Page 3 (3)
and Valve Seat Ring Edition 02H
L16/24
4) After assembling the valves, check - by mothing

the valve- that distance "H"2 between the
upper edge of the cylinder head and the upper
edge of the valve spindle, see fig 3, does not
exceed the maximum value, please see page
500.35.
Fig 3. Measurement of distance H2.

08028-0D/H5250/94.08.12
98.40 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Valve Rotator 505-01.15
L16/24

Shut-off fuel oil
Shut-off cooling oil
Dismantling, inspection and mounting of valve Small screwdriver.

rotator. Ring and open-end spanner, 24 mm.
Starting position
Valve spindle has been removed 505-01.05
Related procedure
Mounting of valve spindles 505-01.05

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

Capacity : 1 man
Data

98.46 - ES0
505-01.15 Valve Rotator Working Card
L16/24
Maintenance and Inspection of Rotocap Note: Having assembled the valve rotator in dry
condition it should be placed in clean lubricating oil
Dirt, especially in the ball pockets due to residues in for a short period of time.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and hinder the
movement of the balls.
Under normal operating conditions rotocap valve

rotators need no servicing.
Rotator performance is satisfactory when the valve

rotates visibly and evenly.
Dismantling of Rotocap
Please see Working Card 505-01.05, steps 3 to 9. Fig. 1.
Overhaul of Rotator Mounting of Rotocap
1) Clean the valve rotator. Please see working card 505-01.05, steps 3 to 9,
opposite direction.
2) Inspect for wear and ball impressions.
3) Remove the retaining ring and disassemble

the individual parts.
4) Replace parts showing wear grooves or de-

pressions formed by the balls.
5) Insert the balls and the tangential springs.
Note: All balls on the inclined races of the ball

pockets must point in the same direction, see Fig. 1.
The inner ring of the spring washer should rest on the

retainer body.
08028-0D/H5250/94.08.12
98.46 - ESO
Working Card
Replacement of Valve Guide 505-01.20
L16/24
Stopped engine Plate no Item no Note

Shut-off fuel oil
Dismantling and mounting of valve guide for inlet Hammer / Lead hammer
and exhaust valve. Nitrogen (N2), or similar.
H7 reamer, 12 mm
Starting position
Valve spindle has been removed 505-01.05
Related procedure

08028-0D/H5250/94.08.12
Working time : 3/4 hour Plate no. Item no. Qty/

Capacity : 1 man 50501 076 4/cyl
50501 088 4/cyl
Data

01.14 - ES0
505-01.20 Replacement of Valve Guide
Working Card
L16/24
When to Replace the Valve Guide
If the clearance exceeds the max. limit, please see

page 500.35, the valve guide must be replaced.
Dismounting of Valve Guide
1) Knock the valve guide out from the bottom of

the cylinder head, by means of a mandrel,
which has a shoulder turning that fits into the
valve guide, see fig 1.
2) Clean the bore of the cylinder head carefully.
3) Inspect for marks that can prevent mounting

of new valve guide.
Fig 1 Dismounting of valve guide
Mounting of Valve Guide
4) Before mounting - cool down the new valve

guide to approx. -70°C with nitrogen or similar.
5) Insert the valve guide into the bore.
6) Knock slightly with the mandrel and a hammer,

see fig 2.
Note: The shoulder of the valve guide must bear

against the cylinder head, by knocking slightly with
the mandrel and a hammer.
7) The valve guide must be reamed with a Ø12H7

reamer through the whole guide after guide
temperature is equlized.
Fig 2 Mounting of valve guide

08028-0D/H5250/94.08.12
01.14 - ESO
Working Card
Replacement of Valve Guide 505-01.20
L16/24
8) Insert a new O-ring in the valve guide, before

mounting of the valve spindle.
Correct mounting can easily be done by the

use of two valve spindles as mounting tool, one
spindle to be used as support and the other
spindle to be used for pushing the O-ring
downwards, see fig 3.
Screw-drivers or other sharp tools should never

be used for this purpose.
9) For mounting of valve spindle, please see

working card 505-01.05.
Fig 3 Inserting a new O-ring in the valve guide

08028-0D/H5250/94.08.12
01.14 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Replacement of Valve Seat Ring 505-01.35
L16/24

Shut-off fuel oil
Replacement of valve seat ring for inlet and Hammer.

exhaust valve. Loctite, 648.
Lub. oil.
Starting position
Inlet and exhaust valves have been

removed 505-01.05
Related procedure
Man power Replacement and wearing parts

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

Capacity : 1 man
50501 123 2/cyl.
50501 172 2/cyl.
Data 50501 184 2/cyl.

01.32 - ES0
505-01.35 Replacement of Valve Seat Ring Working Card
L16/24
Dismounting of Valve Seat Rings Mounting of Valve Seat Rings
When reconditioning of a valve seat ring no longer is 5) Prior to mounting of a new valve seat ring, the
possible due to dimensions exceeding the scrapping bore must be cleaned thoroughly and inspected
criteria, the seat ring has to be replaced. for marks. Marks that can hinder mounting of
the valve seat ring must be removed.
Dismounting of a valve seat ring is carried out by
means of a special extractor tool set comprising the 6) To facilitate the valve mounting of the seat ring
components, see fig 1. it must be cooled down, however, a max. of
-25° C otherwise, the O-ring can be damaged.
7) Place the O-ring on the valve seat ring and

coat with oil/loctite as shown in fig 2, just before
positioning it in the bore.
Coat with
loctite 648
Valve seat ring
O-ring
Coat with oil
Fig 1 Extraction of valve seat ring.
Dismounting of a Valve Seat Ring is Carried Fig 2 Coat with oil/loctite.

out According to the Following Procedure
1) Weld approx. 5 seconds at 3 places around the 8) Prior to mounting of the valve spindle the valve
old valve seat with electrode. seat ring must be ground, to ensure correct
centering af the valve guide and the valve seat
2) Wait 60 seconds while the seat is cooling down ring. This can be done according to working
and the shrink fit compression is relieved. card 505-01.10.
3) Mount the extraction tool and pull out the used

08028-0D/H5250/94.08.12
valve seat. (If the waiting time is not observed

the tool might be damaged).
4) The valve seat is easy removed by turning the

handle.
01.32 - ESO
Working Card
Inspection of Cylinder Head Cooling Water Space 505-01.45
L16/24

Shut-off fuel oil
Inspection of cylinder head cooling water space. Steel brush
Starting position
The cylinder head dismantled

from engine 505-01.00
Related procedure

08028-0D/H5250/94.08.12
Working time : ¼ hour Plate No Item No Qty/

Capacity : 1 man
Data

98.38 - ES0
505-01.45 Inspection of Cylinder Head Cooling Water Space
Working Card
L16/24
Inspection of Cylinder Head Cooling Water

Space
1) Inspect the cooling water inlet at the bottom of

the cylinder head, see fig. 1.
2) Remove all possible deposits.
3) If necessary, clean the cooling water inlet and

cooling water outlet, see fig. 1 with a steel
brush.
Flush the cooling water space after cleaning.
4) Should the cylinder head cooling water space,

contrary to expectation, be blocked with de-
posits, please contact MAN B&W Diesel,
Holeby for further instructions.
Fig. 1 Cooling water spaces to be inspected.
08028-0D/H5250/94.08.12
98.38 - ES0
Workinag Card
Assembly of Cylinder Unit 505-01.50
L16/24

Press Blocking - Reset 52006 104
52006 212
52006 224
Description
Mounting of cylinder head, water jacket, cylinder

liner and piston after inspection/overhaul.
Cylinder unit, dismantled, 505-01.01
Related procedure
Mounting of cylinder unit in engine, 505-01.55

Inspection of valve roller guides, 508-01.00
Working time : 1 1/2 hours Plate no Item no Qty/

08028-0D/H5250/94.08.12
Capacity : 1 man 50501 111 2/cyl

50501 135 1/cyl
50501 196 1/cyl
Data 50610 031 1/cyl
50610 043 1/cyl
Data for pressure and tolerance (Page 500.35) 50610 055 1/cyl
Data for torque moment (Page 500.40) 50610 092 1/cyl
98.47 - ES0
505-01.50 Assembly of Cylinder Unit
Working Card
L16/24
Preparing before Mounting
1) Place the water jacket on the table.
2) Place two new o-rings on the cylinder liner and

slightly lubricate with oil.
3) Mount the cylinder liner with a new flame ring

in the water jacket by means of the lifting tool
for the liner, see fig 1.
Fig 2 Marking on the cylinder liner and the water jacket
7) Mount the cylinder head by means of lifting

tool (plate 52005, item no 38)
8) Mount the five allen screws in the cylinder

head and tighten up all the screws, please see
page 500.40.
Fig 1 Mounting of new flame ring
Mounting the Piston

Note: Be sure the marking on the cylinder liner
corresponds to the marking on the water jacket of Before mounting the piston turn around the cylinder
the assembly,see fig 2. unit.
4) Fit a new sealing ring on the cylinder liner. Note: After an overhaul the cylinder liner must
always be honed and the piston must be fitted with
08028-0D/H5250/94.08.12
5) Mount two roller guides in the water jacket, see new piston rings, see Working Card 506-01.35.
Working Card 508-01.00.
9) Mount the piston guide bush around the cylin-
der unit.
Mounting of Cylinder Head
10) Lift the piston and connecting rod by means of
6) Place two new o-rings at the top of the water a suspension.
jacket and slightly lubricate with oil.
98.47 - ES0
Page 3 (3) Assembly of Cylinder Unit Edition 02H
L16/24
11) Lubricate the piston rings and the cylinder liner

with oil.
12) Slowly lower the piston into the cylinder liner.
Note: Be sure that the "st" mark at the top of the

piston is placed on to the fuel pump side.
13) Place wooden wedges between the connecting

rod and the piston shirt.
14) Remove suspension tool from the connecting

rod.
15) Mount fixing part tool (plate 52006 item 212)

to the connecting rod and the cylinder liner.
08028-0D/H5250/94.08.12
98.47 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Mounting of Cylinder Unit in Engine 505-01.55
L16/24

52021 118
52021 334
52021 180
Mounting of cylinder unit after inspection and/or 52021 202
overhaul. 52021 275
52021 059
Cylinder unit is completely assembled. Lub. oil and copaslip.

Valve gear of respective cylinder is in
the proper position (valve closed).
Control of the surface of the engine.
Related procedure
Adjustment of valve clearance 508-01.10

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

Capacity : 2 men
50501 231 1
50501 243 1
Data 51630 033 8
51230 027 4
99.03 - ES0
505-01.55 Mounting of Cylinder Unit in Engine Working Card
L16/24
Preparring before mounting Mounting of the Big-end Bearing
Before the cylinder unit is mounted in the engine, be 3) Make sure the crank throw is in the top posi-
sure to clean the joint faces carefully. tion.
4) Mount the upper part of the big-end bearing

Placing of the Cylinder Unit in Engine shell just before the connecting rod is landed
on the crankshaft.
1) Place an O-ring around the roller guides and
O-rings around the oil connection between the Note: Lubricate the crankshaft with clean lubricating
engine and the water jacket. oil.
2) Lower the cylinder unit slowly into the engine 5) Land the connecting rod on the crankshaft.
by means of a lifting tool, (plate 52005 item
038). During this the connecting rod must be guided
by hand to ensure correct approach and lan-
ding in the journal.
6) Remove the fixing part, (plate 52006 item

Lifting tool 212).
7) Mount the bearing cap with the inserted lower

shell of the big-end bearing by hand.
Tightening of the Connecting Rod
Cylinder unit Note: Iden.No. on the connecting rod and on the

bearing cap must always be the same.
Fixing tool
08028-0D/H5250/94.08.12
Fig 1 Lifting tool
Fig 2 Clip on/off
99.03 - ES0
Working Card
Mounting of Cylinder Unit in Engine 505-01.55
L16/24
8) Lubricate threads and the contact face of the 13) Place the spacer ring around the nuts with a
connecting rod screws with molycote paste or slot in such a position that the tommy bar can
the like. be used.
9) Mount bolts and nuts and tighten them firmly 14) Tighten the hydraulic jacks and make sure that
with a tommy bar. the cylinder of the jacks bears firmly on the
spacer ring. Tighten up all the nuts, see
For tighting connecting rod bolts, please see description 500.40. For usage of the hydraulic
working card 506-01.25. tools, please see working card 520-01.05.
Note: If new studs or nuts are fit, the nuts must be

Tightening of Cylinder Head Nuts tightened and loosened three times, in order to
compensate for deformation of the thread and in
10) Coat the cylinder stud threads and contact order to ensure a safe minimum load of the studs
faces with copaslip or the like. through the tightening.
11) Fit the cylinder head nuts and make sure that
they run easily and that they bear on their Assembling of Connections
entire contact surfaces.
15) Mount the exhaust clamp between the cylinder
12) Tighten the nuts lightly with a tommy bar. head and the exhaust pipe.
Note: Turn clamps correctly as they are not

symmetrical, see fig 4.
08028-0D/H5250/94.08.12
Fig 4 Correct mounting of clamps.
16) Place new O-rings on water connections and

push the connections into the cylinder head.
17) Secure the water connections with clamps

and tighten bolts on the clamp.
Fig 3 Hydraulic tools for mounting of cylinder head nuts.
99.03 - ES0
505-01.55 Mounting of Cylinder Unit in Engine Working Card
L16/24
18) Place new O-rings on the charge air connection 22) Bleed air from the venting screws on the charge
and push the connections into the next cylin- air cooler.
der head.
23) Bleed air from the venting screws on the engine
19) Secure the charge air connection with a clamp top, or by the flange, connection F3, venting to
and tighten the bolt on the clamp. expansion tank.
20) Mount the high pressure fuel oil pipe, please 24) Open connection G2, L.T. fresh water - outlet.
see working card 514-01.05.
25) Check for leakage.
Ventilation
Adjustment of Valve Clearance
The GenSet is self-ventilating. This means that it is
not necessary for the engine to vent the system 26) Adjust the valve clearance, see working card
before start. 508-01.10.
However, to avoid problems in the ship's installation, 27) Mount the side and top covers.
we recommend to ventilate. This can be done in the
following way:
21) Open connection G1, L.T. fresh water - inlet.
08028-0D/H5250/94.08.12
99.03 - ES0
Plate
Page 1 (2) Kit for Cylinder Unit 50500-04H
L16/24
08028-0D/H5250/94.08.12
02.50 - ES0
Plate
50500-04H Kit for Cylinder Unit Page 2 (2)
L16/24
Ordering Number of Kit for Cylinder Unit

According to list below
Plate 50500-04H / Item 021
Item
No Qty Designation Where to find in the engine instruction book
021 1/C Kit for cylinder unit, complete Plate 50500 Item 021
consisting of:
4/C O-ring Plate 50501 Item 076
1/C Sealing ring Plate 50610 Item 031
2/V O-ring Plate 51402 Item 033
1/V O-ring Plate 51402 Item 104
4/C Seal ring Plate 51630 Item 033

08028-0D/H5250/94.08.12
Please Note that this is a kit supply, and that

any exceeding number of o-rings and gaskets
are not accepted as return goods.
Qty/C = Qty/Cylinder
02.50 - ES0
Plate
Page 1 (2) Kit for Complete Cylinder Unit Exchange 50500-05H
L16/24
08028-0D/H5250/94.08.12
02.50 - ES0
Plate
50500-05H Kit for Cylinder Unit Page 2 (2)
L16/24
Ordering Number of Kit for Cylinder Unit

According to list below
Plate 50500-05H / Item 045
Item
No Qty Designation Where to find in the engine instruction book
045 1/C Kit for cylinder unit, complete Plate 50500 Item 045
consisting of:
4/C Seal ring Plate 51630 Item 033
Please Note that this is a kit supply, and that

any exceeding number of o-rings and gaskets
are not accepted as return goods.
08028-0D/H5250/94.08.12
02.50 - ES0
Plate
Page 1 (2) Cylinder Head 50501-03H
L16/24
08028-0D/H5250/94.08.12
00.43 - ES0
Plate
50501-03H Cylinder Head Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
015 2/C Guide for valve bridge Styr for ventilbro
027 1/C Cylinder head Cylinderdæksel
039 2/C Plug Prop
040 1/C O-ring O-ring
052 1/C Sleeve Foring
088 4/C Valve guide Ventilstyr
123 2/C Valve seat ring, Ventilsædering,

inlet indstrømning
147 2/C Stop screw Stopskrue
159 /I Loctite Loctite
160 2/C Cylindrical pin Cylindrisk stift

exhaust udstødning
206 5/C Screw Skrue
218 1/C Water guide jacket Kølekappe
255 2/C Bolt Bolt
267 1/C Stud Tap
279 1/C Thrust piece Trykstykke

08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
00.43 - ES0
Plate
Page 1 (2) Cylinder Head 50501-11S
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
Plate
50501-11S Cylinder Head Page 2 (2)
L16/24
Item Item
015 2/C Guide for valve bridge Styr for ventilbro
027 1/C Cylinder head Cylinderdæksel
039 2/C Plug Prop
052 1/C Sleeve Foring
088 4/C Valve guide Ventilstyr

inlet indstrømning
147 2/C Stop screw Stopskrue

exhaust udstødning
206 5/C Screw Skrue
218 1/C Water guide jacket Kølekappe
255 2/C Bolt Bolt
267 1/C Stud Tap

08028-0D/H5250/94.08.12
03.50 - ES0
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-03H
L16/24
08028-0D/H5250/94.08.12
98.40 - ES0
Plate
50502-03H Valve Spindles and Valve Gear Page 2 (2)
L16/24
Item Item
010 1/C Rocker arm, exhaust Vippearm, udstøds, 274 2/C Valve spindle, inlet Ventilspindel, indsugn.
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 083 046, 058, 071, 083
022 1/C Rocker arm, inlet Vippearm, indsugning

complete, incl. item komplet inkl. item 034,
034, 046, 071, 083, 105 046, 071, 083, 105
034 2/C Bolt Bolt
046 2/C Bearing bush Leje
058 1/C Rocker arm, exhaust Vippearm, udstøds
071 4/C Nut Møtrik
083 2/C Adjusting screw com- Justérbar skrue komplet

plete, incl. item 095, inkl. item 095, 117, 142
117, 142
095 2/C Circlip Fjederring
105 1/C Rocker arm, inlet Vippearm, indsugning
130 2/C Valve bridge com- Ventilbro komplet, inkl.

plete, incl. item 071, item 071, 129, 154, 166
129, 154, 166
142 2/C Adjusting screw Justérbar skrue
154 2/C Adjusting screw Justérbar skrue
166 2/C Valve bridge Ventilbro
178 4/C Conical ring 2/2 Konisk ring 2/2
191 4/C Rotocap complete Rotationsgiver, komplet
201 4/C Spring Fjeder
213 1/C Screw Skrue
225 1/C Bow Bøjle
249 1/C Shaft Aksel

08028-0D/H5250/94.08.12
262 2/C Valve spindle, exhaust Ventilspindel, udstøds
98.40 - ES0
Plate
Page 1 (2) Cylinder Head, Top Cover 50510-02H
L16/24
08028-0D/H5250/94.08.12
98.41 - ES0
Plate
50510-02H Cylinder Head, Top Cover Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
026 5/C Screw Skrue
038 5/C Washer Skive
051 Top cover Topdæksel

3/E 5 cyl. engine 5 cyl. motor
063 8/E Plug Prop
075 2/E Top cover Topdæksel
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine Qty/E = Qty/Motor
98.41 - ES0
Plate
Page 1 (2) Cylinder Unit 50515-02H
L16/24
08028-0D/H5250/94.08.12
01.11 - ES0
Plate
50515-02H Cylinder Unit Page 2 (2)
L16/24
Item
no Qty Designation Where to find in the engine instruction book
011 1/C Cylinder unit, complete Plate 50515 Item 011

consisting of:
1/C Cylinder head Plate 50501
1/C Valve spindle and valve gear Plate 50502
1/C Piston and connecting rod Plate 50601
1/C Cylinder liner Plate 50610
08028-0D/H5250/94.08.12
01.11 - ES0
Index
Page 1 (1) Piston, Connecting Rod and Cylinder Liner 506
L16/24
Description
Piston, connecting rod and cylinder liner......................................................................506.01 (02H)
Working card
Separation/assembly of piston and connecting rod and fitting of piston rings ....... 506-01.05 (07H)
Piston ...................................................................................................................... 506-01.10 (03H)
Connecting rod........................................................................................................ 506-01.15 (03H)
Criteria for replacement of connection rod big-end and main bearing shells ............ 506-01.16 (02)
Hydraulic tightening of connecting rod screws ....................................................... 506-01.25 (02H)
In-situ inspection of connecting rod big-end bearing .............................................. 506-01.30 (02H)
Inspection and honing of cylinder liner ................................................................... 506-01.35 (02H)
Grinding of seal face on cylinder liner and cylinder head....................................... 506-01.45 (02H)
Dismantling of piston and cylinder liner at low overhaul height.............................. 506-01.50 (02H)
Plates
Piston and connecting rod ...............................................................................................50601-03H

Cylinder liner ....................................................................................................................50610-03H
Your Notes :
08031-0D/H5250/94.09.07
Description 506.01
Page 1 (2) Piston, Connecting Rod and Cylinder Liner Edition 02H
L16/24
Piston Connecting Rod
The piston, which is oil-cooled and of the composite The connecting rod is die-forged. The big-end has a
type, has a body made of nodular cast iron and a horizontal split. The connecting rod and piston are
crown made of forged deformation resistant steel. It disassembled together with the cylinder liner, thus
is fitted with 2 compression rings and 1 oil scraper ensuring a large bearing diameter and a low bearing
ring in hardened ring grooves. pressure.
By the use of compression rings with different barrel- The connecting rod has bored channels for supply-
shaped profiles and chrome-plated running suring of oil from the big-end to the small-end.
faces, the piston ring pack is optimized for maximum
sealing effect and minimum wear rate. The big-end bearing is of the trimetal type coated
with a running layer.
The piston has a cooling oil space close to the piston
crown and the piston ring zone. The heat transfer, The bearing shells are of the precision type and are
and thus the cooling effect, is based on the shaker therefore to be fitted without scraping or any other
effect arising during the piston movement. The cool- kind of adaption.
ing medium is oil from the engine's lubricating oil
system. The small-end bearing is of the trimetal type and is
pressed into the connecting rod. The bush is equip-
Oil is supplied to the cooling oil space through ped with an inner circumferential groove, and a
channels from the oil grooves in the piston pin pocket for distribution of oil in the bush itself and for
bosses. Oil is drained from the cooling oil space the supply of oil to the pin bosses.
through ducts situated diametrically to the inlet chan-
nels.
The piston pin is fully floating and kept in position in

the axial direction by two circlips.
08028-0D/H5250/94.08.12
Fig 1. Piston Fig 2. Connecting Rod
98.46 - ES0
506.01 Description
Edition 02H
Piston, Connecting Rod and Cylinder Liner Page 2 (2)
L16/24
Cylinder Liner
The cylinder liner is made of special centrifugal cast

iron and fitted in a bore in the engine frame. The liner
is clamped by the cylinder head and rests by its
flange on the water jacket.
The liner can thus expand freely downwards when

heated during the running of the engine. The liner is
of the flange type and the height of the flange is
identical with the water cooled area which gives a
uniform temperature pattern over the entire liner
surface. The lower part of the liner is uncooled to
secure a sufficient margin for cold corrosion in the
bottom end. There is no water in the crankcase area.
The gas sealing between liner and cylinder head

consists of an iron ring.
To reduce bore polishing and lube oil consumption a

slip-fit-type flame ring is arranged on the top side of
the liner.
Fig 3. Cylinder Liner
98.46 - ES0
Working Card Separation/Assembly of Piston and Connecting Rod 506-01.05
Page 1 (3)
and fitting of Piston Rings Edition 07H
L16/24

Separation of piston and connecting rod for Wooden wedge, 2 pieces

inspection or/and overhaul. Wooden support
Assembly of the piston and connecting rod after Wire
inspection or/and overhaul.
Starting position
Related procedure
Inspection or/and overhaul of piston, 506-01.10

Inspection or/and overhaul of
connecting rod, 506-01.15
Inspection of connection rod big-end
bearing, 506-01.16
Assembly of cylinder unit 505-01.50

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

Capacity : 1 man 50601 093 1
50601 103 1
50601 127 1
Data

04.21 - ES0
506-01.05 Separation/Assembly of Piston and Connecting Rod Working Card
Page 2 (3)
Edition 07H and fitting of Piston Rings
L16/24
Separation of Piston and Connecting Rod Fittings of Piston Rings
1) Take out the securing ring (seeger circlips) The piston rings should only be fitted to the piston by
with the plier (Plate 52006, Item 177). Push out the use of a special tool; the socalled piston ring
the piston pin and lift the connecting rod away. opener.
If the rings are opened further than necessary there

Assembly of Piston and Connecting Rod is a risk of overstressing, which means that rings will
become permanently distorted and will not confirm
2) Lubricate the piston pin before assembling. to the cylinder inner running surface.
3) For assembly of piston and connecting rod, The piston rings should be installed with the
see point 1, but in the opposite direction. identification mark, which is stamped into the ring
close to the ring joints, facing upwords, see fig 2.
Before fitting the coil spring loaded scraper ring, the

coil spring is dismantled from the ring by removal of
Joint pin for the joint pin. The coil spring is placed and assembled
coil spring Joint coil spring to be
placed opposite to ring joint in the ring groove then the scraper ring is fitted in the
groove in such a way that the ring joint is approximately
180° offset to the spring joint.
Ascertain correct assembling by checking the back

clearance.The back clearance is sufficient when the
Ring joint
face of the ring is below the groove edge when the
ring is pressed against the bottom of the groove.
When installed on the piston the rings should be

Fig 1 Joint coil spring to be placed opposite to ring joint. pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring
and groove.
Adequate clearance is present so the feeler gauge

can be moved all the way round.
To prevent gas leakage through coinciding ring

joints the piston rings should be turned into positions
offsetting the ring joint 180° to each other.
08028-0D/H5250/94.08.12
04.21 - ES0
Working Card Separation/Assembly of Piston and Connecting Rod 506-01.05
Page 3 (3)
and fitting of Piston Rings Edition 07H
L16/24
Piston Ring No 1:
marked with ident.
No "top 1464".
Piston Ring No 2:
marked with ident.
No "top 1465".
Scraper Ring:
marked with ident.
No "top 0258".
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.
Fig 2 Marking of piston and scraper ring.
04.21 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Piston 506-01.10
L16/24

Cleaning and inspection of piston. Replacement Tools for cleaning of piston, steel brush,
of piston ring, scraper ring and control of ring scraper etc.
grooves.
Starting position
Piston has been dismantled from

Related procedure
Assembly of piston and connecting

rod and fitting of piston rings 506-01.05

08028-0D/H5250/94.08.12
Working time : 1 hour Plate No Item No Qty/

Capacity : 1 man
Data

99.33 - ES0
506-01.10 Piston Working Card
L16/24
Inspection of Piston Mounting of Piston Crown
1) Remove the piston and scraper rings. 8) Lubricate the threads and bearing surface with
"molycote-paste G-n Plus".
2) Clean the piston on the outside and on the
inside. Note: always use new bolts when assembling the
piston
3) Inspect the piston ring and scraper ring grooves
for wear, see page 3. 9) Tighten the bolts crosswise with 20 Nm
(corresponding to 35° to 90°).
Check of Piston Bolt Tension 10) Loosen the bolts again.
4) Apply a torque spanner to the piston bolts, 11) Tighten the bolts again with a pretighten torque
adjusted to 20 Nm. of 10 Nm.
5) Turn the torque spanner. 12) Turn the bolts 60° further.
Note: It may turn out that the bolts do not turn during 13) Check the piston bolt tension, see "check of
the test: piston bolt tension".
If Then
The bolts do not The tension are ok

turn during the test
The bolts can Loosen the bolts and

turn during the test tighten as described for
the process of
"Mounting of piston
crown"
Inspection of Piston Crown
For cleaning and inspection of the piston crown, it

must be disassembled.
6) Loosen the bolts and remove the piston crown.

08028-0D/H5250/94.08.12
7) Clean carefully the piston shirt and piston

bolts.
99.33 - ES0
Working Card
Piston 506-01.10
L16/24
The piston crow must be scrapped if:
Piston and oil New ring
Ring grooves.
scraper ring. grooves.
Max. wear limit.
Nominal size. Tolerances.
A) The wear limit on the testing mandrel is (mm) (mm)
(mm)
exceeded, see fig 1A
Piston ring -0.035 +0.145
5 5 5.38
or 1 -0.01 +0.130
Piston ring -0.035 +0.105

B) The clearance between the new piston/scraper 5 5 5.38
2 -0.01 +0.090
ring and the ring groove is exceeded, see fig
1B. Scraper ring
5
-0.035
5
+0.035
5.38
-0.01 +0.020
Note: At each piston overhaul: Table 1. Nominal size, new ring groove tolerance and wear
limit for ring grooves.
- The piston and the scraper ring must be
replaced.
- The cylinder liner must be honed according
to the instructions.
- For position and fittings of piston rings,
please see working card 506-01.05
A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove
If the wear limit on the testing mandrel is

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

between new piston ring/scraper
ring and ring groove: 0.40 mm.
08028-0D/H5250/94.08.12
The handle is marked

with the nominal size.
Fig 1 Wear limits for ring grooves.
99.33 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Connecting Rod 506-01.15
L16/24

52021 275
52021 167
52021 202
Cleaning, inspection and test measurement of 52021 334
connecting rod.
Connecting rod has been Inside micrometer (140 mm).

dismantled from piston 506-01.05 Feeler gauge 0.15 - 0.20 mm.
Related procedure
Assembly of Cylinder Unit 505-01.50
Manpower
Replacement and wearing parts
08028-0D/H5250/94.08.12
Working time : 1/2 hour

Capacity : 1 man Plate No Item No Qty /
Data

99.33 - ES0
506-01.15 Connecting Rod Working Card
L16/24
Cleaning of Connecting Rod Measurement of Big-end Bore
1) Clean all machined surfaces on the connecting For check of ovalness the bearing cap has to be
rod. mounted onto the big-end bore without bearing
shells.
2) Degrease the joint faces, holes and connecting
rod screws with a volatile solvent and blow dry Note: The ident. No on the connecting rod and the
with working air. bearing cap must always be the same, see fig 3.
Visual Inspection of Faces
3) Inspect the joint faces.
Damages, in the form of visible wear marks

and pittings or even cracks, may be in the joint
faces due to relative movements between the
surfaces.
Wear marks and cracks are visible, but not

perceptible with a fingernail. Pittings and impact
marks are both visible and perceptible.
Note: Handle the connecting rod with care. In case

of damaged joint faces caused by improper hand-
ling, the bearing cap can no longer be tightened to
the connecting rod without ovalness of the big-end
bore.
4) Register observed damages in the scheme

"Connecting Rod Inspection" for historic use
only. Please see page 4. Fig 1 Point of measurement
5) Carefully smooth single raised spots in the

serration caused by pitting and impact marks 8) Mount the bearing cap onto the connecting rod
with a filesmall. by means of the connecting rod bolts.
Inspection of Connecting Rod bolts 9) Tighten the bolts with the prescribed pressure,
please see working card 506-01.25.
6) Inspect the connecting rod nuts for seizures in
the threads and pittings on the contact surfaces 10) Measure five different diameters in the groove
08028-0D/H5250/94.08.12
of the screwheads. of the boring, see fig 1.
7) Turn the connecting rod nuts onto bottom 11) Register the measurements in the scheme
position of the bolts. "Connecting Rod Inspection". Please see page
4.
If bolts/nuts Then
12) Calculate the maximum ovalness as the diffe-
have seizures in Renew the bolts/screws rence between biggest and smallest diameter
threads or pittings on measured.
contact surface
13) Check if maximum ovalness is exceeded,
cannot be turned onto Renew the bolts/screws please see page 500.35.
bottom position by hand
99.33 - ES0
Working Card
Connecting Rod 506-01.15
L16/24
If Then For connecting rod No 2 in the example the maximum

ovalness is 0.125 mm and therefore the connecting
maximum ovalness is Renew the complete rod is rejected.
exceeded connecting rod, screws
and bearing shells.
Inspection of Connecting Rod Bush
maximum ovalness is Reuse the connecting rod
not exceeded 14) Inspect the surface of the piston pin and the
connecting rod bush.
15) Measure the clearance between the piston pin

and bush.
16) Check if max clearance is exceeded, see page

500.35.
If the specified clearance is exceeded, contact

MAN B&W Diesel A/S, Holeby for replacement.
Inspection of Bearing Shells for Big-end
Criteria for replacement of connecting rod big-end

bearing, see working card 506-01.16.
Fig 2. "Connecting rod Inspection".
Example of Measurement Results

08028-0D/H5250/94.08.12
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).
Fig 3 The ident No on the connecting rod must always be the
same.
For connecting rod No 1 in the example the maximum
ovalness is 0.07 mm and thus reuse is acceptable.
99.33 - ES0
506-01.15 Connecting Rod Working Card
L16/24
08028-0D/H5250/94.08.12
99.33 - ES0
Working Card Criteria for Replacement of 506-01.16
Page 1 (5)
Connecting Rod Big-end and Main Bearing Shells Edition 02
L16/24
L21/31
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off fuel oil
Description:
Inspection of bearing shells.

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

Big-end bearing, 506-01.30
or
Main bearing and guide bearing 510-01.05
Related procedure:
Mounting af bearing shells:

Big-end bearing, 506-01.30
Main bearing and guide bearing 510-01.05
08028-0D/H5250/94.08.12
Man power: Replacement and wearing parts:
Working time : 1/4 hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

02.26 - ES0
506-01.16 Criteria for Replacement of Working Card
Edition 02 Connecting Rod Big-end and Main Bearing Shells Page 2 (5)
L16/24
L21/31
This paper gives information about the evaluation of Bearing Surface
the connecting rod big-end and main bearing shells
when wear appears on the running surface under Standard Miba bimetal bearings have no tin flash.
normal operating conditions.
Oil is used for protective coating.
Bearing damages caused by incorrect running con-
ditions, like In new condition the bearing has a silvery, bright
color.
- Corrosion
- Overloading, overheating a.s.o. The running surface might become dull silvery after
only a short time of operation.
are not described in this paper.
In these cases, the bearing shells must be exchan- Criteria for bimetal bearing replacement
ged, of course, and in order to avoid further bearing
failures, the cause of the failure must be found and Actual wear can be determined by measuring wall
eliminated. thickness or via clearance measurements in
comparison to the specification for a bearing in new
condition.
New Condition
A bearing should be replaced if the wear limit, as
The running surface has a silvery, bright color, see specified by the engine manufacturer, is reached or
fig 1. can be expected to be reached during the next
period of operation.
Another method is to specify a certain time limit for

the useful service life of the bearing. The individual
time limit (recommended maximum time in operation)
specified by the engine manufacturer is based on the
calculated bearing load, minimum oil film thickness
and load profile.
The useful service life of a bearing is also determined

by the fatigue strength of the lining material under the
respective load profile.
Usual running pattern

Fig 1 Without flash
Typical running pattern after completion of running-
in:
08028-0D/H5250/94.08.12
02.26 - ES0
Page 3 (5)
L16/24
L21/31
Bearings to be reused 3. Damage due to foreign particles
Following pictures shows the typical running pattern Shallow scoring and / or imprints that are few in
where bearing shells are reusable. number. See fig 4.
1. Normal wear
Slightly polished zones and symmetrical running

pattern in the most loaded zone of the bearing. Minor
scoring. See fig 2.
Fig 4 Reusable
4. Minor cavitation after long time in operation
Minor and shallow material removal outside the most

Fig 2 Reusable loaded zone. See fig 5.
2. Minor edge loading
and usual running pattern.

Slightly polished stripes along the side faces. See
fig 3.
08028-0D/H5250/94.08.12
Fig 5 Reusable
Fig 3 Reusable
02.26 - ES0
506-01.16 Criteria for Replacement of Working Card
Page 4 (5)
Edition 02 Connecting Rod Big-end and Main Bearing Shells
L16/24
L21/31
Bearings to be replaced 7. Damage due to foreign particles
Following pictures shows abnormal wear or damages Many scores or multiple deep grooves and / or
that require replacement of bearing shells i.e. imprints. See fig 8 and fig 9.
investigation of reasons.
5. Localized heavy smearing of lining material
due to local disturbance of the oil film. See fig 6.
Fig 8 Replace
– deep scoring, imprints. Lining material locally smeared
Fig 6 Replace
6. More extensive area of damage with seizure

Locally smeared lining material
caused by a severe disturbance of the oil film. See

fig 7.
Fig 9 Replace
– many deep imprints
08028-0D/H5250/94.08.12
Fig 7 Replace
02.26 - ES0
Page 5 (5)
L16/24
L21/31
8. Deep punctual cavitation 10. Fatigue rupture of the lining material
In severe cases the cavitation extends to the steel Mechanism:

shell, spreads along the interface between steel - Development of fine cracks in the lining
shell and lining material, and undermines the AISn20 material
lining. See fig 10. - Network of cracks (crazing)
- Parts of the lining material break out
Fig 10 Replace
Fig 12 Fatigue rupture
9. Deep cavitation
Cavitation at the end of the oil groove.

08028-0D/H5250/94.08.12
Fig 11 Replace
– deep cavitation
02.26 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Hydraulic Tightening of Connecting Rod Screws 506-01.25
L16/24

52021 167
52021 180
52021 202
Tightening procedure for connecting rod bolts.

Check of connecting rod bolts, tightening condit-
ion.
Hand tools
Starting position
Piston, connecting rod, bearing shells and

bearing cap preassembled
Related procedure
Working time : ½ hours Plate No Item No Qty/

Capacity : 2 men
08028-0D/H5250/94.08.12
Data

99.33 - ES0
506-01.25 Hydraulic Tightening od Connecting Rod Screws Working Card
L16/24
1) Mount the connecting rod bolts and tighten the 5) Relieve the hydraulic pressure on the tool.
nuts by hand.
6) Add the hydraulic pressure to the tool once
2) Mount the hydraulic tools, pos. 1, on both more.
connecting rod bolts.
7) Tighten the nuts again.
Be aware of the max. lifting height of the tool
and adjust the distance between the piston Note: The point 5 to 7 can be followed in order to
and the cylinder before adding pressure to the remove tensions in the bolts, if any.
tool. please see working card 520-01.05.
8) If there still is a distance and the nuts still can
3) Connect the hoses and pressure pump to the be tightened then repeat the point 5 to 7.
hydraulic tool.
9) Release the hydraulic pressure on the tool and
4) Add the prescribed hydraulic pressure, (to remove the hydraulic nuts.
both bolts simultaneously), see description
500.40, and tighten the nuts by using a handle. Note: General instruction about hydraulic tightening,
1. Hydraulic tools
08028-0D/H5250/94.08.12
Fig 1 Hydraulic tool for tightening of connecting rod screws
99.33 - ES0
Working Card
Hydraulic Tightening of Connecting Rod Screws 506-01.25
L16/24

52021 299
52021 167
52021 180
52021 202
Tightening procedure for connecting rod bolts.

Check of connecting rod bolts, tightening condit-
ion.
Hand tools
Starting position
Piston, connecting rod, bearing shells and

bearing cap preassembled
Related procedure
Manpower
Working time : ½ hours

Capacity : 2 men
08028-0D/H5250/94.08.12
Data Replacement and wearing parts
Data for pressure and tolerance (Page 500.35) Plate no Item no Qty/
98.38 - ES0
506-01.25 Hydraulic Tightening od Connecting Rod Screws Working Card
L16/24
1) Mount the connecting rod bolts and tighten the 5) Relieve the hydraulic pressure on the tool.
nuts by hand.
6) Add the hydraulic pressure to the tool once
2) Mount the hydraulic tools, pos. 1, on both more.
connecting rod bolts.
7) Tighten the nuts again.
Be aware of the max. lifting height of the tool
and adjust the distance between the piston Note: The point 5 to 7 can be followed in order to
and the cylinder before adding pressure to the remove tensions in the bolts, if any.
tool. please see working card 520-01.20.
8) If there still is a distance and the nuts still can
3) Connect the hoses and pressure pump to the be tightened then repeat the point 5 to 7.
hydraulic tool.
9) Release the hydraulic pressure on the tool and
4) Add the prescribed hydraulic pressure, (to remove the hydraulic nuts.
both bolts simultaneously), see description
500.40, and tighten the nuts by using a handle. Note: General instruction about hydraulic tightening,
08028-0D/H5250/94.08.12
Fig 1 Hydraulic tool for tightening of connecting rod screws
98.38 - ES0
Working Card
Page 1 (3) In-situ Inspectioan of Connecting Rod Big-end Bearing 506-01.30
Edition 02H
L16/24

52021 072
52021 275
52021 167
52021 202
In-situ inspection and/or replacement of 52021 334
connecting rod big-end bearing.
Dismounting and mounting.
Crankcase opened. Open-end spanner 24 mm
Related procedure
Inspection of connecting rod

big-end bearing 506-01.16
Tightening and check of connecting
rod screws 506-01.25

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

98.38 - ES0
506-01.30 In-situ Inspection of Connecting Rod Big-end Bearing Working Card
L16/24
1) Turn the crankshaft into the top position. 7) Slowly turn the crankshaft clockwise until the
connecting rod is resting on the inspection
tool.
Removal of the Connecting Rod Bearing
Cap
Removal of the upper Connecting Rod
2) Loosen the hydraulic bolts by means of the Bearing Shell
hydraulic tools, please see working card 520-
01.05. 8) Mount the connecting rod on the inspection
tool by means of the connecting rod bolt and a
3) Remove the hydraulic tools. nut.
4) Remove the hydraulic nuts and the bearing Note: Make sure that only one connecting rod bolt is
cap with the lower bearing shell by hand. fit in the connecting rod before the crankshaft turns
any further.
Mounting of the Inspection Tool 9) Turn slowly the crankshaft clockwise until it is
possible to remove the upper connecting rod
5) Turn the crankshaft app. 45° clockwise allowing bearing shell.
the connecting rod bolts be removed.
10) Remove the upper connecting rod bearing
6) Mount the inspection tool acc to fig 1. shell.
08028-0D/H5250/94.08.12
Fig. 1 Mounting af the inspection tools.
98.38 - ES0
Working Card
In-situ Inspection of Connecting Rod Big-end Bearing 506-01.30
L16/24
Inspection of Bearing Shells 16) Turn slowly the crankshaft anti-clockwise until
it rests in the connecting rod.
11) Inspect the bearing shells, please see working
card 506-01.16. 17) Remove the inspection tool.
Cleaning of Components before Mounting Mounting of Bearing Cap
12) Clean carefully the joint faces, the bore and the 18) Lubricate threads and contact face of the
bearing shells. connecting rod bolts with Copaslip or the like.
19) Mount the connecting rod bolts.

Mounting of Upper Bearing Shell
20) Turn the crankshaft anti-clockwise until it is in
13) The bearing shell is placed in the bore, the the top position.
contact surfaces of the shells must be parallel
to the contact surface of the connecting rod 21) Mount the bearing cap with the inserted lower
and the bearing cap respectively. big-end bearing shell by hand.
14) Coat the journal with clean lubricating oil. 22) Mount the screws and tighten them by hand.
15) Remove the bolt and nut from the connecting 23) Mount the hydraulic tool and tighten the bolts
rod and inspection tool. according to working card 506-01.25.
08028-0D/H5250/94.08.12
98.38 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Inspection and Honing of Cylinder Liner 506-01.35
L16/24

Inspection and honing of cylinder liner with honing Drilling machine 60-180 rpm.
brush. Honing oil.
Gas oil.
Starting position
Piston and connecting rod

removed 506-01.01
Related procedure
Grinding of seal face on cylinder

head and cylinder liner 506-01.45

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

Capacity : 1 man
Data

99.33 - ES0
506-01.35 Inspection and Honing of Cylinder Liner Working Card
L16/24
Measurement of Cylinder Diameter Honing the Cylinder Liner
While the piston is removed from the cylinder, the Renovation is made in the workshop.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, Prior to honing, deposits of coke and possible wear
with measuring points at TDC-position for the upper- edges at the top of the liner must be removed by
most piston ring, halfway down, and at the bottom of scraping.
the cylinder liner, see fig 1 and page 4.
A used flame ring must be used during the honong
process.
The used flame ring must be cleaned in water.

Subsequently, the flame ring is remounted in the
cylinder before carrying out the honing process.
80-160 rpm.
Fig 1 Measuring points.
The measurements should normally be taken in both

transverse and in longitudinal direction.
When measuring, take care that the measuring tool

has approximately the same temperature as the Fig 2 Flex-honer in cylinder liner.
08028-0D/H5250/94.08.12
liner. When the wear of a cylinder liner exceeds the

value indicated on page 500.35, i.e. when it becomes
too troublesome to maintain adequate service con- Note: Upon completion of the honing process the
ditions, the cylinder liner in question should be used flame ring is discarded. A new flame ring is
replaced. always mounted in the cylinder when replacing the
piston rings.
99.33 -ES0
Working Card
page 3 (4) Edition 02H
L16/24
The honing is made by means of a flex-honer with

grain fineness 80-120. A revolution speed between
80 and 160 rpm is chosen.
In order to achieve a required angle between honing

grooves, see fig 3, the vertical speed is adjusted to
about 1 m/sec. which corresponds to about 2 sec. for 60°
one double movement (the flex- honer is led from
below up and down in 2 sec.)
The procedure must be continued until the cylinder

wall is covered by honing grooves and the surface
has a slight matt appearance without any signs of
glaze. Fig 3 Angle between honing grooves.
During the honing it is important to lubricate freely

with honing oil or cutting oil.
After the honing, the liner is carefully cleaned with

gas oil. Make sure that all abrasive particles are
removed.
08028-0D/H5250/94.08.12
99.33 - ES0
08028-0D/H5250/94.08.12
99.33 - ES0
Working Card
Page 4 (4)
Engine type Report No.

Measurement of Cylinder Liner Engine No. Encl. No.
Running hours Insp. date
Plant Fuel Sign.
Cyl. No. 1 2 3 4 5 6 7 8 9
Cyl.liner ident.No.
Running hours
Inspection and Honing of Cylinder Liner
L A
e
n B
g
t C
h
w
45
i
A s
e
135
C A
r B
B o
s C
s
312
w
i
s
e
C Liner
temp.
°C
Remarks...
506-01.35
L16/24
Edition 02H
Working Card
L16/24

Inspection and honing of cylinder liner with honing Drilling machine 60-180 rpm.
brush. Honing oil.
Gas oil.
Starting position
Piston and connecting rod

removed 506-01.00
Related procedure
Grinding of seal face on cylinder

head and cylinder liner 506-01.45

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

Capacity : 1 man
Data

98.38 - ES0
506-01.35 Inspection and Honing of Cylinder Liner Working Card
L16/24
Measurement of Cylinder Diameter Honing the Cylinder Liner
While the piston is removed from the cylinder, the Renovation is made in the workshop.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, Prior to honing, deposits of coke and possible wear
with measuring points at TDC-position for the upper- edges at the top of the liner must be removed by
most piston ring, halfway down, and at the bottom of scraping.
the cylinder liner, see fig 1 and page 4.
A used flame ring must be used during the honong
process.
The used flame ring must be cleaned in water.

Subsequently, the flame ring is remounted in the
cylinder before carrying out the honing process.
80-160 rpm.
Fig 1. Measuring points.
The measurements should normally be taken in both

transverse and in longitudinal direction.
When measuring, take care that the measuring tool

has approximately the same temperature as the Fig 2. Flex-honer in cylinder liner.
08028-0D/H5250/94.08.12
liner. When the wear of a cylinder liner exceeds the

value indicated on page 500.35, i.e. when it becomes
too troublesome to maintain adequate service con- Note: Upon completion of the honing process the
ditions, the cylinder liner in question should be used flame ring is discarded. A new flame ring is
replaced. always mounted in the cylinder when replacing the
piston rings.
98.38 -ES0
Working Card
page 3 (4) Edition 02H
L16/24
The honing is made by means of a flex-honer with

grain fineness 80-120. A revolution speed between
80 and 160 rpm is chosen.
In order to achieve a required angle between honing

grooves, see fig 3, the vertical speed is adjusted to
about 1 m/sec. which corresponds to about 2 sec. for 60°
one double movement (the flex- honer is led from
below up and down in 2 sec.)
The procedure must be continued until the cylinder

wall is covered by honing grooves and the surface
has a slight matt appearance without any signs of
glaze. Fig 3. Angle between honing grooves.
During the honing it is important to lubricate freely

with honing oil or cutting oil.
After the honing, the liner is carefully cleaned with

gas oil. Make sure that all abrasive particles are
removed.
08028-0D/H5250/94.08.12
98.38 - ES0
08028-0D/H5250/94.08.12
98.38 - ES0
Working Card
Page 4 (4)
Engine type Report No.

Measurement of Cylinder Liner Engine No. Encl. No.
Running hours Insp. date
Plant Fuel Sign.
Cyl. No. 1 2 3 4 5 6 7 8 9
Cyl.liner ident.No.
Running hours
Inspection and Honing of Cylinder Liner
L A
e
n B
g
t C
h
w
45
i
A s
e
135
C A
r B
B o
s C
s
312
w
i
s
e
C Liner
temp.
°C
Remarks...
506-01.35
L16/24
Edition 02H
Working Card Grinding of Seal Face on 506-01.45
Page 1 (2)
Cylinder Liner and Cylinder Head Edition 02H
L16/24

Shut-off fuel oil
Grinding of seal face on cylinder liner, cylinder Grinding pasta

head and cylinder crankcase by hand with grin-
ding tool and grinding pasta.
Starting position
Related procedure
Assembling of cylinder unit, 505-01.50

08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty/

Capacity : 1 man
Data

98.38 - ES0
506-01.45 Grinding of Seal Face on Working Card
Edition 02H Cylinder Liner and Cylinder Head Page 2 (2)
L16/24
Note: The grinding tool is used for both grinding the

groove in the cylinder liner flange (1), the surface of
the cylinder crankcase (2) and the sealing surface on
the cylinder head (3), see fig. 1.
Fig. 3 Grinding tool at cylinder crankcase
Fig. 1 Grinding tool
1) Loosen the sealing ring in liner flange and take

it out.
2) Face-grind the sealing grooves in the cylinder

liner flange, see fig. 2, the surface of the
cylinder crankcase, see fig. 3 and the sealing
surface on the cylinder head, see fig. 4 with
the use of grinding pasta and the grinding tool.
Fig. 4 Grinding tool at cylinder head
3) Move back and forth the tool and lift it out from
time to time.
08028-0D/H5250/94.08.12
4) After grinding , remove carefully all traces of

abrasives and grinding compound.
5) When having ground the contact faces between

cylinder head and cylinder liner it must be
observed that the sealing minimum heighth
above the cylinder liner is according to 500.35.
Fig. 2 grinding tool at cylinder liner
98.38 - ES0
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2) at Low Overhaul Height Edition 02H
L16/24

Dismounting of cylinder unit for inspection and/or Inside micrometer (195 mm)
overhaul. Feeler gauge 0.15 - 0.20 mm
Starting position
Engine stopped and cooled down.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 2 men
Data

99.33 - ES0
506-01.50 Dismantling of Piston and Cylinder Liner Working Card
Page 2 (2)
Edition 02H at Low Overhaul Heights
L16/24
Removal of Cylinder head Removal of Water Jacket, Cylinder Liner,

Piston and Connectinng Rod
1) Prepare removing of the cylinder head
according to working card 505-01.55 pos. 1 to 5) Remove the bearing cap and mount the tool to
15. suport the connecting rod to the cyl. liner,
2) Remove the bolts which hold the cylinder head
and water jacket together. 6) Lift carefully the water jacket, cylinder liner and
piston with connecting rod just enough for
Note: This means that the cylinder head now can be removing the upper connecting rod bearing
removed from the cylinder unit. shell.
3) Mount the lifting tool on the cylinder head. 7) Lift carefully the water jacket, cylinder liner and
piston with connecting rod out of the engine
4) Lift the cylinder head and land it carefully in and land them on wooden support.
wooden support.
Note: The push rods will fall out if they are not
supported by hand.
08028-0D/H5250/94.08.12
99.33 - ES0
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2) at Low Overhaul Height Edition 02H
L16/24

Dismounting of cylinder unit for inspection and/or Inside micrometer (195 mm)
overhaul. Feeler gauge 0.15 - 0.20 mm
Starting position
Engine stopped and cooled down.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 2 men
Data

98.38 - ES0
506-01.50 Dismantling of Piston and Cylinder Liner Working Card
Page 2 (2)
Edition 02H at Low Overhaul Heights
L16/24
Removal of Cylinder head Removal of Water Jacket, Cylinder Liner,

Piston and Connectinng Rod
1) Prepare removing of the cylinder head
according to working card 505-01.55 pos. 1 to 5) Remove the bearing cap and mount the tool to
15. suport the connecting rod to the cyl. liner,
2) Remove the bolts which hold the cylinder head
and water jacket together. 6) Lift carefully the water jacket, cylinder liner
and piston with connecting rod just enough for
Note: This means that the cylinder head now can be removing the upper connecting rod bearing
removed from the cylinder unit. shell.
3) Mount the lifting tool on the cylinder head. 7) Lift carefully the water jacket, cylinder liner and
piston with connecting rod out of the engine
4) Lift the cylinder head and land it carefully in and land them on wooden support.
wooden support.
Note: The push rods will fall out if they are not
supported by hand.
08028-0D/H5250/94.08.12
98.38 - ES0
Plate
Page 1 (2) Piston and Connecting Rod 50601-03H
L16/24
08028-0D/H5250/94.08.12
98.09 - ES0
Plate
50601-03H Piston and Connecting Rod Page 2 (2)
L16/24
Item Item
019 1/C Piston pin Stempelpind
032 2/C Retaining ring Sikringsring
056 1/C Bush for connecting Plejlstangsbøsning

rod
068 1/C Connecting rod 2/2 Plejlstang 2/2
081 1/C Piston 2/2, Stempel 2/2,

incl. item 176 inkl. item 176
093 1/C Piston ring Stempelring
103 1/C Piston ring Stempelring
127 1/C Oil scraper ring Olieskrabering
139 1/C Connecting rod Plejlstangsleje 2/2

bearing 2/2
152 2/C Screw for connecting Plejlstangsskrue

rod
164 2/C Nut Møtrik
176 4/C Bolt Bolt
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
98.09 - ES0
Plate
Page 1 (2) Cylinder Liner 50610-03H
L16/24
08028-0D/H5250/94.08.12
97.07 - ES0
Plate
50610-03H Cylinder Liner Page 2 (2)
L16/24
Item Item
018 1/C Cylinder liner Cylinderforing
031 1/C Sealing ring Tætningsring
092 1/C Flame ring Flammering
08028-0D/H5250/94.08.12
97.07 - ES0
Index
Page 1 (1) Camshaft and Camshaft Drive 507
L16/24
Description
Camshaft and camshaft drive .......................................................................................507.01 (02H)
Working card
Check of Camshaft and camshaft drive.................................................................. 507-01.00 (02H)

Inspection and replacement of camshaft bearing................................................... 507-01.05 (05H)
Adjustment of camshaft for valve and injection timing ........................................... 507-01.20 (05H)
Plates
Intermediate wheel ..........................................................................................................50701-02H

Camshaft (valve camshaft) ..............................................................................................50705-03H
Camshaft (Injection camshaft) .........................................................................................50705-04H
Your Notes :
08031-0D/H5250/94.09.07
Description 507.01
Page 1 (1) Camshafts and Camshaft Drive Edition 02H
L16/24
Camshafts and Camshaft Drive The gear wheel for driving the camshaft as well as a
gear wheel connection for the governor drive are
The inlet and exhaust valves as well as the fuel screwed on to the aftmost section.
pumps of the engine are actuated by two camshafts.
The lubricating oil pipes for the gear wheels are
Due to the two-camshaft design an optimal adjust- equipped with nozzles which are adjusted to apply
ment of the gas exchange is possible without inter- the oil at the points where the gear wheels are in
rupting the fuel injection timing. It is also possible to mesh.
adjust the fuel injection without interrupting the gas
exchange.
The two camshafts are located in the engine frame.

On the exhaust side, in a very high position, the valve
camshaft is located to allow a short and stiff valve
train and to reduce moving masses.
The injection camshaft is located at the service side

of the engine.
Both camshafts are designed as cylinder sections

and bearing sections in such a way that disassembly
of single cylinder sections is possible through the
side openings in the crankcase.
The two camshafts and the governor are driven by

the main gear train which is located at the flywheel
end of the engine. They rotate with a speed which is
half that of the crankshaft.
The camshafts are located in bearing bushes which Fig 1. Twin Camshafts
are fitted in bores in the engine frame; each bearing
is replaceable and locked in position in the engine
frame by means of a locking screw.
08028-0D/H5250/94.08.12
98.45 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Check of Camshaft and Camshaft Drive 507-01.00
L16/24
Stopped engine Plate No Item No Note.

52021 072
52021 202
Description
Checking of gear wheels, bolted connections and Hand tools

lubricating system.
Unbraco top, 8 mm
Ratchet
Extension
Top, 24 mm
Starting position Serrated fork
Related procedure

08028-0D/H5250/94.08.12
Working time : 3 Hours Plate No Item No Qty./

Capacity : 1 man
51106 142 1/cyl
51106 178 1/cyl
Data

98.09 - ES0
507-01.00 Check of Camshaft- and Camshaft Drive Working Card
L16/24
1) Dismount the covers which give access to the 3) Check all screws, nuts and bolted connec-
gear wheels, camshaft and crankcase. tions, including locking devices everywhere in
the gear wheel housing, camshaft housing and
2) Examine all gear wheels for cracks, wear and crankcase to check that they have not worked
deformations. While turning the engine to loose. Tightening torques, please see page
enable inspection allover the circumference of 500.40.
the gear wheels.
4) Start the electrical prelubricating oil pump and

check the oil flow from bearings.
5) Mount the covers.
08028-0D/H5250/94.08.12
98.09 - ES0
Working Card
Inspection and Replacement of Camshaft Bearing 507-01.05
Page 1 (3)
Edition 05H
L16/24

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

shaft bearing.
Replacement of camshaft bearing.
Starting position
Cover for camshaft and gear wheel has been

removed.
Related procedure
Camshaft and camshaft drive, 507-01.00

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

Capacity : 2 men
50705 350 1/eng.
50705 648 1/eng.
Data

01.08 - ES0
507-01.05 Inspection and Replacement of Camshaft Bearing Working Card
Page 2 (3)
Edition 05H
L16/24
To Check Roller Path of Cams
1) While turning the engine, examine the cam

discs and in particular, check the roller path of
all cams for cracks, crackles and 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, the roller must be
replaced by a new one, please see working card
508-01.00.
To Check Camshaft Bearings
2) The wearing surface of the camshaft bearings

cannot be checked without dismounting the
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 be discoloured, as well.
The bearing clearance is measured with a dial

gauge, please see data sheet 500.35.
Fig 1 Removing of spur wheel and the bearing plate.
To Replace Camshaft Bearing for Injection Pull the disconnected sections of the camshaft
or valve camshaft so far aft that the bearing which is to be
replaced is free.
If one or several of the camshaft bearings should be
replaced, the camshaft must be wholly or partly 6) Remove the spur wheel and the bearing plate,
dismantled. see fig 1 so the camshaft can be moved toward
the generator.
Note: Before dismantling last bearing and spur gear
wheel the engine has to be turned so marks at gear 7) Push the bearing out of the bore in the engine
wheels are corresponding, please see Working frame.
Card 507-01.20. Engine must be locked in this
position. 8) Check the lubricating oil ducts to the bearing
08028-0D/H5250/94.08.12
for free flow.

3) The camshaft sections are marked in relation
to each other. 9) For fitting of the bearing it must be cooled down
with CO2 to -90°C below crankcase tempera-
4) Disassemble the camshaft for (toward engine ture.
front) of the bearing that is to be replaced.
10) Inspect the camshaft journal for seizures.
5) Dismount all roller guides that are located aft of
the disassembling position, please see working If necessary, the camshaft section must be
card 508-01.00. entirely removed from the engine, and the
journal concerned must be polished.
01.08 - ES0
Working Card
Inspection and Replacement of Camshaft Bearing 507-01.05
L16/24
11) Coat all the journals of the camshaft section

with clean lubricating oil and push the camshaft
into position, making sure that the marks on
the flanges coincide.
12) Assemble the sections and fit the bolts (coated

with molycote or similar).
13) Tighten the nuts with a torque spanner, please

see data sheet 500.40.
14) Mount all roller guides.

08028-0D/H5250/94.08.12
01.08 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Page 1 (4) Adjustment of Camshaft for Valve and Injection Timing 507-01.20
Edition 05H
L16/24

Shut-off fuel oil
Hand tools
Description
Nominal adjustment of camshaft. (Adjustment of

camshaft in relation to crankshaft).
Starting position
Camshaft assembled as per timing order, mounted

in frame and roller gear house.
If intermediated gearwheel must be changed, the
generator must be dismounted.
Related procedure

08028-0D/H5250/94.08.12
Working time : - hours Plate no Item no Qty/

Capacity : - man
Data

01.08 - ES0
507-01.20 Adjustment of Camshaft for Valve and Injection Timing Working Card
L16/24
Assembly of gear wheels for valve camshaft
and Injection valve camshaft, without
mounted flywheel
Following description is for mounting the gearwheels Upper

in the control drive when alternator, flywheel and intermediate
cover on coupling side are dismantled from the spur wheel
engine.
Small
holes
Mounting of intermediate gearwheels
1) Turn the crankshaft to top dead centre for the Lower

last cylinder (the cylinder nearest to the intermediate
coupling side). spur wheel
2) Mount the upper intermediate gearwheel.

Crankshaft
3) Mount the lower intermediate gearwheel so
the marks on the lower intermediate gear-
wheel are corresponding with the mark on the
crankshaft gearwheel, see fig 1(E2). At the
same time turn the upper intermediate gear-
wheel so that the small holes in the circumfer-
ence of the two intermediate gearwheels are
corresponding, see fig 2.
Fig 2 Position of small holes in the circumference of the two
Note: The punch mark on the crankshaft gearwheel intermediated gearwheels
is placed on the 13 teeth counting counter clockwise
from the joint of the gearwheel, see fig 3.
08028-0D/H5250/94.08.12
Small
holes
13 teeth
Fig 3 13 teeth counter-clockwise from the joint of the gear-

wheel
Fig 1 Marks on gearwheels
01.08 - ES0
Working Card
Page 3 (4) Adjustment of Camshaft for Valve and Injection Timing 507-01.20
Edition 05H
L16/24
4) Tighten up the intermediate gearwheels. Tight- Adjustment of Fuel Injection Camshaft / In-
ening torque, please see page 500.40. jection Timing
1) Unscrew both plugs on the sides at the fuel

Mounting of gearwheel for valve camshaft pump for cylinder no 1. Cylinder numbering,
please see page 500.11.
5) Before mounting the gearwheel, must marks
for crankshaft and lower intermediate gear- 2) Turn the engine to approx. 20° before ignition
wheel correspond, see fig 1(E2). Secondly top dead centre for cylinder no 1.
must the small holes for both intermediate
gearwheels be corresponding. Clean the pressure area of the pump carefully
from fuel by blowing out with pressurized air.
6) Turn the valve camshaft, until the mark on the
gearwheel for valve camshaft corresponds
with the 2 marks on upper intermediate gear-
wheel, see fig 1 (E1).
7) Tighten up the gearwheel. Tightening torque,

please see page 500.40.
Mounting the gearwheel for injection cam-

shaft
8) Before mounting the gearwheel, must marks

for crankshaft and lower intermediate gear-
wheel correspond, see fig 1(E2). Secondly
must the small holes for both intermediate
gearwheels be corresponding.
9) Turn the injection valve camshaft, until the

mark on the gearwheel for valve camshaft
correspond with the 2 marks on upper interme-
diate gearwheel, see fig 1 (E1).
Note: Adjustment of injection valve camshaft is now

needed, please see separately chapter “Adjustment
of Fuel Injection Camshaft / Injection Timing”.
Fig 4 Use a flashlight and a mirror to light through the pump

08028-0D/H5250/94.08.12
01.08 - ES0
507-01.20 Adjustment of Camshaft for Valve and Injection Timing Working Card
L16/24
3) Place a lamp and a mirror in front of the holes 6) Check injection timing from step 2.
as shown in fig 4.
7) If timing of the fuel camshaft is OK, then tighten
4) Look through the pump from one side and at the bolts on the gearwheel. Tightening torque,
the same time turn the engine in its normal please see page 500.40.
directions until the plunger in the barrel cuts off
the light from the flashlight on the other side. 8) Tighten up the plugs. Tightening torque, please
see page 500.40.
Note: Check the stamp on the flywheel. This must
be according to fig 5.
5) If re-adjustment of the camshaft is needed,

then loosen the gearwheel and adjust (tighten
one bolt).
Pump type: Woodward L'Orange
Engine rpm 1000 1200 1000 1200
Light method (E) 5.5° ± 0.5 BTDC 8.6° ± 0.5 BTDC 9.8° ± 0.5 BTDC 12.7° ± 0.5 BTDC
Flywheel circumference
mm/° (3079 : 360) 8.55 8.55 8.55 8.55
~ mm (8.55 x Qty.°) 47 ± 4 mm 74 ± 4 mm 84 ± 4 mm 109 ± 4 mm
Fig 5 Static injection timing
08028-0D/H5250/94.08.12
01.08 - ES0
Plate
Page 1 (2) Intermediate Wheel 50701-02H
L16/24
08028-0D/H5250/94.08.12
01.43 - ES0
Plate
50701-02H Intermediate Wheel Page 2 (2)
L16/24
Item Item
012 1/E Stepped spur gear, Tandhjul, komplet

complete incl. item inkl. item 024, 048,
024, 048, 061 061
024 1/E Spur gear Tandhjul
036 1/E Spur gear, complete Tandhjul, komplet

incl item 061, 120 inkl. item 061, 120
061 2/E Control drive bearing Lejebøsning
073 2/E Bolt Bolt
085 4/E Axial bearing ring Lejering
097 2/E Axle Aksel
107 2/E Washer Skive
119 2/E Nut Møtrik
08028-0D/H5250/94.08.12
01.43 - ES0
Plate
Page 1 (2) Camshaft (Valve Camshaft) 50705-03H
L16/24
08028-0D/H5250/94.08.12
97.48 - ES0
Plate
50705-03H Camshaft (Valve Camshaft) Page 2 (2)
L16/24
Item Item
014 1/C Camshaft part Styreakselsektion 217 2/E Bearing disk, Lejesøle,
piece 9 cyl. engine 9 cyl. motor
026 2/E Bearing disk, Lejesøle, 229 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor
038 2/E Bearing disk, Lejesøle, 230 1/E Axial bearing disk Aksial lejesøle
5 cyl. engine 5 cyl. motor
242 1/E Bearing segment Lejesøle, ende
051 1/E Bearing disk, Lejesøle, end
254 1/E Spur wheel Cylindrisk tandhjul
063 1/E Bearing disk, Lejesøle,
6 cyl. engine 6 cyl. motor 266 Screw Skrue
075 Bearing disk Lejesøle 86/E 6 cyl. engine 6 cyl. motor
1/E 6 cyl. engine 6 cyl. motor 100/E 7 cyl. engine 7 cyl. motor
087 Bearing disk Lejesøle
1/E 6 cyl. engine 6 cyl. motor 278 Washer Skive
099 1/E Bearing disk, Lejesøle, 98/E 7 cyl. engine 7 cyl. motor
6 cyl. engine 6 cyl. motor 112/E 8 cyl. engine 8 cyl. motor
7 cyl. engine 7 cyl. motor 291 Cylindrical pin Cylindrisk stift
301 1/E Bearing plate, com- Lejeplade, komplet
134 1/E Bearing disk, Lejesøle, plete incl. item 313 inkl item 313
313* 3/E Expander plug Ekspansionsprop
8 cyl. engine 8 cyl. motor 325 1/E Intermediate ring, Mellemring,
only for 9L16/24 kun for 9L16/24
8 cyl. engine 8 cyl. motor 337 1/E Damper, Dæmper,
8 cyl. engine 8 cyl. motor 349 7/E Screw, Skrue,
only for 5-8L16/24 kun for 5-8L16/24
8 cyl. engine 8 cyl. motor 350 Camshaft bearing Styreakselleje
08028-0D/H5250/94.08.12
661 7/E Screw, Skrue,
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
97.48 - ES0
Plate
Page 1 (2) Camshaft (Injection Camshaft) 50705-04H
L16/24
08028-0D/H5250/94.08.12
97.48 - ES0
Plate
50705-04H Camshaft (Injection Camshaft) Page 2 (2)
L16/24
Item Item
266 Screw Skrue 469 2/E Bearing disk, Lejesøle,

167/E 5 cyl. engine 5 cyl. motor 7 cyl. engine 7 cyl. motor
227/E 7 cyl. engine 7 cyl. motor 470 2/E Bearing disk, Lejesøle,
278 Washer Skive 8 cyl. engine 8 cyl. motor
291 Cylindrical pin Cylindrisk stift
313* 3/E Expander plug Ekspansionsprop 541 1/E Bearing disk, Lejesøle,
337 1/E Damper, Dæmper,
only for 9L16/24 kun for 9L16/24 553 2/E Bearing disk, Lejesøle,
362 1/C Camshaft part Styreakselsektion
piece 565 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 577 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 589 1/E Axial bearing disk Aksial lejesøle
398 1/E Bearing disk, Lejesøle, 590 1/E Bearing segment Lejesøle, ende
6 cyl. engine 6 cyl. motor end
408 1/E Bearing disk, Lejesøle, 600 1/E Spur wheel, Cylindrisk tandhjul,
6 cyl. engine 6 cyl. motor 5-8 cyl. engine 5-8 cyl. motor
421 Bearing disk Lejesøle 612 1/E Spur wheel, Cylindrisk tandhjul,
624 1/E Bearing plate, com- Lejeplade, komplet
433 Bearing disk Lejesøle plete incl. item 313 inkl. item 313
2/E 9 cyl. engine 9 cyl. motor 636 1/E Ring Ring
445 1/E Bearing disk, Lejesøle, 648 Camshaft bearing Styreakselleje

08028-0D/H5250/94.08.12

97.48 - ES0
Index Operating Gear for Inlet Valves, Exhaust Valves and
Page 1 (1) 508
Fuel Injection Pumps
L16/24
Description
Operating gear for valve and fuel injection pumps .......................................................508.01 (02H)
Working card
Inspection of valve roller guide ............................................................................... 508-01.00 (03H)

Control of valve clearance ...................................................................................... 508-01.10 (09H)
Safe valve adjustment ............................................................................................ 508-01.10 (10H)
Plates
Roller guide and push rods..............................................................................................50801-02H

Your Notes :
08031-0D/H5250/94.09.07
Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition 02H
L16/24
Roller Guides The valve actuating gear is pressure-feed lubricated

from the centralized lubricating system, through the
The fuel injection pumps and rocker arms for inlet and water chamber part and from there into the rocker arm
exhaust valves are operated by the cams on the shaft to the rocker bearing.
camshafts through roller guides. The roller guides for
inlet and exhaust valves are located in bores in the
water jacket for each cylinder.
The roller runs on a bush fitted on a pin that is pressed

into the roller guide and secured by means of a lock
screw.
Operating Gear for Fuel Injection Pumps
The injection pumps which are mounted directly on

the frame are activated via thrust pieces from the
roller guide. The roller guide is incorporated in the fuel
pump as one unit.
The roller is pressed down on to the cam by a spring,

which is fixed between the roller guide and the foot
plate of the fuel injection pump, see also section 514.
Valve Actuating Gear
The rocker arms are actuated through rollers, roller

guides and push rods. The roller guides for inlet and
exhaust valves are mounted in the water jacket part.
For dismantling, a side cover on the push rod chamber
is provided.
Each rocker arm activates two spindles through a

valve bridge with thrust screws and adjusting screws
for valve clearance. Fig 1 Valve operating gear
08028-0D/H5250/94.08.12
98.38 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Inspection of Valve Roller Guide 508-01.00
L16/24

Shut-off fuel oil
Dismounting, inspection and/or overhaul, and

mounting of valve roller guides.
Starting position
Cylinder unit has been removed from engine and

dismantled.
Related procedure
Control and adjusting of valve

clearance, 508-01.10

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

98.47 - ES0
508-01.00 Inspection of Valve Roller Guides Working Card
L16/24
1) Turn the water jacket upside down so the roller

guides can slip out at the water jacket.
2) Examine the surface of the roller and the

tappet housing for marks and secures, if any
they must be polished away.
3) Blow clean the lubricating ducts in the tappet

housing and the roller with air.
4) Excamine the push rod, pin and ball cup for

damage and replace if necessary.
Replacement of Roller and Shaft Pin Fig 1 Inspection of roller guide and roller.
5) Remove the lock screw.
6) Push out the axle.
The roller and axle can now be replaced.
7) Mount the lock screw with loctite 275.
Mounting of Roller Guide
8) Mount the tappet housing with roller in the

water jacket.
Note: Be sure that the recess in the tappet housing

is resting on the cylindrical pin in the roller guide
housing. This ensure that the tappet housing can not
turn in the roller guide housing.
08028-0D/H5250/94.08.12
98.47 - ES0
Working Card
Control of Valve Clearance 508-01.10
Page 1 (2)
Edition 09H
L16/24

Description Hand tols
Control and/or adjusting of valve clearance.
Starting position
Cover for valve cam is removed.

Cover for rocker arm is removed.
Related procedure
Safe valve adjustment 508-01.10 (10H)

Manpower
Plate no Item no Qty/
08028-0D/H5250/94.08.12

Capacity : 1 man
Data See also plate 50502.

Data for tightening torque (Page 500.40)
03.43 - ES0
508-01.10 Control of Valve Clearance Working Card
L16/24
1) Turn the engine so that the roller, rests on the 2) Lift rocker arm in order to open the valves.
circular part of the cam, i.e. the inlet valves and Control that the valves start to open at the
the exhaust valves are closed. same time.
If the valves do not open at the same time,

make valve adjustment according to working
card 508-01.10(10H).
3) Verify clearance between valve bridge and

rocker arm, please see page 500.35 for clear-
ance data.
If the valve clearance have to be adjusted,

please see page 508-01.10 (10H)
Fig 1 Control of valve clearance
08028-0D/H5250/94.08.12
03.31 - ES0
Working Card
Safe Valve Adjustment 508-01.10
L16/24
Safety precautions: Special tools:

Press Blocking - reset
Description: Hand tools:
Verification and/or adjustement of inlet and Screew driver

exhaust valves clearance. Torque wrench
Marking ink
Starting position:
Cover for valve camshaft is removed.

Cover for rocker arms is removed.
Rocker arms are removed.
Related procedure:
Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12
Working time : ½ hours Plate no Item no Qty/

Capacity : 1 man
See also plate 50502
Data:

Data for tightening torque (Page 500.40)
03.43 - ESO
508-01.10 Safe Valve Adjustment Working Card
Page 2 (3)
Edition 10H
L16/24
1) Before adjustment the rocker arms must be

removed.
Fig. 1. Cylinder without valve bridge.

Fig.3. The valve bridge in the vice.
2) Loosen the adjusting nut and turn it back one

turn. 5) Apply marking ink on the end of both valve
spindles. Place the valve bridges on the valve
3) Press the valve bridge to the valve spindle on spindles and press gentle.
the non-adjustable end and turn the adjusting
screw until you feel contact. Tighten the nut.
Fig.2. Adjustment of valve bridge.
4) Place the valve bridge in a vice and apply

correct torque on the nut with a torque wrench. Fig. 4. Marking of valve spindles.
08028-0D/H5250/94.08.12
03.43 - ESO
Working Card
Safe Valve Adjustment 508-01.10
L16/24
6) If the valve bridge is correctly adjusted there 9) Install the rocker arms and adjust the clear-
will be ink on both contact surfaces and the ink ance to specified value.
will be clearly touched on both valve spindles.
If the valve bridge do not clearly touch both

valve spindles then clean the marking ink
return to item 3.
Fig.7. Adjustment of rocker arms.
Fig.5. Control of adjustment of valve bridge. 10) Tighten the nut with torque wrench to correct
torque. Check the valve clearance once more
7) Mark the valve bridge adjusting screw and after the nut is tightend with correct torque.
locking nut clearly to indicate it has been The rocker arm adjusting screw and nut to be
correctly adjusted and tightened. Mark inlet marked clearly to indicate it is correct ad-
and exhaust differently to insure they are not justed.
interchanged.
Fig.8. Tightening and marking of rocker arms.

Fig.6. Marking after adjustment and tightening.
The valves are now correct adjusted and securely

08028-0D/H5250/94.08.12
8) Turn the engine so that the rollers rest on the

fastened to insure safe operation.
circular part of the cam.
Remark
Item 1-6 can be performed, without the cylinder

cover mounted on the engine.
03.43 - ESO
Your Notes :
08031-0D/H5250/94.09.07
Plate
Page 1 (2) Roller Guide and Push Rods 50801-02H
L16/24
08028-0D/H5250/94.08.12
97.43 - ES0
Plate
50801-02H Roller Guide and Push Rods Page 2 (2)
L16/24
Item Item
028 2/C Push rod Stødstang
041 2/C Bolt Bolt
053 2/C Roller Rulle
065 2/C Shaft Aksel
077 2/C Housing for roller Hus for rullestyr

guide
089 2/C Screw Skrue
08028-0D/H5250/94.08.12
97.43 - ES0
Index Control and Safety Systems, Automatics and
Page 1 (1) 509
Instruments
L16/24
Description
Control and safety systems ............................................................................................ 509.01 (11)

Lambda controller .........................................................................................................509.10 (07H)
Communication from the GenSet ................................................................................... 509.55 (07)
Working card
Functional test and adjustment of safety, alarm and monitoring equipment .......... 509-01.00 (02H)
Function test of shutdown..........................................................................................509-01.05 (07)
Adjustment and test of analogous pressure transmitter ......................................... 509-05.03 (03H)
Adjustment and test of analogous temperature transmitter.................................... 509-05.04 (04H)
Mounting and adjustment of pick-ups on engine .................................................... 509-08.00 (01H)
Adjustment of lambda controller ............................................................................. 509-10.00 (05H)
Plates
Governor and governor drive...........................................................................................50901-03H

Regulating device ............................................................................................................50902-04H
Level switch in oil sump (LAL/LAH 28) ............................................................................50920-02H
Fuel oil leakage alarm (LAH 42) ......................................................................................50925-02H
Terminal box ....................................................................................................................50935-02H
Your Notes :
08031-0D/H5250/94.09.07
Description
Safety, Control and Monitoring System 509.01
General
General Description The engine is equipped with the following main

safety, control and monitoring components:
Monitoring and instrumentation on the engine repre-
sents a tailor-made system. The system is designed ● Safety system
to fulfil the following requirements: ● Governor
● Monitoring modules
● Continuous analogue monitoring – base module
● Independent safety system – operation box (OB)
● Easy installation – monitoring of temperatures/pressures
● Simple operation panel (MTP)
● Instrumentation complete – monitoring of exhaust gas temperature
● No maintenance panel (MEG)
● Prepared for CoCoS – monitoring of bearing temperature panel
● Redundant safety system (MBT), option
– bearing temperature display (BTD), option
– oil mist detector, option
In order to fulfil all classification society requirements ● Instrumentation (sensors, wiring, junction
the engine is equipped with monitoring sensors for boxes)
all medias as standard. If just one classification ● Manometers and thermometers
society require one specific measuring point it is ● Output module, option
standard on the engine. Also a built-on safety system ● Alarm panel, option
is standard.
08028-0D/H5250/94.08.12
Fig 1 Monitoring and safety system.
03.33 - ES1
509.01 Safety, Control and Monitoring System Description
Edition 11 Page 2 (6)
General
Safety System The spring-loaded pull rod permits the governor to

give full deflection even if the stop cylinder of the
The safety system is an independent system for manoeuvering system keeps the fuel injection pump
monitoring and controlling the GenSet’s shutdown at "no fuel" position.
functions.
Each fuel injection pump is connected to the com-
The safety system is based on a programme logic mon, longitudinal regulating shaft by means of a
controller (PLC) which automatically controls the spring-loaded arm.
automatically stop (shutdown) in case of:
Should a fuel plunger seize in its barrel, thus blocking
Shutdown the regulating guide, governing of the remaining fuel
injection pumps may continue unaffected owing to
1) Overspeed the spring-loaded linkage between the blocked pump
2) Low lube oil pressure and the regulating shaft.
3) High HT water temp.
4) Emergency stop
5) High bearing temp. (option) Monitoring System
6) Oil mist stop (option)
All media systems are equipped with temperature
Set points and special conditions can be found in the sensors and pressure sensors for local and remote
"Operation Data & Set Points, B 19 00 0" reading.
Connection to and from the power management The sensors for monitoring and alarming are con-
system is hard wire connection. nected to the base module.
Indication of each shutdown can be found on the

operation box and directly on the safety system Base Module
module inside the terminal box.
The base module is the centre of the monitoring
system.
Governor
The base module, the OB-module, the MTP-module
The engine speed is controlled by a hydraulic gover- and the MEG-module are designed by MAN B&W
nor or electronic controller with hydraulic actuator. Diesel A/S, Holeby specifically for this engine type.
Information about the design, function and operation Apart from the electrical main connection to the
of the governor is found in the special governor alternator the ship yard only has to perform the
instruction book. following electrical connection:
The governor is mounted on the flywheel end of the – 24 VDC supply to the safety system.
08028-0D/H5250/94.08.12
engine and is driven from the camshaft via a cylindri- – Cable connection to/from power manage-
cal gear wheel and a set of bevel gears. ment system.
– 24 VDC supply to the base module.
– Modbus communication or interlink to output
Regulating Shaft module.
The governor's movements are transmitted through The vessel’s alarm and monitoring system in the
a spring-loaded pull rod to the fuel injection pump main switch board can be connected to the base
regulating shaft which is fitted along the engine. module by means of a 3-wire MODBUS communica-
tion link. For further information, please see the
description "Communication from the GenSet".
03.33 - ES1
Description
General
In situations where the vessel’s system cannot oper- ● Shutdowns indication:

ate a MODBUS communication unit, MBD-H offers – overspeed
an output module (OM) to be installed in the vessel’s – low lub. oil pressure
control room. – high fresh water temp.
– emergency stop / oil mist
By means of the OM it is possible to connect all digital
and analogue signals to the vessel’s monitoring Please note that the local stop push button must be
system in a conventional manner. activated at least 3 sec. before the engine will stop.
Communication between the base module (BM) and

the output module (OM) takes place via a 3-wire
interlink bus (RS485).
In the base module all the alarms are generated and

delay and cut-off at standstill is done. Set points and
special conditions can be found in "Operation Data
& Set Points, B 19 00 0".
The set points for above redundant safety stop are

adjusted to a higher/lower point as the safety sys-
tem. This will secure that the safety system will
normally stop the engine in a critical situation. Only
in case that the safety system is out of order the
redundant safety stop will be needed.
Operating Box Module (OB)
This module includes the following possibilities:
● Operation of: Fig 2 Operation box module (OB).

– engine start
– engine stop
– remote mode The manual start button must be activated until
– local mode ignition, takes place. If the engine have been without
– blocking/reset mode prelubrication in more than 20 minutes the engine
– lamp test can not be electrical started.
– arrow up - shift upwards through measure-
ments for display The push buttons REMOTE - LOCAL - BLOCKING
– arrow down - shift downwards through is only related to the start function. In case of
measurements for display
08028-0D/H5250/94.08.12
BLOCKING the engine can not be started from local

or from remote (switchboard).
● Indication of:
– Engine rpm The stop function is not depended of the REMOTE
– TC rpm - LOCAL - BLOCKING position.
– Starting air pressure
– Display for digital read out On the local operating box module the pressure,
– Indication of software version temperature and rpm are illustrated by means of a
display: an LED indicates whether it is the working
hours, alternator, pressure, temperature or rpm which
is measured.
03.33 - ES1
General
The display of the operation box module is used to

read each individual measurement chosen by using
"arrow up" or "arrow down" incl. MTP and MEG
measurements. All rpm, pressures and tempera-
tures are indicated in full values. The value displayed
is indicated by flashing of the last segment of the
bargraph on the OB, MTP or MEG module.
If the lamp test button is activated for more than 3

sec. the software version will be displayed.
Fig 4 Monitor temp./press. (MTP)
Monitoring of Exhaust Gas Temperature

Panel (MEG)
The temperature shown on the MEG module is

Fig 3 Monitoring of temperature/pressure module (MTP). indicated with segments illuminated from the left to
the right. The number of segments illuminated de-
pends on the actual temperature of the exhaust gas.
Monitoring of Temp./Pressure Panel (MTP)
All temperatures and pressures shown on the MTP

module's bargraph are indicated with illuminated
segments. When the temperatures and pressures
are within the stated limits, two segments are illumi-
nated in the middle forming a straight line. This
means that it is easy to check the engines' systems,
even at distance.
08028-0D/H5250/94.08.12
Fig 5 Monitoring of exhaust gas temperature module (MEG).

If there is a deviation, the bargraph in question will
start to illuminate the segments upwards or down-
wards, depending on rising or falling measurements,
see fig 4. For emergency operation in case of totally black-out
on the 24 V DC supply the engine is equipped with
It must be mentioned that the latter does not apply to manometers for:
the charge air temperature and charge air pressure,
because they will vary with the engine load. – Lub. oil pressure
– Cooling water pressure
– Fuel oil pressure
03.33 - ES1
Description
General
and thermometers for: Monitoring of Bearing Temperature, MBT

(option)
– Cooling water temp.
– Fuel oil temp. The temperature shown on the MBT module is
indicated with segments illuminated from the left to
the right. The number of segments illuminated de-
pends on the actual temperature of the bearing
temperature.
Display for Bearing Temperature Display,

BTD (option)
On the bearing temperature display the excact meas-

uring value for each individual bearing temperautre
can be read. Furthermore an indication of high
bearing temperature alarm and very high bearing
temperature shutdown are indicated.
Output Module (option)
For alarm systems which cannot be communicated

through the MODBUS protocol, an output module
has been designed. This module includes conven-
tional output signals (4-20 mA) for all analogue
Fig 6 Monitor exh. gas temperature (MEG). measuring values, signals for limit values, and infor-
mation signals from the safety system.
08028-0D/H5250/94.08.12
Fig 7 Monitoring of bearing temperature (MBT), option. Fig 8 Display for bearing temperature (BTD), option.
03.33 - ES1
General
The output module will be delivered in a separate It is important that all alarms leads to prompt inves-
box (IP56) with the dimensions (H/L/W): 380 x 380 x tigation and remedy of the error. No alarm is insignifi-
155 mm. cant. It is therefore important that all engine crew
members are familiar with and well trained in the use
and importance of the alarm system.The most seri-
Alarm Panel (option) ous alarms are equipped with slowdown and/or
shutdown functions.
An alarm panel with 24 alarm points can be con-
nected to the system. The alarm panel can be
installed on the engine or in the engine control room, Instrumentation
see fig 7. The dimensions for the panel are (H/L/W):
144 x 96 x 35 mm. Pressure measurements are generated from the
pressure transmitters.
The exhaust gas temperatures are generated by

NiCr/Ni thermo sensors.
Temperatures are generated by PT100 sensors.
The above transmitters and sensors are specially

designed for installation on diesel engines.
The pressure sensors are placed centrally at the

front of the engine, facilitating easy access for main-
tenance and overhauls, and minimizing wire con-
nections.
The temperature sensors are placed at the measur-

ing point.
Data
Power supply : 24 VDC ±20%,

Fig 9 Alarm panel.
max ripple 10%
Power consumption : < 2 amp
Ambient temp. : -20oC to 70oC
External
communication links : MODBUS ASCII / RTU or
interlink (RS422 / RS485)
08028-0D/H5250/94.08.12
03.33 - ES1
Description
Lambda Controller 509.10
Page 1 (1)
Edition 07H
L16/24
V28/32S
Purpose If the system is activated more than 10 seconds, the
solenoid valve will be shut off and there will be a
The purpose with the lambda controller is to prevent remote signal for "jet system failure".
injection of more fuel in the combustion chamber than
can be burned during a momentary load increase. The jet system is blocked when engine speed is
This is carried out by controlling the relation between below 50 rpm.
the fuel index and the charge air pressure.
During the start procedure the jet system is used as
The Lambda controller is also used as stop cylinder. a charge air booster.
Hereby heavy smoke formation is prevented during

Advantages start procedure.
The lambda controller has the following advantages:
- Reduction of visible smoke in case of sudden

momentary load increases.
- Improved load ability.
- Less fouling of the engine's exhaust gas ways.
- Limitation of fuel oil index during starting

procedure.
Principles for Functioning
Figure 1 illustrates the controller's operation mode. In

case of a sudden load increase, the regulating device
will increase the index on the injection pumps and
hereby the regulator arm (1) is turned, the switch (2)
will touch the piston arm (3) and be pushed down-
wards, whereby the electrical signal is sent to base
module (BM).
Thus the solenoid valve (4) controlled by the BM is

activated, the turbocharger accelerates and increases
the charge air pressure, thereby pressing the piston
(3) backwards in the lambda cylinder (5). When the
lambda ratio is satisfactory, the solenoid valve will be
08028-0D\H5250\94.08.12
de-activated.
Above system is also called jet system.
At a 50% load change the system will be activated for Fig 1 Principle drawing of lambda controller
about 3-8 seconds.
02.41 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Description
Communication from the GenSet 509.55
Page 1 (9)
Edition 07
General
System Layout All signals can be wired up from the OM-

module to the ship’s alarm & monitoring sys-
Fig 1 shows the system layout. The modules BM, tem.
OB, MTP, MEG and safety system are all placed on
the engine. More detailed information on each mod- 3) A simple alarm panel (AP) with 24 LED chan-
ule and sensors can be read in the description nels can be installed in the control room. This
"Safety, Control and Monitoring System". solution only serves digital alarms.
If the alarm system can communicate with MODBUS

Communication ASCII or RTU, there is no need for the OM-module
or AP. All signals can be communicated by the
Communication from the BM-module to the ship’s MODBUS.
alarm & monitoring system can be done in three
ways: In the following please find a description of the
MODBUS protocol and addressing of the signals.
1) In the BM-module there is a MODBUS ASCII
or RTU interface communication.
MODBUS Protocol (BM)
2) An output module (OM) can be placed in the
control room switchboard or alarm disk. Com- The BM has a standard MODBUS ASCII and RTU
munication from the BM-module to the OM- interface which may be selected, by means of a DIP
module is made via the 3 wire module interlink switch on the BM, to be either:
bus.
– RS422 5 wire (Rx+, Rx-, Tx+, Tx-, GND) or
In the OM-module all the signals are converted – RS485 3 wire (Rx+/Tx+, Rx-/Tx-, GND)
into 4-20 mA signals and digital outputs.
08028-0D/H5250/94.08.12
Fig 1 System overview: "monitoring system & safety system"
04.05 - ES1
509.55 Communication from the GenSet
Description
Page 2 (9)
Edition 07
General
The communication setup is: 9600 baud, 8 databits, The general „message frame format“ has the follow-
1 stopbit, no parity. ing outlook:
The BM MODBUS protocol accept one command [:] [SLAVE] [FCT] [DATA] [CHECKSUM] [CR] [LF]
(Function Code 03) for reading analog and digital
input values one at a time, or as a block of up to 32 – [:] 1 char. Begin of frame
inputs. – [SLAVE] 2 char. Modbus slave address
Selected on DIP-switch at BM
MODBUS is defined by the company AEG Modicon print
and the implementated protocol in the BM is de- – [FCT] 2 char. Function code
signed to observe the relevant demands in the latest – [DATA] n X 2 chars data.
protocol description from AEG Modicon: – [CHECKSUM] 2 char checksum (LRC)
– [CR] 1 char CR
„MODBUS protocol, reference guide document No – [LF] 1 char LF (end of frame)
PI-MBUS-300, Rev. G“
Notice: The MODBUS address [SLAVE] should be
Since the standard refers to specific types of hard- adjusted on the DIP-switch (SW 1) on the BM.
ware, it should be noted that all MODBUS addresses Allowed addresses are 1..254 (0 and 255 not in use).
in the list "Summary of Alarms" for the plant in Broadcast packages will not be accepted (to be
question, refers directly to the addresses as they ignored), see fig 2.
appear on the line. These addresses should thus not
be offset by one in any direction. The following function codes (FCT) is accepted:
The following chapter describes the commands in – 03H: Read n words at specific address.
the MODBUS protocol, which are implementated,
and how they work. In response to the message frame, the slave (BM)
must answer with appropriate data. If this is not
possible, a package with the most important bit in
Protocol Description FCT set to 1 will be returned, followed by an excep-
tion code, where the following is supported:
The ASCII version of the MODBUS protocol is used,
where the BM works as MODBUS slave. As this is a – 01: Illegal function
ASCII protocol, all data bytes will be converted to 2- – 02: Illegal data address
ASCII characters (hex-values). Thus, when below is – 03: Illegal data value
referred to „bytes“ or „words“, these will fill out 2 or 4 – 06: BUSY. Message rejected
characters, respectively in the protocol.
SW 1: MODBUS address
08028-0D/H5250/94.08.12
Switch no 1 2 3 4 5 6 7 8
Address:
0 OFF OFF OFF OFF OFF OFF OFF OFF Not allowed
1 ON OFF OFF OFF OFF OFF OFF OFF
2 OFF ON OFF OFF OFF OFF OFF OFF
254 OFF ON ON ON ON ON ON ON
255 ON ON ON ON ON ON ON ON Not allowed
Fig 2 Modbus address
04.05 - ES1
Description
Page 3 (9)
Edition 07
General
FCT = 03H: Read n words The following types of data format have been cho-
sen:
The master transmits an inquiry to the slave (BM) to
read a number (n) of datawords from a given ad- Digital: Consists of 1 word (register):
dress. The slave (BM) replies with the required 1 word: [0000H]=OFF
number (n) of datawords. To read a single register [FFFFH]=ON
(n) must be set to 1. To read block type register (n)
must be in the range 1...32. Integer: Consists of 1 word (register):
1 word: 12 bit signed data
Request (master): (second complement):
[0000H]=0
[DATA] = [ADR][n] [0FFFH]=100% of range
[ADR]=Word stating the address in HEX. [F000H]=-100% of range
[n]=Word stating the number of words
to be read. Notice: 12 bit data format must be used no matter
what dissolution a signal is sampled with. All mea-
Answer (slave-BM): suring values will be scaled to 12 bit signed.
[DATA] = [bb][1. word][2. word]....[n. word] Example 1:

[bb]=Byte, stating number of subsequent
bytes. PI10, range 0-6 bar
[1. word]=1. dataword The value 2.3 bar will be represented as 38.33% of
[2. word]=2. dataword 6 bar = 0621H
[n. word]=No n. dataword
MODBUS Timeout
MODBUS addressing
To prevent lock up of the protocol, ie. a breakdown
In order to be able to read from the different I/O and on the connection, a number of timeouts are to be
data areas, they have to be supplied with an „ad- built in, as specified in the MODBUS protocol speci-
dress“. fication:
In the MODBUS protocol each address refers to a MODBUS specification max. time between charac-
word or „register“. For the GenSet there are following ters in a frame: 10 ms
I/O registers:
MODBUS specification max. time between receipt of
– Block (multiple) I/O registers occupying up to frame and answer: 1 second
32 word of registers (see table 3, 4, 5 and 6).
However the implementation of the protocol in the
Block I/O registers hold up to 32 discrete I/O's placed GenSet Base Module is able to handle much smaller
at adjacent addresses, so it is possible to request timeouts (response times), which may be required in
08028-0D/H5250/94.08.12
any number of I/O's up to 32 in a single MODBUS order to obtain an acceptable worst-case I/O scan
command. Please refer to table 3, 4, 5 and 6 which time:
specifies the block I/Os registers addresses and how
the individual I/O's are situated within the „block". Base Module, max. time between characters in a
frame: 5 ms
Data Format Base Module, max. time between receipt of frame

and answer: 100 ms
The MODBUS protocol does not define the data
format, which therefore can be determined freely.
04.05 - ES1
509.55 Description
Edition 07
Communication from the GenSet Page 4 (9)
General
In the tables below each signal has a importance h) "Safety system failure" consists of following
statement with following meaning: signals: Power supply failure and internal
watch dog alarm.
Required by the classification society or MAN B&W. i) "Safety sensor cable failure" means cable fail-
Recommended by MAN B&W. ure on one or more of following sensors: lub. oil
"Nice to have". pressostate PSL22, cool. water ther-mostate
TSH12, speed pick-up SE90-2 or emergency
In the tables below some signals have a remark with stop switch ZS82 (as option TSH29/27 for L27/
following meaning: 38 or LSH92 for L27/38 and L32/40)
a) Required by American Bureau of Shipping, j) "Local shutdown" only consists of the shut-
ABS. downs (PSL22, TSH, SSH81, and ZS82) in the
b) Required by Bureau Veritas, BV. safety system.
c) Required by Jugoslavenski Register & DnV. k) For L27/38, L21/31 and L32/40 the signal
d) Required by Registro Italiano Navale, RINA. ZS82, also includes high oil mist shutdown,
e) Required by Nippon Kaiji Kyokai, NKK & DnV. LSH92.
f) Bureau Veritas, Lloyds Register of Shipping l) Only available for L27/38 (standard on 8 and 9
and ABS demand alarm point for low/high cyl. engine), L32/40 and L21/31 (option).
heavy fuel oil temp. Normally this is placed at m) Required by Det Norske Veritas, DnV.
yard side as an common alarm for all aux. n) For L16/24 engine type TC rpm range is 0-
engines. The signal can also be generated 80000.
from iTI40. o) Not accepted by all classification societies.
g) "Common shutdown" consists of following sig- p) For GenSets with high voltage alternators.
nals: PSL22, TSH12, SSH81 and ZS82 (as
option TSH29/27 for L27/38 or LSH92 for L27/ General) All alarm signals are already performed
38 and L32/40). Furthermore it consist also of with necessary time delay. F.ex. lub. oil level
the redundant shutdowns performed in the alarms (LAL/LAH28) includes 30 sec. alarm
Base Module. delay. Start air alarm (PAL70) includes 15 sec.
alarm delay. No further delay are needed.
Table 3 (Block scanning)
Signal Name/description Address Data format Importance Remark Meas. range
oLAH42 Drain box high level 4002 Digital Required

oPAL25 Prelub. oil low press. 4003 Digital Required
oSX32 Jet system failure 4004 Digital Required
oUX95-2 Safety system failure 4005 Digital Required h)
oSS86 Common shutdown 4006 Digital Required g)
oTAH98 Alternator winding temp. high 4007 Digital Required
oPAL10 HT water press. inlet low 4008 Digital Required
oPAL70 Starting air press. low 4009 Digital Required
oPDAH21-22 Diff. press. high, lub. oil filter 400A Digital Required
08028-0D/H5250/94.08.12
oPAL 22 Lub. oil press. inlet low 400B Digital Required

oPAL40 Fuel press. low 400C Digital Required
oTAH12 HT water temp. high 400D Digital Required
oTAH21 Lub. oil temp. inlet high 400E Digital Required
oLAL28 Low oil level base frame 400F Digital Recommended b)
oLAH28 High oil level base frame 4010 Digital Recommended
iZS75 Microswitch, turning gear engaged 4011 Digital Recommended b)
oSAH81 Overspeed alarm 4012 Digital Recommended
oTAD60 Exh. gas temp. high or low 4013 Digital Recommended m)
oTAH61 TC temp. outlet, high 4014 Digital Recommended
oTAH62 TC temp. inlet, high 4015 Digital Recommended m)
Cont.
04.05 - ES1
Description
Page 5 (9)
Edition 07
General
Cont. of table 3
iTI12 HT water temp. outlet 4016 Integeter 12 Bit Recommended m) 0-200° C

iTI21/22 Lub. oil temp. inlet 4017 Integeter 12 Bit Recommended a) + m) 0-200° C
iTI40 Fuel oil temp. inlet 4018 Integeter 12 Bit Recommended f) 0-200° C
iTI98-1 Alternator winding temp. 1 4019 Integeter 12 Bit Recommended a) 0-200° C
iTI98-2 Alternator winding temp. 2 401A Integeter 12 Bit Recommended a) 0-200° C
iTI98-3 Alternator winding temp. 3 401B Integeter 12 Bit Recommended a) 0-200° C
iPI10 HT water press. inlet 401C Integeter 12 Bit Recommended a) + m) 0-6 bar
iPI22 Lub. oil press inlet engine 401D Integeter 12 Bit Recommended a) + m) 0-10 bar
iPI40 Fuel oil press. inlet 401E Integeter 12 Bit Recommended 0-16 bar
iPI70 Starting air pressure 401F Integeter 12 Bit Recommended a) 0-40 bar
oSX86-2 Safety sensor cable failure 4020 Digital Recommended i)
oSX83 Start failure 4021 Digital Recommended
Table 3 MODBUS block 1 (multiple i/o) register addressing.

iPSL22 Lub. oil inlet low pressure, stop 4042 Digital Nice to have
iTSH12 HT water outlet high temp., stop 4043 Digital Nice to have
iZS82 (LSH92) Emergency shutdown (oil mist) 4044 Digital Nice to have k)+m)
iSSH81 Overspeed stop 4045 Digital Nice to have
oZS96 Local indication 4046 Digital Nice to have
oZS97 Remote indication 4047 Digital Nice to have
oSA99 (Spare) 4048 Digital
oSS90A Engine running 4049 Digital Nice to have
iTE60-1 Exh. gas temp., cylinder 1 404A Integer 12 Bit Nice to have c) 0-800° C
iTE60-2 Exh. gas temp., cylinder 2 404B Integer 12 Bit Nice to have c) 0-800° C
iTE60-3 Exh. gas temp., cylinder 3 404C Integer 12 Bit Nice to have c) 0-800° C
iTE60-4 Exh. gas temp., cylinder 4 404D Integer 12 Bit Nice to have c) 0-800° C
iTE60-5 Exh. gas temp., cylinder 5 404E Integer 12 Bit Nice to have c) 0-800° C
iTE60-6 Exh. gas temp., cylinder 6 404F Integer 12 Bit Nice to have c) 0-800° C
iTE60-7 Exh. gas temp., cylinder 7 4050 Integer 12 Bit Nice to have c) 0-800° C
iTE61 Exh. gas temp. outlet TC 4053 Integer 12 Bit Nice to have d) 0-800° C
iTE62 Exhaust gas temp. inlet TC 4054 Integer 12 Bit Nice to have e) 0-800° C
iTI01 LT water temp. inlet 4055 Integer 12 Bit Nice to have 0-200° C
iTI31 Charge air temp. 4056 Integer 12 Bit Nice to have 0-200° C
08028-0D/H5250/94.08.12
iPI01 LT water press. inlet 4057 Integer 12 Bit Nice to have 0-6 bar
iPI21 Lub. oil press. inlet filter 4058 Integer 12 Bit Nice to have 0-10 bar
iPI23 Lub. oil TC press. 4059 Integer 12 Bit Nice to have 0-4 bar
iPI31 Charge air press. 405A Integer 12 Bit Nice to have 0-4 bar
oSE90 Engine RPM pickup 405B Integer 12 Bit Nice to have 0-1600 rpm
oSE89 TC RPM pickup 405C Integer 12 Bit Nice to have n) 0-60000 rpm
oUX95-2_Dly (Spare) 405D Digital
oSX84 Stop failure 405E Digital Nice to have
iSS86-3 Shutdown from safety system 405F Digital Nice to have j)
oPAL01 LT water press. inlet 4060 Digital Nice to have
oPAL23 Lub. oil press. TC, low 4061 Digital Nice to have
04.05 - ES1
509.55 Description
Edition 07
General
oSAH89 High TC rpm 40C2 Digital Nice to have m)

oTAH62-2 High exh. gas temp. before TC 40C3 Digital Nice to have m)
oTAH12-2 High cooling water temp. 40C4 Digital Nice to have m)
oTAH60-1 High exh. gas temp cyl. 1 40C5 Digital Nice to have m)
oTAH60-6 High exh. gas temp cyl. 6 40CA Digital Nice to have m)
oTAH60-7 High exh. gas temp cyl. 7 40CB Digital Nice to have m)
oTAH60-8 High exh. gas temp cyl. 8 40CC Digital Nice to have m)
oTAH60-9 High exh. gas temp cyl. 9 40CD Digital Nice to have m)
oUX95-1 Monitoring system failure 40CE Digital Recommended
oSX86-1 Monitoring sensor failure 40CF Digital Recommended
iLAH92 High oil mist alarm (oil splash) 40D0 Digital Nice to have l)+m)
Table 5 MODBUS block 3 (mutiple i/o) register addressing.
Individual scanning
oZS57 Earth connector & diff. protection 4090 Digital Nice to have p)
08028-0D/H5250/94.08.12
04.05 - ES1
Description 509.55
Page 7 (9) Communication from the GenSet Edition 07
General
Following signals are only available as option for engine type L27/38.
iTI29-1 Main bearing temp. 4005H Integer 12 Bit Nice to have 0-800° C
iTI29-9 Main bearing temp. 400AH Integer 12 Bit Nice to have 0-800° C
iTI29-10 Main bearing temp. 400BC Integer 12 Bit Nice to have 0-800° C
iTI29-11 Guide bearing temp. 400CH Integer 12 Bit Nice to have 0-800° C
oTI29-1 Cable break 400DH Digital Nice to have
oTI29-2 Cable break 400EH Digital Nice to have
oTI29-3 Cable break 400FH Digital Nice to have
oTI29-4 Cable break 4010H Digital Nice to have
iTI27-1 Alternator bearing temp. 4018H Integer 12 Bit Nice to have 0-200° C
iTI INTERNT. Compensation resistor 401AH Integer 12 Bit Nice to have 0-200° C
oTSH29/27 High bearing temp. shutdown 401BH Digital Nice to have
oTSH29/27 High bearing temp. shutdown 401CH Digital Nice to have
oTSH29/27A Common alarm main bearing temp. 401DH Digital Nice to have
oTSH29/27B Common alarm main bearing temp. 401EH Digital Nice to have
oUX29/27 Common cable failure 401FH Digital Nice to have
Table 6 MODBUS block 4 (mutiple i/o) register addressing.
Table 7 (Individual scanning of control signals)

Running hours C141 32 bit word 2 registers

Start via MODBUS C1C1 Digital o)
08028-0D/H5250/94.08.12
Stop via MODBUS C201 Digital o)

Start counter C241 32 bit word 2 registers
In fig 8 and 9 some examples of wiring are illustrated.

See also description "Guidelines for cable and
wiring" for further information.
04.05 - ES1
509.55 Description
Edition 07
General
Engine type L16/24, L21/31, L27/38 or L32/40
08028-0D/H5250/94.08.12
Fig 8 MODBUS communication (RS 485 and RS 422).
04.05 - ES1
Description 509.55
Page 9 (9) Communication from the GenSet Edition 07
General
Engine type L27/38 incl. bearing surveillance module
Fig 9 MODBUS communication (RS 485).
Comment: Always connect each engine with

separate serial cable to the alarm system. Do not
connect all auxiliary engines on one serial cable
connection.
08028-0D/H5250/94.08.12
04.05 - ES1
Your Notes :
08031-0D/H5250/94.09.07
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2) Alarm and Monitoring Equipment Edition 02H
L16/24
Stopped engine Plate no. Item no. Note.

Shut-off cooling water See "Related procedure"
Shut-off fuel oil
Function test and adjustment of safety, alarm and See "Related procedure"
monitoring equipment.
Starting position
Related procedure
Functional test of shutdown trip 509-01.05

Analoge pressure transmitter 509-05.03
Analoge temperature transmitter 509-05.04
Working time : hours Plate no. Item no. Qty. /

08028-0D/H5250/94.08.12
Capacity : man
Data

98.38 - ES0
509-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 02H Alarm and Monitoring Equipment Page 2 (2)
L16/24
Maintenance of Monitoring and Safety It is recommended that all functions are tested every
Systems three months according to the mentioned working
cards.
One of the most important parameters of preventive
work is that the alarm system, as well as the shutdown To check these functions use the working cards
and overspeed devices, are functioning 100%. mentioned under related procedure on page 1.
If some of these functions are out of operation, they

must be repaired immediately. If this is not possible
because of the current working situation, the engine
has to be under constant observation until it can be
stopped.
08028-0D/H5250/94.08.12
98.38 - ES0
Working Card
Function Test of Shutdown 509-01.05
General

Shut-off fuel oil
Press button (Blocking - Reset)
Functional test of overspeed trip. Allen key, 4 mm.

Functional test of low lubricating oil pressostate Allen key, 2 mm.
trip. Manometer or test pump.
Functional test of high fresh water thermostat. Large spanner.
Starting position
Functional test and adjustment of safety

alarm and monitoring equipment 509-01.00
Related procedure
Working time : 1 hour Plate no Item no Qty/

08028-0D/H5250/94.08.12
Capacity : 1 man
Data

03.39 - ES0
509-01.05 Function Test of Shutdown Working Card
General
It is of the utmost importance that the shutdown

function is working properly. Therefore, the shutdown
function must be tested at regular intervals according
to the planned maintenance programme 500.25.
Function Test of Overspeed Shutdown

Pressostate
1) Start the engine locally and keep it at no load,
at nominal rpm -
1000 rpm or 1200 rpm for L16/24 engine type
720 rpm or 750 rpm for L27/38 engine type
900 rpm or 1000 rpm for L21/31 engine type.
2) Take a large spanner and put it on the link

between fuel-rack and governor. Slowly force Test valve
the engine rpm over the setpoint, see Description outlet
500.30 and the overspeed will release.
Pressure valve
Warning: Do not raise the speed over 120% of
nominal speed because this could damage the
valves and pistons. Fig 1 Valve – test valve – pressostate
The engine must stop.
3) Reset the overspeed shutdown on the opera- 9) Open the oil pressure valve on the pressure
tion box. block.
10) Reset the low lubricating oil pressure shutdown

Function Test of Low Lubricating Oil on the operation box.
Pressure Shutdown
Function Test of High Fresh Water
4) Start the engine and keep it at no load. Temperature Shutdown
5) Mount the manometer/test pump on the test The functional test of the thermostat, is to be carried
valve outlet, situated right under the pressostate out according to the following procedure.
PSL 22, fig 1.
11) Take the sensor out of the pocket.
6) Close oil pressure valve, fig 1.
12) Test the sensor in a water bath, which is
7) Relieve the pressure slowly and check that the controlled by the temperature or a special
switch changes back to the pressure stated as testing device.
08028-0D/H5250/94.08.12
the shutdown point, see 500.30.

13) Start the engine and keep it at no load.
The engine must stop.
14) Raise the temperature until the switch changes
Note: If adjustment is needed, turn the screw and check that it happens at the stated shutdown
clockwise or anticlockwise, see fig 2. point, see 500.30.
8) Disconnect the manometer/test pump. The engine must stop.
03.39 - ES0
Working Card
Function Test of Shutdown 509-01.05
General
Note: If adjustment is needed, remove the thermostat

cover. Locking screw pos. 5, fig 3, is loosened, and
the range can be set with the spindle, pos. 1, while the
scale, pos. 2, is read at the same time.
15) The sensor is mounted again.
16) Reset the high H.T. water temperature shutdown

on the operation box.
Fig 3 Thermostate
Fig 2 Adjustment of pressostate and thermostate
Alarm System
It is important that all alarms lead to prompt

investigation and remedy of the error.
No alarm is insignificant. It is therefore important that
all engine crew members are
familiar with and well trained in the use and importance
of the alarm system.
The most serious alarms are equipped with slowdown
and/or shutdown functions.
08028-0D/H5250/94.08.12
03.39 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Adjustment and Test of Analog Pressure Transmitter 509-05.03
General

Shut-off fuel oil
Adjustment and test of analog pressure transmit- Testing pump.

ter.
Starting position

alarm and monitoring equipment 509-01.00
Related procedure
Working time : ½ hour Plate no Item no Qty/

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

02.20 - ES0
509-05.03 Adjustment and Test of Analog Pressure Transmitter
Working Card
General
The pressure transmitter registers the actual pres-

sure and converts the pressure to an electrical
signal.
Adjustment
It is possible to adjust the pressure transmitter by

means of the „zero“ screw and the „span“ screw.
1) Adjust the „zero“ screw, see fig 1, to change zero screw

the pressure measurement area.
span screw
2) Adjust the „span“ screw, see fig 1, to change

the value of the electrical signal acc. to the
pressure measurement area. Fig 1 Adjustment of pressure transmitter
Test
It is possible to make a functional test of the pressure

transmitter. This is carried out according to the
following procedure:
3) Shut of system pressure with the valve, see fig

2, pos. 1.
4) Remove the screw, see fig 2, pos. 2
5) Mount the testing apparatus to the connection

and pump on a pressure within the working area
of the transmitter.
6) Read the pressure at the operating box on the

engine and check it according to the pressure
on the testing apparatus.
Fig 2 Test of pressure transmitter
7) Remove the testing apparatus.
8) Mount the screw, see fig 2, pos. 2.
9) Open the valve, see fig 2, pos. 1, for the

system pressure.
08028-0D/H5250/94.08.12
02.20 - ESO
Working Card Adjustment and Test of 509-05.04
Page 1 (2) Analogous Temperature Transmitter Edition 04H
L16/24
Stopped engine Plate no. Item no. Note

Shut-off fuel oil
Adjustment and test of analogous temperature Special testing devices

transmitter, (PT 100 sensor).
Starting position
Related procedure

alarm and monitoring equipment, 509-01.00

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

Capacity : 1 man
Data

98.43 - ES0
509-05.04 Adjustment and Test of Working Card
Edition 04H Analogous Temperature Transmitter Page 2 (2)
L16/24
The nickel-chrome-nickel sensor, which is used only Test

for measurement of the exhaust gas temperature,
generates a mV signal depending on the temperature. 2) Functional test of the PT 100 sensor can be
carried out according to the following proce-
The PT 100 sensor consists of a resistance wire dure.
which changes resistance depending on the tempera-
ture. 3) Take the sensor out of the pocket.
Look and design vary depending on the place of 4) Test the thermostate by submerging the sensor
measurement and manufacture. in the water bath, which is controlled by a
special testing apparatus producing a constant
Adjustment temperature.
1) Since the nickel-chrome-nickel sensor and the If the alarm plant has an instrument unit, the tempera-
PT 100 sensor cannot be adjusted the alarm ture can be read on this.
limit must be set on the alarm plant.
Otherwise the test can be carried out by seeing
Set point, see page 500.30. whether the alarm plant gives an alarm when the alarm
limit stated on page 500.30 is exceeded (if the alarm
plant is adjusted).
5) The sensor is mounted again.
08028-0D/H5250/94.08.12
Fig 1 PT 100 sensor
98.43 - ES0
Working card
Mounting and Adjustment of Pick-ups on Engine 509-08.00
L16/24

Shut-off fuel oil
Stopped lub. oil circulation
Description
Mounting and adjustment of pick-ups on engine.
Hand tools
Starting position
Related procedure
Man power
Working hours : ½ Hours

Capacity : 1 Man
08028-0D/H5250/94.08.12
Data Spare and wearing parts
Data for pressure and tolerance (Page 500.35) Plate no Item no Qty/
00.12 - ES0
509-08.00 Mounting and Adjustment of Pick-ups on Engine Working card
L16/24
Mounting Guidance
Engine rpm pick-up 90-1 and 90-2 and check of plug

for same.
Check to be carried out on stopped engine.
The pick-ups are positioned as indicated on the

enclosure, fig 1.
Fig 2 Placing of pick-up.
Check of Plug
Correct plug, see fig 3, rounded off, black head and

grey wire.
Fig 1 Cover on flywheel, seen from exh. side.
Fig 3 correct plug.
Mounting of Pick-up
Incorrect plug, see fig 4, square, black head and
The pick-up is screwed clockwise until it touches the black wire.
top of a tooth on the gear rim, please see fig 2.
Afterwards, the pick-up is turned one time anti-

08028-0D/H5250/94.08.12
clockwise and then the groove of the thread (see fig

2) is put in 3 o'clock or 9 o'clock position seen from
the socket end, still anti-clockwise.
The pick-up is locked with the counternuts.
Fig 4 Incorrect plug.
00.12 - ES0
Working Card
Adjustment of Lambda Controller 509-10.00
L16/24

Shut off starting air
Shut off cooling water
Shut off fuel oil
Adjustment of lambda controller. Adjustablle spanner, 8"
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : 1/4 hour Plate no Item no Qty. /

Capacity : 1 man
Data

98.48 - ES0
509-10.00 Working Card
Edition 05H
Adjustment of Lambda Controller Page 2 (2)
L16/24
Adjustment of the Lambda Controller
All adjustments are made when the engine is in

standstill position.
1) Check that the free space between the pick-up

and the band steel on the regulating arm is min
1 mm, see fig 1.
Fig 3 Removal of pipe for charge air pressure.
2) Set the "load limit" control knob at max.
3) Set the pump index to 13 mm by an adjustable

spanner on fuel rack arm.
4) Fit the adjustment screw (4), fig. 2, until the

Fig 1 Check of free space.
piston has contact with the spring without com-
pressing it.
5) Fasten the adjustment screw.
6) Adjustment completed.
Adjustment of the Stop Screw.
7) Set the pump index to 23 mm (spring on

08028-0D/H5250/94.08.12
governor full pressed) by an adjustable spanner

on fuel rack arm.
8) Adjust the stop screw, see fig 2, to 110% load

according to te test bed, plus 1.5 index.
Use the index arm on the fuel injection pump
nearest to the lambda controller as the control
for the index.
9) Adjustment completed.
Fig 2 Fit the adjustment screw.
98.48 - ES0
Plate
Page 1 (2) Governor and Governor Drive 50901-03H
L16/24
08028-0D/H5250/94.08.12
01.28 - ES0
Plate
50901-03H Governor and Governor Drive Page 2 (2)
L16/24
Item Item
021 1/E Synchronnizing Synchroniseringsmotor 319 1/E Screw Skrue

motor
320 1/E Wear disc Slidskive
033 1/E Plug screw Propskrue
332 1/E Key Feder
045 1/E Gasket Pakning
344 1/E Shim, set Mellemlæg, sæt
057 4/E Nut Møtrik
356 /I Silastene Silastene
069 2/E Stud Tap
368 1/E O-ring only valid for O-ring anv. kun til
070 1/E O-ring O-ring electronic actuator elektronisk regulator
082 1/E Castle nut Kronemøtrik 381 1/E Actuator, electronic Elektronisk regulator
094 1/E Split pin Split 393 1/E Synchronizing Synchroniseringsmotor

motor
104 1/E Shutdown Shutdownspole
solenoid 403 1/E Governor, Europa Regulator, Europa
116 1/E Governor, Woodward Regulator, Woodward 415 4/E Screw Skrue
128 4/E Screw Skrue
141 1/E Shim (set 0.1 - Mellemlæg (sæt 0,1 - + item 212 require an + Item nr. 212 kræver
0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm) individual matching en individuel tilpasning
(by shims) before (med mellemlæg) før
153 1/E Disc Skive mounting, contact, montering, kontakt MAN
MAN B&W, Holeby. B&W, Holeby
165 1/E Ball bearing Kugleleje
177 1/E Bevel gear wheel Konisk tandhjul
189 1/E Key Feder
190 1/E Castle nut Kronemøtrik
200 1/E Split pin Split
212+ 1/E Housing Hus
224 2/E Stud Tap
236 2/E Pin Stift
248 1/E Plug Prop
261 1/E Screw Skrue
273 1/E Axle journal Akseltap

08028-0D/H5250/94.08.12
285 1/E Bush Bøsning
297 1/E Bevel gear wheel Konisk tandhjul
307 1/E Gear wheel Tandhjul
01.28 - ES0
Plate
Page 1 (2) Regulating Device 50902-04H
L16/24
08028-0D/H5250/94.08.12
98.45 - ES0
Plate
50902-04H Regulating Device Page 2 (2)
L16/24
Item Item
015 1/C Bearing bracket, com- Konsol, komplet inkl. 351 1/E Shaft, 8 cyl. engine Aksel, 8 cyl. motor
plete incl. bush bøsning
363 1/E Shaft, 9 cyl. engine Aksel, 9 cyl. motor
039 2/C Screw Skrue
040 1/C Lever Arm
052 2/C Clamp screw Skrue
064 1/C Spring Fjeder
111 1/E Pull rod, complete Trækstang, komplet
123 1/E Lever Arm
135 1/E Governor arm Regulatorarm
159 1/E Screw Skrue
160 2/E Screw Skrue
172 1/C Adjusting screw Justeringsskrue
184 1/E Stop screw Stopskrue
196 1/E Bracket Konsol
206 2/E Washer Skive
218 Spring pin Fjederstift

231 Nut Møtrik

255 1/E Screw Skrue
280 1/E Bracket Konsol
292 1/E Lever, complete Arm, komplet
302 1/E Cylinder, complete Cylinder, komplet

08028-0D/H5250/94.08.12
98.45 - ES0
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-02H
L16/24
08028-0D/H5250/94.08.12
97.37 - ES0
Plate
50920-02H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
L16/24
Item Item
013 2/E Red. adaptor Red. adapter
049 4/E Screw Skrue
050 4/E Nut Møtrik
062 1/E Plate Plade
098 1/E Pipe for level switch Rør for nivaeukontakt
108 1/E Level switch Niveaukontakt
121 1/E Pipe for level switch Rør for nivaeukontakt
157 1/E O-ring O-ring
169 1/E Dipstick, complete Pejlestok, komplet

incl. item 157 inkl. item 157
182 2/E Red. adaptor Red. adapter
194 /I Glue Lim
08028-0D/H5250/94.08.12
97.37 - ES0
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-02H
L16/24
08028-0D/H5250/94.08.12
98.36 - ES0
Plate
50925-02H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L16/24
Item Item
No. Qty Designation Benævnelse No. Qty Designation Benævnelse
010 1/E Fuel oil leakage alarm, Br.olielækagealarm,

complete komplet
022 1/E Flange Flange
058 1/E Red. adaptor Red.adapter
178 1/E Repair kit for Reparationssæt for

running in filter indkørselsfilter
286 4/E Screw Skrue
298 1/E Red. adaptor Red.adapter
308 1/E Pipe for level switch Rør for niveaukontakt
321 2/E Nut Møtrik
345 1/E Packing ring Pakningsring
08028-0D/H5250/94.08.12
98.36 - ES0
Plate
Page 1 (2) Terminal Box 50935-02H
L16/24
08028-0D/H5250/94.08.12
97.49 - ES0
Plate
50935-02H Terminal Box Page 2 (2)
L16/24
Item Item
015 1/E Operation box (OB) Operation box (OB)
027 1/E Monitor temp./press. Monitor temp./tryk

(MTP) (MTP)
039 1/E Monitor exh. gas Monitor udst.gastemp.

temp. (MEG) (MEG)
040 1/E Safety system (CPU) Sikkerhedssystem

(CPU)
052 2/E Base socket Muffe
064 1/E Base modul (MB) Basemodul (MB)
076 1/E I/O modul I/O modul
123 1/E Fuse 2A Sikring 2A
135 1/E Panel (A1) Panel (A1)
08028-0D/H5250/94.08.12
97.49 - ES0
Index
Page 1 (1) Crankshaft and Main Bearings 510
L16/24
Description
Crankshaft and main bearings......................................................................................510.01 (02H)
Working card
Inspection of main and guide bearing shells .......................................................... 510-01.05 (03H)

Vibration damper .................................................................................................... 510-04.00 (03H)
Plates
Crankshaft........................................................................................................................51001-03H
Flywheel with gear rim .....................................................................................................51003-05H
Vibration damper/turning wheel .......................................................................................51004-04H
Your Notes :
08031-0D/H5250/94.09.07
Description 510.01
Page 1 (1) Crankshaft and Main Bearings Edition 02H
L16/24
Crankshaft and Main Bearings Vibration Damper
The crankshaft, which is a one-piece forging, is A vibration damper is mounted on the crankshaft to
suspended in underslung bearings. The main bea- limit torsional vibrations. The damper consists of a
rings are of the trimetal type, which are coated with primary and a secondary part. Between these, groups
a running layer. To attain a suitable bearing pressure of leaf spring packs are arranged, which are clamped
and vibration level the crankshaft is provided with at their outer ends.
counterweights, which are attached to th/e crank-
shaft by means of one hydraulic screws. These spring packs form, together with the primary
and secondary members, chambers which are filled
At the flywheel end the crankshaft is fitted with a gear with oil. If the exterior member vibrates in relation to
wheel which, through two intermediate wheels, the inner member, the leaf springs are bent and force
drives the camshafts. oil from one chamber into another, retarding the
relative movement of the two parts and thus dam-
Also fitted here is a coupling flange for the connec- ping the torsional vibration. In order to protect the
tion of an alternator. At the opposite end (front end) leaf springs against overloading, their deflection is
there is a gear wheel connection for lube oil and limited by buffers.
water pumps.
The elasticity is determined by careful choise of the
Lubricating oil for the main bearings is supplied leaf springs, the damping factor by the gap between
through holes drilled in the engine frame. From the primary and secondary members.
main bearings the oil passes through bores in the
crankshaft to the big-end bearings and thence
through channels in the connecting rods to lubricate
the piston pins and cool the pistons.
08028-0D/H5250/94.08.12
98.43 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Inspection of Main and Guide Bearing Shells 510-01.05
L16/24

52021 275
52021 167
52021 202
Dismantling, inspection and/or replacement and 52021 334
mounting of main and guide bearing shells.
Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Sopaslip
Related procedure
Criteria for replacement of bearings, 506-01.16

08028-0D/H5250/94.08.12

Capacity : 2 man
Data

99.33 - ES0
510-01.05 Inspection of Main and Guide Bearing Shells Working Card
L16/24
Preparing for Dismantling of the Main and Dismantling of the Main and Guide Bearing
Guide Bearing Cap
1) Dismount crankcase covers in front and 6) Fit the lifting handle, (Plate 52010, Item 035),
opposite the bearing concerned. so as to support the bearing cap.
2) Turn the engine until the crank is in a conven- 7) Work the main bearing cap loose from the
ient possition for carrying out the work. engine frame with a lead hammer or similar.
3) Mount the hydraulic tool and loosen the brac- 8) Lift the main bearing cap a little and unscrew
ing stud nuts, see fig 1. For operating of the the bearing stud nut.
hydraulic tool, please see working card 520-
01.05, 9) Lift out the bearing cap from the engine.
Note: When the removing the bearing cap for the

guide bearing, be carefull not to loose the thrust
washers down in the oil pan.w
Dismantling of Main and Guide Bearing

Shells
10) Remove the bearing shell from the bearing

cap.
11) Fit the tool for the upper main bearing tool, for
dismantling of upper main bearing shell, in the
lubricating hole in the crankshaft and turn out
the upper bearing shell by turning the crank-
shaft, see fig 2.
Fig 1 Mount the hydraulic tool and loosen the bracing stud
08028-0D/H5250/94.08.12
nuts.
4) Mount the hydraulic tools and loosen the main

bearing stud nuts, see fig 1.
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
Fig 2 Tool for removal of upper main bearing shell.
99.33 - ES0
Working Card
Inspection of Main and Guide Bearing Shells 510-01.05
L16/24
Cleaning Mounting of the Main and Guide Bearing

Cap
12) Clean all machined surfaces on frame, bearing
cap, stud, nuts and bearing shells. 17) Raise the bearing cap into possition with lifting
tool. Coat the bearing studs with molycote
pasta or similar. Fit the bearing stud nuts and
Inspection of Main and Guide Bearing Shells tighten them by hand.
13) Inspect the bearing shells according to work- Note: When mounting the guide bearing cap, re-
ing card 506-01.16. member to insert the two thrust washers in the guide
bearing cap.
Mounting of Main and Guide Bearing Shells Make sure that the bearing cap and bearing shells
are in the correct possition.
14) Push the upper main bearing shell as far into
possition as possible. 18) Remove the lifting tool for the bearing cap.
Note: Be sure that the shell is turned correct accord- 19) Mount the hydraulic bracing screws and tighten
ing to the locking pieces. up the first step as prescribed on page 500.40.
For use of hydraulic tools, please see working
15) Fit the tool for upper main and guide bearing in card 520-01.05.
the lubricating hole in the crankshaft and turn
in the upper bearing shell by turning the crank- 20) Tighten the nuts for the bearing cap as pre-
shaft. scribed on page 500.40.
Make sure the shell enters its correct position then 21) Tighten up the bracing screw to second step,
remove the tool for upper main and guide bearing. please see page 500.40.
16) Insert the lower bearing shell in the bearing 22) Tighten the bearings one at a time.
cap according to the locking pieces.
Lubricate the bearing shell and journal with clean

lubricating oil.
Note: never use oil on the outer side of the bearing.

This side must be dry.
08028-0D/H5250/94.08.12
99.33 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Vibration Damper 510-04.00
L16/24

Shut-off fuel oil
Inspection
Starting position
Related procedure
Working time : x hours Plate no Item no Qty /

08028-0D/H5250/94.08.12
Capacity : 1 man
See plate 51004
Data

98.44 - ES0
510-04.00 Vibration Damper Working Card
L16/24
Together with every main revision of the engine the Inner Spring Ends and Groove Flanks
damper is to be inspected as well. Generally an
inspection of this kind is to be carried out every 28- Wear takes place due to lack of oil supply.
30.000 hours of service together with service and the
replacement of certain parts, which are exposed to Spring packs consisting of two conical spring blades
wear. only are clamped in the innerstar groove at their inner
spring ends, thus producing a slight preload of the
Note: Regular inspection and supervision of the springs. The allowable wear will be attained as soon
damper allows for preliminary planning and to order as the preload of the springs is not existing any more
spare parts in time. and an additional clearance of "z" mm per side
between spring ends and groove flanks occures
(totalling 2 x z mm if one side of spring end rests on
Allowable Wear groove flank), see fig 2.
Total wear must not exceed 5% of the rope diameter,

see fig 1. Independent from wear all rubber rings and
gaskets should be renewed whenever damper is
taken apart.
Note: Because of leakage problems vulcanized rub-

ber rings do not suit this application. Use seamless
rings only.
Type z
D 56/49/1 0.23
D 56/50 0.18
D 50/4 0.12
Fig 2 Inner spring ends and groove flanks
Fig 1 Rubber seal ring
General Working Conditions

08028-0D/H5250/94.08.12
Oil pressure at oil inlet of damper to be 2,5 bar

minimum (u.o.s.)
Ambient temperature from -20° to + 120° C (unless

otherwise stated).
98.44 - ES0
Working Card
Vibration Damper 510-04.00
L16/24
Circularity of Outer Member (correction)
The inner ends of the spring packs or intermediate

pieces might not be exactly circular. An eventuel
divergence from circularity must be corrected to be
less than 0.1 mm in diameter measured between
opposed intermediate pieces. This can be achieved
by hits onto the outside of the clamping ring using a
"soft hammer" or radial hits from the inside. For big
dampers a hydraulic cylinder, applied from inside will
be necessary.
If the lateral plates 5 and 7, fig 3 are without a

centering shoulder (to accommodate clamping ring),
lateral plates 5 and 7, fig 3 and clamping ring 3, fig 3
are to be adjusted concentric with a tolerance of
± 0.1 mm.
Appendix
If water mixes with the engine oil - especially seawater

- the lubricating properties of the oil will be reduced
rapidly. In case an exceptional amount of water is
detected in the oil supplied to the damper the remain-
ing oil inside damper is to be replaced by new oil as
well. Even if the damper should be supplied with an air
escape nozzle, which provides a small oil flow through
the damper, this oil circulation is not suitable to
exchange the oil volume inside the damper. The
following procedure is to be followed for a total oil Fig 3 Damper
exchange.
a) To empty the damper totally turn it by 180° a few

times and make sure that the oil outflow has
stopped in any position of the damper.
b) Vent damper before it is put into service again.
In case that the engine bearings are found to be worn

out because of lub. oil which was or is containing
water, the damper is to be inspected for wear and
08028-0D/H5250/94.08.12
corrosion as soon as possible as well. (Total inspec-

tion). See "Allowable wear".
98.44 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Plate
Page 1 (2) Crankshaft 51001-03H
L16/24
08028-0D/H5250/94.08.12
98.41 - ES0
Plate
51001-03H Crankshaft Page 2 (2)
L16/24
Item Item
021 1/E Crankhaft, Krumtap,





082 2/C Nut Møtrik
094 2/C Bolt Bolt
104 2/C Counterweight Kontravægt
116 Plug screw Propskrue

141 8/E Screw Skrue
165 1/E Cylindrical pin Cylindrisk stift
189 4/E Screw Skrue
190 1/E Gearwheel 2/2 Tandhjul 2/2

08028-0D/H5250/94.08.12
98.41 - ES0
Plate
Page 1 (2) Flywheel with Gear Rim 51003-05H
L16/24
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
51003-05H Flywheel with Gear Rim Page 2 (2)
L16/24
Item Item
010 1/E Flywheel, Svinghjul





071 12/E Bolt Bolt
083 1/E Gear rim Tandkrans
095 12/E Screw Skrue
105 12/E Sleeve Afstandsstykke
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
Page 1 (2) Vibration Damper / Tuning Wheel 51004-04H
L16/24
08028-0D/H5250/94.08.12
98.37 - ES0
Plate
51004-04H Vibration Damper / Tuning Wheel Page 2 (2)
L16/24
Item Item
No. Qty Designation Benævnelse No. Qty Designation Benævnelse
016 1/E Vibration damper Svingningsdæmper

6 cyl.-1200 rpm engine 6 cyl.-1200 rpm motor
028 1/E Intermediate ring, Mellemring, undtagen

except 9cyl.-1200 rpm 9cyl.-1200 rpm motor
engine


124 2/E Screw Skrue
136 1/E Intermediate ring, Mellemring,

148 1/E Tuning wheel, Afstemningshjul,

08028-0D/H5250/94.08.12
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
98.37 - ES0
Index
Page 1 (1) Engine Frame and Base Frame 511
L16/24
Description
Engine frame and base frame ......................................................................................511.01 (02H)
Working card
Functional test of crankcase safety relief valves .................................................... 511-01.00 (02H)
Plates
Frame with main bearings ...............................................................................................51101-04H

Front-end box...................................................................................................................51103-06H
Cover on frame ................................................................................................................51106-04H
Cover on frame ................................................................................................................51106-06H
Base frame.......................................................................................................................51111-02H
Your Notes :
08031-0D/H5250/94.09.07
Description
Engine Frame and Base Frame 511.01
Page 1 (1)
Edition 02H
L16/24
Engine Frame On the sides of the frame there are covers for access
to the camshafts and crankcase. Some covers are
The monobloc cast iron engine frame is designed to fitted with relief valves which will operate if oil vapours
be very rigid. All the components of the engine frame in the crankcase are ignited (for instance in the case
are held under compression stress. The frame is of a hot bearing).
designed for an ideal flow of forces from the cylinder
head down to the crankshaft and gives the outer shell
low surface vibrations. Base Frame
Two camshafts are located in the engine frame. The The engine and alternator are mounted on a rigid base
valve camshaft is located on the exhaust side in a frame. The base frame acts as a lubricating oil
very high position and the injection camshaft is reservoir for the engine. The alternator is considered
located on the service side of the engine. as an integral part during engine design. This GenSet
is flexible mounted on the foundation with rubber
The main bearings for the underslung crankshaft are elements under the base frame.
carried in heavy supports by tierods from the interme-
diate frame floor, and are secured with the bearing
caps. These are provided with side guides and held in
place by means of studs with hydraulically tightened
nuts. The main bearing is equipped with replaceable
shells which have the final tolerances.
08028-0D/H5250/94.08.12
Fig 1 Engine Frame
98.41 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Functional Test of Crankcase Safety Relief Valves 511-01.00
L16/24

Shut-off fuel oil
Functional test of crankcase safety relief valves.
Starting position
Related procedure
Working time : 1/4 hour Plate no Item no Qty/

08028-0D/H5250/94.08.12
Capacity : 1 man
51106 237 1/relief valve
51106 477 1/relief valve
Data 51106 524 1/relief valve

98.47 - ES0
511-01.00 Functional Test of Crankcase Safety Relief Valves Working Card
L16/24
Functional Testing
Functional testing of the crankcase safety relief

valves cannot be performed during operation of the
engine, but it must be checked during overhauls that
the valve flap is movable.
When Painting
When painting the engine take care not to block up

the safety relief valves with paint.
Check of Opening Pressure
To check the proper opening pressure proceed as

follows:
1) Remove the relief valve cover from the engine.
2) Place the cover on the floor with the pressure

area upwards. Fig 1 Cover with relief valve
3) Apply a weight at 15 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
98.47 - ES0
Plate
Page 1 (2) Frame with Main Bearings 51101-04H
L16/24
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
51101-04H Frame with Main Bearings Page 2 (2)
L16/24
Item Item
013 1/E Disk Skive 204 Cylindrical pin Cylindrisk stift

025 1/E O-ring O-ring 8/E 6 cyl. engine 6 cyl. motor
037 4/E Retaining ring Sikringsring 10/E 8 cyl. engine 8 cyl. motor
216 Cross bolt Krydsbolt
050 1/E Cylindrical pin Cylindrisk stift 14/E 5 cyl. engine 5 cyl. motor
062 4/C Tierod Stavbolt 18/E 7 cyl. engine 7 cyl. motor
074 4/C O-ring O-ring 22/E 9 cyl. engine 9 cyl. motor
086 Nut Møtrik 228 Nut Møtrik

098 1/E Frame, 5 cyl. engine Stativ, 5 cyl. motor 241 Main bearing shell 2/2 Hovedlejeskal 2/2
108 1/E Frame , 6 cyl. engine Stativ, 6 cyl. motor 8/E 6 cyl. engine 6 cyl. motor
121 1/E Frame, 7 cyl. engine Stativ, 7 cyl. motor 10/E 8 cyl. engine 8 cyl. motor
133 1/E Frame, 8 cyl. engine Stativ, 8 cyl. motor
253 2/E Thrust bearing ring Tryklejering
145 1/E Frame, 9 cyl. engine Stativ, 9 cyl. motor
157 Main bearing cap Hovedlejedæksel

169 1/E Main bearing cap, Hovedlejedæksel,

axial aksial
170 2/E Bolt Bolt
182 Tierod Stavbolt

194 Crown nut Kronemøtrik

08028-0D/H5250/94.08.12

98.48 - ES0
Plate
Page 1 (3) Front End Box 51103-06H
L16/24
08028-0D/H5250/94.08.12
00.14 - ES0
Plate
51103-06H Front End Box Page 2 (3)
L16/24
Item Item
014 1/E Front end box Front end box 349 4/E Screw Skrue
026 5/E Plate Plade 350 8/E Screw Skrue
038 13/E Screw Skrue 362 2/E Flange Flange
051 6/E Washer Skive 374 2/E Gasket Pakning
063 4/E Nut Møtrik 386 16/E Screw Skrue
075 1/E Flange Flange 398 6/E Intermediate piece Mellemstykke
087 3/E Screw Skrue 408 12/E O-ring O-ring
099 3/E Washer Skive 421 1/E Housing for Hus for
lub. oil separator smøreolieseparator
109 1/E Plate Plade
110 4/E Screw Skrue
457 1/E Bracket for by-pass Konsol for centrifugal
134 2/E Packing ring Pakningsring centrifugal filter by-pass filter
146 2/E Thermostatic Termostatelement 469 4/E Screw Skrue

element for lub. oil for smøreolie
158 6/E Sleeve Bøsning
171 6/E Retaining ring Sikringsring
494 1/E Cover Dæksel
183 1/E Plate Plade
195 4/E Stud Tap
516 8/E Screw Skrue
528 8/E Spring washer Fjederskive
217+ 1/E Flange Flange
541 1/E Spring Fjeder
553 1/E Piston Stempel
565 9/E Screw Skrue
266 1/E Housing Hus
278 2/E Thermostatic Termostatelement
element for HT for HT kølevand 612 4/E Screw Skrue
cooling water
08028-0D/H5250/94.08.12
624 1/E Screw Skrue

291 2/E Thermostatic Termostatelement
element for LT for LT kølevand 636 1/E Thrust piece Trykstykke
cooling water
648 1/E Covering plate Dækselplade
00.14 - ES0
Plate
Page 3 (3) Front End Box 51103-06H
L16/24
Item Item
661 1/E Setting screw Skrue
673 1/E Nut Møtrik
+ To be used if cen- + Anvendes hvis ikke

trifugal by-pass filter centrifugal by-pass fil-
is not mounted ter er monteret
08028-0D/H5250/94.08.12
00.14 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Plate
Page 1 (2) Covers on Frame 51106-04H
L16/24
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
51106-04H Covers on Frame Page 2 (2)
L16/24
Item Item
154 1/C Cover Dæksel 370 1/E Cover plate, Dækselplade,

382 1/E Cover plate, Dækselplade,
178 Cover Dæksel 8 cyl. engine 8 cyl. motor
3/E 6 cyl. engine 6 cyl. motor 394 1/E Cover plate, Dækselplade,
5/E 9 cyl. engine 9 cyl. motor 404 1/C Cover Dæksel
191 1/C O-ring O-ring 428 Stud Tap

201 1/C Cover Dæksel 6/E 6 cyl. engine 6 cyl. motor
225 Cover with relief valve Dæksel med reliefventil 7/E 8 cyl. engine 8 cyl. motor
3/E 6, 7, 8 cyl. engine 6, 7, 8 cyl. motor
4/E 9 cyl. engine 9 cyl. motor 441 1/D Cover Dæksel
237 1/C O-ring O-ring 453 1/D Cover Dæksel
249 Screw Skrue 465 1/D Valve flap for safety Ventilklap for sikker-
103/E 5 cyl. engine 5 cyl. motor valve hedsventil
129/E 7 cyl. engine 7 cyl. motor 477 1/D O-ring O-ring
155/E 9 cyl. engine 9 cyl. motor 489 1/D Compression spring Fjeder
right
250 Washer Skive
103/E 5 cyl. engine 5 cyl. motor 490 4/D Distance pipe Afstandsstykke
129/E 7 cyl. engine 7 cyl. motor 500 4/D Coach bolt Bolt
155/E 9 cyl. engine 9 cyl. motor 512 4/D Self locking nut Selvlåsende møtrik
262 1/E Cover Dæksel 524 4/D Washer Skive
274 1/E O-ring O-ring 536 Self locking nut Selvlåsende møtrik
286 1/E Cover Dæksel 6/E 6 cyl. engine 6 cyl. motor
298 1/E O-ring O-ring 7/E 8 cyl. engine 8 cyl. motor

08028-0D/H5250/94.08.12


Qty/D = Qty/Cover Qty/D = Qty/Dæksel
98.48 - ES0
Plate
Page 1 (2) Cover on Frame 51106-06H
L16/24
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
51106-06H Cover on Frame Page 2 (2)
L16/24
Item Item
034 8/E Screw Skrue
046 8/E Locking spring Låsefjederskive

washer
058 4/E Screw Skrue
071 4/E Thrust washer Fjederskive
105 8/E Screw Skrue
117 8/E Lock washer Låseskive
129 1/E Sealing ring Tætningsring
142 4/E Screw Skrue
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
Page 1 (2) Base Frame 51111-02H
L16/24
08028-0D/H5250/94.08.12
98.45 - ES0
Plate
51111-02H Base Frame Page 2 (2)
L16/24
Item Item
018 1/E Base frame, Bundramme,





079 7/E Screw Skrue
080 4/E Screw Skrue
092 4/E Nut Møtrik
126 Screw Skrue

138 Disc Skive

08028-0D/H5250/94.08.12
98.45 - ES0
Index
Page 1 (1) Turbocharger System 512
L16/24
Description
Turbocharger system....................................................................................................512.01 (05H)
Working card
Overhaul of charging air cooler............................................................................... 512-01.00 (02H)

Exhaust pipe compensator ..................................................................................... 512-01.10 (01H)
Cleaning the turbine, dry cleaning .......................................................................... 512-10.00 (03H)
Plates
Charging air cooler ..........................................................................................................51201-06H

Exhaust pipe arrangement...............................................................................................51202-04H
Mounting of turbocharger.................................................................................................51203-07H
Connecting pipe ...............................................................................................................51206-02H
Charge air pipes ..............................................................................................................51230-03H
Your Notes :
08031-0D/H5250/94.09.07
Description 512.01
Page 1 (2) Turbocharger System Edition 05H
L16/24
Fig. 1. Diagram for Combustion Air System
Turbocharger System The charging air cooler is a compact two-stage tube-

type cooler with a large cooling surface. The high
The turbocharger system of the engine, which is a temperature water is passed through the first stage
constant pressure system, consists of an exhaust of the charging air cooler and the low temperature
gas receiver, a turbocharger, a charging air cooler water is passed through the second stage. At each
and a charging air receiver. stage of the cooler the water is passed two times
through the cooler, the end covers being designed
The turbine wheel of the turbocharger is driven by with partitions which cause the cooling water to turn.
the engine exhaust gas, and the turbine wheel drives
the turbocharger compressor, which is mounted on The cooling water for the low temperature stages of
the common shaft. The compressor draws air from the charge air is controlled by the scavenging pres-
08028-0D/H5250/94.08.12
the engine room through the air filters. sure to ensure sufficient scavenging temperature for
burning HFO.
The turbocharger forces the air through the charging
air cooler to the charging air receiver. From the From the exhaust valves, the exhaust gas is led
charging air receiver the air flows to each cylinder through to the exhaust gas receiver where the
through the inlet valves. pulsatory pressure from the individual cylinders is
equalized and passed on to the turbocharger as a
constant pressure, and further to the exhaust outlet
and silencer arrangement.
99.37 - ES0S
512.01 Description
Edition 05H
Turbocharger System Page 2 (2)
L16/24
The exhaust gas receiver is made of pipe sections,

one for each cylinder, connected to each other by
means of compensators to prevent excessive stress
in the pipes due to heat expansion.
To avoid excessive thermal loss and to ensure a

reasonably low surface temperature the exhaust
gas receiver is insulated.
Fig. 2. Constant Pressure Turbocharger System
08028-0D/H5250/94.08.12
99.37 - ES0S
Working Card
Overhaul of Charging Air Cooler 512-01.00
L16/24

Overhaul of charging air cooler.
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : 3-4 hours Plate No Item No Qty/

Capacity : 2 men
51201 030 1/k
51201 113 1/k
Data 51201 150 1/k
51103 014 8/E
98.09 - ES0
512-01.00 Overhaul of Charging Air Cooler Working Card
L16/24
The charging air cooler is normally cleaned and

overhauled at the intervals indicated in the "Planned
Maintenance Program", or if observations prove that Charge air pipe
the cooler does not work adequately, see section
502.
Dismounting of Charging Air Cooler
1) Turn off the cooling water inlet and outlet

valves.
2) Remove the charging air pipe, see fig 1.
Fig 1 Assembly of charging air pipe
Lifting hole
Top plate (5)
A-A
A
Screw (1)
A
08028-0D/H5250/94.08.12
Chamber (4)
Gasket (7)
Gasket (6)
Screw (2) End cover (3)
Fig 2 Charging air cooler
98.09 - ES0
Working Card
Overhaul of Charging Air Cooler 512-01.00
L16/24
Cleaning and Inspecting
7) Clean the cooler element of the water and air

sides.
After using cleaning agents the manufacturing

recommendation must be followed.
The greatest care must be exercised when

dismantling cleaning and mounting the cooler
element, as the thin fins of the tubes cannot
stand impacts and pressure.
Inevertheless, the metal is bent, it should be

carefully straightened, as bent fins will in-
crease the pressure drop across the cooler
considerably.
Fig 3xxxxxxxxx
Removal of charge air cooler
Should one or more cooler tubes become
leaky it/they must immediately be made tight,
3) Mount the lifting tool, see fig 3. either by expanding the tube ends into the tube
plates or by blanking of the tube(s) concerned
4) Attach a tackle hook to the lifting tool bolt and with plugs.
tighten the wire.
It is important that the charging air cooler is not
5) Lift and pull the air cooler out of the cooler leaky as any water that leaks in will be carried
housing and place it on a couple of wooden together with the air into the cylinders where it
planks on the floor. will damage valves, piston rings, and cylinder
liners.
6) Remove screws (2) and end cover (3) reversal
chamber (4), and top plates (5), see fig 2. 8) Also clean the end cover and coat it on the
inside with an anti-corrosion agent.
9) Fouling and deposition in the pipes can be

removed with a hand or machine operated
circular steel brush.
08028-0D/H5250/94.08.12
98.09 - ES0
512-01.00 Overhaul of Charging Air Cooler Working Card
L16/24
Mounting of Charge Air Cooler

1
10) Renew gaskets (6) and (7) before assembling
endcover (3) reversal chamber (4) and top
plate (5). See fig 1.
Note: Before mounting the air cooler the o-ring at the

water connections must be replaced, see fig 4, pos.
1.
11) Lift the air cooler by the lifting tool and push it
carefully half-way into its housing.
12) Remove the lifting tool and push the air cooler
into place.
13) Mount the screws see fig 2, pos. 1 and the Fig 4 Mounting of charging air cooler
charge air pipe, see fig 1.
Out of Service Periods.
At longer periods out of service, recommendations

for the entire system is followed. Please see section
501.
08028-0D/H5250/94.08.12
98.09 - ES0
Working Card
Exhaust Pipe Compensator 512-01.10
L16/24

Shut-off fuel oil
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty./

Capacity : 1 man
Data

97.40 - ES0
512-01.10 Exhaust Pipe Compensator Working Card
L16/24
Description
To minimize toxic gases in the engine room and to

keep the exhaust gas insulation in good condition, it
is necessary to keep the exhaust pipe compensators
tight.
1) Start the engine.
2) Feel and smell for any leak in the exhaust gas

pipe compensators.
Note: If any leak is discovered the compensator in

question must be renewed.
08028-0D/H5250/94.08.12
97.40 - ES0
Working Card
Cleaning the Turbine, dry cleaning 512-10.00
L16/24
Stopped engine Plate No Item No Note.

Shut-off fuel oil
Cleaning the turbine.
Starting position
Related procedure

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

Capacity : 1 man
Data

97.50 - ES0
Working Card
Cleaning the Turbine, dry cleaning 512-10.00
L16/24
5-7 bar
1 Stop valve
2 Container
3 Valve
4 Working air
1 2 3 4
Fig. 2. Dry cleaning.
Dry cleaning Fill the container (2) with granulate. The amount
depending on the type of turbocharger;
Depending on the type of engine and turbocharger,
the arrangement of items may also differ somewhat NR12, NR14, NR15,
from that shown in the schematic. NR17, NR20 .................................. 0.3 liter
Appropriate cleaning materials are granulates from NR24, NR26 .................................. 0.4 liter
nut shells or activated charcoal of a grain size of 1
mm (max. 1.5 mm). NR29, NR34 .................................. 0.5 liter
Connect to the working air system (4).

Cleaning sequence
Connect the "blow gun" to valve (1) and open valve
Please also consult the data plate. (3). Then open valve (1) slowly until a hissing sound
indicates that the granulate is being injected. Injec-
The cleaning is to be carried out at high engine load, tion period: approx 2 min.
min. 75 % MCR.
Dry cleaning must be performed at all injection
Before connecting the "blow gun" open the stop connections (if more than one).
valve (1) and check that the passage is not blocked.
08028-0D/H5250/94.08.12
Close the valve again.
97.50 - ES0
Plate
Page 1 (2) Charging Air Cooler 51201-06H
L16/24
08028-0D/H5250/94.08.12
97.43 - ES0
Plate
51201-06H Charging Air Cooler Page 2 (2)
L16/24
Item Item
017 2/K Top plate Topplade
029 8/K Screw Skrue
030 1/K O-ring O-ring
042 8/K Screw Skrue
054 4/K Plug screw Propskrue
066 4/K Cu-washer Cu-skive
078 4/K Screw Skrue
091 16/K Washer Skive
101 16/K Screw Skrue
113 1/K Gasket end cover Pakning endedæksel
125 1/K End cover Endedæksel
137 1/K Cooler block Kølerblok
149 1/K Reversing cover Vendekammer
150 1/K Gasket Pakning

reversing cover vendekammer
162 1/E Charging air cooler, Charging air cooler,

complete komplet
08028-0D/H5250/94.08.12
Qty/K = Qty/Cooler Qty/K = Qty/Køler
Qty./E = Qty./Engine Qty./E = Qty./Motor
97.43 - ES0
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-04H
L16/24
08028-0D/H5250/94.08.12
99.09 - ES0
Plate
51202-04H Exhaust Pipe Arrangement Page 2 (2)
L16/24
Item Item
024 Gasket Pakning

036 Screw Skrue

048 Nut Møtrik

061 1/C Exhaust manifold Udstødsmanifold
073 1/C Compensator Kompensator
097 1/C Clamping strap 2/2 Holder 2/2
107 2/C Screw Skrue
119 2/C Nut Møtrik
08028-0D/H5250/94.08.12
99.09 - ES0
Plate
Page 1 (2) Mounting of Turbocharger 51203-07H
L16/24
08028-0D/H5250/94.08.12
99.06 - ES0
Plate
51203-07H Mounting of Turbocharger Page 2 (2)
L16/24
Item Item
018 4/E Screw Skrue
043 4/E Screw Skrue
067 1/E Pipe piece for Rørstykke for

5 cyl. 1200 rpm 5 cyl. 1200 rpm
6 cyl. 1000/1200 rpm 6 cyl. 1000/1200 rpm
7 cyl. 1000 rpm 7 cyl. 1000 rpm
080 4/E Screw Skrue
092 4/E Nut Møtrik
102 1/E Socket Muffe
126 1/E Turbocharger foot for Turboladerfod for

7 cyl. 1200 rpm 7 cyl. 1200 rpm
8 cyl. 1000/1200 rpm 8 cyl. 1000/1200 rpm
9 cyl. 1000/1200 rpm 9 cyl. 1000/1200 rpm
138 4/E Bolt Bolt
151 4/E Spring ring Fjederring
163 1/E Casing Hus
175 1/E Closing cover Dæksel
187 /I Sealing compound Tætningsmiddel

(Silastene) (Silastene)
199 1/E Pipe piece for Rørstykke for

7 cyl. 1200 rpm 7 cyl. 1200 rpm
8 cyl. 1000/1200 rpm 8 cyl. 1000/1200 rpm
9 cyl. 1000/1200 rpm 9 cyl. 1000/1200 rpm
210 8/E Screw Skrue
222 8/E Nut Møtrik

08028-0D/H5250/94.08.12
99.06 - ES0
Plate
Page 1 (2) Connection Pipe 51206-02H
L16/24
08028-0D/H5250/94.08.12
99.17 - ES0
Plate
51206-02H Connection Pipe Page 2 (2)
L16/24
Item Item
051 4/E Screw Skrue
229 1/E Connecting pipe Forbindelsesrør
08028-0D/H5250/94.08.12
99.17 - ES0
Plate
Page 1 (2) Charge Air Pipes 51230-03H
L16/24
08028-0D/H5250/94.08.12
02.36 - ES0
Plate
51230-03H Charge Air Pipes Page 2 (2)
L16/24
Item Item
015 1/E Flange Flange 302 4/E Screw, 5-6 cyl. Skrue, 5-6 cyl.
7 cyl. 1000 rpm 7 cyl. 1000 rpm
027 Seal ring Tætningsring
11/E 5 cyl. engine 5 cyl. motor 326 1/E Covering sheet Dækplade
15/E 7 cyl. engine 7 cyl. motor 338 17/E Screw Skrue
19/E 9 cyl. engine 9 cyl. motor 483 1/C Screw Skrue
039 2/E Screw Skrue 495 9/E Screw Skrue
040 Lock washer Låseskive 505 1/E Screw Skrue

052 1/C Intermediate piece Mellemstykke
064 1/C Safety clamp Sikkerhedsring
088 1/E Pipe piece Rørstykke
111 8/E Screw Skrue
123 1/E Pipe piece Rørstykke
135 2/E Screw Skrue
147 1/E Flange, 5-6 cyl. Flange, 5-6 cyl.

7 cyl. 1000 rpm 7 cyl. 1000 rpm

7 cyl. 1200rpm 7 cyl. 1200rpm
172 3/E Screw Skrue
184 5/E Screw Skrue
206 8/E Screw Skrue
218 1/E Compensator Kompensator
231 1/E Diffuser Diffusor

7 cyl. 1000 rpm 7 cyl. 1000 rpm
267 1/E Plate, 8-9 cyl. Plade, 8-9 cyl.

08028-0D/H5250/94.08.12
280 4/E Screw, 8-9 cyl. Skrue, 8-9 cyl.

02.36 - ES0
Index
Page 1 (1) Compressed Air System 513
L16/24
Description
Compressed air system ................................................................................................513.01 (07H)
Working card
Air filter.................................................................................................................... 513-01.21 (01H)

Overhaul, test and inspection of air starter............................................................. 513-01.30 (03H)
Emergency starting valve ....................................................................................... 513-01.40 (02H)
Check of compressed air piping system................................................................. 513-01.90 (03H)
Plates
Air starter .........................................................................................................................51309-08H

Main stop valve ................................................................................................................51315-02H
Air filter.............................................................................................................................51321-02H
Turning gear with attachment ..........................................................................................51325-02H
Overspeed stop valve ......................................................................................................51327-01H
Arrangement of jet system...............................................................................................51330-02H
Your Notes :
08031-0D/H5250/94.09.07
Description
Compressed Air System 513.01
Page 1 (2)
Edition 07H
L16/24
Fig. 1 Diagram for compressed air system.
General Control System
The compressed air system on the engine consists of The air starter is activated electrically with a pneu-
a starting system, starting control system and safety matic 3/2-way solenoid valve. The valve can be
system. Further, the system supplies air to the jet activated manually from the starting box on the
system. engine, and it can be arranged for remote control,
manual or automatic.
The compressed air is supplied from the starting air
receivers (16-30 bar) through a reduction station, from
where compressed air is supplied to the engine.
To avoid dirt particles in the internal system, a strainer

08028-0D/H5250/94.08.12
is mounted in the inlet line to the engine.
Starting System
The engine is started by means of a built-on air starter,

which is a turbine motor with safety clutch and drive
shaft with pinion. Further, there is a main starting
valve.
00.14 - ES1
513.01 Description
Edition 07H
Compressed Air System Page 2 (2)
L16/24
For remote activation the starting coil is connected so Pneumatic Start Sequence
that every starting signal to the starting coil goes
through the safe start function which is connected to When the starting valve is opened, air will be supplied
the basemodule mounted on the engine. to the drive shaft housing of the air starter.
Further, the starting valve also acts as an emergency The air supply will - by activating a piston - bring the
starting valve which makes it possible to activate the drive pinion into engagement with the gear rim on the
air starter manually in case of power failure. engine flywheel.
When the pinion is fully engaged, the pilot air will flow
Safety System to, and open the main starting valve, whereby air will
be led to the air starter, which will start to turn the
As standard the engine is equipped with a pneumati- engine.
cally/mechanically stop cylinder, which starts to
operate if the safety system is activated. The system When the rpm exceeds approx. 158, at which firing
is activated electrically. has taken place, the starting valve is closed whereby
the air starter is disengaged.
Air supply must not be interrupted when the engine is
running.
Optionals
Besides the standard components, the following stan-

dard optional can be built-on:
– Main valve, inlet engine.
08028-0D/H5250/94.08.12
00.14 - ES1
Working Card
Air Filter 513-01.21
General

Shut-off fuel oil
Shut-off nozzle cooling 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
513-01.21 Air Filter Working Card
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
Working Card
Overhaul, Test and Inspection of Air Starter 513-01.30
L16/24

Shut-off fuel oil
Check of air starter 1 flex. male key 4 mm

Disassembly, overhaul and assembly of the air
starter.
Starting position
All connections to the air starter have been remo-

ved, and air starter is removed.
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
51309 278 1 (spare part kit)
Data

98.48 - ES0
513-01.30 Overhaul, Test and Inspection of Air Starter
Working Card
L16/24
It is not nessesary to disassemble the air starter for

inspection, only if overhaul is necessary due to worn
parts.
Inspection
1) Check the drive pinion.
Note: This should be shiny and no special wear must

appear on both side of the teeth.
2) Check with a torque spanner the tighten of the

drive pinion screw. This must be 54-61 Nm.
3) Check the flange cover screw are tighten to 4-

5 Nm.
08028-0D/H5250/94.08.12
Fig 1 Air starter
98.48 - ES0
Working Card
Overhaul, Test and Inspection of Air Starter 513-01.30
L16/24
Disassembly 11) Remove the drive housing seal (16) from the
flange cover.
Always wear eye protection when performing any
maintenance on this air starter. 12) Turn the air starter over and secure it vertically
in a fixture.
Always turn off the air supply and disconnect the air
supply before installing, removing or adjusting any Note: Use care when removing the housing cover
accessory on this air starter or before performing any bolts (12) holding the housing cover (11) to the air
maintenance on this air starter. starter. The liner (9) is spring loaded and will pro-
trude approximately one inch beyong the housing
1) Do not disassemble the air starter any further when released.
than necessary to replace worn parts.
13) To remove the housing cover, slowly loosen
2) When grasping a part in a vise, always use the four housing cover bolts while holding the
leather-covered or copper-covered vise jaws housing cover in place.
to protect the surface of the part and help
prevent distortion. This is paritcularly true of 14) Slide the liner assembly out of the housing.
threaded members.
15) Remove the return spring (8).
3) 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. Assembly
4) Always have a complete set of seals and o- 16) Always press on the inner ring of a ball-type
rings on hand before starting any overhaul of bearing when installing the bearing on a shaft.
the air starter. Never reuse old seals or gas-
kets. 17) Always press on the outer ring of a ball-type
bearing when pressing the bearing into a bear-
5) When disassembling, always mark adjacent ing recess.
parts so the members can be located in the
same relative position when the air starter is 18) Whenever grasping an air starter or part in a
reassembled. vise, always use leather-covered or copper-
covered vise jaws. Take extra care with treaded
6) Never wash the liner assembly (9) in a solvent. parts or housings.
Disassembly of the Air Starter Assembly of the Air Starter
7) Remove the drive pinion screw (1) from the 19) Place the housing (13), front end down so that
drive shaft and remove the drive pinion (2). the return spring (8) can be placed into the
housing.
8) Remove the six flange cap screws (3) from the
housing (13). 20) Slide the liner assembly (9) into the housing.
08028-0D/H5250/94.08.12
Orient the liner so that the notch aligns cor-

9) Remove the flange cover (4) and flange (5) rectly with the housing inlet port and liner air
simultaneously by pulling up on the flange. inlet port aligns with the housing inlet port.
Attach housing cover gasket (10) to housing
10) Remove the front drive shaft bearing (15) from cover.
the flange cover.
98.48 - ES0
513-01.30 Overhaul, Test and Inspection of Air Starter
Working Card
L16/24
21) Attach the housing cover (11) to the housing 29) Attach the drive pinion (2) to the drive shaft
with just one housing cover bolt (12). Engage using the drive pinion screw (1) and Locktite,
only a few threads so that the housing cover tighten to 40-45 ft-lb (54-61 Nm) torque, fig 1.
can be easily rotated.
22) While pushing the liner assembly down against Test and Inspection
the return spring, rotate the housing cover over
the liner to hold it down. Warning ! When 6 bar air pressure is applied to the
air starter, the drive pinion will be rotating at 2,800
23) Tighten the housing cover cap screws to 5-6 ft- rpm and drive shaft and drive pinion will move
lb (6.7-8 Nm) torque. forward 30-32 mm. Keep face and hands away from
rotating drive pinion.
24) Press the drive housing seal (16) into the
flange cover (4) with the sealing lip pointed 30) Orientation: Mounting flange must be ori-
down. ented per the customer's order or engineering
drawing. If orientation is not specified by cus-
25) Press the front drive shaft bearing (15) into the tomer, standard orientation will be supplied.
flange cover.
31) Free speed (all models): Install air starter on
26) Fit the flange (5) onto the flange cover so that a test fixture. Apply 6 bar to the air starter
the counterbore of the flange slides over the motor. Minimum free speed is 2,800 rpm.
shoulder of the flange cover correctly.
32) Confirm overrunning of clutch: Turn the
27) Carefully slide this assembly over the drive drive pinion by hand in the direction of rotation.
shaft. Be careful not to tear the seal lip. Orient The clutch should ratchet smoothly.
the flange correctly.
33) Confirm drive rotation: Turn the drive pinion
28) Tighten the six flange cap screws (3) to 3-4 ft- by hand in the direction of rotation. The clutch
lb (4-5.4 Nm) torque. should ratchet smoothly.
08028-0D/H5250/94.08.12
98.48 - ES0
Working Card
Emergency Starting Valve 513-01.40
L16/24

Shut-off fuel oil
Lubricating, disassembly and reassembly of Small screwdriver

emergency starting valve in starting system.
Starting position
Related procedure
Working time : 1 hour Plate No Item No Qty./

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

98.45 - ES0
Edition 02H
Emergency Starting Valve Page 2 (2)
L16/24
Emergency Starting Valve
The emergency starting valve is placed on the tur-

bine starter and should be tested according to the
planned maintenance programme.
1) Switch the engine to "local" on the operating

box panel.
2) Push the emergency start button with a small

screwdriver, as shown in fig 1, until the engine
ignites.
3) Release the button. The button is springloaded

and will automatically return to the start posi-
tion.
Fig 1 Emergency starting valve.
08028-0D/H5250/94.08.12
98.45 - ES0
Working Card
Check of Compressed Air Piping System 513-01.90
Page 1 (2)
Edition 03H
General

Shut-off fuel oil
Shut-off nozzle cooling oil
Check of compressed air piping system. Screwdriver.
Starting position
Compressed air connected to the engine.
Related procedure

Manpower
Plate no Item no Qty. /
08028-0D/H5250/94.08.12
Capacity : 1 man
Data

02.20 - ES0
513-01.90 Check of Compressed Air Piping System Working Card
General
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. Lubricate valve spindles with graphite
2) Retighten all bolts and nuts in the piping or similar.
system.
7) Connect the air supply and make a function
3) Drain the system for condensed water. This test of the emergency valve. See Descrip-
should be based on observations. tion 513.01.
4) Check flexible connections for leaks and

damages.
It is important that the flexible connections are free

from paint and grease and in healthy condition.
5) Check manometers.
08028-0D/H5250/94.08.12
02.20 - ES0
Plate
Page 1 (2) Air Starter 51309-08H
L16/24
08028-0D/H5250/94.08.12
01.32 - ES0
Plate
51309-08H Air Starter Page 2 (2)
L16/24
Item Item
014 1/S Drive pinion screw Tandhjulsskrue 349 1/S Fittings Fittings
026 1/S Drive pinion, Tandhjul, 350 1/S Reduction Reduktion

incl item 291 inkl. item 291
362 1/S Ball valve Kuglehane
038 1/S Gasket for housing Pakning for
cover motorhusdæksel 374 1/S Fittings Fittings
051 1/S Front drive shaft Forreste 386 1/S Fittings Fittings
bearing drivakselleje
408 1/S Solenoid valve 3/2 Magnetventil 3/2
063 1/S Drive housing seal Tætning for drivgear
421 1/S Nipple Nippel
087 6/S Flange cap screw Dækselskrue for
flange 433 1/S Flange Flange
099 1/S Flange cover Flangedæksel 470 1/S Fittings Fittings
109 1/S Flange Flange 482 1/S Fittings Fittings
134 1/S Return spring Fjeder 494 1/S Filter Filter
158 1/S Housing cover Motorhusdæksel 565 1/S Fittings Fittings
171 4/S Bolt for housing Bolt for motorhus- 577 1/S Nipple (T) Nippel (T)
cover dæksel
589 1/S Nipple Nippel
183 1/S Housing Motorhus
590 1/S Cu-washer Kobberskive
195 1/S Vent plug Afluftningsskrue
600 1/S Safety valve Sikkerhedsventil
217 4/S Mounting bolt Bolt for montering
612 1/S Pressure reduction Trykreduktions-
230 1/S O-ring O-ring valve ventil
242 1/E Air starter com- Startemotor kom- 624 1/S Spare parts kit for Reservedelskit for
plete, ST400 and plet, ST400 og ST400, incl. item ST400, inkl. item
RR100 RR100 014, 038, 051, 063, 014, 038, 051, 063,
087, 217, 230 (not 087, 217, 230 (ikke
254 3/S Screw Skrue shown on the front vist på forsiden)
page)
266 3/S Washer Skive
636 1/S Spare parts kit for Reservedelskit for
278 1/S Spare parts kit for Reservedelskit for item 494, consisting item 494, indeholder
valve RR100 ventil RR100 of element, o-ring element, o-ring
291* 1/S Shaft collar Støttering 648 1/S Spare parts kit for Reservedelskit for
item 325, consisting item 325, indeholder
301 2/S Fittings Fittings of element, gasket element, pakning
08028-0D/H5250/94.08.12
313 1/S Gasket Pakning
325 1/S Strainer, complete Vandsi, komplet
337 1/S Fittings Fittings
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
01.32 - ES0
Plate
Page 1 (2) Main Stop Valve 51315-02H
L16/24
All valves and fittings

has to be approved by
classification society.
08028-0D/H5250/94.08.12
99.03 - EO0
Plate
51315-02H Main Stop Valve Page 2 (2)
L16/24
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
017 1/V Gland flange Ters
029 1/V Stem with disc Spindel med skive
030 1/V Gasket Pakning
042 1/E Stop valve, complete Stopventil, komplet
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./C = Qty./Valve. Antal/V = Antal/Ventil.
99.03 - EO0
Plate
Page 1 (2) Air Filter 51321-02H
General
02.46 - ES0
Plate
51321-02H Air Filter Page 2 (2)
General
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
177 1/E Filter complete Filter komplet
189 1/F Repair kit Reparationssæt

(filter and O-ring) (filter og O-ring)
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
02.46 - ES0
Plate
Page 1 (2) Turning Gear with Attachment 51325-02H
L16/24
08028-0D/H5250/94.08.12

99.03 - ES0
Plate
51325-02H Turning Gear with Attachment Page 2 (2)
L16/24
Item Item
011 1/E Sleeve Bøsning
023 1/E Shaft Aksel
035 1/E Pressure spring Trykfjeder
047 2/E Screw Skrue
059 2/E Screw Skrue
060 1/E Position swich Position switch
084 1/E Spur gear Cylindrisk tandhjul
096 1/E Shaft, complete incl. Aksel, komplet inkl. item

item 023, 035, 072, 084 023, 035, 072, 084
08028-0D/H5250/94.08.12
99.03 - ES0
Plate
Page 1 (2) Overspeed Stop Valve 51327-01H
General

08028-0D/H5250/94.08.12
99.03 - ES0
Plate
51327-01H Overspeed Stop Valve Page 2 (2)
General
Item Item
012 1/E Solenoid valve 3/2, Magnetventil 3/2,

complete komplet
024 1/E Coil Spole
08028-0D/H5250/94.08.12
99.03 - ES0
Plate
Page 1 (2) Arrangement of Jet System 51330-02H
L16/24

08028-0D/H5250/94.08.12
99.03 - ES0
Plate
51330-02H Arrangement of Jet System Page 2 (2)
L16/24
Item Item
019 1/E Pipe Rør
032 1/E Pipe Rør
044 1/E Pipe Rør
081 5/E Pipe clamp Rørholder
115 2/E Straight male stud Ligeforskruning

coupling
140 1/E Solenoid valve 2/2, Magnetventil 2/2,

complete komplet
152 1/E Straight coupling Ligeforskruning
164 1/E Coil Spole
176 1/E Housing Hus
188 2/E Screw Screw
08028-0D/H5250/94.08.12
99.03 - ES0
Index
Page 1 (1) Fuel Oil System 514
L16/24
Description
Internal fuel oil system ..................................................................................................514.01 (02H)
Working card
Dismounting / mounting of fuel injection pump (L'Orange)..................................... 514-01.05 (06H)

Disassembly / assembly and repair of fuel injection pump (L'Orange) .................. 514-01.06 (06H)
Fuel injection valve (L'Orange) ............................................................................... 514-01.10 (08H)
Check of fuel oil piping system ............................................................................... 514-01.90 (04H)
Plates
Fuel injection pump (L'Orange) .......................................................................................51401-07H

Fuel injection valve (L'Orange) ........................................................................................51402-08H
Fuel injection pipe (L'Orange)..........................................................................................51404-07H
Fuel oil arrangement........................................................................................................51430-03H
Fuel injection pump connections (L'Orange) ...................................................................51435-03H
Your Notes :
08031-0D/H5250/94.09.07
Description 514.01
Page 1 (2) Internal Fuel Oil System Edition 02H
L16/24
Fig 1 Diagram for fuel oil system
Fuel Oil System The fuel injection valve is located in a valve sleeve in
the centre of the cylinder head. The opening of the
The built-on fuel oil system consists of inlet pipes for valve is controlled by the fuel oil pressure, and the
fuel oil, mechanical fuel pump units, high-pressure valve is closed by a spring.
pipes as well as return pipes for fuel oil.
The high pressure pipe which is led through a bore in
Waste oil and fuel oil leakages are led to a leakage the cylinder head is surrounded by a shielding tube.
alarm which is heated by means of the inlet fuel oil.
The shielding tube also acts as a drain channel in
order to ensure any leakage from the fuel valve and
Fuel Injection System the high pressure pipe will be drained off.
The engine is provided with one fuel injection pump The complete injection equipment including injection
unit, an injection valve, and a high pressure pipe for pumps and high pressure pipes is well enclosed
08028-0D/H5250/94.08.12
each cylinder. behind removable covers.
The injection pump unit is mounted on the engine

frame. The pump unit consists of a pump housing
embracing a roller guide, a centrally placed pump
barrel and a plunger. The pump is activated by the
fuel cam, and the volume injected is controlled by
turning the plunger.
98.41 - ES0
514.01 Description
Edition 02H
Internal Fuel Oil System Page 2 (2)
L16/24
Running-in Filter
The running-in filter has a fineness of 50 mm and is

placed in the fuel inlet line as an integrated part of the
fuel oil leaking alarm box. Its function is to remove
impurities in the fuel pipe between safety filter and the
engine in the running-in period.
Note: The filter must be removed before ship delivery

or before handling over to the customer.
It is adviced to install the filter every time the extern

fuel pipe system has been dismantled, but it is
important to remove the filter again when the extern
fuel oil system is considered to be clean for any
impurities.
08028-0D/H5250/94.08.12
98.41 - ES0
Working Card Dismounting/Mounting of 514-01.05
Page 1 (3)
Fuel Injection Pump (L'Orange) Edition 06H
L16/24

Shut-off fuel oil
Dismounting/mounting of fuel injection pump. Open-end spanner, 36 mm

Unbraco top and ratchet, 10 mm
Plier for lock ring, outer
Unbraco top, 8 mm
Torque wrench
Tools for cleaning.
Starting position Clean kerosene or gas oil.
Antiseizure product.
Cover for fuel injection pump has been (Copaslip, Molykote GN Plus or similar)
dismounted.
Related procedure
Working time : 2 hours Plate no Item no Qty /

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

01.08 - ES0
514-01.05 Dismounting/Mounting of Working Card
Edition 06H Fuel Injection Pump (L'Orange) Page 2 (3)
L16/24
Dismounting of Fuel Injection Pump
Dismounting of fuel injection pipe.
1) Unscrew the sleeve piece (1).
2) Remove the high pressure pipe.
Fig 1 Dismounting of fuel injection pipe.
Dismounting of Fuel and Drain Pipes
4) The lock ring (1), see fig 2 must be shifted into

the groove in the center of the pipe. Fig 2 Dismounting of fuel and drain pipes.
5) Push the fuel and drain pipes into the adjacent

pump until the injection pump is free, see fig 2.
turer to a uniform delivery quantity of 75% by means
of a pointer. The pointer position for the adjustment
Removal of Fuel Injection Pump value, the "adjustment point", is a 18 mm and can be
read from the scale on the control rack.
6) Separate the spring loaded lever from the
regulating rod on the fuel injection pump. 8) Attach the injection pump to the engine frame,
tighten the 5 screws with a torque, according
7) Remove the screws in the bottom flange and to description 500.40.
take the fuel injection pump away.
9) Reconnect the regulating rod to the spring
08028-0D/H5250/94.08.12
loaded lever.
Mounting of Fuel Injection Pump
New pumps: Remove preserving agents. Assembly of the Pressure Pipe
The injection pumps are adjusted by the manufac- 10) Renew O-ring (pos 2, fig. 4), and coat the high-
pressure connecting threds at the pump and at
the pressure piece including the O-rings.
01.08 - ES0
Working Card Dismounting/Mounting of 514-01.05
Page 3 (3)
L16/24
11) Screw the pressure pipe manually to the pres- Mounting of Fuel and Drain Pipes
sure piece.
15) Check the fuel and leakage pipes, they must
12) The correct positioning of the sealing cone not have any sharp bores on the outer circum-
from the pressure pipe has to be checked. The ference, the inner circumference must be free
sealing cone must be completely ummersed of any residuals.
into the pressure nozzle of the injection pump
(approx. 3.6 mm). The sleeve nut has to be 16) Rub the O-rings in the injection pump with
screwed manually to the pressure socket of paste for lip-type packing.
the injection pump.
17) Mount the pipes opposite order of dismantling
13) Tighten the sleeve nut at the pressure piece point 4-5.
with 65 + 5 Nm.
14) Tighten the sleeve nut at the connecting socket

of the pump with 65 + 5 Nm.
08028-0D/H5250/94.08.12
01.08 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card Disassembly/assembly and Repair of 514-01.06
Page 1 (4)
L16/24

Disassembly/assembly and repair of fuel injection Adjustable spanner 12"

pump Unbraco top and ratchet 5, 8, 10 mm
Plier for lockring, inner
Torque wrench
Aluminium arbor
Tools for cleaning.
Clean kerosene or gas oil.
Starting position Antiseizure product.
(Copaslip, Molykote GN Plus or similar)
Dismounting of fuel injection pump 514-01.05
Related procedure
Mounting of fuel injection pump 514-01.05
Working time : 2 hours Plate no Item no Qty /

Capacity : 1 man
08028-0D/H5250/94.08.12
51402 033 2/valve

51402 104 1/valve
Data
Data for pressure and tolerance(Page 500.35)

01.05 - ES0
514-01.06 Disassembly/assembly and Repair of Working Card
L16/24
If damages occur at the injection pump during the

warranty period the service of the manufacturer or of
a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.
Note! It must be cared during the disassembly of the

injection pump that the workplace is free of chips and
contaminations. It is recommended to clean all parts
with diesel fuel oil, and to place them on a non-
fuzzing cloth.
The complete injection pump must not be placed on

hard or metallic surfaces by the roller. Do not use the
extractable control rack as a handle!
The Following Guidelines shall be

Considered
⇒ Do not mix up parts of the pump element and

of the constant-pressure release valve.
⇒ High-pressure surfaces must be protected

against damage, and cleaned with clean Die-
sel fuel and a non-fuzzing cloth or paper when
they are installed again.
⇒ O-rings on demounted parts shall generally be

replaced by new O-rings before parts are
installed again.
⇒ Only original 0-rings of the manufacturer shall

be used. Apply paste for lip-type sealings to
the 0-rings before installation.
⇒ Cylindrical screws must be coated by graphite

paste on the bearing surface and on the thread;
tighten them crosswise and step by step (in
three steps of equal torque) to the required
tightening torque.
⇒ The cylindrical screws shall be loosened cross-

Fig 1 Fuel injection pump.
wise and step by step (in three steps of equal
08028-0D/H5250/94.08.12
torque), too.
2) Screw off the sliding block (10).

Disassembly of Fuel Pump
3) Loosen the spring force and demount the
1) Press in the roller tappet (14) by means of the installation device.
installation device, see fig 2.
01.05 - ES0
Working Card Disassembly/assembly and Repair of 514-01.06
Page 3 (4)
L16/24
4) Take out the tappet insert (13), roller tappet Installation

(14), roller (22), thrust piece (11), pump spring
(9) and plunger (17/18). 8) Pump elements can be exchanged as compo-
nent groups only. (plunger and barrel).
Caution! Be sure not to damage the plunger.
9) Insert the barrel (7), see fig. 1 carefully into the
5) If necessary remove the lockring (20), guide injection-pump casing (4) with an aluminum
pin (21) and take out the regulating rod (3) as arbor and a non-fuzzing cloth to protect the
well as the plug screw (23) in the opposite end high-pressure surface.
of the regulating rod (3).
10) Mount the connection socket tighten the 4
6) Loosen the 4 cylindrical screws (2) and remove cylindrical screws. Tighten torque 40 Nm.
the connection socket (1) and barrel (7).
Pressure valve is included in connection socket 11) Turn the injection pump vertically by 180 de-
(1) and can be exchanged as a component grees.
group only.
12) Install the control sleeve (19) - care for the
7) Carefully press out the barrel (7) with an alumi- marking!
num arbor.
13) The further assembly is carried in reciprocal
order of disassembly (driving pin of the plunger
in the direction of the slot of the control sleeve).
Guiding screw has to be mounted with loctite
0577.
14) Marking on the driving pin, installed towards

the boring of the control rack.
08028-0D/H5250/94.08.12
Fig 2 Dismounting of roller tappet.
01.05 - ES0
514-01.06 Disassembly/assembly and Repair of Working Card
L16/24
If a pump element is exchanged it is recommended Preservation

to check the pre-stroke. Proceed as follows:
The main functional components of each injection
The injection pump is assembled without pump pump supplied by the manufacturer has been pre-
spring (9) and cavitation screws (6). served during its check-up in the test stand.
The plunger (18) is fixed in the control boring by the P3 gero cut S 102 having a viscosity of 3.5 mm2/sec
measuring pin, see fig. 3. at 20°C according to DIN 53015 is used as preser-
ving agent.
The span between the measuring sleeve and the
roller is measured by a depth micrometer. All external surfaces are primed.
The difference to the required dimension of 10 ± 0.05 The processed external surfaces are coated with
mm has to be newly adjusted by the thrust piece (21), anti-rust grease or preserved with preserving oil
if necessary. Castrol Rustilo DWX31 having a specific gravity of
820 kg/m3 at 15°C according to DIN 51757.
If the prestroke is not correct, the max firing pressure
of the mentioned cylinder will be wrong. This preservation is effective for 2 years.
If the pre-stroke is correct then reassembly the pump

with spring (9) and cavitation screws (6) and tighten Re-preservation
with correct torque acc. to description 500.40.
If the injection pump has not been put into operation
Caution! Secure the guiding screws (10) by Loctite within 2 years after its delivery a re-preservation has
0577. to be carried out. For that purpose, a protective cap
must be removed from the fuel discharge (upper
connection) at the injection pump.
The suction chamber of the injection pump is filled

with preserving agent through the fuel discharge
boring, and closed.
By moving the plunger, the hollows are filled with

preserving agent.
All external surfaces coated with anti-rust agent

must be preserved once more.
The control rack has to be moved in regular intervals

of approx. 3 months to avoid a sticking of the plunger.
08028-0D/H5250/94.08.12
Fig 3 Check of pre-stroke.
01.05 - ES0
Working Card
Fuel Injection Valve (L'Orange) 514-01.10
L16/24

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 has been dismounted. Ring and open end spanner 24 mm
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
51402 116 3/valve

Data

01.44 - ES0
514-01.10 Fuel Injection Valve (L'Orange)
Working Card
L16/24
The fuel injection valve is the single component that 6) Loosen the nozzle nut (5). If it is jammed, then
has the greatest influence on the diesel engine heat the nozzle nut up in hot oil.
condition. Various forms of operation and quality of
fuel oil affect the overhaul intervals. In some cases 7) Remove the injector nozzle (6). Be careful that
it may be necessary to shorten the prescribed inter- the the injector needle does not fall out.
vals.
Attention
Dismounting and Cleaning
Do not damage the lapped surface.
1) Dismount the fuel injection valve from the
cylinder head by means of the special tool as 8) Dismount all other components.
shown in fig 1.
9) All parts must be cleaned with kerosene or gas
2) Mount the fuel injection valve on the pressure oil and a hard brush (not a steel brush).
testing pump.
10) Clean the nozzle holes of charred coke by
Note: Utmost cleanliness and care are required means of the supplied special drill please see
during the disassembly of fuel injection valve. plate 52014 with holder.
3) Loosen the nut, see fig 2, pos 2. 11) Clean carefully the injector body by placing
these in a cleaning liquid and then blow through
4) Then release the pressure spring (3). the parts with dry air.
5) Clean the lower part of the nozzle from carbon-

ized oil disposits.
08028-0D/H5250/94.08.12
Fig 1 Tool for dismounting of fuel injection valve. Fig 2 Fuel injection valve.
01.44 - ES0
Working Card
L16/24
Inspection of the Parts c. Renew the O-rings (pos 4, fig 2).
12) Nozzles are matched by lapping and are there- d. Tighten torque for lock nut (2): 100 Nm.
fore only interchangeable as units.
13) The injector needle, which has been previ- Pressure Testing of Fuel Injection Valve
ously cleaned, wetted by test oil P3 gero cut S
102 or diesel fuel and inserted into nozzle 19) The most effective checking of the fuel injec-
body, is pulled out to approx. one third of its tion valves is obtained through pressure test-
sliding surface. At an almost vertical position, ing, preferably carried out after each overhaul
the injector needle must quickly slide onto the and also in case of irregularities in operation.
tight seat by its deadweight. This check-up has The pressure testing is carried out in the fol-
to be carried out for three almost uniformly lowing way by means of the pressure testing
distributed turning position of the needle. apparatus supplied.
14) If the holes are oval worn, which is checked by 20) Mount the fuel injection valve in the test tool
means of a magnifying glass, the nozzle must again. The bracket to be in such a position that
be scrapped. the nozzle of the injector is pointing down-
wards.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the 21) To flush off possibly existing dirt particles in the
nozzle which, in general, only can be made at fuel system of the injection valve, it is recom-
the manufacturer's works on a special test mended to pump through fuel several times,
stand. while the released pressure spring (3) of the
nozzle holder is increase pressure by means
16) Every effort to refurbish will result in alterations of the lever on the test pump, and adjust the
of these values and malfunction of the nozzle. opening pressure to 450 bar, by the adjusting
If heavy abrasion symptoms, respectively dam- screw (1), see fig. 2, then tighten lock nut (2)
ages are observed at the visual inspection of and check opening pressure again.
the parts, the parts in question must be re-
placed. 22) The fuel injection valve shall properly spray at
a pumping frequency of approx. 1 to 2 strokes/
second, do not expect chattering. The fuel
Reassembling (MDO) must be atomized by uniform jets. After
the jets are cut off, no fuel (MDO) drop shall fall
17) When all parts have been overhauled, found in down from the bottom of the spraying ball
good order and carefully cleaned, assemble during 10 seconds when the injector nozzle is
the fuel injection valve again. vertically placed. Do not expect a nozzle tip
with more than 1000 running hours to perform
18) When assembling the fuel injection valve, pro- like a new nozzle in the test pump.
ceed in the opposite order compared to the
disassembly. Pay attention to the following: 23) All connecting and attached points of the fuel
injection valve must not leak during this check-
08028-0D/H5250/94.08.12
a. Lubricate the threads on the adjusting screw, up.

fig. 2, pos. 1, with lub. oil, and the threads of the
nozzle holder for the nozzle nut. The shoulder If the test conditions are not fulfilled it is necessary to
of the nozzle which is in contact with the nozzle demount the fuel injection valve to determine the
nut, must be lubricated with an antiseizure causes. For that purpose, check the slidability of the
product. injector needle and that the injection nozzle is not
jammed in the nozzle holder.
b. The sealing plane surface of body and nozzle
must be wiped dry with paper.
01.44 - ES0
514-01.10 Fuel Injection Valve (L'Orange) Working Card
L16/24
No Jamming Assembly of the Injection Valve
If the injector nozzle is deformed by the tightening of 25) Coat the O-rings at the injection valve with
the nozzle nut (5), the injector needle will be jammed graphite paste.
in the nozzle body. Then fuel will be leaving the spray
holes as not or only partially atomized straight jet 26) The injection valve has to be inserted into the
only. Tightening torque for nozzle nut (5) 120 Nm. cylinder head. Care for the alignment of the
high-pressure cone connection. The alignment
of the injection valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
Assembly of the Pressure Piece
27) Pull off the immosion-melting coating from the

pressure piece. Blow the fuel borehole clean
by air to remove dirt. Renew and coat the O-
ring (pos 1, fig 4) for the sealing in the cylinder
head with graphite paste.
28) Carefully insert the pressure piece together

with spring lock washers into the cylinder head.
Press the pressure piece thoroughly by hand
down to the sealed seat of the injection valve.
29) The nut including the guiding gasket has to be

screwed on the stud bolt. The pressure piece
must be turned clockwise up to the stop of the
spring lock washer. Tighten the nut with 28
Nm. Care that the wrench is not pressed
against the pressure piece. The tightening
Fig 3 Grinding tool for seat and liner for fuel injection valve. torque is then to small in this case and leak-
ages will be the consequence.
Conditions of Labour Safety
The fuel jets must not be touched under any circum-

stances as they hit through the skin tissue, and
cause blood poisoning. Urgently comply with the
regulations on fire prevention when handling inflam-
mable liquids.
08028-0D/H5250/94.08.12
Mounting of the Fuel Injection Valve in Cyl-

inder Head
24) Before mounting the fuel valve, clean and

inspect the valve sleeve in the cylinder head. If
necessary, grind the seating face with the Fig 4 Fuel injection pipe.
grinding tool, see fig 3.
01.44 - ES0
Working Card
L16/24
30) When the pressure piece has been tightened, 32) Screw the pressure pipe manually to the pres-
the fixing flange for the injection valve must be sure piece.
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve is 33) The correct positioning of the sealing cone
pressed to the sealed seat by an alternate from the pressure pipe has to be checked at
tightening of the nuts. The nuts shall be tight- the pump. The sealing cone must be com-
ened with 9 Nm and with use of antiseizure pletely ummersed into the pressure nozzle of
products. the injection pump (approx. 3.6 mm). The
sleeve nut has to be screwed manually to the
pressure socket of the injection pump.
Assembly of the Pressure Pipe
34) Tighten the sleeve nut at the pressure piece
31) Renew O-ring (pos 2, fig. 4), and coat the high- with 65 + 5 Nm.
pressure connecting threds at the pump and at
the pressure piece including the O-rings. 35) Tighten the sleeve nut at the connecting socket
of the pump with 65 + 5 Nm.
08028-0D/H5250/94.08.12
01.44 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Check of Fuel Oil Piping System 514-01.90
L16/24

Shut-off fuel oil
Description
Hand tools
Check of fuel oil piping system.
Starting position
Engine is running.
Related procedure
Working time : ½ hour Plate no Item no Qty. /

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

01.08 - ES0
514-01.90 Check of Fuel Oil Piping System Working Card
L16/24
Fuel Oil System 4) Move all valves in the piping system.

Lubricate valve spindles with graphite or simi-
Important for starting up new engines or newly lar.
overhauled engines!
5) Check flexible connections for leaks and dam-
The system includes all parts in the internal fuel oil ages.
system, ie main components as pumps, high pres-
sure pipes, pressure piece, injection valve and all It is important that the flexible connections are free
types of connections, all types of pipes as well as from paint and grease and in healthy condition.
leakage alarm and safety filter.
6) Check for any leak of the O-ring for the fuel
These components have to be checked at intervals injection pipe.
according to the "Planned maintenance programme".
When the engine has reached normal working tem-
1) Dismount the covers to the injection pumps. perature and no later than 24 operating hours after
Blow through drain pipes. starting up, the complete fuel oil system has to be
checked according to the above-mentioned instruc-
2) Examine the piping system for leaks. No outer tion book working card "Check of the fuel oil piping
leaks can be permitted. system".
3) Retighten all bolts, nuts and plugs in the piping If the above instructions are not followed carefully,
system. Especially does all high pressure parts there is a risk of oil leakage that can result in
have to be tightened correctly. Please, see dangerous vaporised fuel emission into the engine
working cards in section 514 "Fuel Oil system". room.
Concerning fuel oil condition, see section 504.
08028-0D/H5250/94.08.12
01.08 - ES0
Plate
Page 1 (2) Fuel Injection Pump (L'Orange) 51401-07H
L16/24
08028-0D/H5250/94.08.12
01.08 - ES0
Plate
51401-07H Fuel Injection Pump (L'Orange) Page 2 (2)
L16/24
Item Item
014 1/P Roller guide, com- Rullestyr, komplet inkl. 457* 1/P O-ring O-ring
plete incl. item 026, item 026, 038, 051, 063
038, 051, 063 469* 1/P O-ring O-ring
026* 1/P Roller Rulle 482* 1/P Seal ring Tætningsring
038* 1/P Roller pin Rulletap 516 1/P Shim, Mellemlæg,

set of 4 pcs sæt af 4 stk
051* 1/P Roller guide Rullestyr
565 1/C Fuel Injection Pump, Brændselspumpe,
063* 1/P Bolt Bolt complete as shown komplet som vist på
on front page forsiden
087 1/P Pump element, com- Pumpeelement, kom-
plete incl. item 099, plet inkl. item 099, 109, 577 1/P Cylindrical pin Cylindrisk stift
109, 110, 183, 697, 110, 183, 697, 707
707 600 4/P Screw Skrue
099* 1/P Barrel Cylinder 697* 2/P Support ring Støttering
109* 1/P Plunger Stempel 707* 1/P O-ring O-ring
110* 1/P O-ring O-ring 756 1/P Circlip Snapring
158* 1/P O-ring O-ring 768* 6/P Seal ring Tætningsring
183* 1/P Shim Skive 781* 1/P Lock ring Låsering
205* 1/P Piston spring plate Stempelfjederplade 793 1/P Screw plug Propskrue
229 1/P Pump casing Pumpehus 803* 1/P Seal ring Tætningsring
230 1/P Connecting socket Forbindelsesstykke 815 1/P Pump spring com- Pumpefjeder kom-
complete incl. valve komplet, inkl. ventil- plete, incl. item 205, plet, inkl. item 205, 278,
cones, springs and spindler, fjedre og item 278, 291 291
item 158, 457, 577 158, 457, 577
827 /I Loctite 0577 Loctite 0577
242 1/P Buffer bolt Bolt
839 1/P Seal kit for fuel in- Pakningssæt for
254 1/P Control rack Reguleringsstang jection pump, incl. brændselspumpe,
item110, 158, 457, inkl. item 110, 158,
266 1/P Regulating sleeve Reguleringsbøsning 469, 482, 697, 707, 457, 469, 482, 697,
incl. clamping sleeve inkl. 756, 768, 781, 803, 707, 756, 768, 781,
984 803, 984
278* 1/P Spring plate Fjederplade
984 1/P O-ring O-ring
291* 1/P Pump spring Pumpefjeder
337 1/P Arresting bolt Bolt
349 1/P Blocking screw Låseskrue

08028-0D/H5250/94.08.12
362 1/P Pointer Viser
421 6/P Cylindrical screw Cylindrisk skrue
433 1/P Countersunk screw Skrue
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
01.08 - ES0
Plate
Page 1 (2) Fuel Injection Valve (L'Orange) 51402-08H
L16/24
08028-0D/H5250/94.08.12
00.48 - ES0
Plate
51402-08H Fuel Injection Valve (L'Orange) Page 2 (2)
L16/24
Item Item
021 1/V Injection nozzle, Dyse,

1200 rpm engine 1200 omdr. motor
033 2/V O-ring O-ring
045 1/V Nozzle nut Dysemøtrik
057 1/V Pressure bolt Bolt
069 1/V Adjusting spindle Justebar spindle
070 1/V Pressure spring Trykfjeder
082 1/V Nut Møtrik
094 2/V Cylindrical pin Cylindrisk stift
104 1/V O-ring O-ring
116 1/C Fuel injection valve, Brændselsventil, kom-

complete for 1200 rpm plet for 1200 omdr. mo-
engine, incl. item 021, tor, inkl. item 021, 033,
033, 045, 057, 069, 070, 045, 057, 069, 070, 082,
082, 094, 104, 128 094, 104, 128
128 1/V Nozzle holder Dyseholder
141 1/V Pressure piece Spændestykke
153 2/V Nut Møtrik
165 2/V Sperical disc Skive
273 1/V Injection nozzle, Dyse,

1000 rpm engine 1000 omdr. motor
285 1/C Fuel injection valve, Brændselsventil, kom-

complete for 1000 rpm plet for 1000 omdr. mo-
engine, incl. item 033, tor, inkl. item 033, 045,
045, 057, 069, 070, 082, 057, 069, 070, 082, 094,
094, 104, 128, 273 104, 128, 273 08028-0D/H5250/94.08.12
Qty/V = Qty/Valve Qty/V = Qty/Ventil
00.48 - ES0
Plate
Page 1 (2) Fuel Injection Pipe (L'Orange) 51404-07H
L16/24
08028-0D/H5250/94.08.12
00.48 - ES0
Plate
51404-07H Fuel Injection Pipe (L'Orange) Page 2 (2)
L16/24
Item Item
010 1/C Pressure piece Trykstykke
034 1/C Pressure pipe Højtryksrør
083 1/C Holder, complete Holder, komplet

incl. sleeve inkl. bøsning
095 1/C Nut Møtrik
08028-0D/H5250/94.08.12
Qty/E = Qty./Engine Qty/E = Qty./Motor
00.48 - ES0
Plate
Page 1 (2) Safety Filter 51415-03
General
08028-0D/H5250/94.08.12
03.18 - EO0
Plate
51415-03 Safety Filter Page 2 (2)
General
Qty. Designation Benævnelse Qty. Designation Benævnelse
1 1/E Fuel oil filter duplex, Brændselsoliespalte-

complete filter, komplet
2 2/F Screw plug Propskrue
3 2/F Gasket Pakning
10 6/F Bolt Bolt
11 2/F Cover Dæksel
12 2/F O-ring O-ring
13 8/F Nut Møtrik
16 1/F Ball valve Kugleventil
18 1/F Cock Hane
19 2/F O-ring O-ring
20 1/F Circlip ring Sikringsring
21 1/F Plug key Prop
22 2/F Filter element Filterelement
37 8/F Bolt Bolt
38 8/F Nut Møtrik
70 2/F Screw Skrue
72 2/F Nut Møtrik
73 2/F Spring washer Fjederskive

08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Qty./Engine
Qty./F = Qty./Filter Qty./F = Qty./Filter
03.18 - EO0
Plate
Page 1 (2) Fuel Oil Arrangement 51430-03H
L16/24
08028-0D/H5250/94.08.12
99.33 - ES0
Plate
51430-03H Fuel Oil Arrangement Page 2 (2)
L16/24
Item Item
012 1/E Screw Skrue 288 3/E Gasket Pakning
024 2/E Washer Skive 311 12/E Screw Skrue
036 1/E Pipe, Rør, 323 3/E Packing ring Pakningsring

fuel oil inlet tilgang brændolie
335 8/E Screw Skrue
coupling 347 4/E Screw Skrue
073 2/E Reduction Reduktion 359 12/E Nut Møtrik
085 1/E Pipe clamp Rørholder 360 1/E Pipe, Rør,

fuel oil outlet afgang brændolie
097 1/E Screw Skrue
372 1/E Pipe, drain Rør, dræn
107 1/E Pipe, Rør,
fuel oil outlet afgang brændolie 384 2/E Pipe, Rør,
fuel oil inlet tilgang brændolie
coupling 396 1/E Bracket Konsol
120 1/E Pipe, drain Rør, dræn 406 1/E Pipe clamp Rørholder
132 1/E Pipe holder Rørholder 418 2/E Screw Skrue
144 2/E Screw Skrue
156 1/E Adjustable elbow Justebar

coupling vinkelforskruning
168 1/E Pipe Rør
181 1/E Adjustable elbow Justerbar

193 1/E Adjustable elbow Justerbar

203 1/E Pipe Rør

coupling
227 1/E Pipe Rør
240 5/E Slotted cheese head Kærvskrue

screw
08028-0D/H5250/94.08.12
252 1/E Non-return valve Kontraventil
264 3/E Straight male stud Forskruning

coupling
276 1/E Screw Skrue
99.33 - ES0
Plate
Page 1 (2) Fuel Injection Pump Connections (L'Orange) 51435-03H
L16/24
08028-0D/H5250/94.08.12
00.50-ES0
Plate
51435-03H Fuel Injection Pump Connections (L'Orange) Page 2 (2)
16/24
Item Item
Qty Designation Qty Designation
No No
021 5/C Screw
045 1/C O-ring
057 1/C Spring pin
069 Insert pipe
8/E 5 cyl. engine
10/E 6 cyl. engine
12/E 7 cyl. engine
14/E 8 cyl. engine
16/E 9 cyl. engine
070 4/C Retaining ring
082 Insert pipe
4/E 5 cyl. engine
5/E 6 cyl. engine
6/E 7 cyl. engine
7/E 8 cyl. engine
8/E 9 cyl. engine
094 2/C Retaining ring
104 2/E Plug
116 1/E Plug
141 1/E Screw
153 1/E Cover plate
165 2/E Screw
177 2/E Stud
189 1/E Connecting socket
190 2/E Nut
200 2/E O-ring
212 1/E O-ring
224 2/E Connecting pipe
236 1/E Connecting pipe
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50.
* = Only available as part of a spare parts kit.

Qty/E = Qty/Engine
00.50-ES0
Index
Page 1 (1) Lubricating Oil System 515
L16/24
Description
Internal lubricating oil system .......................................................................................515.01 (04H)
Working card
Lubricating oil pump................................................................................................ 515-01.00 (03H)

Prelubricating pump................................................................................................ 515-01.05 (03H)
Lubricating oil filter .................................................................................................. 515-01.10 (02H)
Lubricating oil, thermostatic valve........................................................................... 515-01.20 (03H)
Check of lubricating oil piping system .................................................................... 515-01.90 (02H)
Lubricating oil cooler............................................................................................... 515-06.00 (03H)
Centrifugal bypass filter .......................................................................................... 515-15.00 (03H)
Plates
Lubricating oil pump.........................................................................................................51501-06H

Lubricating oil filter ...........................................................................................................51502-04H
Prelubricating pump.........................................................................................................51504-04H
Lubricating oil cooler........................................................................................................51506-03H
Centrifugal bypass filter ...................................................................................................51515-02H
Prelubricating pump arrangement ...................................................................................51535-02H
Your Notes :
08031-0D/H5250/94.09.07
Description 515.01
Page 1 (2) Internal Lubricating Oil System Edition 04H
L16/24
Fig 1 Diagram for Internal Lubricating Oil System
Lubricating Oil System The main groups of components to be lubricated are:
All moving parts of the engine are lubricated with oil 1 - Turbocharger.
circulating under pressure. 2 - Main bearings, big-end bearing etc.
3 - Camshaft drive.
4 - Governor drive.
System Flow
5 - Rocker arms.
The lubricating oil pump draws oil from the oil sump 6 - Camshaft.
and pushes the oil through the cooler and filter to the
main lubricating oil bore, from where the oil is distri- ad 1) For priming and during operation the turbo-
buted to various lubricating points. From the lubricating charger is connected to the lub. oil circuit of the
points the oil returns by gravity to the oil sump.The oil engine. The oil serves for bearing lubrication
pressure is controlled by an adjustable spring-loaded and also for dissipation of heat.
relief valve built into the system.
ad 2) Lubricating oil for the main bearings is sup-
08028-0D/H5250/94.08.12
plied through holes in the engine frame. From

the main bearings it passes through bores in the
crank-shaft to the connecting rod big-end bea-
rings.
98.50 - ES0
515.01 Description
Edition 04H
Internal Lubricating Oil System Page 2 (2)
L16/24
Channels have been bored into the connecting Lubricating Oil Cooler
rods for supply of oil from the big-end bearings
to the small-end bearings, which has an inner The lubricating oil cooler is of the plate type. The
circumferential groove, and a pocket for distri- cooler is mounted on the front-end box.
bution of oil in the bush itself. For supply of oil
to the pin bosses and the piston cooling.
Thermostatic Valve
From the front main bearings channels have
been bored in the crankshaft for lubricating of The thermostatic valve is a fully automatic 3-way
the pump drive. valve with thermostatic elements set at fixed tem-
perature.
ad 3) The camshaft drive gear wheels are being
lubricated via the oil-mist principle. Oil-mist is
being generated by oil, which is led out from the Lubricating Oil Filter
bearing in the intermediate wheels.
The lubricating oil filter is a full-flow depth filter of the
ad 4) From bores in the engine frame the governor duplex paper cartridge type, with a fineness of 10-15
drive is being pressure lubricated. microns, and a safety filter with a fineness of 60
microns.
ad 5) The lubricating oil to the rocker arms is led
through bores in the engine frame to each
cylinder head. The oil continues through bores Pre-lubricating
in the cylinder head to lubricate the rocker arms
and valve bridges. Further, lub oil is led to the The engine is equipped with an electric-driven prelub.
movable parts in need of lubrication. pump mounted parallel to the main pump. The pump
is arranged for automatic operation, ensuring stand-
ad 6) Lubrication to the fuel pump is supplied via still of the prelubricating pump when the engine is
the fuel camshaft bearing. running, and running during engine stand-still in stand-
by position by the engine control system.
Lubricating Oil Pump
The lubricating oil pump, which is of the helical gear

type, is mounted in the front-end box of the engine and
is driven by the crankshaft.
08028-0D/H5250/94.08.12
98.50 - ES0
Working Card
Lubricating Oil Pump 515-01.00
L16/24

Shut-off fuel oil
Disassembly, overhaul and assembly of lubrica- Feeler gauge 0.1 mm, min length 40-50 cm
ting oil pump Feeler gauge 0.3 mm, min length 40-50 cm
Feeler gauge 0.35 mm, min length 40-50 cm
Starting position
Lubricating oil cooler 515-06.00
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
51501 018 2/p

51501 102 4/p
Data

98.47 - ES0
515-01.00 Lubricating Oil Pump Working Card
L16/24
Preparing before Dismounting Mounting
For access to the lubricating oil pump it is necessary 8) Change the O-rings on the pump.
to remove the lubricating oil cooler. Please see
worcking card 515-06.00. 9) Mount the pump by the bolts and tighten these
according to description 500.40.
Dismounting 10) Re-new the O-rings for oil and water connections
to the lub. oil cooler.
1) Remove the bolts which are holding the lub. oil
pump. 11) Mount the lub. oil cooler to the frame plate.
2) Use the spring bolts to push out the pump.
Overhaul
3) Remove the bolt (1) and the spur wheel (2), see
fig 1.
4) Remove the bolt (3) and the cover (4), see fig 1.
Take out the pinion spindles (5) and clean all parts in
gas oil and with a hard bush, (never use a steel bush).
The parts are blown clean with working air.
5) Check the wear of the bearing bush.
6) If the bearing bush is to be removed the existing

Fig 1 Lubricating oil pump
bearing bush is plugged out by means of a
mandrel, the bores are cleaned, see fig 2, and
new bearing bush is mounted.
The bush is cooled down to -130°C, the housing
or cover has room temperature.
Note: criteria for replacement of bearing bush, see A,

fig 3.
7) Mount the pinion spindels (5) the cover (4) and

the bolt (3), the spur wheel (2) and the bolt (1),
see fig 1. Tighten the bolts according to page
500.40.
08028-0D/H5250/94.08.12
Note: check that the oil pump can run easily when the
pump is assembled.
Fig 2 Bores to be cleaned
98.47 - ES0
Working Card
Lubricating Oil Pump 515-01.00
A min. 0.1 mm
max. 0.3 mm
If Then
feeler gauge 0.1-0.3 mm OK

can come into the pump
feeler gauge 0.1 mm Replace bearing bush

can not come into the
pump
feeler gauge 0.35 mm Replace bearing bush

can come into the pump
Fig 3 Check of bearing bush

08028-0D/H5250/94.08.12
98.47 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Prelubricating Pump 515-01.05
L16/24

Shut-off fuel oil
Dismantling, replacement of the mechanical seals Ring and open end spanner, 13 mm.
and assembly of prelubricating pump. Ring and open end spanner, 15 mm.
Socket spanner, 15 mm.
Adjustable spanner.
Screw driver.
Lubricating light oil and grease.
Starting position Vessels for cleaning.
Related procedure
Working time : 2-3 Hours Plate no Item no Qty. /

Capacity : 1 man
08028-0D/H5250/94.08.12
See Plate 61504
Data

98.47 - ES0
Edition 03H Prelubricating Pump Page 2 (4)
L16/24
Periodic Overhauls 2) Shut off the suction to the pump and block the
electric motor starting button.
Periodic overhauls for the purpose of avoiding func-
tional trouble are not normally necessary for the 3) Loosen the screws which hold the motor and
prelubricating pumps. When properly used, there is pump together and lift away the motor.
very little wear on the pump screws.
4) Remove the front end cover of the pump (1). Do
If oils and other liquids with abrasive properties are not damage the joint (2) between front end cover
pumped periodic overhauls may nevertheless be and pump body.
carried out so that worn parts can be replaced in good
time. The intervals between such overhauls are 5) Press the stationary seal with o-ring (27 and 23)
determined by experience in each individual case. see fig. 2, out of the front cover.
Impurities in the pumped liquid or careless handling

during dismantling and reassembly can result in
damage to the lapped sealing surfaces. Dismantling
and reassembling the seal should therefore be carried 23 24
out in conditions of scrupulous cleanliness and
carefulness and every effort must be made to avoid
touching the sealing surfaces with the fingers. The
carbon ring must be carefully handled. 25
Warning: It must not get in touch with grease.
Dismantling
1) Turn the motor, using the fan beneath the fan

casing, until the set screw (20) see fig. 1, which
27
locks the pump shaft to the motor shaft is 18
accessible in one of the inspection holes in the
pump body back off the stop screw all the way.
Fig 2. Shaft seal
1 2 3 6) Remove the power rotor (17) fig. 1, from the

pump body. If only the seal is to be replaced, the
idlers can remain in the pump body.
4
5
6 7) Remove the rotary seal ring (24) fig. 1.
7
22 8) Press the rotating seal (18) out of the power
08028-0D/H5250/94.08.12
8
21 rotor (17). Due to the rubber bellows (25) fig. 2,
9
20 the necessary press-off power may be
comparatively big.
10
11
12
19 18 17 16 15 14 13
Fig 1. Prelubricating pump.
98.47 - ES0
Working Card
Prelubricating Pump 515-01.05
L16/24
Reassembly
The fit of the rotary seal on the pump shaft is rather

hard. To prevent damage of the bellows (25) it is
advisable to clean the pump shaft from possible
coating like particles of coke from oil etc.
Polish the pump shaft by means of an emery or

cleaning cloth to get a smooth finish. This preparation
facilitates the mounting of the rotary seal.
The reassembly will take place in reverse order: Fig. 3.
9) After cleaning wipe the shaft over with light oil

(not grease). Press the rotating seal (18) with 17) The power rotor shall be forced up on the motor
removed rotary seal ring (24) onto the rotor shaft by means of a screw driver put into the
shaft. groove of the power rotor shaft, see fig. 3.
Thereafter screw the set screw (20) firmly
10) Check that the bellows are pressed against the against the motor shaft. This is necessary to
locating ring of the spring. Keep the seal pressed ensure a correct play of the idler rotors.
in that position for half a minute until the bellows
stick. 18) Check that the pump rotates freely when the
motor is rotated by hand.
11) Mount the rotary seal ring (24) with its smaller
surface turning upwards, taking care that the Open the valves in the pipe lines and re-establish the
grooves in the seal ring are in line with the electric supply to the motor. Proceed in accordance
dimples of the retaining sleeve. with the instructions "Starting-up".
12) Insert the power rotor in the pump casing (3). Note: Do not let the pump run for more than one
minute without working.
13) Wipe over the outside of the stationary seat with
its o-ring gasket (27 and 23) with light oil and
press the seat into the front cover. Maintenance
14) Mount the front cover (1) to the pump casing (3) The seal is self-adjusting and requires no subsequent
making sure not to forget the joint (2) which seal tightening.
between the pump casing and the front cover.
If copious leakage occurs, this is the usual sign of
15) Screw the set screw (20) into the power rotor far wear, which may be due to such causes as incautious
enough to be guided into the keyway in the starting, dirty oil, poor alignment or running without oil.
motor shaft.
08028-0D/H5250/94.08.12
16) Mount the electric motor on the pump so that Starting

the set screw (20) enters the motor-shaft keyway.
Tighten the screws joining pump and motor Starting should always take place with fully open
flanges. valves in the suction and delivery lines.
As the prelubricating pump is self-priming it carries off

the air in the suction line and the noise reveals when
the pump begins to work. It is essential for the air to
be led off without any appreciable counterpressure in
the delivery line.
98.47 - ES0
515-01.05 Prelubricating Pump Working Card
L16/24
As soon as the pump has started to work normally, the Direction rotation
by-pass valve must be set by means of a pressure
gauge at the required pressure. When the pump is ready to be started, check that the
dive motor rotates in the correct direction as indicated
Set the by-pass valve, with the screw (10) fig 1, on the on the pump by briefly switching it on and by watching
end cover of the pump body. Turning to the right the fan impeller of the electric motor.
increases the opening pressure. Do not set the valve
at pressures higher than necessary. Note: Do not check the direction of rotation without
prior filling the pump with oil.
This pressure setting should be maintained while the
pump is in operation.
If the pump refuses to work properly after having been

started, it must not be allowed to run for more than
about half a minute. Fresh attempts to make the pump
go may be made at intervals of about a minute and in
conjunction with these attempts the bypass valve
tension should be increased slightly. If thes does not
help, something must be wrong and the fault must be
located and remedied before the pump is put into
operation.
08028-0D/H5250/94.08.12
98.47 - ES0
Working Card
Lubricating Oil Filter 515-01.10
L16/24

Shut-off fuel oil
Description
Hand tools
Replacement of paper filter element(s).
Cleaning of safety filter and filter housing. Open-end ring spanner, 19"
Allen key, 6 mm
Allen key, 10 mm
Starting position
Related procedure
Manpower
Working time : 1 hour
Capacity : 1 man Plate no Item no Qty. /
08028-0D/H5250/94.08.12
51502 013 2x3/E

Data 51502 049 2x1/E

98.45 - ES0
Edition 02H
Lubricating Oil Filter Page 2 (3)
L16/24
Please note: Never open the filter while it is in use. Note: Our filter elements are of the disposable type.
The filter to be cleaned must be out of operation. Always change to new original filter.
10) Clean the filter housing and the cap.

Normal Running
11) Check the seal in the cap. Change if needed.
1) The valve is in position 2 or 4, see fig 2, and the
element not in use is vented and ready to use 12) Assemble the filter in reverse order.
(standby).
13) Switch to position 2 or 4 and vent the exchanged
element by means of the vent screw.
Changing the Filter
2) Switch to position 3, fig 2, and wait 5 minutes.

Then continue to position 1 or 5, fig 2.
Vent screws
3) Wait 2 minutes.
4) Open the vent screw on the filter out of service.
5) Wait 20 minutes
6) Dismantle the cover.
7) Dismantle the filter housing cap.
8) Remove the inner safety element. Clean the

element with detergent. Check that it is intact.
9) Remove the outer elements. Fig 1 Vent screws
08028-0D/H5250/94.08.12
98.45 - ES0
Working Card
Lubricating Oil Filter 515-01.10
L16/24
Pos.
Fig 2 Name plate for lubricating oil filter.

08028-0D/H5250/94.08.12
98.45 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Lubricating Oil, Thermostatic Valve 515-01.20
L16/24

Shut-off fuel oil
Inspection of thermostatic valve and replacement

of elements.
Starting position
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
51103 146 2/E
Data

98.47 - ES0
515-01.20 Lubricating Oil, Thermostatic Valve Working Card
L16/24
Adjustment and Maintenance Check the Element
The thermostatic valve cannot be adjusted and 10) Place the element in a bucket of water -12° C
under normal working conditions maintenance is not below the nominal rating and stir the water
required. However, in some cases it is necessary to vigorously with the element for 5 minutes (the
replace the element. sliding valve should not be off its seat).
11) Next, place the element in water

10° C above the nominal rating and stir vigorously
for 5 minutes. The element should not be fully
stroked.
This is determined by immediately placing the ele-

ment back in the valve housing, and pushing the
element spider fully into its counterhore. If the
resistance of the sliding valve overtravel spring can
be felt, the element is fully stroked. Perform the last
step quickly before the element has cooled.
Note: do not use oil as the test bath.
On every high temperature elements, water and

glycol may be used.
Fig 1 Lubricating oil thermostatic valve.
Replacement of the Element
1) Unscrew the bolts (1) and remove the cover (2),

see fig 1
2) Remove the lock ring (3).
3) Remove the sleeve and element (4 and 5).
4) Thoroughly clean the sleeve (5).
5) Replace it or check, see "check the element".

08028-0D/H5250/94.08.12
6) Remount the element (4) by wriggling it some-

what over side.
7) Mount the sleeve (5)
8) Mount the lock ring (3).
9) Renew the gasket and mount the cover (2).

Fig 2 Placing of lubricating oil thermostatic valve.
Tighten the bolt (1) according to page 500.40.
98.47 -ES0
Working Card
Check of Lubricating Oil Piping System 515-01.90
L16/24

Shut-off fuel oil
Check and examination of the lubricating oil piping

system.
Starting position
Engine is running.
Related procedure
Working time : ½ hour Plate no Item no Qty /

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

98.41 - ES0
515-01.90 Check of Lubricating Oil Piping System Working Card
L16/24
Checks to be Carried Out
1) Examine the external connections for leaks.
2) Retighten all bolts and nuts in the external

system.
3) Check flexible oil vapour discharge hose con-

nections for leaks and damages.
Note: It is important that the flexible connections are

free from paint and grease and in healthy condition.
Concerning lubricating oil condition, see section 504.
08028-0D/H5250/94.08.12
98.41 - ES0
Working Card
Lubricating Oil Cooler 515-06.00
L16/24

Shut-off fuel oil
Separation, cleaning and assembling. Ring and open end spanner 10 mm

Replacement of plates and gaskets. Ring and open end spanner 55 mm
Ring and open end spanner 30 mm
Adjustable spanner
Starting position
Cooling water and lub. oil have been drained from

cooler/engine. All external pipes are disconnected.
Related procedure
Working time : 4 hours Plate No Item No Qty./

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

98.43 - ES0
515-06.00 Lubricating Oil Cooler Working Card
L16/24
Introduction Upon completion of the procedure “Cooling and

Pressure Relief”, separate the frame by retaining
Cleaning of the cooler must take place, when the two or four diagonally placed bolts.
pressure drop on the oil and water side exceeds an
allowable value and/or if oil cannot be sufficiently Note: Take care that the pressure plate does not tilt!
cooled.
Loosen the bolts uniformly and diagonally (max. 10
mm at a time), then push the pressure plate towards
Separation the end support. When the pressure plate is not tight
anymore, the plates can be removed.
Cooling and Pressure Relief
Note: When using plate heat exchangers on board
Before opening the plate heat exchanger, it must be ships, the pressure plate must be secured in order
cooled down to below 40o C and be without pressure! to avoid danger during the movements of the ship.
The cooling must not exceed 10o C per minute.

The pressure drop must not exceed 10 bar per Cleaning
minute.
The capacity and corrosion resistance of the plate
Note: If these norms are exceeded, the guarantee heat exchangers depend on the cleanness of the
will cease to be valid. plates. Any coating on the plates can be removed
manually.
Separation of Edge-clamped Frame

Manual Cleaning
Mount the bolts, see fig. 1.
Clean the plates with a soft brush and a suitable
detergent. In the case of dense coating of scale or
organic materials, the plates must be put in a bath
with detergent.
Note: Never use a steel brush, metal scraper or the

like.
A high-pressure cleaner can be used with care,

however, never with sand or other abrasives added.
Detergents
A detergent is suitable, if it removes any coating on

the plates without causing any damage to plates and
08028-0D/H5250/94.08.12
gaskets.
Note: It is of great importance that decomposition of

the protective film on the stainless steel does not
Fig 1 Mounting of oil cooler in front-end box. take place - the film preserves the corrosion resis-
tance of steel.
Do not use chlorine-containing agents such as

hydrochloricacid (HCI)!
98.43 - ES0
Working Card
L16/24
Oil and fats are removed by using a water emulsify- Replacement of Plates and Gaskets
ing oil solvent, e.g. BP-system cleaner.
Marking
Organic and greasy coatings are removed by using
sodium hydroxide (NaOH): The plates are marked with material codes and
reference numbers at each end, plus codes for non-
- max. concentration 1.5% glued gaskets, if any, and stamped with letters V
(1.5% concentration corresponds to 3.75 l and H at either end (fig 1).
30% NaOH per 100 l water).
- max. temperature 85o C. When facing the gasket, the plate is designated as a
left plate, when letter V turns upwards - and as a right
Stone and lime/calcareous deposits are removed by plate when letter H turns upwards. Inlets and outlets
using nitric acid (HNO3): of the V-plates are taking place through the corner
holes Nos 1 and 4. Inlets and outlets of the H-plates
- max. concentration 1.5% take place through corner holes Nos 2 and 3.
(1.5% concentration corresponds to 1.75 l
62% HNO3 per 100 l water).
- max. temperature 65o C. Replacement of Plates
Note: The nitric acid has an important constructive Before mounting a spare plate in the plate stack,
effect on the protective film of stainless steel. please make sure that the spare plate is identical
with the faulty one.
Control of Cleaning Fluid Concentrations Note: The same corner holes must be opened and
letters V and H must be placed properly.
Sodium hydroxide (NaOH) solution is titrated with
0.1 n hydro-chloric acid (HCI) with methyl orange or
methyl red as an indicator. Replacement of Glued Gaskets
Nitric acid (HNO3) solution is titrated with 0.1 n On Plate 51506 stated are gasket and glue quantity.
sodium hydroxide (NaOH) with phenolphtalin as an
indicator. Please use a degreasing agent on the new gaskets.
The concentration of the cleaning fluid in % can be The first plate after the end cover and the connector
calculated from the titration result with of the follow- grid must have gaskets in all grooves. The gaskets
ing formula: must be cut according to the existing gaskets.
Concentration = bxnxm % Loosen the glued gaskets by heating the plate in

a x 10 water at 100o C. Clean the plates and remove the
coatings, if any.
a : ml cleaning fluid taken out for titration
b : ml titration fluid used as a cover
08028-0D/H5250/94.08.12
n : the molecular concentration of titration fluid

m : The molecular weight of the cleaning fluid
(NaOH) the molecular weight 40, HNO3
molecular weight 63)
98.43 - ES0
515-06.00 Lubricating Oil Cooler Working Card
L16/24
Cleaning of New Gaskets and Plates The plates with the gaskets are mounted in the frame
which is lightly clamped. In the case of using rubber
New gaskets and gasket grooves of the plates are grooves, they are assembled to the minimum mea-
cleaned with a cloth moistened with degreasing sure stated on the engine sign plus 0.2 mm per plate.
agent. The glued surfaces must be absolutely clean
- without finger prints etc. Heat up the plate heat exchanger to 90-100° C by
means of water or steam.
Please use our cleaning fluid, which conforms to
suppliers recommendations. Please note:
Alternatively, please use: - The temperature must be kept for 1 1/2-2

hours.
- Trichloroethylene - The liquid pressure must be kept as low as
- Chlorothene VG possible.
- Acetone
- Methyl ethyl ketone If there is no possibility of heating the plate heat
- Ethylacetat exchanger, it must be placed in a place as warm as
possible with connections dismounted.
It is important that all degreasing agent be evapo-
rated, before glue is applied. This will normally take At 20° C the drying time will be approx. 48 hours. At
approx. 15 min. at 20o C. 40° C, the drying time is approx. 24 hours.
Clean the new gaskets on the glued surfaces with

fine-grained sandpaper instead of the degreasing Assembling
agent supplied.
If the plates are dismounted, they must be properly
assembled according to plate item numbers.
Gluing
The fixed cover has number 1 and serial numbers for
Pliobond 25, which is a solvent-based nitrile rubber the subsequent plates, and intermediate frames, if
glue (25% solids). The glue is applied with a brush any, are numbered 2, 3, 4, 5 etc.
in a thin layer on the backs of the gaskets and the
gaskets must be dried in a clean place free of dust.
Serial number
(please state when
Apply a thin layer of glue on the gasket grooves of Material Code ordering single plates)
the plates and press the gaskets down into the
gasket grooves.
1 2
The insertion of the gaskets starts at both ends of the
plate - and continues with the straight sections along
the edges.
08028-0D/H5250/94.08.12
The gluing process is most easily performed by

placing the gaskets and the plates on a table. After
pressing the gaskets into the grooves of the plate, Four last digits Four last digits are ref.
H number of the plate. (only
it is stacked. are ref. number
or on plates for non-glued
of plate
V gasket)
Fig 2 Plate with serial no etc.
98.43 - ES0
Working Card
L16/24
Serial numbers are stamped in the right top corner of Fastening

the plates. Further, please note that the gasket side
must face the fixed cover. Fasten the nuts crosswise until the movable cover to
the measure x at each nut.
Cyl x
5 82.5 mm
6 86.3 mm
7 100.0 mm
8 117.3 mm
9 131.1 mm
Fig 3 Measuring x
08028-0D/H5250/94.08.12
98.43 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Page 1 (3) Centrifugal Bypass Filter Edition 03H
L16/24

Shut-off fuel oil
Cleaning procedure, cleaning intervals. Big adjustable spanner.

Maintenance intervals and procedures. Tools for cleaning.
Starting position
With the engine stopped or filter isolated by means

of a valve.
Related procedure
Working time : 1 hour Plate no Item no Qty/

Capacity : 1 man
08028-0D/H5250/94.08.12
51515 301 1/Filter

51515 313 1/Filter
Data 51515 325 1/Filter

98.47 - ES0
515-15.00 Centrifugal Bypass Filter Working Card
Edition 03H Page 2 (3 )
L16/24
Cleaning Procedure 5) Remove stand tube (075) and clean.
6) Remove sludge from inside the rotor by means

1) Isolate the filter by closing the valve for lubrica- of a spatula and wipe clean. Ensure that all rotor
ting oil inlet to the filter. components are throughly cleaned and free
from deposits of dirt before reassembling the
2) Slacken cover clamp ring (266). Unscrew cover rotor.
fixing nut and lift off cover.
Note: Failure to do so could cause an out-of-
3) Lift off rotor assembly having allowed oil to drain balance condition which will accelerate bearing
from nozzles. The rotor should be removed and and spindle wear.
replaced on the spindle with extreme care in
order to ensure that the bearings are not 7) Clean nozzle with brass wire. Examine top and
damaged. bottom bearings in tube assembly. If damaged
or worn - replace tube assembly complete.
4) Unscrew rotor cover nut (026) and separate Examine O-ring and renew if damaged.
cover (038) from body.
8) Replace paper insert (if mounted).
9) Reassemble rotor complete and tighten top nut.

026
Note: Ensure that rotor cover and rotor body are
038 always matched by balance number and pin location.
Do not interchange rotor cover.
10) Examine spindle journals. If damaged or worn

- replace with body assembly complete.
11) Reassemble filter complete checking that rotor

075
revolves freely. Then replace filter body cover
Tighten cover nut and secure safety clamp. The
266 clamp ring should be securely fitted at all times
and the filter should not be run without the clamp
ring fitted.
12) Open for lubricating oil.
13) With filter running check all joints for leakage.

Check for excessive vibration.
026 Cover nut
038 Cover
075 Stand tube
266 Cover clamp ring Maintenance - Bearings and Spindle
08028-0D/H5250/94.08.12
All rotors are correctly balanced before leaving the

Fig 1 Centrifugal bypass filter factory. An out-of-balance condition can occur as a
result of an uneven build up of sludge in the rotor or as
a result of excessive bearing or spindle wear.
Dependent on the conditions, wear will eventually

take place on the spindle and bearings and these
should be replaced with factory fitted assemblies
only.
98.47 - ES0
Page 3 (3 ) Centrifugal Bypass Filter Edition 03H
L16/24
To Check Bearing Clearances Spindle top journal diameter 14.98 mm Min.
Spindle bottom journal diameter 21.63 mm Min.
This is most easily done by applying a dial gauge to Top bearing bore diameter 15.06 mm Max.
the outside of the rotor opposite each bearing in turn Bottom bearing bore diameter 21.69 mm Max.
and measuring the total play thus:
The spindle and body assembly and the rotor bearing
14) Apply dial gauge and measure play. tube assembly are factory assembled items and
should only be replaced with complete assemblies.
15) Turn rotor 90° and repeat measurement.
16) Re-apply dial gauge at 90° to previous position

and repeat.
17) Turn rotor 90° and repeat.
The highest reading is the play in the bearing.
The maximum clearances when new are 0.08 mm at

top and 0.06 mm at bottom bearing. If the clearance
exceeds 0.25 mm top or 0.2 mm bottom then check
the sizes of the individual components and replace as
necessary.
08028-0D/H5250/94.08.12
98.47 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Plate
Page 1 (2) Lubricating Oil Pump 51501-06H
L16/24
08028-0D/H5250/94.08.12
98.48 - ES0
Plate
51501-06H Lubricating Oil Pump Page 2 (2)
L16/24
Item Item
031 1/E Lubricating oil pump, Smøreoliepumpe, kom-

comp. 5-6 cyl. engine plet 5-6 cyl. motor
incl. item 018, 055, 067, incl. item 018, 055, 067,
079, 092, 102, 114, 126, 079, 092, 102, 114, 126,
151, 175, 187, 199 151, 175, 187, 199
043 1/E Lubricating oil pump, Smøreoliepumpe, kom-

comp. 7-9 cyl. engine plet 7-9 cyl. motor
incl. item 018, 055, 067, inkl. item 018, 055, 067,
080, 092, 102, 114, 138, 080, 092, 102, 114, 138,
163, 175, 187, 199 163, 175, 187, 199
055 3/P Cylindrical pin Cylindrisk stift
067 6/P Screw Skrue
079 1/P Pump housing, Pumpehus,

complete incl. item komplet inkl. item
102, 126, 151 102, 126, 151
5-6 cyl. engine 5-6 cyl. motor
080 1/P Pump housing, Pumpehus,

complete incl. item komplet inkl. item
102, 138, 163 102, 138, 163
092 1/P Cover Dæksel
102 4/P Bush Bøsning
114 6/P Screw Skrue
126 1/P Gear wheel, Tandhjul,




175 1/P Cylindrical gear wheel Cylindrisk tandhjul
187 1/P Washer Skive
199 1/P Screw Skrue

08028-0D/H5250/94.08.12
98.48 - ES0
Plate
Page 1 (2) Lubricating Oil Filter 51502-04H
L16/24
08028-0D/H5250/94.08.12
99.06 - ES0
Plate
51502-04H Lubricating Oil Filter Page 2 (2)
L16/24
Item Item
013 6/E Filter cartridge Filterindsats 300 1/E Lever Arm
025 2/E Cover Dæksel 312 1/E Latch pin Låsestift
037 8/E Screw Skrue 324 1/E Spring pin Fjederstift
050 2/E Cover, complete incl. Dæksel, komplet inkl.

item 216 item 216
062 2/E Safety filter Sikkerhedsfilter
074 4/E Spacer ring Afstandsring
086 2/E Cover, complete Dæksel, komplet
098 8/E Screw Skrue
108 2/E Covering, complete Skærm for dæksel,

incl. item 228, 241, 253 komplet inkl. item 228,
241, 253
121 6/E Screw Skrue
133 1/E Shaft Aksel
145 1/E Shaft Aksel
170 1/E Plate Plade
194 1/E Plate Plade
204 6/E Screw Skrue
216 2/E Guide ring Styrering
228 2/E Cover Skærm
241 2/E Screw Skrue
253 2/E Retaining ring Sikringsring
265 2/E Filter guide with safety Filterstyr med sikker-

valve hedsventil
08028-0D/H5250/94.08.12
277 2/E Spring Fjeder
289 2/E Screw Skrue
290 2/E Distance piece Afstandsstykke
99.06 - ES0
Plate
Page 1 (2) Prelubricating Pump 51504-04H
L16/24
99.07 - ES0
Plate
51504-04H Prelubricating Pump Page 2 (2)
L16/24
Item Item
014 1/P Front cover Fordæksel 516 1/E Ball bearing, rear Kugleleje, bagside
026 1/P Joint Pakning 528 1/E Ball bearing, front Kugleleje, forside
038 1/P Pump casing Pumpehus
051 8/P Screw Skrue
063 1/P Socket Muffe
075 1/P Set screw Sætskrue
087 2/P Counter flange, Modtryksflange,

complete komplet
099 2/P Joint Pakning
109 1/P Joint Pakning
110 1/P Rear cover Endedæksel
122 2/P Idler rotor, only Friløbsrotor, kun tilgæn-

available together gelig sammen med item
with item 217 217
134 1/P Regulating screw Reguleringsskrue
146 1/P Retaining ring Låsering
158 1/P Valve cover Ventildæksel
171 1/P Sealing washer Pakning
195 1/P Valve spring Ventilfjeder
205 1/P Valve piston Ventilstempel
217 1/P Power rotor, only Drivrotor, kun tilgænge-

available together lig sammen med item
with item 122 122
229 1/P Drip ring Dræn
230 1/P Shaft seal, Akseltætning,

complete komplet
242 1/E Pump, complete Pumpe, komplet

with el-motor med el-motor
08028-0D/H5250/94.08.12
374 1/E Pump, complete Pumpe. komplet

without el-motor uden el-motor
494 1/E El-motor, El-motor,

complete komplet
99.07 - ES0
Plate
Page 1 (2) Lubricating Oil Cooler 51506-03H
L16/24
08028-0D/H5250/94.08.12
98.12 - ES0
Plate
51506-03H Lubricating Oil Cooler Page 2 (2)
L16/24
Item Item
015 1/K Plate Plade
027 4/K O-ring O-ring
040 4/K O-ring, oval O-ring, oval
052 8/K Screw Skrue
064 1/K Plug screw Propskrue
076 1/K Packing ring Pakningsring
088 1/K Plate Plade
111 1/K Plate Plade
123 10/K Self locking nut Selvlåsende møtrik
135 10/K Washer Skive
159 /I Gasket Pakning
160 /I Plate Plade
172 1/E Lubricating oil cooler, Smøreoliekøler,





' 9 cyl. engine 9 cyl. motor
231 /I Glue Lim
243 /I Cleaning fluid Rensevædske

08028-0D/H5250/94.08.12
Qty/K = Qty/Cooler Qty/K = Qty/Køler
98.12 - ES0
Plate
Page 1 (2) Centrifugal By-pass Filter 51515-02H
L16/24
08028-0D/H5250/94.08.12
97.47 - ES0
Plate
51515-02H Centrifugal By-pass Filter Page 2 (2)
L16/24
Item Item
014 1/F Body , complete incl. Sokkel, komplet inkl. 301 1/F Cover nut fixing kit, Dækselmøtrikskit, inde-
item 026, 038, 051, 063, item 026, 038, 051, 063, consisting of item 134, holdende item 134, 146,
075, 087, 099, 109 075, 087, 099, 109 146, 158, 171 158, 171
026 1/F Valve body Ventilsokkel 313 1/F Valve kit, consisting of Ventilkit, indeholdende
item 026, 038, 051, 063, item 026, 038, 051, 063,
038 1/F Valve handle Ventilhåndtag 075, 087 075, 087
051 1/F Nyloc nut Møtrik 325 1/F Seals kit, consisting of Tætningskit, indehold-
item 087, 099, 109, 158, ende item 087, 099, 109,
063 1/F Valve adaptor Ventiladapter 242 158, 242
075 1/F Valve stop Ventilstop 337 1/E Centrifugal by-pass fil- Centrifugal by-pass fil-
ter, complete as ter, komplet som vist på
087 1/F Valve seal Ventiltætning shown on front page forsiden
099 1/F Flange gasket Flangepakning
109 1/F Filter body O-ring Filtersokkel O-ring
110 1/F Cover, complete incl. Dæksel, komplet inkl.

item 122, 134, 146, 158, item 122, 134, 146, 158,
171 171
122 1/F Cover Dæksel
134 1/F Cover nut pin Stift for dækselmøtrik
146 1/F Cover fixing nut Dækselmøtrik
158 1/F Cover nut O-ring Dækselmøtrik O-ring
171 1/F Cover nut collar
183 1/F Band clamp Spændering
195 1/F Rotor, complete incl. Rotor, komplet inkl. item

item 205, 217, 229, 230, 205, 217, 229, 230, 242,
242, 254, 266, 278, 291 254, 266, 278, 291
205 1/F Nozzle Dyse
217 1/F Bearing tube Lejerør
229 1/F Stand tube Standrør
230 1/F Circlip Låsering
242 1/F Rotor O-ring Rotor O-ring
254 1/F Pin Stift

08028-0D/H5250/94.08.12
266 1/F Rotor cover nut Rotordækselmøtrik
278 1/F Paper insert Papirindsats
291 1/F Stiffner plate Plade
Qty/F = Qty/Filter Qty/F = Qty/Filter
97.47 - ES0
Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-02H
L16/24
08028-0D/H5250/94.08.12
00.14 - ES0
Plate
51535-02H Prelubricating Oil Arrangement Page 2 (2)
L16/24
Item Item
037 1/E Adjustable straight Justerbar

male stud coupling ligeforskruning
049 1/E Male stud coupling Vinkelforskruning
050 1/E Ball valve Kugleventil
062 1/E Straight male Ligeforskruning

stud coupling
074 1/E Equal tee coupling, T-forskruning,

complete komplet
086 1/E Pipe Rør
098 2/E Adjustable elbow Justerbar vinkel
108 1/E Non-return valve Kontraventil
121 1/E Reducing adaptor Reduktionsadapter
133 1/E Non-return valve Kontaventil
145 2/E Threaded sleeve Bøsning
169 1/E Bleeding screw Skrue
170 1/E Pipe Rør
182 1/E Pipe Rør
194 1/E Pipe Rør
204 2/E Screw Skrue
08028-0D/H5250/94.08.12
00.14 - ES0
Index
Page 1 (1) Cooling Water System 516
L16/24
Description
Internal cooling water system .......................................................................................516.01 (04H)
Working card
Check of cooling water system ............................................................................... 516-01.90 (02H)

Cooling water, thermostatic valve........................................................................... 516-04.00 (02H)
HT and LT water pumps ......................................................................................... 516-10.00 (01H)
Plates
High and low temperature fresh water pumps.................................................................51610-03H

Cooling water pipes .........................................................................................................51630-02H
Your Notes :
08031-0D/H5250/94.09.07
Description 516.01
Page 1 (1) Internal Cooling Water System Edition 04H
L16/24
The cooling water system consists of a low tempe-

rature system and a high temperature system.
Both the low and the high temperature systems are

cooled by treated water.
The water in the low temperature system passes

through the low temperature circulating pump which
drives the water through the second stage of the
charge air cooler and then through the lubricating oil
cooler before it leaves the engine together with the
high temperature water.
The high temperature cooling water system

passes through the high temperature circulating
pump and then through the first stage of the charge air
cooler before it enters the cooling water jacket and the
cylinder head. Then the water leaves the engine with
the low temperature water.
Both the low and high temperature water leaves the

engine through separate three-way thermostatic
valves which control the water temperature.
It should be noted that there is no water in the engine

frame.
Fig 1 Integral cooling water system.
Thermostatic Valves
The thermostatic valves are fully automatic three-

way valves with thermostatic elements set at fixed
temperatures.
08028-0D/H5250/94.08.12
99.03 - ES0
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Check of Cooling Water System 516-01.90
L16/24

Shut-off fuel oil
Check of cooling water system.
Starting position
Engine is running.
Related procedure

08028-0D/H5250/94.08.12
Working time : ½ hour Plate no Item no Qty./

Capacity : 1 man
Data

98.41 - ES0
516-01.90 Check of Cooling Water System Working Card
L16/24
Checks to be Carried Out 4) Check the condition of the outermost of the two
O-rings (which make up the tightening between
1) Examine the cooling water connections for the water jacket and the combustion space) by
leaks. means of the inspection holes in the cylinder
cover.
2) Check flexible connections for leaks.
Concerning check of the fresh water condition, see
It is important that the flexible connections are free section 504.
from paint and grease and in healthy condition.
3) Check O-rings in water connections between

cylinder covers and also between cylinder
covers and front-end box.
08028-0D/H5250/94.08.12
98.41 - ES0
Working Card
Cooling Water, Thermostatic Valve 516-04.00
L16/24

Shut-off fuel oil
Inspection of thermostatic valve and replacement

of elements.
Starting position
Cooling water drained from engine (if necessary).
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

98.41 - ES0
516-04.00 Cooling Water, Thermostatic Valve Working Card
L16/24
The thermostatic valves cannot be adjusted and 5) Remount a new element (4) by wriggling it
under normal conditions maintenance is not re- somewhat over side.
quired. However, in some cases it is necessary to
clean or replace elements. 6) Mount lock ring (2) in the recees.
7) Clean the sealing surface of the casing. Tighten

Replacement of Elements bolts according to page 500.40.
1) Remove the casing by unscrewing bolts (1),

see fig 1.
2) Remove lock ring (2).
3) Remove element (4) from the casing.
4) Thoroughly clean sleeve (3).
Fig 2 Seen from front end of the engine.
Fig 1 Cooling water thermostatic valve.

08028-0D/H5250/94.08.12
98.41 - ES0
Working Card
HT and LT Water Pumps 516-10.00
L16/24

Shut-off fuel oil
Disassembly, overhaul and assembly of HT and

LT pumps.
Starting position
Related procedure
Working time : 1 hours Plate No Item No Qty /

08028-0D/H5250/94.08.12
Capacity : 1 man
51610 010 4/E
51610 022 2/E
Data 51610 095 2/E
51610 250 1/E
98.41 - ES0
516-10.00 HT and LT Water Pumps Working Card
L16/24
After the cooling water thermostat casing is removed Inspection of the Pump
the cooling water pumps can be dismounted.
6) Inspect the shaft for seizures after removing
1) Remove the screws (1), see fig. 1 and pull out the shaft seal and bearings, also inspect the
the pump by means of the spring bolts. impeller for pittings and caviations. Clean all
parts carefully.
Assembling of the Pump
7) Fit new bearings (13) and (14) together with a

new shaft seal (15).
8) Mount the shaft in the housing and lock it with

the lock ring (11).
9) Fit the spur wheel (4) and washer (3) with the
screw (2) and tight it according to page 500.40.
10) Fit carefully the slide ring joint (10), then fit the
washer (8) and the impeller (9) and tight the nut
(7) according to page 500.40.
11) Mount the cover (6) with the screw (5) and tight
them according to page 500.40.
12) Fit new o-rings on the pump housing and pump

cover, then mount the pump in the front end
box with the screws (1), see fig. 1 and tight
them according to page 500.40.
Fig 1 HT and LT water pumps
Disassembling of the Pump
2) Remove the screw (2), see fig 2 and pull of the

washer (3) and spur wheel (4).
08028-0D/H5250/94.08.12
3) Remove the bolt (5) and the cover (6).
4) Remove the nut (7) with disc (8), then remove

impeller (9) and the slide ring joint (10).
5) Take out the lock ring (11), then pull out the
shaft (12) with bearings (13) and (14) and the
shaft seal (15).
Fig 1 HT and LT water pumps
98.41 - ES0
Plate
Page 1 (2) High- and Low Temperature Fresh Water Pumps 51610-03H
L16/24
08028-0D/H5250/94.08.12
97.51 - ES0
Plate
51610-03H High- and Low Temperature Fresh Water Pumps Page 2 (2)
L16/24
Item Item
034 1/P Depp groove ball Radialkugleleje

bearing
046 1/P Ball bearing Kugleleje
058 1/P Retaining ring Sikringsring
071 1/P Retaining ring Sikringsring
083 1/P Shaft seal Pakdåse
095 1/P Slide ring joint Roterende pakning
105 2/E Fresh water pump, Ferskvandspumpe,

complete as shown komplet som vist
on front page på forside
117 4/P Screw Skrue
129 1/P Pump housing Pumpehus
130 1/P Impeller Løbehjul
142 1/P Cover Dæksel
154 4/P Screw Skrue
166 4/P Lock washer Låseskive
178 1/P Shaft Aksel
191 1/P Self locking nut Selvlåsende møtrik
201 1/P Disc Skive
213 1/P Spur gear Cylindrisk tandhjul
225 1/P Washer Skive
237 1/P Screw Skrue

08028-0D/H5250/94.08.12
Qty./P = Qty./Pump Qty./P = Qty./Pumpe
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
97.51 - ES0
Plate
Page 1 (2) Cooling Water Connections 51630-02H
L16/24
08028-0D/H5250/94.08.12
98.45 - ES0
Plate
51630-02H Cooling Water Connections Page 2 (2)
L16/24
Item Item
033 Seal ring Tætningsring

045 Screw Skrue

069 Lock washer Låseskive

070 2/C Intermediate piece Mellemstykke
082 2/C Safety clamp Sikkerhedsring
094 2/E Stud Tap
104 2/E Nut Møtrik
08028-0D/H5250/94.08.12
98.45 - ES0
Index
Page 1 (1) Special Equipment 517
L16/24
Description
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Alternator 518
L16/24
Description
Your Notes :
08031-0D/H5250/94.09.07
Index
Page 1 (1) Specific Plant Information 519
L16/24
Description
Resilient mounting of generating sets ..........................................................................519.03 (03H)
Working card
Fitting instruction for resilient mounting of GenSets .................................................. 519-03.00 (24)

Replacement of conicals......................................................................................... 519-03.05 (02H)
Maintenance of conicals ......................................................................................... 519-03.10 (02H)
Plates
Conical element ...............................................................................................................51903-02H

Your Notes :
08031-0D/H5250/94.09.07
Description
Resilient Mounting of Generating Sets 519.03
L16/24
Resilient Mounting of Generating Sets 1) The support between the bottom flange of the
conical mounting and the foundation is made
On resiliently mounted generating sets, the diesel with a loose steel shim. This steel shim is
engine and the alternator are placed on a common adjusted to an exact measurement (min. 75
rigid base frame mounted on the ship's/machine mm) for each conical mounting.
house's foundation by means of resilient supports,
Conical type. 2) The support can also be made by means of two
steel shims, at the top a loose steel shim of at
All connections from the generating set to the external least 75 mm and below a steel shim of at least
systems should be equipped with flexible connec- 10 mm which are adjusted for each conical
tions and pipes. Gangway etc. must not be welded to mounting and then welded to the foundation.
the external part of the installation.
Resilient Support
A resilient mounting of the generating set is made with

a number of conical mountings. The number and the
distance between them depend on the size of the
plant. These conical mountings are bolted to the top
flange of the base frame (see fig 1).
The setting from unloaded to loaded condition is

normally between 5-11 mm for the conical mounting.
The support of the individual conical mounting can be

made in one of the following three ways:
08028-0D/H5250/94.08.12
Fig 1 Resilient mounting of generating sets.
Fig 2 Support of conicals.
99.44 - ES1
519.03 Resilient Mounting of Generating Sets
Description
L16/24
3) Finally, the support can be made by means of Adjustment of Engine and Alternator on
chockfast. It is necessary to use two steel Base Frame
shims, the top steel shim should be loose and
have a minimum thickness of 75 mm and the The resiliently mounted generating set is normally
bottom steel shim should be cast in chockfast delivered from the factory with engine and alternator
with a thickness of at least 10 mm. mounted on the common base frame. Eventhough the
engine and alternator have been adjusted by the
Irrespective of the method of support, the 75 mm steel factory with the alternator rotor placed correctly in the
shim is necessary to facilitate a possible future stator and the crankshaft bend of the engine is within
replacement of the conical mountings, which are the prescribed tolerances.
always replaced in pairs.
08028-0D/H5250/94.08.12
99.44 - ES1
Working card
Fitting Instructions for Resilient Mounting of GenSets 519-03.00
L16/24
L21/31

Shut-off fuel oil
Mounting and adjustment instruction for new Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Starting position
The foundation should be welded and milled off

on shim surfaces.
Related procedure
Replacement of conicals 519-03.05
Manpower Spare and wearing parts

08028-0D/H5250/94.08.12
Working hours : 2 hours Plate no Item no Qty/

Capacity : 2 men
Data

03.50 - ES1
519-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
L16/24
L21/31
Mounting and Adjustment Instructions for 5) Position the jacking bolt with a through-going
New Generating Sets (Method 1) of minimum 75 mm.
Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests com-
ments pletely on the foundation.
If the conical elements have not been mounted by 7) Check that all the jacking bolts have full con-
the factory, they must be mounted on the prepared tact with the foundation.
brackets on the base frame. In case they have been
mounted by the factory, please start with item 4. 8) Loosen the nut (7).
1) Remove nut (7) and ring (6) from the conical 9) Turn all the internal buffers by applying a
element. spanner to the hexagon (S = 19) to check that
they can move freely.
2) Fit the conical element to the bracket on the
suspended equipment by means of fixing the
central buffer (2), the ring (6) and nut (7). If all internal buffers Then
3) Tighten the nut (7) by hand and simultane- Can move freely Let conical elements set-
ously block the central buffer (2) by applying a tle for 48 hours.
spanner to the hexagon (S = 19) on the top of
the central buffer (2). Cannot be moved Turn the jacking bolts
freely clockwise to release the
4) Position the four jacking bolts in the tapped internal buffer.
holes (8) in the bottom flange.
08028-0D/H5250/94.08.12
Fig 2 Conical element.
Fig 1 Conical mounting.
03.50 - ES1
Working card
L16/24
L21/31
Adjustment of Conical Elements after 48
Hours Settling Drill the mounting holes in the steel shim according
to the conical base casting dimensions.
After the conical elements have been deflected
under static load for 48 hours, the loaded height (H1)
see fig 1, should be measured and compared to the Mounting of the Completed Steel Shim
recommended loaded height.
13) Turn the internal buffer anticlockwise until it
10) Care must be taken, during levelling of the contacts the base casting to secure the loaded
installation, to ensure that individual mount- height of each conical element.
ings are not overloaded. The variation in laden
height should not exceed 2 mm and should 14) Lift the generating set with crane or hydraulic
ideally be less. The laden height can be meas- jack.
ured between top and base casting at H, on
two sides (see fig 1). 15) Remove all the jacking bolts.
H1 + H2 + H3 ----- HN 16) Position each completed steel shim.

Ex: Average =
Number of conical elements
17) Lower the generating set until it rests com-
pletely in itself.
If Then
18) Number each steel shim together with each
Difference exceeds Level the conical ele- conical element.
ment
2 mm. by adjusting the jacking
bolts - commencing with Adjustment of Internal Buffer
the conical element with
the largest deviation. 19) Turn the internal buffer clockwise (downwards)
until it makes contact with the steel shim or
Difference does not ex- The height of the steel foundation.
ceed 2 mm shim can be measured.
20) Turn the internal buffer anticlockwise (upwards)
until it obtains contact with the base casting.
The difference between the two sides of a conical
mounting should not be more than 0.5 mm. This must be four full turns.
21) Turn the internal buffer two full turns clockwise

Measuring of Steel Shim (downwards) and check with a feeler gauge
between the base casting of the conical ele-
11) Measure the steel shim on several points to ment and the steel shim that the internal buffer
08028-0D/H5250/94.08.12
obtain the highest possible accuracy during (2), see fig 1, does not touch the steel shim or
preparation. foundation.
22) Tighten the nut (7) with a torque of 300 Nm and

Fabricating Steel Shim block the central buffer (2) with a spanner (S =
19) at the same time.
12) Make sure that the minimum height of the steel
shim is 75 mm to secure a future replacement
of the steel shim.
03.50 - ES1
Page 4 (4)
Edition 24
L16/24
L21/31
Mounting of Conical Elements on the Foun- or
dation
b) Drill the mounting holes in the foundation by
23) Drill four mounting holes in the foundation for means of the drilling pattern from the installa-
each conical element, either tion drawing.
a) Mark the positions of the mounting holes on The drilling has to be done on beforehand and
the foundation through the conical element. the set must be aligned with the foundation
holes before the work starts to avoid further
(Re)move the set completely so that the mark- removal of the set.
ings can be reached by drilling with conven-
tional tools. 24) Fix the conical element and the steel shim to
the foundation with four bolts.
Place the set on its former position by aligning
it with the drilled holes. Note! After completion of all works the buffer clear-
ance must be checked, see points 19, 20, 21 and 22.
08028-0D/H5250/94.08.12
03.50 - ES1
Working card
L16/24
L21/31

Shut-off fuel oil
Measurement tool
Starting position

on shim surfaces.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 2 men
Data

03.50 - ES1
L16/24
L21/31
Mounting and Adjustment Instructions for A 75 mm supporting steel shim, complete with holes
New Generating Sets (Method 2) for four jacking bolts and mounting holes drilled
according to conical base casting dimensions, is
Make Ready for Adjustment of Conical Ele- required.
ments
4) Position the supporting steel shim as per fig 1
If the conical elements have not been mounted by and locate the conical element by means of
the factory, they must be mounted on the prepared dowel pins.
mounted by the factory, please start with item 4. 5) Position the jacking bolts in the tapped holes in
the supporting steel shim as per fig 1.
1) Remove nut (7) and ring (6) from the conical
element. 6) Position the jacking bolts with a through-going
of minimum 10 mm, see fig 1.
2) Fit the conical element to the bracket on the
suspended equipment by means of fixing the 7) Lowed generating set until it rests completely
central buffer (2), the ring (6) and nut (7). on the foundation.
3) Tighten the nut (7) by hand and simultane- 8) Check that all jacking bolts have full contact
ously block the central buffer (2) by applying a with the foundation.
spanner to the hexagon (S = 19) on the top of
the central buffer (2). 9) Loosen the nut (7).
10) Turn all the internal buffers by applying a

spanner to the hexagon (S = 19) to check that
they can move freely.
08028-0D/H5250/94.08.12
Fig 1 Conical mounting. Fig 2 Conical element.
03.50 - ES1
Working card
L16/24
L21/31
If all internal buffers Then Measuring of Steel Shim
Can move freely Let conical elements set- 12) Measure the steel shim on several points to
tle for 48 hours. obtain the highest possible accuracy during
preparation.
Cannot be moved Turn the three jacking
freely bolts in the supporting
steel shim clockwise, or Fabricating Steel Shim
anticlockwise to release
the internal buffer. 13) Make sure that the minimum height of the steel
shim is 10 mm to secure the future replace-
ment of the supporting steel shim.
Adjustment of Conical Elements after 48
Hours Settling Drill the mounting holes in the steel shim according
to the conical base casting dimensions.
After the conical elements have been deflected
see fig 1, should be measured and compared to the Mounting of the Completed Steel Shim
recommended loaded height.
14) Lift the generating set 1 mm totally be means
11) Care must be taken, during levelling of the of the three jacking bolts.
installation, to ensure that individual mount-
ings are not overloaded. The variation in laden 15) Position each completed steel shim.
height should not exceed 2 mm and should
ideally be less. The laden height can be meas- 16) Re-lower the generating set by means of the
ured between top and base casting at H, on three jacking bolts until it rests completely in
two sides (see fig 1). itself.
H1 + H2 + H3 ----- HN
Ex: Average = Number of conical elements Adjustment of Internal Buffer
17) Turn the internal buffer clockwise (downwards)

If Then until it makes contact with the steel shim or
foundation.
Difference exceeds Level the conical element
2 mm. by adjusting the jacking 18) Turn the internal buffer anticlockwise (upwards)
bolts - commencing with until it obtains contact with the base casting.
the conical element with
the largest deviation. This must be four full turns.
08028-0D/H5250/94.08.12
Difference does not ex- The height of the steel 19) Turn the internal buffer two full turns clockwise
ceed 2 mm shim can be measured. (downwards) and check with a feeler gauge
ment and the steel shim that the internal buffer
The difference between the two sides of the conical (2), see fig 1, does not touch the steel shim or
mounting should not be more than 0.5 mm. foundation.
20) Tighten the nut (7) with a torque of 300 Nm and

block the central buffer (2) with a spanner (S =
19) at the same time.
03.50 - ES1
L16/24
L21/31
Mounting of Conical Elements on the Foun- or
dation
b) Drill the mounting holes in the foundation by
21) Remove the dowel pins. means of the drilling pattern from the installa-
tion drawing.
22) Drill four mounting holes in the foundation for
each conical element, either The drilling has to be done on beforehand and
the set must be aligned with the foundation
a) Mark the positions of the mounting holes on holes before the work starts to avoid further
the foundation through the conical element. removal of the set.
(Re)move the set completely so that the mark- 23) Fix the conical element and the supporting
ings can be reached by drilling with conven- steel shim/steel shim to the foundation with
tional tools. four bolts.
Place the set on its former position by aligning 24) Weld the lowest steel shim to the foundation.
it with the drilled holes.
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
Working card
L16/24
L21/31

Shut-off fuel oil
Measurement tool
Starting position

on shim surfaces.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 2 men
Data

03.50 - ES0
L16/24
L21/31
Mounting and Adjustment Instructions for A 75 mm supporting steel shim, complete with tapped
New Generating Sets (Method 3) holes for three jacking bolts, four mounting holes and
four tapped holes, drilled according to the conical
Make Ready for Adjustment of Conical Ele- base casting dimension, is required see fig 1.
ments
4) Position the supporting steel shim as per fig 1
If the conical elements have not been mounted by and locate the conical element by means of
the factory, they must be mounted on the prepared four hold-down bolts.
mounted by the factory, please start with item 4. 5) Position the jacking bolts in the tapped holes in
the supporting steel shim as per fig 1.
1) Remove nut (7) and ring (6) from the conical
element. 6) Position the jacking bolts with a through-going
of minimum 10 mm plus permitted thickness,
2) Fit the conical element to the bracket on the as specified from the chockfast supplier, see
suspended equipment by means of fixing the fig 1.
central buffer (2), the ring (6) and nut (7).
7) Lowed the generating set until it rests com-
3) Tighten the nut (7) by hand and simultane- pletely on the foundation.
ously block the central buffer (2) by applying a
spanner to the hexagon (S = 19) on the top of 8) Check that all jacking bolts have full contact
the central buffer (2). with the foundation.
08028-0D/H5250/94.08.12
Fig 2 Conical element.
Fig 1 Conical mounting.
03.50 - ES1
Working card 519-03.00
Page 3 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 26
L16/24
L21/31
If all internal buffers Then Measuring of Steel Shim and Chockfast
Can move freely Let conical elements set- 10) The steel shim should be at least 10 mm heigh.
tle for 48 hours.
Check the minimum permitted thickness of
Cannot be moved Turn the three jacking chockfast for the load and surface of this appli-
freely bolts in the supporting cation with chockfast supplier.
steel shim clockwise, or
anticlockwise and
slacken the four hold- Fabricating Steel Shim
down bolts to release the
internal buffer. Make sure that the minimum height of the steel shim
is 10 mm to secure a future replacement of the
supporting steel shim.
Adjustment of Conical Element after 48 Hours
Settling 11) Drill the mounting holes in the steel shim
according to the mounting holes in the sup-
After the conical elements have been deflected porting steel shim.
see fig 1, should be measured and compared to the
recommended loaded height. Adjustment of Internal Buffer
9) Care must be taken, during levelling of the 12) Turn the internal buffer clockwise (downwards)
installation, to ensure that individual mount- until it makes contact with the steel shim or
ings are not overloaded. The variation in laden foundation.
height should not exceed 2 mm and should
ideally be less. The laden height can be meas- 13) Turn the internal buffer anticlockwise (upwards)
ured between top and base casting at H, on until it obtains contact with the base casting.
two sides (see fig 1).
This must be four full turns.
H1 + H2 + H3 ----- HN
Ex: Average = Number of conical elements 14) Turn the internal buffer two full turns clockwise
(downwards) and check with a feeler gauge
If Then ment and the steel shim that the internal buffer
(2), see fig 1, does not touch the steel shim or
Difference exceeds Level the conical element foundation.
2 mm. by adjusting the jacking
bolts - commencing with 15) Tighten the nut (7) with a torque of 300 Nm and
the conical element with blocking the internal buffer (2) with a spanner
08028-0D/H5250/94.08.12
the largest deviation. at the same time, see fig 1.
Difference does not ex- The height of the steel

ceed 2 mm shim and the chockfast Mounting of Conical Elements on the Foun-
can be measured. dation
16) Drill mounting holes in the foundation accord-

The difference between the two sides of the conical ing to the supporting steel shim/steel shim and
mounting should not be more than 0.5 mm. chockfast, either
03.50 - ES1
L16/24
L21/31
a) Mark the positions of the mounting holes on or
the foundation through the supporting steel
shim. b) Drill the mounting holes in the foundation by
means of the drilling pattern.
(Re)move the set completely so that the mark-
ings can be reached by drilling with conven- The drilling has to be done on beforehand and
tional tools. the set must be aligned with the foundation
holes before the work starts to avoid further
Place the set on its former position by aligning removal of the set.
it with the drilled holes.
Make sure that the mounting bolts are isolated from
the chockfast.
Note! After completion of all works, the buffer clear-

ance must be checked, see points 13, 14, 15 and 16.
08028-0D/H5250/94.08.12
03.50 - ES1
Working card
Replacement of Conicals 519-03.05
L16/24

Shut-off fuel oil
Replacement of conicals. Hydraulic jack
Starting position
Safety precautions.
Related procedure
Fitting instructions for resilient mounting.

08028-0D/H5250/94.08.12
Working hours : hours Plate no Item no Qty/

Capacity : 2 men
51903 013 4/E
Data

98.41 - ES0
519-03.05 Replacement of Conicals Working card
L16/24
Replacement of Conicals
1) Loosen all the holding down-bolts for the conicals 3) Lift the GenSet until the steel shim can be
in one side. 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 51903.
Nut
Conical mounting 5) Lower the GenSet again.
Adjusting screw
Holding down bolts
6) Repeat items 1-5 for the other side.
Steel shim
7) Adjust the conicals, please see working card
Foundation 519-03.00 "Fitting Instructions for Resilient
Bracket
Mounting of GenSet.
Deck
Jack
Fig 1 Removal of conicals
One pair
08028-0D/H5250/94.08.12
Fig 2 The conicals must be replaced in pairs
98.41 - ES0
Working Card
Maintenance of Conicals 519-03.10
L16/24

Shut-off fuel oil
Control and adjustment of conicals. Ring and open-end spanner.

Feeler gauge, 2 mm.
Starting position
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

98.41 - ES0
519-03.10 Maintenance of Conicals Working Card
L16/24
Visual Check Result of Clearance Check
What to Check If Then
everything is OK check is completed

1) Check for oil deposits on the rubber element.
everything is not OK adjust conicals which do not com-
2) Check for loose mounting bolts. ply with the clearance demands
acc. to item 5-10. Recheck
3) Check for damage in the rubber element. all conicals acc. to item 4.
everything is still not OK replace conical acc. to

Result of Visual Check Working Card 519-03.05
If Then
everything is OK continue to next conical Adjustment of Conicals

oil deposits on rubber clean rubber element 5) Remove protective cap by loosen the nut (1).
element are observed
loose mounting bolts fasten mounting bolts

6) Turn internal buffer (2) clockwise until it makes
contact with the steel shim (4).
damage to conicals replace conical according to
is observed Working Card 519-03.05 7) Turn internal buffer (2) anti-clockwise until it
makes contact with the conical base casting
(3). This must be done in four full rotations.
Clearance Check
8) Turn internal buffer (2) two full rotations
What to Check clockwise. This will ensure full vertical
movement for the buffer.
4) Check clearance on all conicals between steel
shim and internal buffer through the slot in the 9) Check all conicals again.
base casting of the conical (see fig 1) with a
feeler gauge of approx. 2 mm. 10) Tighten the nut (1), see page 500.40 and at the
same time block the internal buffer (2) with a
spanner.
1. Nut
2. Internal buffer
08028-0D/H5250/94.08.12
2
3. Conical base casting
4. Steel shim
3
Fig 1 Conical
98.41 - ES0S
Plate
Page 1 (2) Flexible External Connections 51902-04H
L16/24
Item
Fig. Designation Connection
No
Fuel oil, inlet A1 018
Fuel oil, outlet A2 031
Waste oil, outlet A3 043
Lubricating oil from separator, C3 079

inlet
Lubricating oil to separator, C4 080

outlet
Lub. oil overflow, outlet C15 092
Oil vapour discharge, outlet C13 126

08028-0D/H5250/94.08.12
Venting to expansion tank/ F3/F4 163

Fresh water for preheating
99.09 - ES0
Plate
51902-04H Flexible External Connections Page 2 (2)
L16/24
Item
Fig. Designation Connection
No
HT freshwater, inlet F1 209
HT freshwater, outlet F2 210
LT freshwater/raw water, G1 222

inlet
LT freshwater/raw water, G2 234

outlet
Compressed air, inlet K1 271
Exhaust gas, outlet (DN 250) P2 305
Exhaust gas, outlet (DN 400) P2 329
08028-0D/H5250/94.08.12
99.09 - ES0
Plate
Page 1 (2) Conical Element 51903-02H
L16/24
08028-0D/H5250/94.08.12
97.49 - ES0
Plate
51903-02H Conical Element Page 2 (2)
L16/24
Item Item
013 1/M Conical element, Konisk understøtning,

complete komplet
025 4/M Screw Skrue
08028-0D/H5250/94.08.12
Qty/M = Qty/Conical mounting. Qty/M = Qty/Conical montering.
97.49 - ES0
Index
Page 1 (1) Tools 520
L16/24
Working card
Function of the hydraulic tools ................................................................................ 520-01.05 (02H)

Application of hydraulic tools .................................................................................. 520-01.06 (06H)
Your Notes :
08031-0D/H5250/94.09.07
Page 1 (7) Function of the Hydraulic Tools Edition 02H
General

Shut-off fuel oil
Safety hints andd function of hydraulic tools.
Starting position
Application of hydraulic tools 520-01.06
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
Edition 02H 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 be
We expressly point out that a conscientious handling exceeded in any case and is to be watched at
of the device as well as the accessories is of highest the manometer of the pressure generator dur-
importance. To ignore these rules or separate hints ing the complete tensioning or loosening pro-
means danger to life or danger of injuries! See Safety cedure. When having achieved the given pres-
Hints. sure, stop the pressurization immediately.
10. During the pressurization when tensioning or

Safety Hints loosening the bolt connection, always watch
the admissible stroke of the device. Exceeding
Beside regarding the general accident-prevention this stroke is connected with insufficient gener-
rules, the safe handling of the device and the hydrau- ating of tensioning force because the device is
lic accessories demand especially the consideration tensioned in itselve or the hydraulic pressure is
of the following hints. When disregarding even single bleeded automaticly.
items, you can cause danger to life and/or danger of
injuries! 11. On principle, when connecting high-pressure
hoses it has to be taken care that the connec-
1. When leakages occur during the pressuriza- tions are correct (see also separate hints).
tion, bleed pressure immediately and seal the
leakage or replace defect parts. 12. The hydraulic hoses have to be installed in a
way that they are not run over by vehicles or
2. In case of repair, use exclusively original spare unnecessarily walked over by people. Never
parts. Inexpert substitution of damaged parts lay hoses across sharp objects (danger of
by non-original spare parts is prohibited. cuts) and never bend or jam them in.
3. All assembly parts are to be handled in corre- 13. Never hold or transport the device by using the
spondence to the working cards only. A change high-pressure hoses.
in the procedure or another operation of the
device is not allowed. 14. An incorrect working manometer that doesn´t
show the right pressure leads to overstressing
4. Make sure that the components to be tensioned of the parts and to an incorrect bolt connection.
do not exceed the admissible strain. Apart from damaged parts an incorrect bolt
connection can also cause conditions that are
5. In order to use the device, the thread has to be danger to life. Therefore take care that the
sufficiently exceeding in order to avoid that the manometer shows the right value or the
turn of a thread cracks, see item 4. tensioning force is checked in an other way (for
example by using a master manometer).
08028-0D/H5250/94.08.12
6. During the pressurization the people involved Tensioning forces can be checked for example
have to remain in an appropriate distance. by measuring the linear deformation. Dam-
Staying in direction towards the bolt axis is aged manometers have to be exchanged im-
forbidden. mediately.
7. Tensioning pressures or tensioning forces are

to be given or changed by authorized person-
nel only while considering the admissible com-
ponent loads, see item 4.
99.43 - ES0
General
Working Hints
In order to achieve a bolt connection of high preci-

sion, 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 some clean the components with fluff-free cleaning mate-
devices. rial. You can also apply compressed air. Having
The turnable connection unit consists of the follow- checked the components for damages and oiled
ing components: them slightly, apply new seals by help of the entry
guide and reassemble 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 hydrau-
lic oil.
Furthermore, an entry guide is available or con- - For replacements, use exclusively new
08028-0D/H5250/94.08.12
tained 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
Edition 02H
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 a towards each other (consider centering shoulder).
pressureless condition, first pull back the cou-
pling 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 hydrau-
lic 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
pressure can be bleeded
Þ Always consider the safety and working
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 the When screwing on the device take care that the
components to be tensioned are correctly positioned support sleeve at the cylinder is correctly centered
towards each other. Then screw the device onto the (consider centering shoulder).
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 sleeve or the support cylinder fits tight to the flange,
device take care that the support sleeve at the
08028-0D/H5250/94.08.12
turn back the device by at least the value (slit

cylinder is correctly centered (consider centering measure) which the bolt and the components spring
shoulder). back elastically during the loosening procedure.
Screw the device until the support sleeve or the Hint: The adjusted slit measure may never exceed
support cylinder fits exactly to the flange. The piston the admissible stroke of the device! Furthermore,
of the device must be at its zero position. Further- take care that the window for the adjusting rod are
more, take care that the hydraulic connector and the well accessible.
window for the adjusting rod is well accessible. Having made all hydraulic connections correctly,
see fig. 2, start the pressurization.
99.43 - ES0
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 surization. Pressurize again until the original
immediately. 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 further. (Attention: consider the admissible
components spring back during the loosening proce- stroke of the device!) Now repeat the loosen-
dure. The slit measure, however, must be lower than ing procedure explained above.
the 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 to back by a too low measure prior to the pres-
the piston or the cylinder since then the device can surization. Pressurize again and turn the main
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 the
be bled. The bolt connection is loosened. Before piston since the device can be tensioned in
unscrewing the device, bring the piston back to its itself.
zero position, see fig. 4. After that, the hydraulic
hoses can be decoupled. In order to prevent impuri-
ties, it is advisable to close coupling sockets and Adjustment and Turn Back of the Main Nut
coupling nipples at once by protecting caps. The
device can be unscrewed from the bolt. During the pressurization of the device, the bolt is
Þ
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
Þ
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 pres- main nut after the pressurization according to the
sure by help of which the connection was bolt and component deformations, (see Loosening
tensioned! Should it not be possible to loosen Procedure.
the main nut when reaching the original
tensioning pressure interrupt the pressuriza-
08028-0D/H5250/94.08.12
Hint: During the loosening procedure, never turn

tion immediately. Find the cause with expert back the main nut until it fits to the piston or the
staff. cylinder since the main nut sticks after the depressu-
Þ
rization.
Always consider the safety and working 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
520-01.05 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
After each pressurization it must be ensured that the protect the device from unnecessary damages. After
piston of the device is brought back to its zero removing the hydraulic connector, you can also
position. On principle, it has to be considered that carefully lead 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 cylin-
The piston return stroke is done by a screw-down at der.
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 an compressed air for the cleaning, but never aggres-
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
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 corrosion
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
Your Notes :
08031-0D/H5250/94.09.07
Working Card
Application of Hydraulic Tools 520-01.06
L16/24

Shut-off cooling water See page 2-4
Shut-off fuel oil
Application of hydraulic tools.
Starting position
Function of hydraulic tools 520-01.05
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

01.35 - ES0
520-01.06 Application of Hydraulic Tools Working Card
L16/24
This working card gives the information for application

of hydraulic tools, to be used in connection with
working card 520-01.05.
Fig 1 Spur gear.
08028-0D/H5250/94.08.12
Fig 2 Cross bolt and tierod.
01.35 - ES0
Working Card
Application of Hydraulic Tools 520-01.06
L16/24
Fig 3 Connection of hydraulic tools.

08028-0D/H5250/94.08.12
Fig 5 After main bearing.
Fig 4 Main bearing
01.35 - ES0
Edition 06H
Application of Hydraulic Tools Page 4 (4)
L16/24
Fig 6 Counter weight and connection rod.

08028-0D/H5250/94.08.12
01.35 - ES0
Working Card
Hand Lever Pump 520-01.07
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
520-01.07 Hand Lever Pump Working Card
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, especially
this pressure or the max. pressure of the hand lever 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 Turn the carrying handle with counter-clockwise
brake liquid, since these can lead to damages or rotation out of his fixing. Then turn it into the hand
even to destruction of the pump and/or the parts lever of the pump against the stopping face.
connected with it. Choose a place of assembling and
operation where the pump can always stand safe Attention: If the carrying handle is not srewed-in into
and firm on a horizontal plain. There should always the hand lever, it can cause injuries while using the
be sufficient space for operating the pump. i 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
pump to great heat, fire or extreme coldness, since neccessary, 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 (see
Check the manometer of the pump for the needed drawing) with an allen key SW 2,5 by about one turn.
hydraulic pressure, given by an authorized person, Close the depressurization valve tightly. Now pump
not to be exceeded. Make sure that the pressure you at the hand lever until oil flows out of the breather
want to generate is also admissible for all connection screw bladder-free. Only then are you allowed to
parts. close the breather screw. The pump is now vented
and ready for operation.
All pressure connections and connecting elements
have to be clean and undamaged. High-pressure After each operation and for the transport, close the
connections from the pump to the tools have to be tank breather in order to avoid the hydraulic oil’s
established correctly prior to any pressurization. running out.
Disregard leads to danger to life. Please see working
card 520-01.06.
Pressurization
Attention - Danger on injuries
Loads being lifted by the pump may never be held by - Open the tank breather with the square wrench
the pump valves alone. Use additional non-return
08028-0D/H5250/94.08.12
approx. one turn.

valves or safety relief valves and secure the load by
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
Working Card
Hand Lever Pump 520-01.07
General
- Pump at the hand lever until the wanted pres- Attention: Inside of the adjusting screw is another
sure is achieved. Check the pressurization at grub screw with inner hexagon (wrench size 4 mm)
the manometer and take care of possible to 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 the
Remark: The pump is with two stages. The change adjusting screw!
from the first stage to the second stage happens
automatical at a system pressure of about 30 bar. The regulation of the adjusting screw follows gradually
in approx. 10° - steps. After everv adjusting step the
Attention: The pump is not equipped with an internal grub screw is to screw in until it fits closely and
pressure relief valve. The use of a manometer and approx. a l/4 turn to loosen.
the control of the system pressure during
pressurization is indispensable. Check by carefully pumping if the change-over pres-
sure wanted has been reached. If necessary, repeat
Attention: Do not stand directly over the moving line the procedure as described above.
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
pressurization, immediately release the hydraulic
pressure and seal the leakage or renew defect parts.
Depressurization
- Open the depressurization valve slowly by a

turn to the left.
- Make sure that the hydraulic pressure at the

manometer has been completely released.
Consider the returning time of the hydraulic oil.
Adjustment of change-over pressure from

stage 1 to stage 2
In exeptional case, it can be useful to adjust the

08028-0D/H5250/94.08.12
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 maximizes the change-over pressure.
99.43 - ES0
520-01.07 Hand Lever Pump Working Card
General
Analysis and Correction of Malfunction Pressure Port
Correction of malfunctions The pressure port of the pump is produced according

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 or more pressure consumers. A selection of pres-
problem and correcting it yourself. sure ports please find in the annex.
For this, uncouple or unscrew all consumer and high-
pressure hoses from the pump. Attention - Danger to life
Prior to the pump’ s start-up please make sure that,
no matter which pressure port you chose, all
connection elements are in a perfect condition.
Malfunction Correction
Convince yourself of the fact that these are correctly
No pressurization 1. Check the oil level and, if connected and suitable for the necessary pressure.
necessary, fill it up as
described in chapter
Attention - High-pressure hydraulic
maintenance and storage.
2. Close depressurization valve. On principle, when leakages occur during the
3. Visual inspection whether pressurization, immediately release the hydraulic
there are leakages. If so, pressure and seal the leakane or renew defect parts.
seal them.
4. Vent the pump as described
in chapter initial start-up and
venting. Maintenance and Storage
Insufficient pressurization 1. Check the oil level and, if
necessary, fill it up, as
The pump should be lubricated frequently at the
described in chapter movable parts. Protect it from contamination because
(prior to any corrections, mainteance and storage. dirt in the oil or in the pressure port can lead to the
open de-pressurization 2. Close depressurization valve. pump’ s failure. A dry storage avoids the steel parts’
valve and release hydraulic 3. Visual inspection whether ther
pressure completely) are leakages. If so, seal them.
getting rusty.
4. Vent the pump as described The storage and transport of the pump should always
in chapter initial start-up and be done in a horizontal position. Thus, you avoid a
venting. possibly necessary venting of the pump during its
Pressure drop 1. Visual inspection whether
start-up.
there are leakages. If so,
(prior to any corrections, seal them. For checking the oil level, please open the
open de-pressurization 2. Close depressurization valve. depressurization valve and let the oil completely flow
valve and release hydraulic
pressure completely).
back into the tank. Open the oil filler cap and fill up
hydraulic oil according to IS0 VG 32, if neccessary.
If the problem cannot be solved, please contact MAN Do not overcharge the tank. Close the oil filler
B&W Diesel Holeby. cap.
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

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Instruction book for:

MAN B&W Diesel Identification No for Instruction Book

Identification No for Description 000 . 00

Identification No for Working Card 000 - 00 . 00

Section No. and Function

See page 500.50 concering order of spare parts

HEAD OFFICE DIESEL ENGINE SALES AFTER SERVICE(A/S) PART SALES

Tell 82-5 5-280-0114 Tell 82-55-280-0540 Tell 82-55-280-0590 Tell 82-55-280-0540-558

www.stxengine.co.kr www.stxengine.co.kr www.stxengine.co.kr www.stxengine.co.kr

OPERATION Operation of Engine

Engine Performance and Conditio

Specification and Treatment

Piston, Connecting Rod, and Cylinder Liner

Camshaft and Camshaft Drive

Operating Gear for Inlet Valves,

Crankshaft and Main Bearings

Engine Frame and Base Frame

Compressed Air System

Fuel Oil System

Lubricating Oil System

Cooling Water System

Specific Plant Information

Main data for engine .....................................................................................................500.00 (03H)

(Marine engines only)

It is important that all MAN B&W Diesel A/S engines

In accordance with Chapter I of the Code of Federal

Cyl. Nos. available : 5-6-7-8-9

Power range : 450-900 kW (610-1220 BHP)

Speed : 1000/1200 rpm

Stroke/bore ratio : 1.5:1

Piston area per cyl. : 201 cm2

Swept volume per cyl. : 4.8 ltr.

Compression ratio : 15.2:1

Max. combustion pressure : 170 bar

Turbocharging principle : Constant pressure system and intercooling

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

Power lay-out MCR version

Speed rpm 1000 1200

Mean piston speed m/sec. 8 9.6

Mean effective pressure bar 22.4 20.7

Max. combustion pressure bar 170 170

Power per cylinder kW/cyl. 90 100

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

Power per cylinder kW/cyl. 99 110

The book is a basic instruction manual for the par-

The first five sections (500-504) of the book serve as

The last section (520) comprises tools.

The engine is divided into a number of main com-

Each of these sections starts with technical de-

In particular, welding or work which causes the

Fire Opening of cocks may cause discharge of hot liquids

Feeling Over Turning with Air

Feel-over Sequence Check and Maintain

Engine Type Identification

MCR : Maximum continuous rating

Temperature Alarm High

Specification of letter code for measuring devices

1st letter Following letters

V Viscosity S Switching, Stop