L28/32H Instruction Manual - Marine: Four-Stroke Genset Compliant With Imo Tier Ii

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L28/32H

Instruction Manual - Marine


Four-stroke GenSet
compliant with IMO Tier II
MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Engine data 500/600

Preface Description A6000


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

Operation of engine 501/601

Operating Description 601.01 (21H)


Out of service Description 601.05 (17H)
Starting-up after out of service periods Description 601.10 (17H)
Guidelines for longterm low-load operation on HFO Description 601.15 (03H)
Guidelines regarding MAN Diesel GenSets operating on low Description 601.16 (02H)
sulphur fuel oil

Performance and condition 502/602

Engine performance and condition Description 602.01 (12H)


Evaluation of readings regarding combustion condition Description 602.02 (11H)
Condensate amount Description 602.05 (08H)
Engine performance data Working card 602-01.00 (03H)

Trouble shooting 503/603

Starting failure Description 603.01 (08H)


Faults in fuel oil system Description 603.02 (09H)
Disturbances during running Description 603.03 (08H)
Ignition in crankcase Description 603.04 (09H)
Trouble shooting guide for centrifugal by-pass filter Description 603.05 (08H)
Trouble shooting guide for turbine starter Description 603.06 (09H)
Trouble shooting guide for cooling water system Description 603.09 (08H)
Trouble shooting guide for lubricating oil cooler Description 603.10 (01H)

Media specification 504/604

Quality requirement for lube oil (SAE30) for heavy fuel oil operation Description 604.01 (27H)
(HFO)
MAN Diesel

Index GenSet

L28-2

Text Index Drawing No.

Quality requirem. for lube oil (SAE30) for operation with gas oil, diesel Description 604.01 (26H)
oil (MGO/MDO) and biofuel
Treatment and maintenance of lubricating oil Description 604.03 (11H)
Criteria for cleaning/exchange of lubricating oil Description 604.04 (17H)
Lubricating points Description 604.05 (01H)
Lubricating points Description 604.05 (02H)
Lubricating oil in base frame Description 604.06 (16H)
Specific lube oil consumption - SLOC Description 604.07 (02H)
Heavy fuel oil (HFO) specification Description 3.3.3-01
Diesel oil (MDO) specification Description 3.3.2-01
Gas oil / diesel oil (MGO) specification Description 3.3.1-01
Bio fuel specification Description 3.3.1-02
Viscosity-temperature diagram (VT diagram) Description 3.3.4-01
Fuel oil cleaning Description 604.30 (01H)
Engine cooling water specifications Description 3.3.7-01
Cooling water inspecting Description 000.07-01
Cooling water system cleaning Description 000.08-01
Water specification for fuel-water emulsions Description 3.3.10-01
Specifications for intake air (combustion air) Description 3.3.11-01

Cylinder head 505/605

Cylinder head Description 605.01 (14H)


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

Piston/connecting rod 506/606

Piston, connecting rod and cylinder liner Description 606.01 (10H)


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

GenSet Index

L28-2

Text Index Drawing No.

Camshaft 507/607

Camshaft and camshaft drive Description 607.01 (05H)


Camshaft and camshaft drive Working card 607-01.00 (01H)
Inspection and replacement of camshaft bearing Working card 607-01.05 (01H)
Adjustment of camshaft for valve and injection timing Working card 607-01.20 (04H)
Intermediate wheel Plate 60701-06H
Camshaft and camshaft bearing Plate 60705-22H

Operating gear 508/608

Operating gear for valves and fuel injection pumps Description 608.01 (12H)
Inspection of valve roller guides Working card 608-01.00 (01H)
Inspection of fuel injection pump roller guide Working card 608-01.05 (01H)
Control and adjustment of valve clearance Working card 608-01.10 (01H)
Roller guide and push rods Plate 60801-17H

Control/safety 509/609

Control and safety system Description 609.01 (20H)


Instruments and automatics Description 609.05 (11H)
Lambda controller Description 609.10 (15H)
Starting box Description 609.35 (06H)
Converter for engine- and turbocharger RPM signal Description 609.40 (01H)
Functional test and adjustment of safety, alarm and monitoring Working card 609-01.00 (01H)
equipment
Functional test and adjustment of overspeed trip Working card 609-01.05 (01H)
Adjustment and test of ON/OFF pressostate Working card 609-05.00 (02H)
Adjustment and test of ON/OFF thermostate Working card 609-05.01 (02H)
Function and test of level switch (LAL 25) Working card 609-05.02 (02H)
Adjustment and test of analogous transmitter Working card 609-05.03 (02H)
Adjustment and test of analogous temperature transmitter Working card 609-05.04 (02H)
Adjustment of lambda controller Working card 609-10.00 (16H)
Governor and governor drive Plate 60901-13H
Governor and governor drive Plate 60901-14H
Governor and governor drive Plate 60901-15H
Regulating mechanism Plate 60902-18H
Overspeed device Plate 60903-38H
Instrument panel Plate 60905-20H
Instrument panel Plate 60905-27H
Instrument panel Plate 60905-32H
Thermometer Plate 60907-19H
Pressostate, thermostate, diff. pressostate and pressure transmitter Plate 60907-02H
Prelubricating oil alarm (LAL 25) Plate 60919-01H
Level switch in oil sump (LAL/LAH 28) Plate 60920-01H
Local starting box - No 1 Plate 60935-13H
Local starting box - No 1 Plate 60935-16H
Local starting box - No 2 Plate 60935-14H
Local starting box - No 2 (incl. high lub. oil temp.) Plate 60935-15H
Engine control box Plate 60936-08H
Termnal box Plate 60936-07H
Converter Plate 60956-01

Crankshaft 510/610

Crankshaft and main bearings Description 610.01 (12H)


Checking of main bearings alignment (deflection), hydraulic Working card 610-01.00 (10H)
tigthened connecting rod
MAN Diesel

Index GenSet

L28-2

Text Index Drawing No.

Inspection of main bearing shells Working card 610-01.05 (05H)


Inspection of guide bearing shells Working card 610-01.10 (08H)
Vibration damper Working card 610-04.00 (01H)
Crankshaft Plate 61001-15H
Crankshaft Plate 61001-21H
Resilient gear wheel Plate 61002-07H
Coupling for central drive lub. oil pump Plate 61002-11H
Coupling for central drive lub. oil pump Plate 61002-12H
Coupling for central drive lub. oil pump Plate 61002-13H
Coupling for central drive lub. oil pump Plate 61002-14H
Resilient gear wheel Plate 61002-15H
Resilient gear wheel Plate 61002-16H
Resilient gear wheel Plate 61002-17H
Flywheel with gear rim Plate 61003-02H
Flywheel with gear rim Plate 61003-05H
Flywheel with gear rim Plate 61003-06H
Torsional vibration damper Plate 61004-05H
Torsional vibration damper Plate 61004-12H
Torsional vibration damper Plate 61004-13H
Torsional vibration damper Plate 61004-14H
Torsional vibration damper Plate 61004-15H
Torsional vibration damper Plate 61004-16H
Tuning wheel Plate 61004-06H

Engine frame/Oil pan 511/611

Engine frame and base frame Description 611.01 (07H)


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

Turbocharger 512/612

Turbocharger system Description 612.01 (28H)


Cleaning the turbocharger in service, water washing of compressor Description 612.05 (07H)
Cleaning the turbocharger in service, dry cleaning - turbine Description 612.10 (09H)
Cleaning the turbocharger in service, water washing - turbine side Description 612.15 (02H)
Overhaul of charging air cooler Working card 612-01.00 (02H)
Charge air cooler housing - draining Working card 612-01.05 (02H)
Water washing of compressor side - turbochager type NR15/R - Working card 612-05.00 (03H)
NR20/R - NR24/R - NR26/R
Dry cleaning of turbocharger - turbine side Working card 612-10.00 (02H)
Water washing of turbine side Working card 612-15.00 (01H)
Charging air cooler - freshwater Plate 61201-12H
Charging air cooler - freshwater Plate 61201-13H
Charging air cooler - freshwater Plate 61201-14H
Charging air cooler - freshwater Plate 61201-15H
Charging air cooler - seawater Plate 61201-16H
Charging air cooler - seawater Plate 61201-17H
Charging air cooler Plate 61201-29H
Exhaust pipe arrangement Plate 61202-23H
Exhaust pipe arrangement with welded compensator Plate 61202-32H
Exhaust pipe arrangement Plate 61202-26H
MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Exhaust pipe arrangement with welded compensator Plate 61202-28H


Exhaust pipe arrangement Plate 61202-27H
Exhaust pipe arrangement with welded compensator Plate 61202-42H
Water washing of compressor side Plate 61205-02H
Steam trap Plate 61208-01H
Blowgun for dry cleaning of turbocharger Plate 61210-02H

Compressed air system 513/613

Compressed air system Description 613.01 (20H)


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

Fuel oil system 514/614

Internal fuel oil system Description 614.01 (25H)


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

Lubricating oil system 515/615

Internal lubricating oil system Description 615.01 (29H)


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

Index GenSet

L28-2

Text Index Drawing No.

Lubricating oil, thermostatic valve Working card 615-01.20 (01H)


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

Cooling water system 516/616

Cooling water system Description 616.01 (17H)


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

Special equipment 517/617

Kit for cylinder unit Kit 61704-02H


Kit for overspeed device Kit 61743-01H
Kit for covers on frame Kit 61751-01H

Specific plant information 519/619

Resilient mounting of generating sets Description 619.03 (10H)


Fitting instructions for resilient mountings of gensets Working card 619-03.00 (21H)
Fitting instructions for resilient mountings of gensets Working card 619-03.00 (22H)
Fitting instructions for resilient mountings of gensets Working card 619-03.00 (23H)
Replacement of conicals Working card 619-03.05 (01H)
Maintenance of conicals Working card 619-03.10 (01H)
Flexible external connections Plate 61902-03H
Conical element Plate 61903-04H

Tools 520/620

Introduction to spare part plates for tools Description 620.01 (01H)


Function of the hydraulic tools Working card 620-01.05 (03H)
Application of hydraulic tools Working card 620-01.06 (01H)
Hand lever pump Working card 620-01.07 (01H)
Maintenance of hydraulic tools Working card 620-01.10 (01H)
Tightening with torque spanner Working card 620-01.15 (01H)
MAN Diesel

GenSet Index

L28-2

Text Index Drawing No.

Tool combinations for tightening of connecting rod screws Working card 620-01.20 (01H)
Max. pressure indicator Working card 620-01.25 (02H)
Tools for cylinder head Plate 62005-03H
Tools for piston, connecting rod and cylinder liner Plate 62006-11H
Tools for operating gear for inlet valves, exhaust valves and fuel Plate 62008-03H
injection pumps
Tools for control and safety systems, automatics and instruments Plate 62009-02H
Tools for crankshaft and main bearing Plate 62010-07H
Tools for crankshaft and main bearing Plate 62010-10H
Tools for crankshaft and main bearing Plate 62010-11H
Tools for fuel oil system and injection equipment Plate 62014-02H
Tools for lubricating oil system Plate 62015-02H
Hydraulic tools Plate 62021-08H
Tools for low overhaul height, piston, cylinder liner and connecting Plate 62050-01H
rod
Operating manual for testing tool (Fuel injection valve) Description GXO-D001
Engine data

500/600
MAN Diesel & Turbo

Instruction Manual for:

MAN Diesel & Turbo Identification No. for Instruction Manual.

Identification No. for Description: 000 . 00

Function

Section No.

Identification No. for Working Card: 000 - 00 . 00

Sub-function

Function

Section No.

Identification No. for Plates: 00000 - 00 H

H for Holeby

Edition

Section No. and Function

For ordering of spare parts, see page 500.50 / 600.50

All data provided in this document/manual is non-binding. This data serves informational purposes only and
is especially not guaranteed in any way.

Depending on the subsequent specific individual projects, the relevant data may be subject to changes and
will be assessed and determined individually for each project. This will depend on the particular characteri-
stics of each individual project, especially specific site and operational conditions.

If this document/manual is delivered in another language than English and doubts arise concerning the
translation, the English text shall prevail.

Original instructions

2011.06.28
MAN Diesel & Turbo

MAN Diesel & Turbo | PrimeServ


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

24-hour hotline number:


+49 1801 15 15 15
http://www.mandieselturbo.com/primeserv

Copyright 2011 © MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany, registered with the Danish
Commerce and Companies Agency under CVR Nr.: 31611792, (herein referred to as “MAN Diesel & Turbo”).

This document/manual must not, either wholly or partly, be copied, reproduced, made publich or in any other way made
available to any third party without the written to this effect from MAN Diesel & Turbo.

MAN Diesel & Turbo PrimeServ Holeby MAN Diesel & Turbo
H. Christoffersensvej 6 GenSet & Powerplant Branch of MAN Diesel & Turbo SE,
4960 Holeby Service & Spare Parts Germany
Denmark CVR No.: 31611792
Phone: +45 54 69 31 00 Fax : +45 54 69 30 31 Head office: Teglholmsgade 41
Fax: +45 54 69 30 30 After office hours : +45 40 14 40 45 2450 Copenhagen SV, Denmark
[email protected] German Reg.No.: HRB 22056
[email protected] Amtsgericht Augsburg
www.mandieselturbo.com

2011.06.28
MAN Diesel & Turbo

Description
Page 1 (1) Warning

General

Warning !

(Marine engines only)

It is important that all MAN Diesel & Turbo engines


are operated within the given specifications and
performance tolerances specified in the engines'
Technical Files and are maintained according to
the MAN Diesel & Turbo maintenance instructions
in order to comply with given emissions regulations.

In accordance with Chapter I of the Code of Federal


Regulations, Part 94, Subpart C, §94.211 NOTICE
is hereby given that Chapter I of the Code of Federal
Regulations, Part 94, Subpart K, §94.1004 requires
that the emissions related maintenance of the die-
sel engine shall be performed as specified in MAN
Diesel & Turbo instructions including, but not limited
to, the instructions to that effect included in the
Technical File.

12.06 - ES0
MAN Diesel & Turbo Questionnaire – Technical Documentation

Your opinion counts!

Your opinion counts!


Your opinion is valuable to us as it helps us to evaluate our services and to continuously improve the
quality of our Technical Documentation.
May we ask you for a few minutes of your time to complete and then return this questionnaire to
[email protected]:
Your company: Very Rather Rather Very
Your position: satisfied Satisfied dissatisfied dissatisfied

How do you rate the overall level of satisfaction with the


manuals supplied?
Which improvements would you suggest to be made in the future?

Ring binders and organisation


Comments/suggestions:

Labelling of ring binders


Comments/suggestions:

Structuring of information and documents


Comments/suggestions:

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


Comments/suggestions:

Preparation of CDs/DVDs (navigation, etc.)


Comments/suggestions:

Readability of texts and drawings (paper, CD/DVD)


Comments/suggestions:

Comprehensibility of contents
Comments/suggestions:

Scope of information provided


Comments/suggestions:
Customer satisfaction

1 (1)
MAN Diesel & Turbo

Description
Main Particulars 600.00
Page 1 (1) Edition 07H

L28/32H
Cycle : 4-stroke

Configuration : In-line

Cyl. Nos. available : 5-6-7-8-9

Power range : 1050-1980 kW

Speed : 720/750 rpm

Bore : 280 mm

Stroke : 320 mm

Stroke/bore ratio : 1.14:1

Piston area per cyl. : 616 cm2

Swept volume per cyl. : 19.7 ltr.

Compression ratio : 13.9:1

Max. combustion pressure : 130 bar

Turbocharging principle : Constant pressure system and inter­cool­ing

Fuel quality acceptance : HFO (up to 700 cSt/50° C, RMK700)


MDO (DMB) - MGO (DMA, DMZ)
according ISO8217-2010

Power lay-out MCR version

Speed rpm 720 750

Mean piston speed m/sec. 7.7 8.0

Mean effective pressure bar 17.8 17.9

Max. combustion pressure bar 130 130

Power per cylinder kW/cyl. 210 220

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

Power per cylinder kW/cyl. 230 240

11.36 - ES1 - Tier II - WB2 - GenSet


MAN Diesel & Turbo

Description 600.01
Page 1 (1) Introduction Edition 08H

General

Introduction Description

This instruction book provides general information The book is a basic instruction manual for the particu-
on the engine design, operation and maintenance. lar engine supplied, with plant-adapted infor­mation
It can also be used as a reference when ordering such as basic media-system drawings, electrical
spare parts. Reliable and economical operation of wiring diagrams and test bed reports.
the plant is conditional upon its correct operation
and maintenance in accordance with MAN Diesel & The first five sections (500-504) of the book serve
Turbo’s instructions. Emissions-related maintenance as a guide to engine operation, and the next fifteen
of the diesel engine shall be performed as speci- sections (505-519) contain technical de­scrip­tions,
fied in MAN Diesel & Turbo’s instructions and any spare parts illustrations with appurtenant parts lists,
additional instructions to that effect included in the as well as working cards.
Technical File. Consequently, it is essential that the
engine room personnel are fully acquainted with the The last section (520) comprises tools.
contents of this book and the Technical File.
The engine is divided into a number of main com-
Every care is taken to ensure that all information in ponents/as­semblies, each of which is described in
this instruction book is present and correct. a section of this book (section 505-519).

This book must not, either wholly or partly, be copied, Each of these sections starts with technical de­
reproduced, made public or in any other way made scriptions of the systems/components, followed by
available to any third party without the written consent working cards and the spare parts illustration plates
to this effect from MAN Diesel & Turbo. and parts lists.

If an instruction book is delivered in another language


than English and doubts arise concerning the trans-
lation, the English text shall prevail.
08028-0D/H5250/94.08.12

Fig. 1. Structuring of instruction book.

10.47 - ES0
MAN Diesel
Description
Safety 600.02
Page 1 (2)
Edition 06H

General
General Spares

Proper maintenance, which is the aim of this book, Large spare parts should, as far as possible, be pla-
constitutes the crucial point in obtaining optimum ced well strapped near the area of application and
safety in the engine room. The general measures accessible by crane. The spare parts should be well
mentioned here should therefore be a natural routine preserved against corrosion and protected against
to the entire engine room staff. mechanical damage. The stock should be checked
at intervals and replenished in time.

Cleanliness
Light
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the Ample working light should be permanently installed
engine room when the ship is in port, the ventilation at appropriate places in the engine room, and port-
should be stopped and ventilating ducts, skylights, able working light, in explosion-proof fittings, should
and doors in the engine room should be closed. be obtainable everywhere.

In particular, welding or work which causes spreading


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

Fire The opening of cocks may cause discharge of hot


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

Hand tools should be placed easily accessible on Crankcase work


tool boards. Special tools should be fastened to tool
panels (if supplied) in the engine room close to the Check beforehand that the starting air supply to the
area of application. No major objects must be left engine is shut off.
unfastened, and the floor and passages should be
kept clear.

91.12 - ES0U
MAN Diesel
600.02 Safety Description
Page 2 (2)
Edition 06H

General

Feeling over Turning with air

Whenever repairs or alterations have been made to After prolonged out-of-service periods or overhaul
the running gear, apply the "Feel-over sequence" work which may involve a risk of accumulation of
until ensured that there is no undue heating, oil- liquid in the combustion spaces, turning with open
mist formation, blow-by, or failure of cooling water indicator cocks should always be effected, through
or lubricating oil systems. at least two complete revolutions.

Feel-over sequence Check and maintain

Feel-over after 5-15 and 30 minutes' idle running and Lubricating oil condition, filter elements and mea-
finally when the engine is running at full load. See suring equipment.
also "Starting-up sequence" in the section 602.

91.12 - ES0U
MAN Diesel & Turbo

Description 600.05
Page 1 (1) Cross Section Edition 07H

L28/32H

10.36 - ES1
MAN Diesel

Description 600.10
Page 1 (1) Key for Engine Designation Edition 02H

General

Engine Type Identification

The engine types of the MAN B&W programme are identified by the following figures:

6 L 28/32 H MCR

No of cylinders

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

Engine Type

L : In-line
V : V-built

Cyl. diam/stroke

16/24 : 160/240
21/31 : 210/310
23/30 : 225/300
27/38 : 270/380
28/32 : 280/320
32/40 : 320/400

Design Variant

Rating
08028-0D/H5250/94.08.12

MCR : Maximum continuous rating


ECR : Economy continuous rating

04.08 - ES1
MAN Diesel
Description 600.11
Page 1 (1) Designation of Cylinders Edition 01H

L28/32H

Front End Flywheel end

Exhaust Side / Right Side

Control Side / Camshaft Side / Left Side


08028-0D/H5250/94.08.12

89.17 - ES1S-L
MAN Diesel & Turbo

Description
Page 1 (1) Engine Rotation Clockwise 600.12
Edition 02H

General

Direction of rotation seen from flywheel end “Clockwise”

Engine

Alternator

10.39 - ES1
MAN Diesel & Turbo

Description
Code Identification for Instruments 600.20
Page 1 (2) Edition 03H

General

Explanation of Symbols

TI Measuring device
40 Local reading

Temperature Indicator
No. 40 *

Measuring device
PI Sensor mounted on engine/unit
22 Reading/identification mounted in a panel on the engine/unit

Pressure Indicator
No. 22 *

Measuring device
TAH Sensor mounted on engine/unit
12 Reading/identification outside the engine/unit

Temperature Alarm High


No. 12 *

Measureing device
PT Sensor mounted on engine/unit
22 Reading/identification in a panel on the engine/unit and reading/indication out-
side the engine/unit

Pressure Transmitting
No. 22 *

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

Specification of letter code for measuring devices


1st letter Following letters
F Flow A Alarm
L Level D Differential
P Pressure E Element
S Speed, System H High
T Temperature I Indicating
U Voltage L Low
V Viscosity S Switching, Stop
X Sound T Transmitting
Z Position X Failure
V Valve, Atuator

11.19 - ES1
MAN Diesel & Turbo
600.20 Code Identification for Instruments Description
Edition 03H Page 2 (2)

General
Standard Text for Instruments

Diesel Engine/Alternator

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

HT Water System
10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler
10A FW inlet to engine 14A FW inlet to air cooler 18 inlet to fresh water cooler
11 outlet from each cylinder 14B FW outlet from air cooler 19 preheater
12 outlet from engine 15 outlet from HT system 19A inlet to prechamber
13 inlet to HT pump 16 outlet from turbocharger 19B outlet from prechamber

Lubricating Oil System


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

Charging Air System


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

Fuel Oil System


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

Nozzle Cooling System


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

Exhaust Gas System


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

Compressed Air System


70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system
71 inlet to stop cylinder 75 microswitch for turning gear 79
72 inlet to balance arm unit 76 inlet to turning gear
73 control air 77 waste gate pressure

Load Speed
80 overspeed air 84 engine stop 88 index - fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocharger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine start 87 ready to start

Miscellaneous
91 natural gas - inlet to engine 94 cylinder lubricating 97 remote
92 oil mist detector 95 voltage 98 alternator winding
93 knocking sensor 96 switch for operating location 99 common alarm
100 inlet to MDO cooler 101 outlet to MDO Cooler 102 alternator cooling air

11.19 - ES1
MAN Diesel
Description
Introduction to Planned Maintenance Programme 600.24
Page 1 (1)
Edition 02H

General
General 4. Related procedures - indicates other works,
depending on this work - or works which would be
The overhaul intervals are based on operation on expedient to carry out.
a specified fuel oil quality at normal service output,
which means 70-100% of MCR. 5. Indicates x number of men in x number of hours
for accomplishing the work.
In the long run it is not possible to obtain a secure
and optimal economic running without an effective The stated consumption of hours is only intended
maintenance system. as guide.

With the structure and amount of information in the Experience with the specific station/crew may lead
maintenance programme, it can be integrated in the to a bringing up-to-date.
entire ship's/power station's maintenance system or
it can be used separately. 6. Refers to data, which are required for carrying
out the work.
The crux of the maintenance system is the key dia-
gram, see page 600.25, indicating the inspection 7. Special tools, which must be used. Please note
intervals for the components/systems, so that the that not all tools are standard equipment.
crew can make the necessary overhauls, based on
the engines' condition and/or the time criteria. 8. Various requisite hand tools.

The stated, recommended intervals are only for 9. Indicates the components/parts, which it is
guidance as different service conditions, the quality advisible to replace during the maintenance work.
of the fuel oil and the lubricating oil, treatment of the Please note, that this is a condition for the intervals
cooling water, etc, will decisively influence on the stated.
actual service results and thus the intervals between
necessary overhauls.

Experience with the specific plant/crew is to be used


for adjustment of time between overhaul. Further it
is to be used for adjusting the timetable stated for
guidance in the working cards.

1
7
Working cards
2
Each of the working cards can be divided into two:
a front page and one or several pages, describing
and illustrating the maintenance work. 3
8
The front page indicates the following:
08028-0D/H5250/94.08.12

1. Safety regulations, which MUST be carried


through before the maintenance work can start.
5
9
2. A brief description of the work. 6

3. Reference to work, which must be carried out,


if any, before the maintenance work can start.

Fig 1. Guidance instruction for working cards.

94.35 - ES0S
MAN Diesel
Description 600.25
Page 1 (4) Planned Maintenance Program Edition 33H

L28/32H

Time Between Overhaul

Overhauled parts
Working

Observations
● = Overhaul to be carried out
Description

3th month
Card

Check new/

after -hours

200

8000
16000
32000

Weekly
50

2000

Montly
■ = Check the condition

Daily
No.

Operating of Engine:

Readings of data for Engine and Generator, with refe-


rence to "Engine Performance Data", section 602-1........ ■ 602-01.00

Cylinder Head:

Inlet and exhaust valve - Overhaul and regrinding of


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

Cylinder head cooling water space - Inspection............... ■ 605-01.45


Cylinder head nut - Retightening...................................... 200 605-01.40

Piston, Connecting Rod and Cylinder Liner:

Inspection of piston.......................................................... ■ 606-01.10


Piston ring and scraper ring............................................. ● 606-01.10

Piston pin and bush for connecting rod - Check of


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

Connecting rod - Retightening.......................................... 200 ■ 606-01.25


Cylinder liner - Cleaning, honing and measuring............. ● 606-01.35
Cylinder liner removed - Check the water space and
08028-0D/H5250/94.08.12

guide ring in frame............................................................ ■ 606-01.40

Camshaft and Camshaft Drive:

Camshaft - Inspection of gear wheels, bolt, connections


etc..................................................................................... 200 ■ 607-01.00
Camshaft bearing - Inspection of clearance..................... ■ 607-01.05
Camshaft adjustment - Check the condition..................... ■ 607-01.20

Lubrication of camshaft bearing - Check.......................... ■ 607-01.00

09.48 - ES0
MAN Diesel
600.25 Description
Edition 33H
Planned Maintenance Program Page 2 (4)

L28/32H

Time Between Overhaul

Overhauled parts
Working

Observations
● = Overhaul to be carried out
Description

3th month
Card

Check new/

after -hours
50

2000
8000
200

32000

Weekly
16000

Montly
■ = Check the condition

Daily
No.

Operating Gear for Inlet Valves, Exhaust Valves and


Fuel Injection Pumps:

Roller guide for valve gear................................................ ■ 608-01.00


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

Roller guide housing......................................................... ■ 608-01.10


Inlet and exhaust valve - Check and adjustment of valve
clearance.......................................................................... ■ 608-01.10

Lubricating of operating gear - Check.............................. ■ 608-01.00


608-01.05

Control and Safety System, Automatics and


Instruments:

Safety, alarm and monitoring equipment ......................... ■ 609-01.00

Jet system - Adjustment................................................... ■ 609-01.00


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

Governor - Check oil level, see governor instruction
book, section 609............................................................. ■

Crankshaft and Main Bearing:



Checking of main bearings aligment, (autolog)................ ■ 610-01.00
Inspection af main bearing............................................... ■ 610-01.05
Inspection of guide bearing.............................................. ■ 610-01.10

Vibration damper - Check the condition........................... ■ 610-04.00


08028-0D/H5250/94.08.12

Lubricating of gear wheel for lub. oil pump and cooling


water pump etc................................................................. ■
Counter weight - Retightening, see page 600.40............. 200 ■

Main- and guide bearing cap - Retightening.................... 200 ■ 610-01.05


610-01.10

09.48 - ES0
MAN Diesel
Description 600.25
Page 3 (4) Planned Maintenance Program Edition 33H

L28/32H

Time Between Overhaul

Overhauled parts
Working

Observations
● = Overhaul to be carried out
Description

3th month
Card

Check new/

after -hours
50

2000
8000
200

32000

Weekly
16000

Montly
■ = Check the condition

Daily
No.

Engine Frame and Bedplate:

Holding down bolts - Retightening, see page 600.40....... 200 ■


Bolts between engine frame and base frame -
Retightening, see page 600.40........................................ 200 ■

For flexible mounted engines - Check anti-vibration


mountings......................................................................... 200 ■ 619-03.00
Safety cover - Function test.............................................. ■ 611-01.00

Turbocharger System:

Dry cleaning of turbine side.............................................. ● 612-10.00


Wet cleaning of turbine side............................................. ● 612-15.00
Water washing of compressor side.................................. ● 612-05.00

Cleaning of air filter - Compressor side (see turbo-


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

Charging air cooler housing - Draining............................. ●


Exhaust pipe - Compensator............................................ ■

Compressed Air System:

Air starter motor - Dismantling and inspection................. ■ 613-01.30


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


08028-0D/H5250/94.08.12

Dirt separator - Dismantling and cleaning........................ ●


Muffler - Dismantling and cleaning................................... ●

Compressed air system - Draining................................... ● 613-01.90


Compressed air system - Check of the system................ ■ 613-01.90

Drain of bowl..................................................................... ● 613-01.21


(filter element to be replaced when pressure drop
exceeds 0.7 bar)

09.48 - ES0
MAN Diesel
600.25 Description
Edition 33H
Planned Maintenance Program Page 4 (4)

L28/32H

Time Between Overhaul

Overhauled parts
Working

Observations
● = Overhaul to be carried out
Description

3th month
Card

Check new/

after -hours
50

2000
8000
200

32000

Weekly
16000

Montly
■ = Check the condition

Daily
No.

Fuel Oil System and Injection Equipment:

Fuel oil filter - Dismantling and cleaning........................... ● 614-01.15


Fuel oil feed pump............................................................ ● 614-10.00
Fuel oil injection pump - Dismantling and cleaning.......... ● 614-01.05

Fuel injection valve - Adjustment of opening pressure..... 200 ■ 614-01.10


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

Fuel oil system - Check the system.................................. ■ 614-01.90


Nozzle cooling system - Check the system...................... ■ 614-01.90

Fuel oil - Oil samples after every bunkering, see sec.604.

Lubricating Oil System:

Lubricating oil pump - Engine driven................................ ■ 615-01.00


Lubricating oil filter - Cleaning and exhange.................... ● 615-01.10
Lubricating oil cooler........................................................ ● 615-06.00

Prelubricating pump - El. driven....................................... ■ 615-01.05


Thermostatic valve........................................................... ■ 615-01.20
Centrifugal filter - Cleaning and exhange of paper........... ● 615-15.00

Lubricating oil - Oil samples, see section 604.................. ■


Lubricating oil system - Check the system....................... ■ 615-01.90

Cooling Water System:

Cooling water pump - Engine driven (sea water and


fresh water)...................................................................... ■
08028-0D/H5250/94.08.12

Thermostatic valve........................................................... ■
Cooling water system - Check the system....................... ■ 616-01.90

Cooling water system - Water samples, see sec. 604...... ■ ■

09.48 - ES0
MAN Diesel & Turbo

Description
Operation Data & Set Points 600.30
Page 1 (2) Edition 50H

L28/32H

Acceptable
Normal Value at Full load value at shop
at ISO conditions test or after Alarm Set point Autostop of engine
repair

Lubricating Oil System

Temp. before cooler SAE 30 TI 20 60-75° C <75° C TAH 20 90° C


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

Pressure after filter MDO PI 40 2.5-5 bar PAL 40 1.5 bar


HFO PI 40 5-16 bar (A) PAL 40 4 bar
Leaking oil LAH 42 leakage
Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar (B)
Temp. nozz. cool. oil, outlet eng. TI 51 80-90° C 95° C (B)
Cooling Water System

Press. LT-system, inlet engine PI 01 1-2.5 bar (D) >1.3 bar PAL 01 0.4 bar + (C)
Press. HT-system, inlet engine PI 10 1.5-4.6 bar >1.8-<6 bar PAL 10 0.4 bar + (C)
Temp. HT-system, inlet engine TI 10 60-75° C
Temp. HT-system, outl. cyl.units TI 11 70-85° C <85° C
Temp. HT-system, outlet engine TAH 12 90° C TSH 12 95° C
TAH 12-2 93° C
Temp. raise across cyl. units max. 10° C
Exhaust Gas and Charge Air

Exh. gas temp. before TC TI 62 425-475° C TAH 62 550° C


TAH 62-2 600° C
Exh. gas temp. outlet cyl. TI 60 270-380° C TAH 60 410° C
Diff. between individual cyl. average TAD 60 average (F)
±25° C ±50° C
Exh. gas temp. after TC TI 61 275-350° C TAH 61 500° C
Ch. air press. after cooler PI 31 2-2.5 bar
Ch. air temp. after cooler TI 31 35-55° C <55° C TAH 31 65° C
Compressed Air System

Press. inlet engine PI 70 7-9 bar >7.5-<9 bar PAL 70 7 bar

Specific plants will not comprise alarm equipment and autostop for all parameters listed above. For specific plants additional parameters
can be included. For remarks to some parameters, see overleaf.

10° C change in ambient temperature correspond to approx. 15° C exhaust gas temperature change

11.33 - ES1
MAN Diesel & Turbo

600.30 Operation Data & Set Points


Descriptoin
Edition 50H Page 2 (2)

L28/32H

Acceptable
Normal Value at Full load value at shop
at ISO conditions test or after Alarm Set point Autostop of engine
repair

Speed Control System


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

Remarks to individual Parameters E. Limits for Turbocharger Overspeed Alarm


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

B. Nozzle Cooling Oil System


F. Exhaust Gas Temperatures
The nozzle cooling oil system is only applied for Tier
II marine and stationary engines. The exhaust gas temperature deviation alarm is
normally ±50° C with a delay of 1 min., but at start-up
C. Cooling Water Pressure, Alarm Set Points. the delay is 5 min. Furthermore the deviation limit is
±100° C if the average temperature is below 200° C.
As the system pressure in case of pump failure will
depend on the height of the expansion tank above G. Turbocharger Speed
the engine, the alarm set point has to be adjusted
to 0.4 bar plus the static pressure. Normal value at full load of the turbocharger is de-
pendent on engine type (cyl. no) and engine rpm.
D. Press. LT -system, inlet engine (PI 01) The value given is just a guide line. Actual values
can be found in the acceptance test protocol.
With two-string cooling water system the normal
value can be higher, max. 4.0 bar.

11.33 - ES1
MAN Diesel & Turbo

Description
"Green Passport" 600.33
Page 1 (1) Edition 02H

General
In 2009 IMO adopted the „Hong Kong International
Convention for the Safe and Environmentally Sound
Recycling of Ships, 2009“

Until this convention enters into force the recommen-


datory guidelines “Resolution A.962(23)” (adopted
2003) apply. This resolution has been implemented
by some classification societies as “Green Passport”.

MAN Diesel & Turbo is able to provide a list of ha-


zardous materials complying with the requirements
of the IMO Convention. This list is accepted by
classification societies as a material declaration for
“Green Passport”.

This material declaration can be provided on request.

11.08 - ES0
MAN Diesel & Turbo

Description
Data for Pressure and Tolerance 600.35
Page 1 (2) Edition 16H

L28/32H

Section Description mm. / bar

605 Safety valve to be adjusted to 170 bar


Maximum inner diameter, valve guide 18.35 mm.
For grinding of valve spindle and valve seat ring
(see also working card 605-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H" 1 6.5 mm.
Maximum height of spindle above cylinder head, "H" 2 108.0 mm

606 Piston and piston ring grooves (see working card 606-01.10)
Clearance between connecting rod bush and piston pin 0.15 - 0.25 mm.
Maximum ovalness in big-end bore (without bearing) 0.10 mm.
New cylinder liner, inside diameter 280.03 - 280.08 mm.
Maximum inside diameter cylinder liner 280.60 mm.

607 Clearance between camshaft and camshaft bearing 0.13 - 0.22 mm.
Maximum clearance between camshaft and camshaft bearing 0.35 mm.
Clearance between tooths on intermediate wheel 0.20 - 0.30 mm
Plunger lift at TDC, injection timing:
IMO Tier II - D2, 720 rpm 8.30+0.05 mm*
IMO Tier II - D2, 750 rpm 8.27+0.05 mm*
*) for information on max settings check the engine's IMO Technical file.
Plunger Lift, World Bank II**
**) Standard injection timing value is based on ISO condition.
Special injection timing of engines can be necessary due to
Power plant size and/or Ambient conditions.

608 Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm.
Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.90 mm.
Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm.

609 Clearance between pick-up and impulse wheel 1 ±0.3 mm


Adjustment of Lambda controller.
(see working card 609-10.00)

610 Clearance (equal on both sides) between main bearing cap and frame,
before tightening of bracing screw (side screw) 0.06 ± 0.02 mm
Deflection of crankchaft (autolog) (see working card 510-01.00)
Clearance between crankshaft and sealing ring, (upper and lower part) 0.3 - 0.4 mm.
Clearance in main bearing 0,2-0,344 mm
Clearance in guide bearing (axial) 0.15 - 0.46 mm
Maximum clearance in guide bearing (axial) 0.8 mm
Clearance between bearing and gearwheel shaft:
Clearance when new bearings are mounted 0.125-0.200
Maximum clearance 0.250
Clearance axial 0.2-0.3

611 Opening pressure of safety relief valves (on crankcase), max: 0.20 bar

12.08 - ESO, Tier II


MAN Diesel & Turbo

600.35 Data for Pressure and Tolerance Description


Edition 16H Page 1 (2)

L28/32H

Section Description mm. / bar

614 Maximum combustion pressure at full load Max 133 bar


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

12.08 - ESO, Tier II


MAN Diesel & Turbo

Description 600.40
Page 1 (2) Data for Tightening Torque Edition 18H

L+V28/32H

Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar

605 Cylinder head stud (in frame) Stud M 39 200 Loctite 243
Nut for cylinder head stud Nut M 39 x 3 700 Oil / Molykote
(Unimol gl 82)

606 Connecting rod screw


(see working card 606-01.25) Molykote
Connecting rod screw (hydraulic Stud M 39 x 3 (Unimol gl 82)
tightening) Nut M 39 x 3 700 –

Molykote
607 Camshaft assembling Nut M 12 85 (Unimol gl 82)
Gear wheel on camshaft Screw M 12 70 –
Intermediate wheel shaft Nut M 22 x 1.5 250 –
Intermediate wheel assembling Nut M 12 50 –
Gear wheel on crankshaft Nut M 12 50 –

608 Housing for valve gear Screw M 16 160 –


Rocker arm bracket Nut M 12 40 –

610 Main bearing stud (in frame) Stud M 56 200 Loctite 243
Molykote
Nut for main bearing stud Nut M 52 x 3 900 (Unimol gl 82)
Main bearing side screw - L28/32H Screw M 24 350 –
Main bearing side screw - V28/32H Screw M 30 600 –
Counterweight on crankshaft Screw M 26 x 1.5 300 –
Vibration damper on crankshaft Nut M 30 500 –
Flywheel mountng (witout fitted bolt) Nut M30 1350 oil
Flywheel mounting (with fitted bolt)
- L28/32H Nut M 30 1350 –
- V28/32H Nut M 30 480 –
Gear rim on flywheel Screw M 16 75 –

611 Frame / baseframe Nut M 24 500 –

(3 x cross-tightening
614 Fuel-pump connecting piece Screw M 10 60 20 - 40 - 60 Nm) –
Fuel-pump top flange (barrel) Screw M 12 100 –
Fuel-pump cavitation plugs Plug M 20 x 1.5 100 - 120 –
Fuel-pump mounting Screw M16 150 –
Fuel-valve (nozzle nut) Nut M 26 x 1.5 100 - 120 –
Fuel-valve mounting Nut M 16 30 –
Fuel-valve (lock nut) Nut M 16 x 1.5 100 –
High pressure pipe Nut M 22 x 1.5 60 –

09.24
MAN Diesel & Turbo

600.40 Description
Edition 18H Data for Tightening Torque Page 2 (2)

L+V28/32H

Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar

Molykote
615 Gear wheel on lub. oil pump Nut M 30 x 2 400 (Unimol gl 82)

616 Impeller and gear wheel on fresh-


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

619 Conical elements mounting


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

Sandwich elements mounting


- V28/32H
Upper mounting Screw M 16 165 –
Lower mounting Screw M 16 165 –

09.24
MAN Diesel & Turbo

Description
Declaration of Weight 600.45
Page 1 (1) Edition 01H

L28/32H

Section Component Plate No. Item No. Weight in Kg.

605 Cylinder Head, incl. rocker arms 60501-60502 255


60508-60510

606 Piston, complete 60601 08 40


Piston Pin 60601 01 19
Connecting Rod, complete 60601 06 81
Cylinder Liner, complete 60610 10 119
Cooling Water Jacket 60610 15 33

607 Camshaft, section 60705 02, 16, 20 29

608 Housing for Roller Guide 60801 20 17

609 Governor, complete 60901 01-09-10 28

611 Main Bearing Cap 61101 26 75


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

612 Turbocharger, complete See special


instruction
Intermediate piece 61202 26 9
Air Cooler 61203 38 450
Inlet Bend 61203 33 93
Charging Air Cooler Housing 61203 34 350

613 Air Starter 61309 63 40

614 Fuel Injection Pump 61401 01-02 15


Fuel Injection Valve 61402 02 5
Fuel Oil Feed Pump 61410 22 22

615 Lubricating Oil Pump 61501 35 45


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

616 Thermostatic Valve 61604 11 29


Cooling Water Pump 61610 19 30

00.32 - ES0U
MAN Diesel & Turbo

Description 600.50
Page 1 (2) Ordering of Spare Parts Edition 06H

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

Information found on the name­plate of the engine(s)


Example:
Name of customer Name of Plant/Vessel IMO No Engine type Engine Engine builder
serial No
Mercy Ship Africa Mercy L7803188 5L21/31 SB5L21-10799 MAN Diesel & Turbo
or Licensee

Information found on each plate at the instruction manual:

Plate No Edition No Item No Qty. Description


51435 13 440 1 Leak oil pipe

12.11 - ES0
MAN Diesel & Turbo

Description
Ordering of Spare Parts 500.50
600.50
Page 2 (2)
Edition06H
Edition 03

General


Name of customer Name of Plant/Vessel IMO No

Engine type Engine No Engine Builder

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

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

12.11 - ES0
MAN Diesel & Turbo

Description 600.51
Page 1 (1) How to Return Spare Parts and/or Tools Edition 05H

General

How to return spare parts and/or tools

If the unfortunate situation occurs that your spare - If you return to Holeby instead of Frederikshavn,
parts do not fit or is damaged in any way, you need you will have to pay freight charges of minimum
to return your spare parts to us. EUR 70,-

The return procedure is as follows: Please return by cheapest mean to the below address:

Send an email to our office via - Spare Parts:


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

Note: Please be aware that it is only spare parts


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

- If you return your spare parts and/or tools with-


out a written agreement you will be charged a
fee for unauthorised returns.
08028-0D/H5250/94.08.12

11.09 - ES0
MAN Diesel
Description
Service Letters 600.55
Page 1 (1)
Edition 01H

General

Description

In order to ensure the most efficient, economical and Since new service letters might be of great impor-
up-to-date operation of our engines, we regularly send tance to the operation of the plant, we recommend
out "Service Letters" containing first-hand information that engine staff file them as supplements to the
regarding accumulated service experience. relevant chapters of this instruction book.

The service letters can either deal with specific


engine types, or contain general instructions and
recommendations for all engine types, and are used
as a reference when we prepare up-dated editions
of instruction books.
08028-0D/H5250/94.08.12

91.14 - ES0
MAN Diesel
Description
Conversion Table 600.60
Page 1 (3) Edition 01

General

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

Quantity Name Symbol 1 kn (knot) = 1 nautical mile/h 1.852 km/h = 0.5144 m/s
Cincerning other conversions, see table for length
length metre m
mass kilogram kg
time second s Density
electric current ampere A
absolute temperature* kelvin K 1 lb/cub. ft 16.02 kg/m3
amount of substance mole mol
luminous intensity candela cd
Force (1 kg m/s2 = 1 N)
* Also named "thermodynamic temperature"
1 kp (kilopound)* 9.807 N
Supplementary SI Units 1 poundal** 138.3 x 10-3 N
1 lbf (pound force) 4.448 N
Quantity Name Symbol
* Can occasionally be found stated as kgf (kilogram force).
plane angle radian rad Standard acceleration of free fall gn = 9.80665 m/s2
solid angle steradian sr ** Unit of force in the ft-lb-s system

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


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

time minute min 1 min = 60 s


time hour h 1h = 60 min Dynamic viscosity (N s/m2)
plane angle degree ° 1° = (p/180) rad
volume litre l 1l = 1 dm3 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)
pressure bar bar 1 bar = 105 Pa 1 poundal s/sq.ft 1.488 N s/m2
1 lbf/sq.ft 47.88 N s/m2

Length (m) poise is a special name taken from the CGS system. 1 P = 0.1 Pa s
1 cP = 1 mPa s = 10-3 Pa s
1 in (inch) 25.40 mm = 0.0254 m
1 ft (foot) = 12 inches 0.3048 m Kinematic viscosity (m2/s)
1 yd (yard) = 3 ft = 36 inches 0.9144 m
1 statute mile = 1760 yds 1609 m 1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *
1 n mile (international nautical mile) 1852 m
* 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name
taken from the CGS system. 1 St = 10-4 m2/s
SI Prefixes
Energy, Work (1 Nm = 1 J, Wh)
Factor Prefix Symbol Factor Prefix Symbol
1 cal I.T* 4.187 J*
1018 exa E 10-1 deci d 1 kpm 9.807 J
1015 peta P 10-2 centi c 1 hph (metric) 2.648 x 106 J = 0.7355 kWh
08028-0D/H5250/94.08.12

1012 tera T 10-3 milli m 1 ft. lbf 1.356 J


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

Area (m2)

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


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

04.37 - ES0
MAN Diesel
600.60 Conversion Table Description
Edition 01 Page 2 (3)

General

Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W) Specific heat capacity (J/(kg K))


1 kpm/s 9.807 W 1 kcalI.T./(kg x °C) 4.187 x 103 J/(kg K)
1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW 1 BTU*/(lb x °F) = 1 kcalI.T. /(kg °C) 4.187 x 103 J/(kg K)
1 kcalI.T./h 1.163 W
1 ft lbf/s 1.356 W * British Thermal Unit (see table for energy conversions)
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 BTU/h 0.2931 W
Heat conductance (W/(m K))
Moment of Force, Torque (kg m2/s2 = Nm) 1 calI.T./(cm x s x °C) 418.7 W/(m K)
1 kcalI.T./(m x h x °C) 1.163 W/(m K)
Can easily be derived from the above tables. 1 BTU*/(ft x h x °F) 1.731 W/(m K)

* British Thermal Unit (see table for energy conversions)


Moment of Inertia (kg m2)

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


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

Specific fuel oil consumption (SFOC)


Specific fuel consumption* (g/kWh)
Reference conditions
1 g/hph (metric) 1.360 g/kWh Specific fuel oil consumption values refer to brake power,
and the following reference conditions:
* See also table for specific fuel oil consumption values
Reference conditions (ISO)

Temperature difference (K) Blower inlet temperature 25°C 298 K


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

Temperature levels (K)


(see "Derived SI Units with special Names)

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

Derived Si Units with Special Names


08028-0D/H5250/94.08.12

Quantity Name Symbol Expressed in basic,


supplementary or
derived SI units

frequency hertz Hz 1 Hz = 1 s-1


force newton N 1N = 1 kg m/s2
pressure, stress pascal Pa 1 Pa = 1 N/m2*
energy, working quantity of heat joule J 1J = 1 Nm
power watt W 1W = 1 J/s
electric potential (DC) volt V 1V = 1 W/A
temperature Celsius °C 1°C = 1 k**

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


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

04.37 - ES0
MAN Diesel
Description
Conversion Table 600.60
Page 3 (3) Edition 01

General

Volume (1 m3 = 1000 l)

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


1 cub. ft (cubic foot) 28.32 x 10-3 m3 = 28.32 l
1 gallon* (imperial, UK) 4.546 x 10-3 m3 = 4.546 l
1 gallon* (US) 3.785 x 10-3 m3 = 3.785 l
1 barrel (US petroleum barrel) = 42 gallon (US) 0.1590 m3
1 bbl (dry barrel, US) 0.1156 m3
1 register ton = 100 cub. ft 2.832 m3

* 1 gallon = 4 quarts = 8 pints

Mass (kg)

1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg


1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg
1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg
1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg
1 slug* 14.59 kg

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

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

1 kp/cm2 = 1 at = 0.9678 atm 98.07 x 103 Pa = 0.9807 bar


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

* Mercury. 1 mm Hg = 1 Torr
Values in table provided gn = 9.80665 m/s2
** Water column (WC)

Some physical data in SI units


Nomenclature
t = temp. in °C ΔK = temperature difference
r = density in kg/m3 Cp = heat capacity in J/(kg DK)

t ρ Cp t Cp
range
08028-0D/H5250/94.08.12

Water 18 999 4.18 x 103


Lubricating oil (approx.)* 15 900 1.96 x 103
Atmospheric air (dry) (p=1 bar) 0 1.276 998 0-150 1005
Exhaust gas 200-400 1080
* Viscosity: 100-140 cSt at 40°C
750 mm Hg = 1 bar = 105 Pa
1 atm (standard pressure at sea level) = 760 mm Hg = 1013 mbar
Gas constant for air and exhaust gas = 287 J/(kg x K)
Water, heat of evaporation 100°C 1.013 bar 2.256 x 106 J/kg
Fuel oil. Lower calorific value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)

04.37 - ES0
MAN Diesel

Description
Page 1 (3) Basic Symbols for Piping 600.65
Edition 01H

General

No Symbol Symbol designation No Symbol Symbol designation


2.14 Spectacle flange
1. GENERAL CONVENTIONAL SYMBOLS
1.1 Pipe 2.15 Orifice

1.2 Pipe with indication of direction of flow 2.16 Orifice

1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint

1.4 Appliances 2.18. Snap coupling

1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere

1.6 High-pressure pipe


3. VALVES, GATE VALVES, COCKS AND FLAPS
1.7 Tracing Valve, straight through

1.8 Enclosure for several components as-sem- Valve, angle


bled in one unit
Valve, three-way
2. PIPES AND PIPE JOINTS

2.1 Crossing pipes, not connected Non-return valve (flap), straight

2.2 Crossing pipes, connected Non-return valve (flap), angle

2.3 Tee pipe Non-return valve (flap), straight screw


down
2.4 Flexible pipe Non-return valve (flap), angle, screw down

2.5 Expansion pipe (corrugated) general Safety valve

2.6 Joint, screwed Angle safety valve

2.7 Joint, flanged Self-closing valve

2.8 Joint, sleeve Quick-opening valve


08028-0D/H5250/94.08.12

2.9 Joint, quick-releasing Quick-closing valve

2.10 Expansion joint with gland Regulating valve

2.11 Expansion pipe Ball valve (cock)

2.12 Cap nut Butterfly valve

2.13 Blank flange Gate valve

05.02 - ES0
MAN Diesel

600.65 Basic Symbols for Piping


Description
Page 2 (3)
Edition 01H

General

No Symbol Symbol designation No Symbol Symbol designation


3.17 Double-seated changeover valve
4. CONTROL AND REGULATION PARTS
3.18 Suction valve chest 4.1 Fan-operated

3.19 Suction valve chest with non-return valves 4.2 Remote control

3.20 Double-seated changeover valve, straight 4.3 Spring

3.21 Double-seated changeover valve, angle 4.4 Mass

3.22 Cock, straight through 4.5 Float

3.23 Cock, angle 4.6 Piston

3.24 Cock, three-way, L-port in plug 4.7 Membrane

3.25 Cock, three-way, T-port in plug 4.8 Electric motor

3.26 Cock, four-way, straight through in plug 4.9 Electromagnetic

3.27 Cock with bottom connection 4.10 Manual (at pneumatic valves)

3.28 Cock, straight through, with bottom conn. 4.11 Push button

3.29 Cock, angle, with bottom connection 4.12 Spring

3.30 Cock, three-way, with bottom connection 4.13 Solenoid

3.31 Thermostatic valve 4.14 Solenoid and pilot directional valve

3.32 Valve with test flange 4.15 By plunger or tracer

3.33 3-way valve with remote control (actuator)


5. APPLIANCES
3.34 Non-return valve (air) 5.1 Mudbox
08028-0D/H5250/94.08.12

3.35 3/2 spring return valve, normally closed 5.2 Filter or strainer

3.36 2/2 spring return valve, normally closed 5.3 Magnetic filter

3.37 3/2 spring return valve contr. by solenoid 5.4 Separator

3.38 Reducing valve (adjustable) 5.5 Steam trap

3.39 5.6 Centrifugal pump


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

05.02 - ES0
MAN Diesel

Description
Basic Symbols for Piping 600.65
Page 3 (3) Edition 01H

General

No. Symbol Symbol designation No. Symbol Symbol designation

5.7 Gear or screw pump


6. FITTINGS

5.8 Hand pump (bucket) 6.1 Funnel / waste tray

5.9 Ejector 6.2 Drain

5.10 Various accessories (text to be added) 6.3 Waste tray

5.11 Piston pump 6.4 Waste tray with plug

5.12 Heat exchanger 6.5 Turbocharger

5.13 Electric preheater 6.6 Fuel oil pump

5.14 Air filter 6.7 Bearing

5.15 Air filter with manual control 6.8 Water jacket

5.16 Air filter with automatic drain 6.9 Overspeed device

5.17 Water trap with manual control


7. READING INSTR. WITH ORDINARY DESIGNATIONS
5.18 Air lubricator 7.1 Sight flow indicator

5.19 Silencer 7.2 Observation glass

5.20 7.3 Level indicator


Fixed capacity pneumatic motor with direc-
tion of flow
5.21 Single acting cylinder with spring returned 7.4 Distance level indicator

5.22 Double acting cylinder with spring returned 7.5 Recorder

5.23 Steam trap


08028-0D/H5250/94.08.12

05.02 - ES0
Operation of engine

501/601
MAN Diesel
Description
Operating 601.01
Page 1 (3)
Edition 21H

L+V28/32H
Preparations for Starting

The following describes what to do before starting, 4. Open the fuel oil supply to the feed pump.
when the engine has been out of service for a lon-
ger period of time, or if major overhauls has been Starting on HFO: circulate preheated fuel through
made. the pumps until correct working temperatures has
been obtained. Takes normally 30-60 minutes.
1. Check the oil level in the base frame (or in
the lub. oil tank if the engine is with dry sump), air 5. Check the pressure in the starting air receiver(s)
lubricator and in the govenor. and open the starting air supply (blow-off water, if
any, drain the starting air system before opening.
Start-up the prelubricating pump.
6. Check that the sealing oil system for the injec-
The engine shall be prelubricated at least 2 minutes tion pumps are working correct.
prior to start.
7. Check in the regulating gear:
Check oil pressures before and after the filter.
- That all fuel pumps are at index "0" when the
2. Open the cooling water supply, start separate regulating shaft is in the STOP position.
cooling water pumps where installed, and check the
cooling water pressure. - That each fuel pump can be pressed by hand
to full index when the regulating shaft is in the STOP
Note: To avoid shock effects owing to large tempe- position, and that the pumps return automatically to
rature fluctuations just after the start, it is recom- the "0" index when the hand is removed.
mended:
- That the spring-loaded pull rod is working
a) to preheat the engine, cooling water of at least correctly.
60 °C should be circulated through the frame and
cylinder head for at least 2 hours before start. - That the stop cylinder for regulating shaft
works properly, both when stopping normally and
- either by means of cooling water from engines at overspeed and shut down.
which are running or by means of a built-in preheater
(if installed). - Testing is made by simulating these situati-
ons.
or
8. Open the indicator valves and turn the engine
b) When starting without preheated cooling water, some few revolutions, check that no liquid is flowing
the engine must only be started on MDO (Ma-rine out from any of the indicator valves during the tur-
Diesel Oil). ning.

The engine should not be run up to more than 50% Slow-turning must always be carried out, before the
load to begin with, and the increase to 100% should engine is started after prolonged out of-service pe-
take place gradually over 5 to 10 minutes. riods and after overhauls, which may involve a risk
of liquid having collected in the cylinders.
Note: When starting on HFO (Heavy Fuel Oil), only
item "a" should be used. 9. Close the indicator valves.

3. Open the nozzle cooling oil supply (only when 10. Disengage the turning gear, if fitted. Check
started on HFO), circulate preheated oil through the that it is locked in the "OUT" position.
nozzles for at least 15 minutes.

96.30 - ES0U
MAN Diesel
601.01 Description
Edition 21H
Operating Page 2 (3)

L+V28/32H

Starting 6. The exhaust gases should be free from smoke


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

1. The lubricating oil pressure must be within Stopping


the stated limits and must not fall below the stated
minimum pressure. The paper filtering cartridges 1. Before stopping, it is recommended to run
must be replaced before the pressure drop across the engine at reduced load, or to idle for about 5
the filter reaches the stated maximum value, or the minutes for cooling-down purposes.
pressure after the filter has fallen below the stated
minimum value. Dirty filter cartridges cannot be 2. The engine is stopped by keeping the fuel
cleaned for re-use. pump delivery rate at "0", by turning the "load- limit"
knob on the governor to "0", or by activating the
2. The lubricating oil temperature must be kept wi- remote stopping device.
thin the stated limits indicated on the data sheet.

3. The fuel oil pressure must be kept at the stated Start and Stop on HFO
value, and the filter must be cleaned before the
pressure drop across the filter reaches the stated Start and stop of the engine should take place on
maximum value. HFO in order to prevent any incompatibility problems
by change-over to MDO.
4. The cylinder cooling water temperature must be
kept within the limits indicated and the temperature MDO should only be used in connection with main-
rise across the engine should not exceed 10°C. tenance work on the engine or longer periods of
engine standstill.
5. The cooling water temperature at the charging
air cooler inlet should be kept as low as possible; Before starting on HFO the engine must be properly
however, not as low as to produce condensation preheated. as described in "Preparations for starting"
water in the charging air space. and as below.

Adjustment takes place in the external system out- Stopping the engine on HFO is no problem, but it
side the engine, and the amount of cooling water should be ensured that the temperature of fuel pipes
must be so adjusted that the temperature rise across not are reduced to a level below the pour point of
the charging air cooler is 3 - 5 °C. the fuel, otherwise reestabilishing of the circulation
might cause problems.

96.30 - ES0U
MAN Diesel
Description
Operating 601.01
Page 3 (3)
Edition 21H

L+V28/32H

Starting on MDO

For starting on MDO there are no restrictions except


lubricating oil viscosity may not be higher than 1500
cSt (5° C SAE 30, or 10° C SAE 40).

Initial ignition may be difficult if the engine and


ambient temperature are lower than 5° C, and 15°
C cooling water temperature.

96.30 - ES0U
MAN Diesel
Description
Out-of Service 601.05
Page 1 (2)
Edition 17H

General

1. Stand-by Engines 4.3. Open up all filters to check that filter elements
are intact. Filter cartridges in the lub. oil filter is to be
During engine standstill in stand-by position, the replaced before start after repair or due to excessive
media cooling water, fuel oil and nozzle oil should differential pressure. After eremoval, dirty elements
be continuously circulated at temperatures similar can be examined for particles of bearing metal at
to the operation conditions. the bottom of the paper lamellae.
(The elements can not be used again).
The engine shall be prelubricated 2 minutes prior
to start, if there is not intermittent or continuous pre- 4.4. Check the cylinder walls.
lubricating installed. intermittent prelub. is 2 min
every 10 minutes. 4.5. Take deflection measurements of the crank-
shaft.

2. Maintenance during Standstil 4.6. A lubricating oil sample should be send to a


laboratory for immediate analysis.
in periods, duringe stand-still of the engine (not in
stand-by position) it is recommended, that the pre- 4.7. Drain plugs are unscrewed from the bottom of
lubricating oil pump is startet minimum 10 minutes turbochargers, or the drain cock is opened, if there
once every week and that the engine during the is installed drain fasilities in the exhaust gas system
prelubricating period is turnd 2-3 revolutions.. this should be opened.

3. Laid-up Vessels 5. Works during Repairs

During the lay-up period (and also when laying-up the The following should be made during the major
vessel), we recommend that our special instructions repairs.
for preservation of the engines, are followed.
5.1. Retighten all bolts and nuts in the crankcase
and check their locking devices. Also retighten
4. Works before Major Repairs foundation bolts.

4.1 After stopping the engine, while the oil is still 5.2. Check the various gear wheel drives for the
warm, start the electrically driven prelubrication camshaft(s).
pump, open up the crancase and camshaft housing
and check that the oil is flowing freely from all bea- 5.3. Remedy leakages of water and oil in the en-
rings. Also take off the top covers on the cylinder gine, and blow through blocked-up drain pipes.
heads and make sure that oil is not supplied for
lubrication of rocker arms, as non-return valves are 5.4. Drain starting air pipes of water.
fitted which do not open until the oil pressure at the
inlet to the rocker arms exceeds 1 bar. 5.5. Empty the oil sump of lubricating oil and remove
the sludge, if not done within a period of one year.
08028-0D/H5250/94.08.12

After overhaul of pistons, bearings, etc. this check Very thoroughly clean the sump and subsequently
should be repeated before starting the engine. coat with clean lubricating oil.

4.2. After stopping the prelubricating pump, check


the bottom of the oil sump for fragments of babbitt 6. Works after Repairs
from bearings, and check crankpin and main bea-
rings clearances with a feeler gauge. Measure the 6.1. If an opening-up of engine or lubricating oil
bearing clerance at the top, at the bottom, and 10 system may have caused ingress of impurities,
degrees above and below the joints at both sides. cleaning should be carried out very carefully before
starting the engine.

92.02 - ES0U
MAN Diesel
601.05 Description
Edition 17H
Out-of Service Page 2 (2)

General
The differential pressure across the lub. oil filter 6.7 b) Adjustment speed: Switch-in generator on
must be watched very carefully after cleaning and the switchboard and set the load to about 40%. On
starting-up the engine. Be sure to replace filter cart- reaching normal oil temperatures in governor and
ridges in due time. engine, increase the load instantaneously to about
80% ( by starting major pump or compressor). This
6.2. After restoring normal lubricating oil circulation, must not cause the frequency to fall by more than
turn the engine at least two revolutions by means of some 8%, and the engine must return to a constant
the turning rod to check the movability of the relevant r.p.m. about 3 seconds (although this r.p.m. will be
parts of the engine. a little lower than before owing to the speed drop
of
6.3. Close drain cocks in the turbocharger (or in the governor). If the engine is operated in parallel
the exhaust gas system if mounted). with other engines, an even sharing of load shall be
established within about 3 seconds. If the gover-
6.4. Lubricate bearings and rod connections in the nor reacts too slowly, compensating adjustment
manoeuvring gear. Disconnect the governor and is effected as indicated in Woodward's instruction
move the rod connections by hand to check that the manual (Compensating adjustment).
friction in bearings and fuel pumps is sufficiently low.
If repair of bearings or alignment of engine has been Note: It is a condition for this test that the engine
made, checks 1, 2, and 5 should be repated. and turbocharger are in perfect operating condition,
so that they can be elimated as possible sources
6.5. Cheks to be made just before starting of the of error.
engine are mentioned under 601.01.
6.7 c) Hunting: Run the engine at synchronous
6.6. Add cooling water and check with pressure r.p.m., and without load. Provided the governor oil
on the system for leakage at the upper and lower is warm, the regulating lever must not perform any
cy-linder liner sealings and at cooling water connec- major periodical movments, and neither must there
tions. be any variation up and down in the engine speed. If
that is the case, repeat the compensating adjustment
6.7. Check the governor as follows: according to Woodward's instruction manual.
Start up the engine and run it at the synchronous
number of revolutions. 6.7 d) Speed Drop: in case of unsatisfactory load
sharing between two ore more engines this can be
6.7 a) Speed setting: Check before switching-in rectified by increasing the speed drop of the engine
generator on the switchboard that the servomotor that is subject to the greatest load (or by reducing
adjusts the r.p.m. with a suitable quickness after ac- the setting of the other engines).
tuation of the synchronizer knob on the switchboard.
The range from - 5% to + 5% from the syn-chronous The setting shoul not normally be increased beyond
r.p.m. should be tested. 70 on the scale, and satisfactory parallel operation
can generally be obtained at settings between 40
and 60.
08028-0D/H5250/94.08.12

92.02 - ES0U
MAN Diesel

Description
Starting-up after Out of Service Periods 601.10
Page 1 (1)
Edition 17H

L+V28/32H

The following enumerates checks are to be made After the last feel-over, repeat check 4 page 601.05,
immediately after starting, during load increase, and see also Ignition in Crankcase page 603.04 in sec-
during normal running. The sequence has been ac- tion 603.
cordingly.
After repair or renewal of cylinder liners, piston rings
In the following it is assumed that the engine has or bearings, allowance must be made for a running-
been out of service for some time, for instance due in period, i.e. the engine load should be increased
to repairs and gradually as indicated in the tables below. The engine
output is determined on the basis of the fuel index and
- checks during out of service periods have been the load on the electric switchboard. The turbocharger
carried out as described in the previous chapter. speed gives some indication of the engine output, but
is not directly proportional to the output throughout
When starting after such an out-of-service period, the the service period.
following checks must be made in the stated order in
addition to normal surveillance and recording. Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for certain
that there areno hot spots in the engine. Then incre-
1. To be made immediately after starting: ase the speed to the normal rpm and connect to the
switchboard and put on load.
1.1. See that the turbocharger is running.
The load increase during the starting-up sequence
1.2. See that the lubricating oil pressure is in order. may, for instance, be:

1.3. See that all cylinders are firing (see exhaust 25 % load for 2 hours
temperatures). 50 % load for 2 hours
75 % load for 2 hours
1.4. See that everyting is normal for the engine speed, 100 % load may be put on.
fuel oil, cooling water and system oil.
The pump index indicated in the tables has been given
1.5. Check by simulation of the overspeed shutdown as a percentage of the index at full load. To enable
device that the engine stops. The overspeed setting the index to be read directly off the fuel pumps the
should be according to " Set Points and Operation following formula can be employed:
Data " section 600.
I = I% x IF
100
2. To be made during the starting-up, but only
if required after repairs or alterations made: IF = Index at full load (from testbed table)

2.1. If the condition of the machinery is not well-known, I% = Index expressed as % of full load index
especially after repairs or alterations, the "feel-over (stated in the preceding starting-up
sequence" should always be followed. sequence).
08028-0D/H5250/94.08.12

that is:
Following the alteration of the pump index of the one or
After 5-15 and 30 minutes' idle running, open the two cylinders concerned it must be checked that when
crankcase and the camshaft housing and feel-over in the STOP position the governor is able to move all the
on the surfaces of all moving parts where friction may fuel pumps to an average pump index not exceeding
arise and cause undue heating. 2 or 3, thus excluding the possibility of racing of the
engine when the propeller is declutched.
Feel: Main bearings, big-end bearings, (alternator),
and camshaft bearings, piston pins, cylinder liners, After completing the starting-up sequence, make
roller guides and gear wheels. sure that all fuel pumps are set at the same index and
that the governor can cause all fuel pumps to move
to "0" index.

96.30 - ES0U
MAN Diesel & turbo

Description
Guidelines for Longterm Low-Load Operation on HFO 601.15
Page 1 (1) Edition 03H

General

Part load/low load operation and turbocharger. HFO-operation at loads lower than
20% MCR should therefore only take place within
In certain ship and power station operation modes the certain time limitations according to the curves.
diesel generating sets are exposed to part load/low
load operation. After a certain period of HFO-operation at loads lower
than 20% MCR, a change to MDO should take place
During manoeuvring of the ship all diesel generating in order to prevent further retardation of the engine
sets are often started up for safety reasons, result- performance condition. Alternatively, the engine load
ing in low should be raised to 70% MCR over a period of 15
load operation of all the engines. During harbour stay minutes and maintained here for some time in order
one diesel generator could be low-loaded when only to burn off the carbon deposits, thus re-establishing
hotel purposes are consuming electricity. adequate performance condition. After such a "clean
burning period" low load operation on HFO can be
Island mode operation of diesel generating sets in continued.
power stations is frequently exposed to low load
operation like on a ship. However, the operator must be aware of the fact
that fouling in the combustion air inlet channels,
At part load/low load it is important to maintain if any, will not be cleaned at high load operation.
constant media temperatures, i.e. for cooling water, Extensive low load running can therefore result in
lubricating oil and fuel oil in order to ensure adequate the need for manual cleaning of the combustion air
combustion chamber temperature and thus complete inlet channels.
combustion.
If special application conditions require continuous
At loads lower than 20% MCR there is a risk of time HFO-operation at loads lower than 20% MCR and
dependant retardation of the engine performance occasionally performed "clean-burning" periods are
condition due to fouling of the exhaust gas channels inconvenient or impossible, special equipment and
and combustion air channels, combustion chambers arrangements must be established.

Load %
20
­ dmissible low-load operation
A Necessary operating period
(load percent/period) on HFO. with min. 70% load after low-
load operation on HFO.

15 Running-up period to 70%


load: approx. 15 min.

a b 70% load
10 HFO or MDO

5
a b

Operating period (h) Operating period (h)


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

Fig 1 Low-load operation.

08.20 - ES1
MAN Diesel & Turbo

Description Guidelines Regarding MAN Diesel & Turbo GenSets 601.16


Page 1 (1) Operating on Low Sulphur Fuel Oil Edition 02H

General
Exhaust emissions from marine diesel engines have Low sulphur distillates
been the focus of recent legislation. Apart from nitrous
oxides (NOx), sulphur oxides (SOx) are considered In general our GenSet is developed for continuous
to be the most important pollution factor. A range of operation on HFO as well as on MDO/MGO. Occa-
new regulations have been implemented and others sionally changes in operation mode between HFO
will follow (IMO, EU Directive, and CARB). These and MDO/MGO are considered to be within normal
regulations demand reduction of SOx emissions operation procedures for our engine types and do
by restricting the sulphur content of the fuel. That is thus not require special precautions.
to say sulphur limits for HFO as well as mandatory
use of low sulphur distillate fuels for particular ap- Running on low sulphur fuel (< 0.1% S) will not cause
plications. This guideline covers the engine related problems, but please notice the following restrictions:
aspects of the use of such fuels.
In order to avoid seizure of the fuel oil injection pump
Low sulphur HFO components the viscosity at engine fuel oil inlet must
be > 2.0 cSt. In order achieve this it may be necessary
From an engine manufacturer’s point of view there to install a fuel oil cooler, when the engine is running
is no lower limit for the sulphur content of HFO. We on MGO. This is both to ensure correct viscosity and
have not experienced any trouble with the currently avoid heating up the service tank, which is important
available low sulphur HFO, that are related to the as the fuel oil injection pumps are cooled by the fuel.
sulphur content or specific to low sulphur HFO. This
may change in the future if new methods are applied When operating on MDO/MGO a larger leak oil
for the production of low sulphur HFO (desulphuriza- amount from fuel oil injection pumps and fuel oil
tion, uncommon blending components). MAN Diesel injection valves can be expected compared to op-
& Turbo will monitor developments and inform our eration on HFO.
customers if necessary.
In order to carry out a quick change between HFO
If the engine is not operated permanently on low and MDO/MGO the change over should be carried
sulphur HFO, then the lubricating oil should be se- out by means of the valve V1-V2 installed in front
lected according to the highest sulphur content of of the engine.
the fuels in operation.
For the selection of the lubricating oil the same ap-
plies as for HFO. For temporary operation on distillate
fuels including low sulphur distillates nothing has to
be considered. A lubricating oil suitable for operation
on diesel fuel should only be selected if a distillate
fuel is used continuously.

10.16 - ES1
Performance and
condition

502/602
MAN Diesel & Turbo

Description
Engine Performance and Condition 602.01
Page 1 (3) Edition 12H

L+V28/32H

Performance Data and Engine Condition An increase in charge air temperature involves a cor-
responding increase in the exhaust gas temperature
During operation small changes in the engine condi- level by a ratio of about 1:1.5, i.e. 1°C higher charge
tion take place continuously as a result of combustion, air temperature causes about 1.5°C higher exhaust
including fouling of airways and gasways, formation gas temperature.
of deposits, wear, corrosion, etc. If continuously
recorded, these changes in the condition can give Reduction of the charge air pressure results in a cor-
valuable information about the operational and responding reduction of the compression pressure
maintenance condition of the engine. Continuous and max. combustion pressure.
observation can contribute to forming a precise and
valuable basis for evaluation of the optimum operation When checking the max. pressure adjustment of the
and maintenance programmes for the individual plant. engine, it is therefore to be ensured that the existing
charge air pressure is correct.

Engine Performance Data


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

12.04 - ES0
MAN Diesel & Turbo

602.01 Engine Performance and Condition Description


Page 2 (3)
Edition 12H

L+V28/32H

When evaluating operational results, a distinction is If, for any reason, the surface temperature of the fuel
to be made between changes which affect the whole valve nozzle is lower than the condensation tempera-
engine (all cylinder units) and changes which occur ture of sulphuric acid, sulphuric acid condensate
in only one or a few cylinders. can form and corrosion take place (cold corrosion).
The formation of sulphuric acid also depends on the
Deviations occuring for a few cylinders are, as a rule, sulphur content in the fuel oil.
caused by malfunctioning of individual components,
for example a fuel valve with a too low opening pres- Normally, the fuel nozzle temperature will be higher
sure, blocked nozzle holes, wear or other defects, an than the approx. 180°C at which cold corrosion
inlet or exhaust valve with wrongly adjusted clearance, starts to occur.
burned valve seat, etc.
Abrasive particles in the fuel oil involve heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
Turbochargers Therefore, abrasive particles are to the greatest pos-
sible extent to be removed at the purification.
Fouling of the turbine side of the turbocharger will,
in its first phase, manifest itself in increasing turbo-
charger revolutions on account of increased gas Exhaust Valves
velocity through the narrowed nozzle ring area. In
the long run, the charging air quantity will decrease The overhaul intervals for exhaust valves is one of
on account of the greater flow resistance through the the key parameters when the reliability of the entire
nozzle ring, resulting in higher wall temperatures in engine is to be judged. The performance of the
the combustion chambers. exhaust valves is therefore extremely informative.

Service experience has shown that the turbine side is Especially under unfavourable conditions, fuel quali-
exposed to increased fouling when operating on HFO. ties with a high vanadium and sodium content will
promote burning of the valve seats. Combinations of
The rate of fouling and thereby the influence on vanadium and sodium oxides with a corrosive effect
the operation of the engine is greatest for small will be formed during combustion. This adhesive ash
turbochargers where the flow openings between the may, especially in the event of increased valve tem-
guide vanes of the nozzle ring are relatively small. peratures, form deposits on the seats. An increasing
Deposits occur especially on the guide vanes of the sodium content will reduce the melting point and
nozzle ring and on the rotor blades. In the long run, thereby the adhesive temperature of the ash, which
fouling will reduce the efficiency of the turbocharger will involve a greater risk of deposits. This condition
and thereby also the quantity of air supplied for the will be especially unfavourable when the va na weight
combustion of the engine. A reduced quantity of air ratio increases beyond 1:3.
will result in higher wall temperatures in the combus-
tion spaces of the engine. The exhaust valve temperature depends on the actual
maintenance condition and the load of the engine.
Detailed information and instructions regarding With correct maintenance, the valve temperature is
water washing of the turbocharger are given in the kept at a satisfactory low level at all loads. The air
instruction manual. supply to the engine (turbocharger/air cooler) and the
maximum pressure adjustment are key parameters
in this connection.
Fuel Valves
It is important for the functioning of the valves that
Assuming that the fuel oil is purified effectively and the valve seats are overhauled correctly in accord-
that the engine is well-maintained, the operational ance with our instructions.
conditions for the fuel valves and the overhaul in-
tervals will not normally be altered essentially when The use of rotocaps ensures a uniform distribution
operating on HFO. of temperature on the valves.

12.04 - ES0
MAN Diesel & Turbo

Description
Page 3 (3) Engine Performance and Condition 602.01
Edition 12H

L+V28/32H
Air Inlet Valves Engine Room Ventilation, Exhaust System

The operational conditions of the air inlet valves are Good ventilation of the engine room and suitable loca-
not altered substantially when using residual fuel. tion of the fresh air intake on the deck are important.
Sea water in the intake air might involve corrosive
attack and influence the overhaul intervals for the
Fuel Injection Pumps exhaust valves.

Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room
operation of the fuel injection pumps will not be very should correspond to approximately 1.5 times the air
much affected. consumption of the engines and possible boilers in
operation. Under-pressure in the engine room will
The occurrence of increasing abrasive wear of plunger involve an increased exhaust temperature level.
and barrel can be a consequence of insufficient
purification of the fuel oil, especially if a fuel which The exhaust back-pressure measured after the turbo-
contains residues from catalytic cracking is used. chargers at full load must not exceed 300 mm water
Water in the fuel oil increases the risk of cavitation in column. An increase in the exhaust back-pressure will
connection with pressure impulses occurring at the also cause an increased exhaust valve temperature
fuel injection pump cut-off. A fuel with a high asphalt level, and increased fuel consumption.
content has deteriorating lubricating properties and
can, in extreme cases, result in sticking of the fuel
injection pump plungers.

12.04 - ES0
MAN Diesel & Turbo

Description Evaluation of Readings Regarding 602.02


Page 1 (1)
Combustion Condition Edition 11H

General

PRESSURE DROP
INCREASING
(limit 50%)
Air filters
fouled.

PRESSURE DROP
INCREASING
(limit 50%)
Air side of
ALL CYLINDERS cooler fouled.
Exhaust temp. increa-
sing:
Air system fouled TEMP. DIFFERENCE
(Air filter-blower-cooler). TOO LARGE
Exhaust system fouled Water flow too small
(nozzle ring, turbine
wheel).

TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.

ONE CYLINDER DECREASING CHARGE


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

Please also see Description 602.01,


Engine Performance and Condition

11.23 - ES0
MAN Diesel

Description
Condensate Amount 602.05
Page 1 (2) Edition 08H

General

Ambient air temperature (1 bar)

(Above atmospheric)
10 20 30 40 50 60 70
0.10
of air in kg water / kg air

r
ba
1.0

r
0.08

ba
0
2.

air pressure
0.06

r
ba
Max. water content

Charge
0
of atmosphere

3.
Water content

I %
%
0%

%
%

60
70
80
90
10

0.04

A B

in air tank
Pressure
0.02

II

30 bar
III

Relative 0
air humidity 30 40 50 60 70

Charge air temperature after cooler.


Air temperature in tank.

Fig. 1. Nomogram for calculation of condensate amount.

General Condensation of water in the engine's charge air


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

the diagram. The ability to absorb the water depends


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

91.37 - ES1S
MAN Diesel

602.05 Condensate Amount


Description
Edition 08H Page 2 (2)

General
Solution according to diagram: Amount of Condensate Water in Air Tanks.

Water content of air (l) 0.033 kg/kg The volume of condensate in the air tank is determin-
Max. water cont. of air (ll) 0.021 kg/kg ed by means of the curve at the bottom to the right
of the diagram, representing an operating pressure
Amount of condensate in charge air recceiver. of 30 bar.

= (l - ll) x le x P Example:
= (0.033 - 0.021) x 8.2 x 1260 = 123 kg/h
Amount of condensate in air tank.

Draining of Condensation Water. Volumetric capacity of tank(V) 4000 dm³


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

Water content of air (l) 0.033 kg/kg


Max. water cont. of air (lll) 0.0015 kg/kg

Amount of condensate in air tank

= (I - III) x m.
= (0.033 - 0.0015) x 138 = 4.35 kg.
08028-0D/H5250/94.08.12

91.37 - ES1S
MAN Diesel & Turbo

Working Card 602-01.00


Page 1 (4) Engine Performance Data Edition 03H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62005 10 Max. pressure
Shut-off fuel oil indicator
Shut-off cooling oil
Stopped lub. oil circul.

Description: Hand tools:

Measurements of engine performance data.

Starting position:

Engine is running.

Related procedure:

Man power: Replacement and wearing parts:

Working time : ½ hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

11.25 - ES0
MAN Diesel & Turbo

602-01.00 Engine Performance Data Working Card


Edition 03H Page 2 (4)

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

1 2 3 4 5 6 running Hours
Engine RPM Fuel Type Turbocharger Turbocharger
7 8
Visc. 9
Density Type Serial No. 10 RPM

Switchboard
Effect (kW) Voltage (V) Current (A) cos ϕ /kVAr
11 12 13 14

Cylinder Data
Ave-
15 Cylinder No. 1 2 3 4 5 6 7 8 9 16 rage

17 Fuel Pump Index

18 Maximum Pressure (bar)

19 Compress. Pressure (bar)

20 Exhaust Temp. (° C)

21 Cooling Water (°C)

Turbocharger
Temp. inlet blower (° C) Pressure before blower (mmWC) Temp. after blower (° C)
22 23 24

Press. air cooler (mmWC) Temp. charge air (° C) Press. charge air (bar)
25 26 27
Temp. exhaust gas before TC (° C) Temp. exhaust gas after TC (° C) Press. exhaust gas after TC (mmWC)
28 29 30

Lubricating Oil System


Temp. after engine (° C) Press. before filter (bar) Press. after filter (bar)
31 32 33
Temp. inlet engine (° C) Press. before TC (bar)
34 35 36

Cooling Water System


LT temp. inlet air cooler (° C) LT temp. outlet air cooler (° C) LT press. inlet air cooler (bar)
37 38 39

LT temp. inlet lub. oil cooler (° C) LT temp. outlet lub. oil cooler (° C) LT temp. inlet alternator (° C)
40 41 42
LT temp. outlet alternator (° C) HT FW temp. inlet engine (° C) HT FW press. inlet engine (bar)
43 44 45

Fuel Oil System


Fuel oil temp. inlet engine (° C) Fuel oil press. before engine (bar)
46 47
Nozz. cool. oil press. inlet engine (bar) Nozz. cool. oil temp. outlet engine (° C) Sign.
48 49 50

11.25 - ES0
MAN Diesel & Turbo

Working Card
Engine Performance Data 602-01.00
Page 3 (4) Edition 03H

L28/32H

The Instruction for Filling in the Diagram "Engine Cylinder Data.


Performance Data".
15. Cylinder no. - can be read on engine plate.
The numbers in the instruction are commensurate A/B is used for V-engines.
with the numbers on the diagram.
16. Average for all engine cylinders for point: 17-
The automatic symbols mentioned in the instruction 18-19-20-21.
TI 01, TI 03, PI 01 etc, refer to the diagrams printed
in the instruction books for specified plants. 17. Fuel pump index - can be read on each of
the high pressure fuel oil injection pumps.

Engine Performance Data. 18. Max pressure (bar) can be read for each
cylinder by means of indicator or Pmax gauge.
1. Name of ship, if stationary name of plant.
19. Compression pressure (bar) - can be read for
2. Engine type. each cylinder by means of the indicator measure-
ment, which is carried out during idling by nominal
3. Engine no. RPM.

4. Date/year of observations. 20. Exhaust temperature (°C)


- Thermometer TI 60.
5. Hour, time of observations.
21. Water outlet cylinder (°C) (jacket cooling)
6. Total engine running hours - engineer's log- - Thermometer TI 11.
book.

7. Engine revolutions per minute (RPM) - can be Turbocharger.


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

Switchboard. 26. Charge air temperature (°C). Temperature of


the charge air in the charge air receiver.
11. Effect alternator (kW) - can be read on the - Thermometer TI 31.
main switchboard.
27. Pressure charge air (bar). Pressure of the
12. Voltage (V) - can be read on the switchboard. charge air in the charge air receiver.
- Pressure gauge PI 31.
13. Current (A) - can be read on the switchboard.
28. Tempereture of the exhaust gas before TC
14. Cos ϕ/kVAr - can be read on the switchboard. (°C) - Thermometer TI 62.

11.25 - ES0
MAN Diesel & Turbo

602-01.00 Engine Performance Data Working Card


Edition 03H Page 4 (4)

L28/32H
29. Temperature of the exhaust gas after TC (°C) 40. Temperature of the low temperature (LT) cool-
- Thermometer TI 61. ing water (sea, raw or fresh) at inlet lub. oil cooler
(°C)
30. Pressure of the exhaust gas after the TC (bar) - Thermometer TI 07.
- Pressure gauge PI 61.
41. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at outlet lub. oil cooler
Lubricating Oil System. °C)
- Thermometer TI 03.
31. Temperature of the lub. oil inlet cooler (°C)
- Thermometer TI 20. 42. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at inlet alternator (°C)
32. Pressure of the lub. oil before the filter (bar) - Thermometer TI 04.
- Pressure gauge PI 21.
43. Temperature of the low temperature (LT) cool-
33. Pressure of the lub. oil after the filter (bar) ing water (sea, raw or fresh) at outlet alternator (°C)
- Pressure gauge PI 22. - Thermometer TI 05.

The filter element should be replaced with a pres- 44. Temperature of the high temperature (HT)
sure drop across the filter of 1.5 bar. fresh water (FW) at inlet engine (°C)
- Thermometer TI 10.
34. Temperature of the lub. oil inlet engine (°C)
- Thermometer TI 22. 45. Pressure of the high temperature (HT) fresh
water (FW) of outlet engine (°C)
35. Pressure of the lub. oil before the turbocharger - Thermometer TI 10.
(bar).
- Pressure gauge PI 23.
Fuel Oil System.

Cooling Water System. 46. Temperature of the fuel oil at inlet engine (°C)
- Thermometer TI 40.
37. Temperature of low temperature (LT) cooling
water (sea, raw or fresh) at inlet charge air cooler 47. Pressure of the fuel oil before engine (bar)
(°C) - Pressure gauge PI 40.
- Thermometer TI 01.
48. Nozzle cooling oil pressure at inlet engine
38. Temperature of low temperature (LT) cooling (bar)
water (sea, raw or fresh) at outlet charge air cooler - Pressure gauge PI 50.
(°C)
- Thermometer TI 02. 49. Nozzle cooling oil pressure at outlet engine
(bar)
39. Pressure of the low temperature (LT) cooling - Pressure gauge PI 51.
water (sea, raw or fresh) at inlet charge air cooler
(bar) 50. Signature.
- Pressure gauge PI 01.

11.25 - ES0
Trouble shooting

503/603
MAN Diesel
Description
Starting Failures 603.01
Page 1 (1)
Edition 08H

General

Trouble Possible cause Trouble shooting

Engine turns as soon as shut-off Faults in electrical system Check electrical parts
valve is opened, without start
but-ton being activated

Engine does not turn when start Air pressure in starting air recei- Start compressors, re-charge air
button is activated ver too low receiver

Main valve(s) closed Open valve at receiver and stop


valve interposed in line between
receiver and engine

Pinion does not engage the fly Check the air starter for broken
wheel clutch jaws or other broken parts

Air motor runs, pinion engages Check the air motor for broken
but does not rotate shafting, bearing or clutch jaws

Faults in electrical system Check electrical parts

Engine turns too slowly or ir- Worn air motor parts Remove and disassemble the
regularly when start but-ton is air motor. Examine all parts and
depressed re-place any that are worn or
damag-ed. Use the guidelines for
determi-ning unserviceable parts

Start valve is sticking in close Check start valve


position
08028-0D/H5250/94.08.12

90.46 - ES0U
MAN Diesel

Description
Faults in Fuel Oil System 603.02
Page 1 (3)
Edition 09H

L+V28/32H

Trouble Possible cause Trouble shooting

Engine turns on starting air, but Sluggish movement of Lubricate and mobilize rod con-
ignition fails. Fuel pumps are not manoeuvring gear nections in manoeuvring gear
actuated
Governor setting incorrect Adjust governor, see special in-
struction manual

Overspeed or another shutdown Cancel shutdown function


function is activated

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


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

Piston in Lambda controller is Check pressures and tempera-tu-


actuated owing to uncancelled shut- res. Check for faults in shut-down
down function (1) devices

Failures in governor Check that governor is working


properly. For further fault location,
see special instr. manual

Incorrect adjustment of Check rod connec. Check that


manoeuvring gear fuel pump index is corresponding
to "Adjustments after trials" in
testbed chart

Engine turns on starting air, but Incorrect adjustment of limiter Adjust setting of limiter cylinder
no fuel is injected owing to failu- cylinder
res in fuel system
Fuel oil service tank empty Pump oil into the tank

Air in fuel pumps and fuel injection Vent the fuel pumps unitl fuel
valves (2) with-out air bubbles appears. If
ignition fails in just one cyl., vent
the re-spective fuel injection valve.
If igni-tion still fails, install a spare
valve before attempting to start
the engi-ne again.

Worn-out fuel pump Change fuel pumps


08028-0D/H5250/94.08.12

Defective fuel injection valves or Change defective fuel valves


valve nozzles (4)

Too low pressure before fuel injec- Increase the fuel oil feed pump
tion pumps (3) pressure

Engine turns on starting air, fuel Water in the fuel Drain off water and repeat venting
is injected, but ignition fails of fuel pumps

Fuel valves or nozzles defective (4) Change defective fuel valves, see
Working Card 614-01.10.

Cont.

02.47 - ES0
MAN Diesel

603.02 Faults in Fuel Oil System Description


Edition 09H Page 2 (3)

L+V28/32H

Trouble Possible cause Trouble shooting

Compression during start too low (5) Check intake and exhaust valve
for tight closing. Check cyl. wear
and piston rings

Incorrect timing of camshaft (6) Check fuel pump timing advance,


and fuel valve opening pressure
as well as camshat adjustment

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

Fuel pump index to high Check rod connection in mano-


euvring gear. Check that gover-
nor is working properly. Limiter
cylinder to be set lower

Remarks

1) If the shut-down function is due to overspeed, 4) If the fuel is forced into the cylinder through
the shut-down activation is cancelled by reset- a defective fuel valve or through worn-out
ting the overspeed device and thus venting the atomizer holes, no or too sluggish atomization
Lambda controller/air cylinder. may prevent ignition, possibly followed by too
violent ignition.

2) Whether air is present in the fuel oil system is


seen be repeating the venting of fuel pumps. 5) To obtain ignition temperature in the cylinders,
The cause may be that a fuel valve is kept in the compression pressure during star ting
open position (spindle sticking or spring bro- should be normal, see the testbed chart. This
ken). Heating of fuel to a too high temperature can be checked by measuring the compression
may have a similar effect owing to formation pressure during starting. Cylinders having too
of gas in the fuel. If a sticking valve is found, it low compression should be inspected.
08028-0D/H5250/94.08.12

should be changed and overhauled. It should be


cheked that no oil has collected on the piston
crown. Air in the fuel oil system may also be 6) Major alterations of the combustion charac-
the result of the fuel oil feed pump sucking-in teristics of the fuel may demand adjustment
air through a defective stuffing box or a leaky of the timing of the fuel pumps. One or more
seal. cam-shaft sections may be incorrectly fitted
(after dismantling). Too high opening pressure
of the fuel valves will also delay the injection.
3) If the fuel oil pressure drops, the filter may be
clogged up, or the by-pass at the feed pump
may have opened.

02.47 - ES0
MAN Diesel

Description
Faults in Fuel Oil System 603.02
Page 3 (3)
Edition 09H

L+V28/32H
7) Oil on the piston crown will in most cases have
leaked down from a defective fuel valve. As
these oil accumulations are dangerous, the
lea-kage should be found and remedied before
the engine is started again.
08028-0D/H5250/94.08.12

02.47 - ES0
MAN Diesel

Description
Disturbances during Running 603.03
Page 1 (3)
Edition 08H

L+V28/32H

Trouble Possible cause Trouble shooting

Exhaust temperature(s) (All cyls.) Increased charging air See Working Card 612-01.00.
increase(s) temperature due to ineffective air
coolers

(All cyls.) Fouling or air and gas Reduce load and water-wash tur-
passages bine. Clean air filters and coolers

(All cyls.) Insufficient cleaning of See Description 604.25.


fuel oil or changed combustion
characteristics

(All cyls.) Wrong position of cam- Check Pmax. Check camshaft ad-
shaft (Maladjustment) justment

(Single cyls.) Fuel valve or valve See Working Card 614-01.10.


nozzle defective

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


valves (1) ce cyl. head with defective valve

(Single cyls.) Blow-by-leaky com- See Working Card 606-01.00.


bustion chamber (2)

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


cam pump

Exhaust temperature(s) (All cyls.) Decreased charging air Check that thermostatic valve (by-
decrease(s) temperature pass valve) in cold water system
is working properly and correctly
set

(Single cyls.) Air in fuel pump(s) Venting of fuel pump(s) until fuel
and fuel injection valve(s) without air bubbles appears.
Check feed pump pressure

(Single cyls.) Spindle in fuel valve Change and overhaul defective


sticking (3) fuel valve

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


sticking or leaking assembly
08028-0D/H5250/94.08.12

Engine RPM decreases Pressure before fuel pumps too Raise fuel oil feed pump pressure
low to normal. Check filter

Fuel valve or fuel pump defective Change defective valve or pump

Water in the fuel Drain off water and vent the fuel
pumps

Governor defective (4) Replace defective governor

Increased internal friction in See "Ignition in Crankcase"


engine (5)

Cont.

05.08 - ES0
MAN Diesel

603.03 Description
Edition 08H
Disturbances during Running Page 2 (3)

L+V28/32H

Trouble Possible cause Trouble shooting

Engine stops Shut-down Check pressure and temperatu-


res. If OK, check for faults in shut-
down devices. See also Starting
Failures

Smoky exhaust Turbine RPM lagging behind en- Reasonably smoke is normal
gine RPM when RPM increases; no measu-
res cal-led for. If smoky exhaust
during normal running, clean
turbine(s) and check valves

Air supply too low Fouling of air and gas passages,


see section 612.

Fuel valves or nozzles defective See Working Card 614-01.10.

"Trumpets" at nozzle holes. Fai- Overhaul fuel valves. Re-establish


lure of cooling (especially during nozzle-cooling
hea-vy-oil operation) (6)

Exhaust valve knocking Adjsuting screw for valve set- Inspect and replace defective
ting loose. Push rod thrust disc parts as necessary
da-maged

Rising cooling water temperature Pump stopped. Increased friction Stop the engine. Check the
(7) cooling water. Find cause of incre-
ased friction and remedy fault

Lubricating oil pressure fails Lubricating oil pump defective. (8) Stop the engine. For further de-
Filters/cooler fouled tails, see "Ignition in crankcase"

Alternator Short circuit Flywheel must be dismounted and


guide pin replaced
08028-0D/H5250/94.08.12

Remarks

1) This manifests itself by rise of the exhaust 2) Blow-by means a serious danger of piston
temperature and falling of the compression seizure, and the engine must if possible be
and maximum combustion pressure of the stopped and the piston in question pulled. If
respective cylinder. this is not possible, the fuel pump index must,
as described above, be moved to stop. Leaky
To limit the damage to the valves, these should piston rings will normally result in a heavy
be changed immediately, if possible, or the fuel excess pressure in the crankcase.
pump of the cylinder concerned should be put
out of operation by moving the index to stop
and locking it in this position.

05.08 - ES0
MAN Diesel

Description
Disturbances during Running 603.03
Page 3 (3)
Edition 08H

L+V28/32H
3) If this happens the fuel pump barrel and plun- 6) If the cooling of the atomizers fails (if arranged
ger must be changed, and if, to obtain full for oil cooling) while running, carbon deposits
load of the respective cylinder, it is necessary will build up round the nozzle holes, sometimes
to increase the fuel pump index by more than in the shape of small cones or trumpets which
10 index degrees, the fuel pump is in most causes the engine to smoke, or ot will cause
cases worn out. Usually this is confirmed by sticking of the valve spindle. For this reason the
inspection of the fuel pump plunger on which nozzle cooling should be well maintained.
the helical cut-off edge will show a pitted and
corroded area where material is plucked out.
In that case the pump can be provided with a 7) If the cooling water temperature for the entire
new barrel and plunger. engine has risen to 90-100° C, it should be
checked - by opening the test cocks, if fitted on
the discharge from cylinders - whether steam
4) The governor will not reduce the fuel pump has developed. If this is the case, there is no
delivery to zero in case of, for instance, failure water on the cooling surfaces, which may the-
of the governor oil pump, but the engine speed refore be heated unduly. To avoid heat stresses
will start fluctuating. arising in cylinder liners and cylinder heads, if
the water returns too early, the engine should
When the governor is defective the engine be stopped and left to cool, while the discharge
is protected against racing by the overspeed valve is closed. After 15 minutes it is opened
trip, i.e. the engine is stopped automatically in a little to allow the water to rise slowly in the
case of excessive speed. It is essential, there- cooling jackets. Check filling at test cocks. Make
fore, that the overspeed trip is kept in perfect crankcase inspection to ascertain that internal
order. Regarding governor failure, see special water leakage has not arisen. Remember slow
instruction book. turning withopen indicator valves at subsequent
starting-up.

5) Usually a bearing failure will not slow down the


engine appreciably, but the seizure of a piston in 8) If the lubricating oil pressure drops below the
the cylinder liner might do so. If a PG-governor minimum mentioned in Data; Find the cause
is employed, the index will increase and exhaust of the pressure drop and remedy the defect
temperatures rise. If such cases occur, repair before re-starting the engine. Feel over 5-15-
is necessary before starting the engine again. 30 minutes after starting, and again when full
Feel over and look out for oil mist. load is obtained. See section 602.
08028-0D/H5250/94.08.12

05.08 - ES0
MAN Diesel

Description
Ignition in Crankcase 603.04
Page 1 (1)
Edition 09H

L+V28/32H
Cause 1. Stop the engine

During running, the atmosphere in the crankcase 2. Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of coarse oil drops is flung around everywhere.
If undue friction and thus heating arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is transmitted otherwise after stopping of the engine. When opening up,
to the crankcase, the heated surface will cause keep clear of possible flames. Do not use naked
evaporation of the lubricating oil splashed on to it. light and do not smoke.
When the oil vapours condense they form a multi-
tude of minute drops suspended in the atmosphere, 3. Take off all doors on one side of the crankcase.
i.e. a milky white oil mist is formed, able to nourish Cut off starting air. Engage turning gear, if fitted.
and spread a flame if ignited. Such ignition may be
caused by the same "hot spot" which produced the 4. Locate the hot spot. Powerful lamps should be
oil mist. If a large quantity of oil mist has developed employed at once (in explosion-proof fittings). Feel
before ignition, the burning may cause considerable over all sliding surfaces (bearings, liners, pistons,
pressure rise in the crankcase, forsing the relief roller guides, etc.).
valves to open. In a few cases, when presumably
the whole crankcase has been filled with oil mist, the Look for squeezed-out bearing metal and discolo-
consequential explosion has thrown off crankcase ration by heat (blistered paint, burned oil, heated
doors and caused fire in the engine room. steel).

Every precaution should therefore be taken to (A) 5. Prevent further heating, preferably by making
avoid "hot spots" and (B) discover oil mist in time. a permanent repair. Special attention should be
given to ensure lubricating oil supply and satisfac-
tory condition of the frictional surfaces involved.
A. "Hot spots" in crankcase. It is equally important to replace filter elements in
time.
Overheating of bearings is a result of too bad or
failing lubrication possibly caused by pullution of 6. Start electrically driven lubricating oil pump and
the lubricating oil. check oil flow from all bearings and splash pipes in
crankcase while turning the engine through at least
It is therefore important that the lubricating oil filtration two revolutions. See Description 601.05, Point 4.1.
equipment is in perfect condition. Filter cartridges
must not be used again, if they have been removed 7. Stop and feel over. Look out for oil mist.
from the filter. Check of the oil condition by analysis
is recommended. Especially the frictional surfaces that caused the
heating should be felt over (5-15-30 minutes after
starting, and again when full load is obtained). See
B. Oil mist in crankcase. Description 601.10, Point 2.
08028-0D/H5250/94.08.12

Presence of oil mist may by noted at the vent pipe, 8. In case it has not been possible to locate the
which is usually fitted to the top of the engine hot spot, point 7 should be intensified and repeated
frame. until the cause of the oil mist has been found and
remedied. In very rare cases oil mist could be due
Measures (in case of white oil mist). to "atomization" of lubricating oil by the action of
an air jet (for instance blow-by, or blow-by through
Warning: Keep away from doors and relief valves on cracked piston).
crankcase. Do not stay unnecessarily in doorways
near doors of the engine room casing.

96.30 - ES0U
MAN Diesel

Description
Trouble Shooting Guide for Centrifugal By-pass Filter 603.05
Page 1 (1)
Edition 08H

L+V28/32H

Tabulated below are the corresponding remedial


actions to be taken if the following faults are obser-
ved:

Trouble Possible cause Trouble shooting

Oil leakage through cover nut Missing or damaged O-ring (see Replace O-ring
Item 29, Plate 61515)

Seal face damaged Replace O-ring

Excessive vibrations Rotor out of balance owing to un-


even build-up of deposit on rotor
walls resulting from:

Missing or damaged O-ring, al- Replace O-ring


lowing leakage (see Item 23, Plate
61515)

O-ring seat on rotor joint faces Replace rotor assembly


damaged

Rotor assembly inadequately Tighten and bring to notice of main-


tightened tenance staff

Standtube incorrectly seated or Re-fit or replace if damaged


damaged

Dirt deposit not completely remo- Clean and bring to notice of main-
ved tenance staff

Rotor castings distorted through Replace rotor assembly


maltreatment

Rotor assembly components fitted Follow sequence in Working Card


in wrong sequence 615-15.00 in section 615.

Bushes loose or worn in tube as- Fit nes bearing tube assembly
sembly

96.30 - ES0U
MAN Diesel

Description 603.06
Page 1 (2) Trouble Shooting Guide for Turbine Starter Edition 09H

L+V28/32H

Trouble Possible cause Trouble shooting

Motor will not run. No air supply. Check for blockage or damage to
air supply lines or tank.

Damaged motor assembly (12). Inspect motor assembly and power


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

Foreign material in motor and/or Remove motor assembly and piping


piping. and remove the blockage.

Blocked exhaust system. Remove housing exhaust cover (1)


and check for blockage.

Defective control or relay valve. Replace control valve or relay valve.

Loss of power Low air pressure to starter. Check air supply.

Restricted air supply line. Check for blockage or damage to


air lines.

Relay valve malfunctioning. Clean or replace lines or relay


valve. Lubricate relay valve.

Exhaust flow restricted. Check for blocked or damaged


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

Damaged motor assembly. Replace motor assembly.

Drive (36) of (57) will not engage. No pressure to drive housing port. Check air supply.

Internal drive housing ports Remove blockage.


blocked.

Fluid in drive unit components. Remove fluid.

Damaged or worn piston assembly Replace damaged or worn parts.


(54), o-rings or seals.

O-rings and seals dry. Relubricate o-rings and seals.


08028-0D/H5250/94.08.12

Motor runs, pinion engages, but Damaged or broken drive train. Disassemble drive train and replace
does not rotate flywheel. worn or damaged parts.

Excessive butt engagement. Damaged drive pinion (36) or (63) Inspect drive pinion and flywheel
or flywheel. and replace if necessary.

Damaged starter drive (36) or (57) Inspect drive components and


components. replace worn or damaged parts.

Cont. ....

94.34 - ES0U-G
MAN Diesel
603.06 Description
Edition 09H
Trouble Shooting Guide for Turbine Starter Page 2 (2)

L+V28/32H

Trouble Possible cause Trouble shooting

Low air pressure. Check air supply.

Wrong drive pinion. Replace with proper drive pinion.

Oil blowing out of exhaust. Oil in air supply line. Inspect air line and remove source
of oil.

Splash deflector retaining screw (5) Install splash deflector retaining


or pipe plug missing. screw or pipe plug.

Worn or damaged rotor seals or Replace static seals on outside of


static o-rings. motor or send motor to Inger-soll-
Rand to be rebuilt.

Oil leaking from gear case (28). Worn or damaged o-rings. Replace o-rings.

Loose joints. Make sure that joints fit properly


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

Excessive high-speed operation. Operate according to recommen-


dations.

High number of start cycles. Replace worn components.

Loose or leaking pipe plugs (10) Tighten or replace pipe plugs using
or (11). Ingersoll-Rand No SMB-441 pipe
sealant.

Splash deflector retaining screw Tighten splash deflector retaining


loose or pipe plug missing. screw or replace pipe plug.

Air or gas leakage. Loose joints. Make sure that joints fit properly
and starter assembly cap screws
are tightened to 60 ft-lb (81 Nm)
torque. Make sure all seals and
o-rings fit and seal properly at their
perimeters. If they do not replace
with new seals and o-rings.

Excessive high-speed operation. Operate according to recommen-


dations.

High number of start cycles. Replace worn components.

Loose or leaking pipe plugs. Tighten or replace pipe plugs.

Splash deflector retaining screw Tighten splash deflector retaining


loose or pipe plug missing. screw or replace pipe plug.

94.34 - ES0U-G
MAN Diesel
Description
Trouble Shooting for Cooling Water System 603.09
Page 1 (1)
Edition 08H

General

Description The pump bearings are lubricated automatically with


oil from the lubricating oil system of the engine.
The built-on fresh water pump in the high tempera-
ture (HT) circuit is of the centrifugal type and is If the pump leaks and the shaft sealing rings are
mounted on the front cover of the engine and is worn, it is recommended to replace the shaft seal,
driven through a gearing. see work card 616-02.00.

Trouble Possible cause Trouble shooting

The pump does not work after Pump draws in air at suction side Check packings and pipes for
start tightness

The system is not filled-up Check the level in the expansion


tank

Air cannot escape on delivery side Vent the system

Leaking shaft seal Check the shaft seal

Pump capacity drops after nor- Air leakages of shaft seal Overhaul the shaft seal
mal operation
Fouled impeller Clean the impeller

Pump does not give maximum Suction valve not fully open Open the suction valve
delivery
Defective seals Replace the seals

Worn impeller and worn wear rings Overhaul the pump

Note! Running troubles with the pump, apart from


mechanical faults, are most often due to leaks in the
suction line. It is essential, therefore, that all packings
and gaskets are in order and that they are renewed
when necessary. Even a thiny hole in the suction line
will reduce the pump capacity.
08028-0D/H5250/94.08.12

91.14 - ES0U
MAN Diesel
Description 603.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01H

General
Trouble Shooting. In case of fatigue fracture, this will normally neces-
sitate a replacement of all plates and gaskets - as
In case of damage to plates or gaskets, it will often there may be a risk of fatigue fracture in all the
be necessary to replace them. material.
First examine very carefully the external conditions In case of corrosion, all plates must be examined
around the plate heat exchanger in order to localize carefully!
the cause of the damage! For work to be carried out see working card 615-
05.00.

Visible Leakage

Trouble Possible cause Trouble shooting

Leakage. Too high pressure. Reduce the pressure to the correct


working pressure, see page 600.30
"Operating Data & Set Points".

Leakage. Insufficient tightening Tighten up the plate heat exchanger


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

If the plate heat exchanger is still leaky,


procede with phase 2.

Leakage. Fouled or deformed plates. Separate the plate heat exchanger


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

Leakage. Gaskets. Separate the plate heat exchanger.


08028-0D/H5250/94.08.12

(Even after tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension) Replace the gaskets.
Assemble the plate heat exchanger
and start it up again.

Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the plate. Replace defective plates and gaskets,
gaskets) if any.
Assemble the plate heat exchanger
and start it up again.

92.08 - ESOU
MAN Diesel
603.10 Description
Edition 01H Trouble Shooting for Lubricating Oil Cooler Page 2 (2)

General

Non-Visible Leakage

Trouble Possible cause Trouble shooting

Reduced heat transmission and/or Fouled plates or choked plate chan- Separate the plate heat exchanger and
increasing pressure drop. nels. check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger
and start it up again.

Leakage. Holes in plates. A suspected leakage can be localized


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

Leakage. Holes in plates. Close down the plate heat ex-


(The fluids get mixed) Corrosion or fatigue fracture. changer.
Separate the plate heat exchanger.
(Phase 2)
Put all plates to dry. Suspend the plates
in the plate heat exchanger again and
tighten it.
Circulate medium at full capacity on
one plate side (every second plate
channel). Keep the other plate channels
unpressurised and free from liquid!
Stop the circulation after a few minutes
of operation and open the plate heat ex-
changer again. Take care to avoid water
spraying onto the dry plate side!
08028-0D/H5250/94.08.12

By a careful study of the plates it will


be possible to find moist areas, if any,
on the otherwise dry plate sides.
Check these areas with a dye pen-
etrant!
Replace defective plates and gas-
kets.
Before assembling, clean all plates
and gaskets.
Assemble the plate heat exchanger
and check to find more defective
plates, if any, by putting one side under
pressure.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!

92.08 - ES0U
Media specification

504/604
MAN Diesel & Turbo

Description Specification for lubricating oils (SAE30) for 604.01


Page 1 (5) heavy fuel oil operation (HFO) Edition 27H

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

Properties/characteristics Unit Test method Limit values


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

11.01 - ES1 - 3.3.6 (2011-01-04)


MAN Diesel & Turbo

604.01 Specification for lubricating oils (SAE30) for Description


Edition 27H heavy fuel oil operation (HFO) Page 2 (5)

L28/32H
V28/32H
Medium-alkaline lubricating oil For tips on selecting the base number, refer to the
table entitled “Base number to be used for various
The prepared oil (base oil with additives) must have operating conditions".
the following properties:
Evaporation tendency
Additives
The evaporation tendency must be as low as pos-
The additives must be dissolved in the oil and their sible as otherwise the oil consumption will be ad-
composition must ensure that as little ash as pos- versely affected.
sible is left over, even if the engine is provisionally
operated with distillate oil. Additional requirements

The ash must be soft. If this prerequisite is not met, The lubricating oil must not contain viscosity index
it is likely the rate of deposition in the combustion improver. Fresh oil must not contain water or other
chamber will be higher, particularly at the exhaust contaminants.
valves and at the turbocharger inlet casing. Hard
additive ash promotes pitting of the valve seats and Lubricating Oil Selection
causes the valves to burn out, it also increases me-
chanical wear of the cylinder liners.
Engine SAE–Class

Additives must not increase the rate at which the 23/30H, 28/32H, 23/30A, 28/32A
filter elements in the active or used condition are At cooling water temperatures > 32° C a
30
blocked. SAE40 oil can be used.
In this case please contact MAN Diesel
Washing ability Table 2 Viscosity (SAE class) of lube oils

The washing ability must be high enough to prevent


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

The neutralisation capability (ASTM D2896) must


be high enough to neutralise the acidic products
produced during combustion. The reaction time of
the additive must be harmonised with the process
in the combustion chamber.

11.01 - ES1 - 3.3.6 (2011-01-04)


MAN Diesel & Turbo

Description Specification for lubricating oils (SAE30) for 604.01


Page 3 (5) heavy fuel oil operation (HFO) Edition 27H

L28/32H
V28/32H
approx. BN of fresh Engines / Operating conditions
oil (mg KOH/g oil)
Marine diesel oil (MDO) with a lower quality (ISO-F-DMC) or heavy fuel oil with a sulphur
20 content of less than 0.5 %

generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
30 For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF
with exclusive HFO operation only with sulphur content < 1.5 %.

With unfavourable operating conditions 23/30A, 28/32A and 28/32S and also where corre-
sponding requirements in relation to the oil service life and washing ability exist. In general
40 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF with
exclusive HFO operation providing the sulphur content is greater than 1.5 %.

32/40, 32/44CR, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is
50 insufficient with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil
consumption).
Table 3 Base number to be used for various operating conditions

Operation with low sulphur fuel Speed controller

To comply with the emissions regulations, the sul- Multigrade oil 5W40 should ideally be used in me-
phur content of fuels used nowadays varies. Fuels chanical-hydraulic controllers with a separate oil
with a low-sulphur content must be used in envi- sump. If this oil is not available when filling, 15W40
ronmentally-sensitive areas (SECA). Fuels with a oil can be used instead in exceptional cases. In this
high sulphur content may be used outside SECA case, it makes no difference whether synthetic or
zones. In this case, the BN number of the lubricat- mineral-based oils are used.
ing oil selected must satisfy the requirements for
operation using fuel with a high-sulphur content. The military specification for these oils is O-236.
A lubricating oil with low BN number may only be
selected if fuel with a low-sulphur content is used Lubricating oil additives
exclusively during operation.
The use of other additives with the lubricating oil, or
However, the results obtained in practise that dem- the mixing of different brands (oils by different man-
onstrate the most efficient engine operation are the ufacturers), is not permitted as this may impair the
factor that ultimately decides which additive fraction performance of the existing additives which have
is permitted. been carefully harmonised with each another and
also specifically tailored to the base oil.
Cylinder lubricating oil
Selection of lubricating oils / warranty
In engines with separate cylinder lubrication, the
pistons and cylinder liners are supplied with lubri- The majority of mineral oil companies are in close
cating oil via a separate lubricating oil pump. The regular contact with engine manufacturers and can
quantity of lubricating oil is set at the factory ac- therefore provide information on which oil in their
cording to the quality of the fuel to be used and the specific product range has been approved by the
anticipated operating conditions. engine manufacturer for the particular application.
Irrespective of the above, lubricating oil manufac-
Use a lubricating oil for the cylinder and lubricating turers are liable in any case for the quality and char-
circuit as specified above. acteristics of their products. If you have any ques-
tions, we will be happy to provide you with further
information.

11.01 - ES1 - 3.3.6 (2011-01-04)


MAN Diesel & Turbo

604.01 Specification for lubricating oils (SAE30) for Description


Edition 27H heavy fuel oil operation (HFO) Page 4 (5)

L28/32H
V28/32H
Oil during operation If the engine is operated provisionally with low-sul-
phur diesel fuel for more than 1000 h and is sub-
There are no prescribed oil change intervals for sequently operated once again with HFO, a lubri-
MAN Diesel & Turbo medium speed engines. The cating oil with a BN of 20 must be used. If the BN
oil properties must be regularly analysed. The oil 20 lubricating oil by the same manufacturer as the
can be used for as long as the oil properties remain lubricating oil used for HFO operation with higher
within the defined limit values (see table entitled BN (30 or 40), an oil change will not be required
"Limit values for used lubricating oil“). An oil sample when effecting the changeover. It will be sufficient
must be analysed every 1-3 months (see mainte- to use BN 20 oil when replenishing the used lubri-
nance schedule). The quality of the oil can only be cating oil.
maintained if it is cleaned using suitable equipment
(e.g. a separator or filter). If you wish to operate the engine with HFO once
again, it will be necessary to change over in good
Temporary operation with gas oil time to a lubricating oil with a higher BN (30 – 40).
If the lubricating oil with higher BN is by the same
Due to current and future emission regulations, manufacturer as the BN 20 lubricating oil, the
heavy fuel oil cannot be used in designated regions. changeover can also be effected without an oil
Low-sulphur diesel fuel must be used in these re- change. In doing so, the lubricating oil with higher
gions instead. BN (30 – 40) must be used to replenish the used
lubricating oil roughly 2 weeks prior to resuming
If the engine is operated with low-sulphur diesel HFO operation.
fuel for less than 1000 h, a lubricating oil which is
suitable for HFO operation (BN 30 – 40 mg KOH/g)
can be used during this period.

Limit value Procedure

Viscosity at 40 °C 75-160 mm2/s ISO 3104 or ASTM D 445

Base Number (BN) at least 50% of fresh oil ISO 3771

Flash Point (PM) at least 185 °C ISO 2719

Water Content max. 0.2% (max. 0.5% for brief periods) ISO 3733 or ASTM D 1744

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

depends on engine type and operating


Metal Content
conditions

Guide value only


Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm

Table 4 Limit values for used lubricating oil

11.01 - ES1 - 3.3.6 (2011-01-04)


MAN Diesel & Turbo

Description Specification for lubricating oils (SAE30) for 604.01


Page 5 (5) heavy fuel oil operation (HFO) Edition 27H

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

Manufacturer Base Number [mg KOH/g]

20 30 40

AGIP  Cladium 300 - SAE30 Cladium 400 - SAE30

BP Energol ICHFX 203 Energol ICHFX 303 Energol ICHFX 403

CASTROL TLX Plus 203 TLX Plus 303 TLX Plus 403

CEPSA  Troncoil 3030 Plus Troncoil 4030 Plus

CHEVRON Taro 20DP30 Taro 30DP30 Taro 40XL 30


(TEXACO, CALTEX) Taro 20DP30X Taro 30DP30X Taro 40XL30X

Mobilgard M330 Mobilgard M340


EXXON MOBIL 
EXXMAR 30 TP 30 EXXMAR 40 TP 30

PETROBRAS Marbrax CCD320 Marbrax CCD330 Marbrax CCD340

REPSOL Neptuno NT 2030 Neptuno NT 3030 Neptuno NT 4030

SHELL Argina S 30 Argina T 30 Argina X 30

Aurelia XL 3030 Aurelia XL 3040


TOTAL Lubmarine 
Aurelia TI 3030 Aurelia TI 3040
Table 5 Approved lubricating oils for heavy fuel oil-operated MAN Diesel & Turbo fourstroke engines.

11.01 - ES1 - 3.3.6 (2011-01-04)


MAN Diesel & Turbo

Description Quality Requirements for Lube Oil (SAE30) for Opera- 604.01
Page 1 (5) tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Edition 26H

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

Properties/characteristics Unit Test method Limit values


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

10.20 - ES1 - 3.3.5 (2010-02-25)


MAN Diesel & Turbo

604.01 Quality Requirements for Lube Oil (SAE30) for Opera- Description
Edition 26H tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Page 2 (5)

L28/32H
V28/32H
Doped lubricating oils (HD-oils) Additional requirements

The base oil to which the additives have been add- The lubricating oil must not contain viscosity index
ed (doped lubricating oil) must have the following improver. Fresh oil must not contain water or other
properties: contaminants.

Additives Lubricating Oil Selection

The additives must be dissolved in the oil and their


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

be high enough to neutralise the acidic products cording to the quality of the fuel to be used and the
produced during combustion. The reaction time of anticipated operating conditions.
the additive must be harmonised with the process
in the combustion chamber. Use a lubricating oil for the cylinder and lubricating
circuit as specified above.
Evaporation tendency

The evaporation tendency must be as low as pos-


sible as otherwise the oil consumption will be ad-
versely affected.

10.20 - ES1 - 3.3.5 (2010-02-25)


MAN Diesel & Turbo

Description Quality Requirements for Lube Oil (SAE30) for Opera- 604.01
Page 3 (5) tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Edition 26H

L28/32H
V28/32H
Speed controller Temporary operation with gas oil

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

Oil during Operation

There are no prescribed oil change intervals for


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

values for used lubricating oil“). An oil sample must


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

10.20 - ES1 - 3.3.5 (2010-02-25)


MAN Diesel & Turbo

604.01 Quality Requirements for Lube Oil (SAE30) for Opera- Description
Edition 26H tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Page 4 (5)

L28/32H
V28/32H
Tests Approved lubricating oils SAE 30
Base Number
We can analyse heavy fuel oil for customers at our Manufacturer
10161) [mgKOH/g]
laboratory. A 0.5 l sample is required for the test.
Cladium 120  SAE 30
AGIP
Sigma S SAE 30 2)
Danger!
BP Energol DS 3153
Improper handling of fuels Castrol MLC 30
CASTROL Castrol MHP 153
If fuels are improperly handled, this can pose a Seamax Extra 30
danger to health, safety and the environment. The Taro 12 XD 30
relevant safety information by the fuel supplier must CHEVRON
Delo 1000 Marine SAE 30
(Texaco, Caltex)
be observed. Delo SHP30
Exxmar 12 TP 30
Note! Mobilgard 312
EXXON MOBIL
Mobilgard ADL 30 2)
No liability assumed if these oils are used Delvac 1630
PETROBRAS Marbrax CCD310
MAN Diesel SE will not assume liability for any
Q8 Mozart DP30
problems associated with using these oils.
REPSOL Neptuno NT 1530
Gadinia 30
Gadinia AL30
SHELL
Sirius FB30 2)
Sirius/Rimula X30 2)
MarWay 1530
STATOIL
MarWay 1030
TOTAL Lubmarine Disola M3015
Table 3 Lubricating oils (SAE30) which have been ap-
proved for the use in MAN Diesel four-stroke engines running
on gas oil and Diesel oil

1)
If marine diesel oil with a low quality (ISO-F-DMC) is used,
a base number (BN) of roughly 20 should be used.
2)
with a sulphur content of less than 1%
08028-0D/H5250/94.08.12

10.20 - ES1 - 3.3.5 (2010-02-25)


MAN Diesel & Turbo

Description Quality Requirements for Lube Oil (SAE30) for Opera- 604.01
Page 5 (5) tion with Gas Oil, Diesel Oil (MGO/MDO) and Biofuel Edition 26H

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

10.20 - ES1 - 3.3.5 (2010-02-25)


MAN Diesel & Turbo
Description 604.03
Page 1 (4) Treatment and maintenance of lubricating oil
Edition 11H

L32/40, L28/32H, V28/32H


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

2012.05.15 - ES1
MAN Diesel & Turbo
604.03 Description
Treatment and maintenance of lubricating oil Page 2 (4)
Edition 11H

L32/40, L28/32H, V28/32H


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

2012.05.15 - ES1
MAN Diesel & Turbo
Description 604.03
Page 3 (4) Treatment and maintenance of lubricating oil
Edition 11H

L32/40, L28/32H, V28/32H


Example 1 Three 1000 kW engines operating on HFO connec-
For multi-engine plants, one separator per engine in ted to a common self-cleaning separator with a
operation is recommended. daily effective separating period of 23 hours:

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

Check of lubricating oil system


For cleaning of the lubricating oil system after over-
hauls and inspection of the lubricating oil piping
system the following checks must be carried out:
1. Examine the piping system for leaks.
2. Retighten all bolts and nuts in the piping sys-
tem.
3. Move all valves and cocks in the piping system.
Lubricate valve spindles with graphite or similar.
4. Blow through drain pipes.
5. Check flexible connections for leaks and dam-
1 Interconnected valves ages.
6. Check manometers and thermometers for pos-
Figure 2: Example 2 sible damages.

2012.05.15 - ES1
MAN Diesel & Turbo
604.03 Description
Treatment and maintenance of lubricating oil Page 4 (4)
Edition 11H

L32/40, L28/32H, V28/32H


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

Oxidation of oils
At normal service temperature the rate of oxidation
is insignificant, but the following factors will acceler-
ate the process:
High temperature
If the coolers are ineffective, the temperature level
will generally rise. A high temperature will also arise
in electrical pre-heaters if the circulation is not con-
tinued for 5 minutes after the heating has been
stopped, or if the heater is only partly filled with oil.
Catalytic action
Oxidation of the oil will be accelerated considerably
if catalytic particles are present in the oil. Wear par-
ticles of copper are especially harmful, but also fer-

2012.05.15 - ES1
MAN Diesel & turbo

Description 604.04
Page 1 (2) Criteria for Cleaning/Exchange of Lubricating Oil Edition 17H

General
Replacement of Lubricating Oil Unit : cSt (mm2/s)

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

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

Evaluation of the Lubricating Oil Condition Max. value : 0.2 %

Based on the analysis results, the following guidance Unit : Weight %


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

Normal min. max.
value value value 4. Base Number (BN)
SAE 30 [cSt@40° C] 95 - 125 75 160
Min. value : The BN value should not be lower
SAE 30 [cSt@100° C] 11 - 13 9 15 than 50% of fresh lubricating oil
value, but minimum BN level never
SAE 40 [cSt@40° C] 135 - 165 100 220 to be lower than 10-12 at operat-
ing on HFO!
SAE 40 [cSt@100° C] 13.5 - 15.0 11 19
Unit : mg KOH/g

Possible test
method : ASTM D-2896, ISO 3771

07.11 - ES1
MAN Diesel & turbo

604.04 Description
Edition 17H Criteria for Cleaning/Exchange of Lubricating Oil Page 2 (2)

General
The neutralization capacity must secure that the acidic Unit : Weight %
combustion products, mainly sulphur originate from
the fuel oil, are neutralized at the lube oil consumption Possible test
level for the specific engine type. Gradually the BN method : ASTM D-893 procedure B in n-
will be reduced, but should reach an equilibrium. Heptane, DIN 51592

Additionally
5. Total Acid Number (TAN) test : If the level in n-Heptane insolub­les
is considered high for the type of
Max. value : 3.0 acc. to fresh oil value oil and appli­ca­tion, the test could
be followed by a sup­ple­men­tary
Unit : mg KOH/g determination in To­lu­ene.

Possible test Total insolubles is maily derived from products of


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

Metal content Remarks Attention limits


6. Insolubles Content
Iron Depend upon max. 50 ppm
Max. value : 1.5 % generally, depending upon Chromium engine type and max. 10 ppm
Copper operating condi- max. 15 ppm
actual dispersant value and the Lead tions max. 20 ppm
increase in vis­co­si­ty. Tin max. 10 ppm
Aluminium max. 20 ppm
Silicon max. 20 ppm

07.11 - ES1
MAN Diesel

Description 604.05
Page 1 (1) Lubricating Points Edition 01H

General
Lubricating Oil Types used in the Engine.

Description Lub. Oil Type

Engine system lubricating oil. SAE 30 oil according to lubricating oil specification on page 604.01.

Turbocharger Engine system lubricating oil.

Governor See Governor instruction in section 609.

Air lubricator SAE 10W non-detergent oil.

Alternator See special instructions in section 618 or separate instruction.

Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12

92.02 - ES0U
MAN Diesel
Description 604.05
Page 1 (1) Lubricating Points Edition 02H

General
Lubricating Oil Types used in the Engine.

Description Lub. Oil Type

Engine system lubricating oil. SAE 40 oil according to lubricating oil specification on page 604.01.

Turbocharger Engine system lubricating oil.

Governor See Governor instruction in section 609.

Air lubricator SAE 10W non-detergent oil.

Alternator See special instructions in section 618 or separate instruction.

Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12

93.05 - ES0U
MAN Diesel
Description
Page 1 (1) Lubricating Oil in Base Frame 604.06
Edition 16H

L28/32H

Type L28/32H 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.

Min. level H2 (mm) 265 265 265 265 265


08028-0D/H5250/94.08.12

Max. level H3 (mm) 365 365 365 365 365

Min. litre H2 792 935 1078 1220 1362

Max. litre H3 1111 1311 1511 1710 1910

06.39 - ES1
MAN Diesel
Description 604.07
Page 1 (2) Specific Lubricating Oil Consumption - SLOC Edition 02H

General

Engine type RPM SLOC [g/kWh]

L16/24 1000/1200 0.4 - 0.8

L21/31 900/1000 0.4 - 0.8

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

L27/38 720/750 0.4 - 0.8

L28/32H 720/750 0.6 - 1.0

V28/32H 720/750 0.6 - 1.0

V28/32S 720/750 0.4 - 0.8

L32/40 720/750 0.7 - 1.1

Please note that only maximum continuous rating The engine maximum continuous design rating (PMCR)
(PMCR (kW)) should be used in order to evaluate the must always be used in order to be able to compare
SLOC, see the description 504.07. the individual measurements, and the running hours
since the last lubricating oil adding must be used
Please note, during engine running-in the SLOC may in the calculation. Due to inaccuracy *) at adding
exceed the values stated. lubricating oil, the SLOC can only be evaluated
after 1,000 running hours or more, where only the
The following formula is used to calculate the average values of a number of lubricating oil addings
SLOC: are representative.

SLOC [g/kWh] = Note *)


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

The lubricating oil density, ρ @ 15°C must be known


08028-0D/H5250/94.08.12

in order to convert ρ to the present lubricating oil


temperature in the base frame. The following formula
is used to calculate ρ:

ρlubricating oil [kg/m3] =

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

04.46 - ES1
MAN Diesel
Description 604.07
Page 2 (2) Specific Lubricating Oil Consumption - SLOC Edition 02H

General
08028-0D/H5250/94.08.12

04.46 - ES0
MAN Diesel & Turbo 3.3.3

Heavy fuel oil (HFO) specification

6680 3.3.3-01
Prerequisites
MAN four-stroke diesel engines can be operated with any heavy fuel oil
obtained from crude oil that also satisfies the requirements in Table 1, pro-
viding the engine and fuel processing system have been designed accord-
ingly. To ensure that the relationship between the fuel, spare parts and
repair / maintenance costs remains favorable at all times, the following points
should be observed.

Heavy fuel oil (HFO)


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

are installed.
Important Even though the fuel properties specified in the table entitled "The fuel speci-
fication and corresponding properties for heavy fuel oil" satisfy the above
requirements, they probably do not adequately define the ignition and com-
bustion properties and the stability of the fuel. This means that the operating
behaviour of the engine can depend on properties that are not defined in the
specification. This particularly applies to the oil property that causes forma-
tion of deposits in the combustion chamber, injection system, gas ducts and
2012-05-16 - de

exhaust gas system. A number of fuels have a tendency towards incompati-


bility with lubricating oil which leads to deposits being formed in the fuel
delivery pump that can block the pumps. It may therefore be necessary to
exclude specific fuels that could cause problems.
General

Blends The addition of engine oils (old lubricating oil, ULO –used lubricating oil) and
additives that are not manufactured from mineral oils, (coal-tar oil, for exam-
ple), and residual products of chemical or other processes such as solvents

6680 3.3.3-01 EN 1 (12)


3.3.3 MAN Diesel & Turbo

(polymers or chemical waste) is not permitted. Some of the reasons for this
are as follows: abrasive and corrosive effects, unfavourable combustion
6680 3.3.3-01

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

Sediment (potential) Weight % 0.1


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

ing oil, old oil). Fuel is consid-


ered as contaminated with
lubricating oil when the follow-
ing concentrations occur:
General

Ca > 30 ppm and Zn > 15


ppm or Ca > 30 ppm and P >
15 ppm.

2 (12) 6680 3.3.3-01 EN


MAN Diesel & Turbo 3.3.3

Asphaltene content Weight % 2/3 of coke residue Combustion properties

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

Heavy fuel oil (HFO) specification


2012-05-16 - de

General

6680 3.3.3-01 EN 3 (12)


3.3.3 MAN Diesel & Turbo
6680 3.3.3-01
Heavy fuel oil (HFO) specification

2012-05-16 - de
General

Figure 1: ISO 8217-2010 specification for heavy fuel oil

4 (12) 6680 3.3.3-01 EN


MAN Diesel & Turbo 3.3.3

6680 3.3.3-01
Heavy fuel oil (HFO) specification
2012-05-16 - de

General

Figure 2: ISO 8217-2010 specification for heavy fuel oil (continued)

6680 3.3.3-01 EN 5 (12)


3.3.3 MAN Diesel & Turbo
6680 3.3.3-01

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

prevent the formation of asphalt in heavy fuel oil). A settling tank is sufficient
for heavy fuel oils with a viscosity of less than 3802/s at 50 °C. If the heavy
fuel oil has a high concentration of foreign matter, or if fuels in accordance
with ISO-F-RM, G/H/K380 or H/K700 are to be used, two settling tanks will
be required one of which must be sized for 24-hour operation. Before the
content is moved to the service tank, water and sludge must be drained from
the settling tank.
Separators A separator is particularly suitable for separating material with a higher spe-
cific density – water, foreign matter and sludge, for example. The separators
2012-05-16 - de

must be self-cleaning (i.e. the cleaning intervals must be triggered automati-


cally).
Only new generation separators should be used. They are extremely effective
General

throughout a wide density range with no changeover required, and can sep-
arate water from heavy fuel oils with a density of up to 1.01 g/ml at 15 °C.

6 (12) 6680 3.3.3-01 EN


MAN Diesel & Turbo 3.3.3

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


tion)" shows the prerequisites that must be met by the separator. These limit

6680 3.3.3-01
values are used by manufacturers as the basis for dimensioning the separa-
tor and ensure compliance.
The manufacturer's specifications must be complied with to maximize the
cleaning effect.

Application in ships and stationary use: parallel installation


1 Separator for 100 % flow rate 1 Separator (reserve) for 100 % flow
rate

Figure 3: Location of heavy fuel oil cleaning equipment and/or separator


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

Definition Particle size Quantity


Inorganic foreign matter < 5 µm < 20 mg/kg
including catalyst particles
Al+Si content -- < 15 mg/kg
Water content -- < 0.2 % by vol. %
Table 2: Achievable proportion of foreign matter and water (after separation)
Water It is particularly important to ensure that the water separation process is as
2012-05-16 - de

thorough as possible as the water takes the form of large droplets, and not a
finely distributed emulsion. In this form, water also promotes corrosion and
sludge formation in the fuel system and therefore impairs the supply, atomi-
sation and combustion of the heavy fuel oil. If the water absorbed in the fuel
General

is seawater, harmful sodium chloride and other salts dissolved in this water
will enter the engine.

6680 3.3.3-01 EN 7 (12)


3.3.3 MAN Diesel & Turbo

Water-containing sludge must be removed from the settling tank before the
separation process starts, and must also be removed from the service tank
6680 3.3.3-01

at regular intervals. The tank's ventilation system must be designed in such a


way that condensate cannot flow back into the tank.
Vanadium/Sodium If the vanadium/sodium ratio is unfavorable, the melting point of the heavy
fuel oil ash may fall in the operating area of the exhaust-gas valve which can
lead to high-temperature corrosion. Most of the water and water-soluble
sodium compounds it contains can be removed by pretreating the heavy fuel
oil in the settling tank and in the separators.
The risk of high-temperature corrosion is low if the sodium content is one
third of the vanadium content or less. It must also be ensured that sodium
does not enter the engine in the form of seawater in the intake air.
If the sodium content is higher than 100 mg/kg, this is likely to result in a
higher quantity of salt deposits in the combustion chamber and exhaust-gas
system. This will impair the function of the engine (including the suction func-
tion of the turbocharger).
Under certain conditions, high-temperature corrosion can be prevented by
using a fuel additive that increases the melting point of the heavy fuel oil ash
(also see "Additives for heavy fuel oils”).
Ash Fuel ash consists for the greater part of vanadium oxide and nickel sulphate
(see above chapter for more information). Heavy fuel oils containing a high
proportion of ash in the form of foreign matter, e.g. sand, corrosion com-
pounds and catalyst particles, accelerate the mechanical wear in the engine.
Catalyst particles produced as a result of the catalytic cracking process may
be present in the heavy fuel oils. In most cases, these are aluminium silicate
particles that cause a high degree of wear in the injection system and the
engine. The aluminium content determined, multiplied by a factor of between
5 and 8 (depending on the catalytic bond), is roughly the same as the pro-
portion of catalyst remnants in the heavy fuel oil.
Homogeniser If a homogeniser is used, it must never be installed between the settling tank
and separator as otherwise it will not be possible to ensure satisfactory sepa-
ration of harmful contaminants, particularly seawater.
Flash point (ASTM D 93) National and international transportation and storage regulations governing
the use of fuels must be complied with in relation to the flash point. In gen-
eral, a flash point of above 60 °C is prescribed for diesel engine fuels.
Low-temperature behaviour The pour point is the temperature at which the fuel is no longer flowable
(ASTM D 97) (pumpable). As the pour point of many low-viscosity heavy fuel oils is higher
than 0 °C, the bunker facility must be preheated, unless fuel in accordance
Heavy fuel oil (HFO) specification

with RMA or RMB is used. The entire bunker facility must be designed in
such a way that the heavy fuel oil can be preheated to around 10 °C above
the pour point.
Pump characteristics If the viscosity of the fuel is higher than 1000 mm2/s (cST), or the tempera-
ture is not at least 10 °C above the pour point, pump problems will occur.
For more information, also refer to “Low-temperature behaviour
(ASTM D 97)”.
Combustion properties If the proportion of asphalt is more than two thirds of the coke residue (Con-
2012-05-16 - de

radson), combustion may be delayed which in turn may increase the forma-
tion of combustion residues, leading to such as deposits on and in the injec-
tion nozzles, large amounts of smoke, low output, increased fuel consump-
General

tion and a rapid rise in ignition pressure as well as combustion close to the
cylinder wall (thermal overloading of lubricating oil film). If the ratio of asphalt
to coke residues reaches the limit 0.66, and if the asphalt content exceeds
8%, the risk of deposits forming in the combustion chamber and injection

8 (12) 6680 3.3.3-01 EN


MAN Diesel & Turbo 3.3.3

system is higher. These problems can also occur when using unstable heavy
fuel oils, or if incompatible heavy fuel oils are mixed. This would lead to an

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

quality, flow properties and combustion quality, the bunker operator is


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

General

6680 3.3.3-01 EN 9 (12)


3.3.3 MAN Diesel & Turbo
6680 3.3.3-01

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


D Density [in kg/m3] at 15° C B The ignition characteristics can
be poor and require adapting the
engine or the operating condi-
tions.
CCAI Calculated Carbon Aromaticity C Problems identified may lead to
Index engine damage, even after a
short period of operation.
1 Engine type 2 The CCAI is obtained from the
straight line through the density
and viscosity of the heavy fuel
Heavy fuel oil (HFO) specification

oils.

Figure 4: Nomogram for determining the CCAI – assigning the CCAI ranges to engine
types
The CCAI can be calculated using the following formula:
CCAI = D - 141 log log (V+0.85) - 81
Sulphuric acid corrosion The engine should be operated at the cooling water temperatures prescribed
in the operating handbook for the relevant load. If the temperature of the
2012-05-16 - de

components that are exposed to acidic combustion products is below the


acid dew point, acid corrosion can no longer be effectively prevented, even if
alkaline lubricating oil is used.
The BN values specified in Section 3.3.6 are sufficient, providing the quality
General

of lubricating oil and the engine's cooling system satisfy the requirements.

10 (12) 6680 3.3.3-01 EN


MAN Diesel & Turbo 3.3.3

Compatibility The supplier must guarantee that the heavy fuel oil is homogeneous and
remains stable, even after the standard storage period. If different bunker oils

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

change in future if new methods are used for the production of low-sulphur
heavy fuel oil (desulphurisation, new blending components). MAN Diesel &
Turbo will monitor developments and inform its customers if required.
If the engine is not always operated with low-sulphur heavy fuel oil, corre-
sponding lubricating oil for the fuel with the highest sulphur content must be
selected.
2012-05-16 - de

Improper handling of operating fluids


If operating fluids are improperly handled, this can pose a danger to
health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.
General

6680 3.3.3-01 EN 11 (12)


3.3.3 MAN Diesel & Turbo
6680 3.3.3-01

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

2012-05-16 - de
General

12 (12) 6680 3.3.3-01 EN


MAN Diesel & Turbo 3.3.2

Diesel oil (MDO) specification

6680 3.3.2-01
Marine diesel oil
Other designations Marine diesel oil, marine diesel fuel.
Origin Marine diesel oil (MDO) is supplied as heavy distillate (designation ISO-F-
DMB) exclusively for marine applications. MDO is manufactured from crude
oil and must be free of organic acids and non-mineral oil products.

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

Oxidation resistance g/m3 ISO 12205 < 25


Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Copper strip test - ISO 2160 <1
Other specifications:
2012-03-21 - de

British Standard BS MA 100-1987 Class M2


ASTM D 975 2D
ASTM D 396 Nr. 2
General

Table 1: Marine diesel oil (MDO) – characteristic values to be adhered to


* For engines 27/38 with 350 resp. 365 kW/cyl the viscosity must not exceed
6 mm2/s @ 40 °C, as this would reduce the lifetime of the injection system.

6680 3.3.2-01 EN 1 (2)


3.3.2 MAN Diesel & Turbo
6680 3.3.2-01

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

Improper handling of operating fluids


If operating fluids are improperly handled, this can pose a danger to
Diesel oil (MDO) specification

health, safety and the environment. The relevant safety information by


the supplier of operating fluids must be observed.

Analyses
2012-03-21 - de

We can analyse fuel for customers at our laboratory. A 0.5 l sample is


required for the test.
General

2 (2) 6680 3.3.2-01 EN


MAN Diesel & Turbo 3.3.1

Gas oil / diesel oil (MGO) specification

6680 3.3.1-01
Diesel oil
Other designations Gas oil, marine gas oil (MGO), diesel oil
Gas oil is a crude oil medium distillate and therefore must not contain any
residual materials.

Military specification
Diesel oils that satisfy specification F-75 or F-76 may be used.

Specification
The suitability of fuel depends on whether it has the properties defined in this
specification (based on its composition in the as-delivered state).
The DIN EN 590 and ISO 8217-2010 (Class DMA or Class DMZ) standards
have been extensively used as the basis when defining these properties. The
properties correspond to the test procedures stated.
Properties Unit Test procedure Typical value
Density at 15 °C ≥ 820.0
kg/m3 ISO 3675 ≤ 890.0
Kinematic viscosity at 40 °C ≥2
mm2/s (cSt) ISO 3104 ≤ 6.0
Filterability*
in summer and °C DIN EN 116 ≤0
in winter °C DIN EN 116 ≤ -12
Flash point in closed cup °C ISO 2719 ≥ 60
Sediment content (extraction method) weight % ISO 3735 ≤ 0.01
Water content Vol. % ISO 3733 ≤ 0.05
Sulphur content ISO 8754 ≤ 1.5
Ash weight % ISO 6245 ≤ 0.01 Gas oil / diesel oil (MGO) specification
Coke residue (MCR) ISO CD 10370 ≤ 0.10
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Cetane number or cetane index - ISO 5165 ≥ 40
Copper strip test - ISO 2160 ≤1
2011-07-06 - de

Other specifications:
British Standard BS MA 100-1987 M1
ASTM D 975 1D/2D
General

Table 1: Diesel fuel (MGO) – properties that must be complied with.

6680 3.3.1-01 EN 1 (2)


3.3.1 MAN Diesel & Turbo

* The process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining
6680 3.3.1-01

the cloud point in accordance with ISO 3015

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

Improper handling of operating fluids


If operating fluids are improperly handled, this can pose a danger to
health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.

Analyses
Gas oil / diesel oil (MGO) specification

We can analyse fuel for customers at our laboratory. A 0.5 l sample is


required for the test.
2011-07-06 - de
General

2 (2) 6680 3.3.1-01 EN


MAN Diesel & Turbo 3.3.1

Bio fuel specification

6680 3.3.1-02
Biofuel
Other designations Biodiesel, FAME, vegetable oil, rapeseed oil, palm oil, frying fat
Origin Biofuel is derived from oil plants or old cooking oil.

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

TAN (total acid number) < 5 mg KOH/g DIN EN ISO 660


Filterability < 10 °C below the lowest temper- EN 116
ature in the fuel system
2011-03-25 - de

Table 1: Non-transesterified bio-fuel - Specifications


General

6680 3.3.1-02 EN 1 (2)


3.3.1 MAN Diesel & Turbo

Improper handling of operating fluids


6680 3.3.1-02

If operating fluids are improperly handled, this can pose a danger to


health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.

Analyses
We can analyse fuel for customers at our laboratory. A 0.5 l sample is
required for the test.
Bio fuel specification

2011-03-25 - de
General

2 (2) 6680 3.3.1-02 EN


MAN Diesel & Turbo 3.3.4

Viscosity-temperature diagram (VT diagram)

Viscosity-temperature diagram (VT diagram)


Explanations of viscosity-temperature diagram

Viscosity-temperature diagram (VT diagram)


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

Determining the viscosity-temperature curve and the required preheating temperature


Example: Heavy fuel oil with
2011-03-25 - de

Prescribed injection viscosity Required temperature of heavy fuel oil


180 mm²/s at 50 °C in mm²/s at engine inlet* in °C
≥ 12 126 (line c)
General

≤ 14 119 (line d)
Table 1: Determining the viscosity-temperature curve and the required preheating
temperature

6680 3.3.4-01 EN 1 (2)


3.3.4 MAN Diesel & Turbo

* With these figures, the temperature drop between the last preheating
device and the fuel injection pump is not taken into account.
Viscosity-temperature diagram (VT diagram)

A heavy fuel oil with a viscosity of 180 mm2/s at 50 °C can reach a viscosity
of 1000 mm2/s at 24 °C (line e) – this is the maximum permissible viscosity of
fuel that the pump can deliver.
A heavy fuel oil discharge temperature of 152 °C is reached when using a
recent state-of-the-art preheating device with 8 bar saturated steam. At
higher temperatures there is a risk of residues forming in the preheating sys-
tem – this leads to a reduction in heating output and thermal overloading of
the heavy fuel oil. Asphalt is also formed in this case, i.e. quality deterioration.
The heavy fuel oil lines between the outlet of the last preheating system and
the injection valve must be suitably insulated to limit the maximum drop in
temperature to 4 °C. This is the only way to achieve the necessary injection
viscosity of 14 mm2/s for heavy fuel oils with a reference viscosity of 700
mm2/s at 50 °C (the maximum viscosity as defined in the international specifi-
cations such as ISO CIMAC or British Standard). If heavy fuel oil with a low
reference viscosity is used, the injection viscosity should ideally be 12 mm2/s
in order to achieve more effective atomisation to reduce the combustion resi-
due.
The delivery pump must be designed for heavy fuel oil with a viscosity of up
to 1 000 mm2/s. The pour point also determines whether the pump is capa-
ble of transporting the heavy fuel oil. The bunker facility must be designed so
as to allow the heavy fuel oil to be heated to roughly 10 C above the pour
point.

Viscosity
The viscosity of gas oil or diesel oil (marine diesel oil) upstream of the
engine must be at least 1.9 mm2/s. If the viscosity is too low, this may
cause seizing of the pump plunger or nozzle needle valves as a result
of insufficient lubrication.

This can be avoided by monitoring the temperature of the fuel. Although the
maximum permissible temperature depends on the viscosity of the fuel, it
must never exceed the following values:
Viscosity-temperature diagram (VT diagram)

▪ 45 °C at the most with MGO (DMA) and MDO (DMB) and


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

2 (2) 6680 3.3.4-01 EN


MAN Diesel

Description 604.30
Page 1 (2) Fuel Oil Cleaning Edition 01H

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

Water content fuel oil and if more than one centrifuge is available,
below 1 % Parallel operation parallel operation in order to obtain an even lower
flow rate may be considered. However, in view of the
Extreme Density at 15°C Purifier / Purifier above results and recommendations serious consid-
conditions below 0.991 erations should be given to installing new equipment
in correspondance with today's fuel qualities and flow
High content Series operation recommendation.
of catalyst fines Purifier + Clarifier

Table 1. Cleaning of HFO.

92.04 - ES0S
MAN Diesel
604.30 Description
Edition 01H Fuel Oil Cleaning Page 2 (2)

General

For the determination of centrifuging capacity, we Flow Rate


generally advise to follow the recommendations of Related to Rated Capacity of Centrifuge
the centrifuge maker, but the curves on fig. 1, can %
be used as a guidance. 100
80
A Homogenizer may be installed in the fuel oil system
60
as a supplement to the centrifuges to homogenize
possible water and sludge still present in the fuel 40
after centrifuging. 20

Separation Temperature
°F °C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
100
15 25 45 75 130 cSt/80°C

Log scales 30 60 80 180 380 600 cST/50°C

200 400 600 1500 3500 6000 sec. RI/100°F

Fig. 1. Flowrate through centrifuge related to nominel capa-


city of centrifuge.

08028-0D/H5250/94.08.12

92.04 - ES0S
MAN Diesel & Turbo 3.3.7

Engine cooling water specifications

6680 3.3.7-01
Preliminary remarks
As is also the case with the fuel and lubricating oil, the engine cooling water
must be carefully selected, handled and checked. If this is not the case, cor-
rosion, erosion and cavitation may occur at the walls of the cooling system in
contact with water and deposits may form. Deposits obstruct the transfer of
heat and can cause thermal overloading of the cooled parts. The system
must be treated with an anticorrosive agent before bringing it into operation
for the first time. The concentrations prescribed by the engine manufacturer
must always be observed during subsequent operation. The above especially
applies if a chemical additive is added.

Requirements
Limit values The properties of untreated cooling water must correspond to the following
limit values:
Properties/Characteristic Properties Unit
Water type Distillate or fresh water, free of foreign matter. -
The following are prohibited: Seawater, brack-
ish water, river water, brines, industrial waste
water and rainwater.
Total hardness max. 10 °dH*
pH value 6.5 - 8 -
Chloride ion content Max. 50 mg/l**
Table 1: Cooling water - properties to be observed

*) 1°dH (German hard- ≙ 10 mg CaO in 1 litre of water ≙ 17.9 mg CaCO3/l


ness)
≙ 0.357 mval/l ≙ 0.179 mmol/l
**) 1 mg/l ≙ 1 ppm

Testing equipment The MAN Diesel water testing equipment incorporates devices that deter-
mine the water properties referred to above in a straightforward manner. The
manufacturers of anticorrosive agents also supply user-friendly testing equip-
Engine cooling water specifications
ment. For information on monitoring cooling water, refer to Work Card
000.07.

Additional information
Distillate If distilled water (from a fresh water generator, for example) or fully desalina-
ted water (from ion exchange or reverse osmosis) is available, this should
ideally be used as the engine cooling water. These waters are free of lime
and salts which means that deposits that could interfere with the transfer of
heat to the cooling water, and therefore also reduce the cooling effect, can-
2012-05-09 - de

not form. However, these waters are more corrosive than normal hard water
as the thin film of lime scale that would otherwise provide temporary corro-
sion protection does not form on the walls. This is why distilled water must
General

be handled particularly carefully and the concentration of the additive must


be regularly checked.

6680 3.3.7-01 EN 1 (8)


3.3.7 MAN Diesel & Turbo

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

overriding importance. The temporary hardness is determined by the carbo-


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

Damage to the cooling water system


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

Processing of engine cooling water


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

rosive chemical or an emulsifiable slushing oil.


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

Treatment of the cooling water


2012-05-09 - de

The engine must not be brought into operation without treating the
cooling water first.
General

2 (8) 6680 3.3.7-01 EN


MAN Diesel & Turbo 3.3.7

6680 3.3.7-01
Additives for cooling water
Only the additives approved by MAN Diesel and listed in the tables under the
section entitled "Approved cooling water additives“ may be used.
Required approval A cooling water additive may only be permitted for use if tested and
approved as per the latest directives of the ICE Research Association (FVV)
"Suitability test of internal combustion engine cooling fluid additives.” The test
report must be obtainable on request. The relevant tests can be carried out
on request in Germany at the staatliche Materialprüfanstalt (Federal Institute
for Materials Research and Testing), Abteilung Oberflächentechnik (Surface
Technology Division), Grafenstraße 2 in D-64283 Darmstadt.
Once the cooling water additive has been tested by the FVV, the engine
must be tested in the second step before the final approval is granted.
Only in closed circuits Additives may only be used in closed circuits where no significant consump-
tion occurs, apart from leaks or evaporation losses.

Chemical additives
Sodium nitrite and sodium borate based additives etc. have a proven track
record. Galvanised iron pipes or zinc sacrificial anodes must not be used in
cooling systems. This corrosion protection is not required due to the prescri-
bed cooling water treatment and electrochemical potential reversal can occur
due to the cooling water temperatures which are normally present in engines
nowadays. If necessary, the pipes must be deplated.

Slushing oil
This additive is an emulsifiable mineral oil with added slushing ingredients. A
thin film of oil forms on the walls of the cooling system. This prevents corro-
sion without interfering with the transfer of heat and also prevents limescale
deposits on the walls of the cooling system.
The significance of emulsifiable corrosion-slushing oils is fading. Oil-based
emulsions are rarely used nowadays for environmental protection reasons
and also because stability problems are known to occur in emulsions.

Anti-freeze agents
If temperatures below the freezing point of water in the engine cannot be
Engine cooling water specifications
excluded, an anti-freeze solution that also prevents corrosion must be added
to the cooling system or corresponding parts. Otherwise, the entire system
must be heated. (Military specification: Sy-7025).
Sufficient corrosion protection can be provided by adding the products listed
in the table entitled "Anti-freeze solutions with slushing properties" while
observing the prescribed concentration. This concentration prevents freezing
at temperatures down to -22 °C. However, the quantity of anti-freeze solu-
tion actually required always depends on the lowest temperatures that are to
be expected at the place of use.
2012-05-09 - de

Anti- freezes are generally based on ethylene glycol. A suitable chemical anti-
corrosive agent must be added if the concentration of the anti-freeze solution
prescribed by the user for a specific application does not provide an appro-
priate level of corrosion protection, or if the concentration of anti-freeze solu-
General

tion used is lower due to less stringent frost protection requirements and
does not provide an appropriate level of corrosion protection. For information
on the compatibility of the anti-freeze solution with the anticorrosive agent

6680 3.3.7-01 EN 3 (8)


3.3.7 MAN Diesel & Turbo

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


chemical additives indicated in the table „Nitrite-Containing Chemical Addi-
6680 3.3.7-01

tives“, their compatibility with ethylene glycol-based antifreezes has been


proved. Anti-freeze solutions may only be mixed with one another with the
consent of the manufacturer, even if these solutions have the same composi-
tion.
Before an anti-freeze solution is used, the cooling system must be thoroughly
cleaned.
If the cooling water contains an emulsifiable slushing oil, anti-freeze solution
must not be added as otherwise the emulsion would break up and oil sludge
would form in the cooling system.
Observe the applicable environmental protection regulations when disposing
of cooling water containing additives. For more information, consult the addi-
tive supplier.

Biocides
If you cannot avoid using a biocide because the cooling water has been con-
taminated by bacteria, observe the following steps:
▪ You must ensure that the biocide to be used is suitable for the specific
application.
▪ The biocide must be compatible with the sealing materials used in the
cooling water system and must not react with these.
▪ The biocide and its decomposition products must not contain corrosion-
promoting components. Biocides whose decomposition products con-
tain chloride or sulphate ions are not permitted.
▪ Biocides that cause foaming of cooling water are not permitted.

Prerequisite for effective use of an anticorrosive agent

Clean cooling system


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

Work Cards 000.03 and 000.08 by MAN Diesel).


Loose solid matter in particular must be removed by flushing the system
thoroughly as otherwise erosion may occur in locations where the flow veloc-
ity is high.
The cleaning agents must not corrode the seals and materials of the cooling
system. In most cases, the supplier of the cooling water additive will be able
to carry out this work and, if this is not possible, will at least be able to pro-
vide suitable products to do this. If this work is carried out by the engine
operator, he should use the services of a specialist supplier of cleaning
agents. The cooling system must be flushed thoroughly following cleaning.
2012-05-09 - de

Once this has been done, the engine cooling water must be treated immedi-
ately with anticorrosive agent. Once the engine has been brought back into
operation, the cleaned system must be checked for leaks.
General

4 (8) 6680 3.3.7-01 EN


MAN Diesel & Turbo 3.3.7

Regular checks of the cooling water condition and cooling water

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

Concentrations of chemical additives


The chemical additive concentrations shall not be less than the
minimum concentrations indicated in the table „Nitrite-containing
chemical additives“.

Excessively low concentrations can promote corrosion and must be avoided.


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

Subsequent checks of cooling water are especially required if the cooling


water had to be drained off in order to carry out repairs or maintenance.
General

6680 3.3.7-01 EN 5 (8)


3.3.7 MAN Diesel & Turbo
6680 3.3.7-01

Protective measures
Anticorrosive agents contain chemical compounds that can pose a risk to
health or the environment if incorrectly used. Comply with the directions in
the manufacturer's material safety data sheets.
Avoid prolonged direct contact with the skin. Wash hands thoroughly after
use. If larger quantities spray and/or soak into clothing, remove and wash
clothing before wearing it again.
If chemicals come into contact with your eyes, rinse them immediately with
plenty of water and seek medical advice.
Anticorrosive agents are generally harmful to the water cycle. Observe the
relevant statutory requirements for disposal.

Auxiliary engines
If the same cooling water system used in a MAN Diesel & Turbo two-stroke
main engine is used in a marine engine of type 16/24, 21/ 31, 23/30H, 27/38
or 28/32H, the cooling water recommendations for the main engine must be
observed.

Analysis
We analyse cooling water for our customers in our chemical laboratory. A 0.5
l sample is required for the test.

Permissible cooling water additives

Nitrite-containing chemical additives


Manufacturer Product designation Initial dosing for Minimum concentration ppm
1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)

Drew Marine Liquidewt 15 l 15,000 700 1,050


One Drew Plaza Maxigard 40 l 40,000 1,330 2,000
Boonton
New Jersey 07005
USA
Engine cooling water specifications

Wilhelmsen (Unitor) Rocor NB Liquid 21.5 l 21,500 2,400 3,600


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

Nalco Nalcool 2000 30 l 30,000 1,000 1,500


TRAC 102 30 l 30,000 1,000 1,500
TRAC 118 3l 3,000 1,000 1,500
General

Maritech AB Marisol CW 12 l 12,000 2,000 3,000


P.O.Box 143
S-29122 Kristianstad

6 (8) 6680 3.3.7-01 EN


MAN Diesel & Turbo 3.3.7

Manufacturer Product designation Initial dosing for Minimum concentration ppm

6680 3.3.7-01
1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)

Uniservice N.C.L.T. 12 l 12,000 2,000 3,000


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

Nitrite-free additives (chemical additives)


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

Emulsifiable slushing oils


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

General

6680 3.3.7-01 EN 7 (8)


3.3.7 MAN Diesel & Turbo

Anti-freeze solutions with slushing properties


6680 3.3.7-01

Manufacturer Product designation Minimum concentration


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

2012-05-09 - de
General

8 (8) 6680 3.3.7-01 EN


MAN Diesel & Turbo 000.07

Cooling water

6682 000.07-01
inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The fresh water used to fill the cooling water circuits must satisfy the specifi-
cations. The cooling water in the system must be checked regularly in
accordance with the maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the concentration of the anti-
corrosive agent.

Tools/equipment required
Equipment for checking the The following equipment can be used:
fresh water quality ▪ The MAN Diesel & Turbo water testing kit, or similar testing kit, with all
necessary instruments and chemicals that determine the water hardness,
pH value and chloride content (obtainable from MAN Diesel & Turbo or
Mar-Tec Marine, Hamburg)
Equipment for testing the When using chemical additives:
concentration of additives ▪ Testing equipment in accordance with the supplier's recommendations.
Testing kits from the supplier also include equipment that can be used to
determine the fresh water quality.

Testing the typical values of water


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

Cooling water
General

6682 000.07-01 EN 1 (2)


000.07 MAN Diesel & Turbo
6682 000.07-01

Testing the concentration of anticorrosive agents


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

2011-06-21 - de
Cooling water
General

2 (2) 6682 000.07-01 EN


MAN Diesel & Turbo 000.08

Cooling water system

6682 000.08-01
Cleaning
Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-
tive cooling of parts. Contamination and deposits must be regularly elimina-
ted.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.

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

nents being cooled.


Rust that has been flushed out may have an abrasive effect on other parts of
the system, such as the sealing elements of the water pumps. Together with
2010-02-09 - de

the elements that are responsible for water hardness, this forms what is
known as ferrous sludge which tends to gather in areas where the flow
velocity is low.
General

Products that remove limescale deposits are generally suitable for removing
rust. Suitable cleaning agents are listed alphabetically in the table entitled
"Cleaning agents for removing lime scale and rust deposits". Products by

6682 000.08-01 EN 1 (3)


000.08 MAN Diesel & Turbo

other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to clean-
6682 000.08-01

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

Only carry out the cleaning operation once the engine has
cooled down
Start the cleaning operation only when the engine has cooled down.
2010-02-09 - de

Hot engine components must not come into contact with cold water.
Open the venting pipes before refilling the cooling water system.
Blocked venting pipes prevent air from escaping which can lead to
thermal overloading of the engine.
General

2 (3) 6682 000.08-01 EN


MAN Diesel & Turbo 000.08

Cleaning products can cause damage

6682 000.08-01
The products to be used can endanger health and may be harmful to
the environment.
Follow the manufacturer's handling instructions without fail.

The applicable regulations governing the disposal of cleaning agents or acids


must be observed.

Cooling water system


2010-02-09 - de

General

6682 000.08-01 EN 3 (3)


MAN Diesel & Turbo 3.3.10

Water specification for fuel-water emulsions

Water specification for fuel-water emulsions


Prerequisites
The water used for the fuel-water emulsion is an operating fluid that must be
carefully selected, processed (if necessary) and monitored. If this is not done,
deposits, corrosion, erosion and cavitation may occur on the fuel system
components that come into contact with the fuel-water emulsion.

Specifications
Limit values The characteristic values of the water used must be within the following limit
values:
Properties/ Characteristic value Unit
Characteristic
Water type Seawater, brackish water, river water, brines, -
industrial waste water and rainwater, distilled
or fresh water
Total hardness max. 10 ºdH*
pH value 6.5 - 8 -
Chloride ion content max. 50 mg/l
Table 1: Fuel-water emulsion - characteristic values to be observed

*) 1º dH (German hard- ≙ 10 mg CaO ≙ 17.9 mg CaCO3/l


ness) in 1l water
≙ 0.357 mval/l ≙ 0.179 mmol/l

Testing instruments The MAN Diesel water testing kit contains instruments that allow the water
characteristics referred to above (and others) to be easily determined.

Additional information
Distillate If distillate (e.g. from the fresh water generator) or fully desalinated water (ion
exchanger) is available, this should ideally be used for the fuel-water emul-
sion. These types of water are free of lime and salts. Water specification for fuel-water emulsions
Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. It is largely determined by the calcium and magnesium
salts. The temporary hardness depends on the hydrocarbonate content in
the calcium and magnesium salts. The lasting (permanent) hardness is deter-
mined by the remaining calcium and magnesium salts (sulphates).
Water with hardness greater than 10°dH (German total hardness) must be
blended or softened with distillate. It is not necessary to increase the hard-
ness of extremely soft water.
2011-03-25 - de

Treatment with anticorrosive agents not required


Treatment with anticorrosive agents is not required and must be
omitted.
General

6680 3.3.10-01 EN 1 (1)


MAN Diesel & Turbo 3.3.11

Specifications for intake air (combustion air)

Specifications for intake air (combustion air)


General
The quality and condition of intake air (combustion air) have a significant
effect on the power output, wear and emissions of the engine. In this regard,
not only are the atmospheric conditions extremely important, but also con-
tamination by solid and gaseous foreign matter.
Mineral dust in the intake air increases wear. Chemicals and gases promote
corrosion.
This is why effective cleaning of intake air (combustion air) and regular main-
tenance/cleaning of the air filter are required.
When designing the intake air system, the maximum permissible overall pres-
sure drop (filter, silencer, pipe line) of 20 mbar must be taken into considera-
tion.

Requirements
Gas engines or dual-fuel engines may only be equipped with a dry filter. An
oil filter should not be installed, because they enrich air with oil mist, which is
not permissible for gas operated engines. Filters of efficiency class G4
according to EN 779 must be used. The concentrations downstream of the
air filter and/or upstream of the turbocharger inlet must not exceed the fol-
lowing limit values:
Properties Typical value Unit *
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm3
Chlorine max. 1.5
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 5
Salt (NaCl) max. 1
* One Nm3 corresponds to one cubic meter of
gas at 0 °C and 101.32 kPa. Specifications for intake air (combustion air)
Table 1: Intake air (combustion air) - typical values to be observed

Intake air shall not contain any flammable gases


Intake air shall not contain any flammable gases. Make sure that the
combustion air is not explosive.
2012-01-17 - de

General

6680 3.3.11-01 EN 1 (1)


Cylinder head

505/605
MAN Diesel & Turbo
Description 605.01
Page 1 (1) Cylinder head
Edition 14H

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

Air inlet and exhaust valves


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

1990.10.29 - ES0
MAN Diesel & Turbo

Working Card 605-01.00


Page 1 (2) Dismantling of Cylinder Head Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62021 10
Shut-off fuel oil 62021 01 Oil injector,
Shut-off cooling oil (complete)
Stopped lub. oil circul.
62021 50 6 Piece
62021 51 1 Piece
62021 15
Description: 62005 01
62021 25 Hydraulic tools
Dismantling of cylinder head for inspection 62014 15
and/or overhaul.

Starting position:

Cooling water has been drained from engine. Hand tools:

Ring and open end spanner 14 mm.


Ring and open end spanner 17 mm.
Ring and open end spanner 24 mm.

Related procedure:

Dismounting of piston and connecting


rod, 606-01.00
Dismounting and inspection of inlet valve,
exhaust valve and valve guide, 605-01.05
Safety valve, 605-01.25
Dismantling, overhaul and test
pressure of fuel oil valve, 614-01.10

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty./


Capacity : 2 men

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel & Turbo
605-01.00 Working Card
Edition 01H Dismantling of Cylinder Head Page 2 (2)

L/V28/32H
1) Open the drain cock and vent cock for cool­
ing water. 8) Remove the exhaust pipe flange screws.

2) Take off the rocker arm top cover. 9) Remove the cylinder head nuts, as shown,
by means of hydraulic jacks, see working card
3) Take off the cover which gives access to the 620-01.05.
injection pump.
10) Mount the lifting tool on the cylinder head.
4) Disconnect the fuel oil high-pressure pipe.
11) Attach the hook to the lifting tool and lift the
5) Disconnect the cooling oil pipes, (inlet and cylinder head away.
outlet.

6) Disconnect the rocker arm lubricating oil pi­
pe. V28/32H
L28/32H
7) Remove the thermometer attachment bran-
ch (cooling water outlet pipe).

Fig. 2

Fig. 1

91.45 - ES0S
MAN Diesel & Turbo

Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05


Page 1 (3) Valve Guide Edition 06H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62005 01
Shut-off fuel oil 62005 05
Shut-off cooling oil 62005 25/30 Extra tools
Stopped lub. oil circul. 62005 55

Description

Dismounting of inlet and exhaust valve, inspec-


tion of valve guide and mounting of inlet and
exhaust valve. Hand tools

Ring and open end spanner, 19 mm.


Ring and open end spanner, 24 mm.
Starting position Small screw driver.
Measuring tools.
Cylinder head, dismantled from
engine 605-01.00

Related procedure

Reconditioning of valve spindle seat


and valve seat ring, 605-01.10
Valve rotator, 605-01.15
Replacement of valve guide, 605-01.20
Replacement of valve seat ring, 605-01.35
Mounting of cylinder head, 605-01.45

Man power Replacement and wearing parts

Working time : 1 hour Plate no Item no Qty. /


Capacity : 1 man
60501 017 4/cyl.
Data

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

00.43 - ES0
MAN Diesel & Turbo

605-01.05 Inspection of Inlet Valve, Exhaust Valve and Working Card


Edition 06H Valve Guide Page 2 (3)

L+V28/32H
Dismantling of Inlet and Exhaust Valve 3) Turn back the rocker arm and remove the spring-
Spind­les loaded valve bridge over the valve spindles.

1) Land and fasten the cylinder head upon the spe­­ 4) After having removed the valve bridge and
cial work table and remove the lifting tool. turn­ed the rocker arm back, the tool should
be fit­ted by means of the screws (A), see fig 2
tightened in the threaded holes in the cy­linder
Or as an Alternative: head.

and the cylinder head on the floor upon wood­en


L
supports and remove the lifting tool.

2) Mount the supporting devices for the valve


spindle heads on the work table.

Or as an Alternative:

Place wooden blocks under the valve spindle heads.

V28/32H
L28/32H

Fig 2

5) Now compress the valve springs by tigh­ten­


ing the nut (B), after which the cone rings can
be re-moved, see fig 3.

Fig 1 Fig 3

00.43 - ES0
MAN Diesel & Turbo

Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05


Edition 06H
Page 3 (3)
Valve Guide

L+V28/32H

6) Release the springs again. Remove the nut Inspection of valve guide
(B) and the traverse (C). Now valve rotator
and springs can be removed. 10) Too much clearance between valve spindle
and spindle guide may cause in­creas­ed lub. oil
7) Remove the supporting devices under the work consumption, fouling up of the spindle guide and
table and take out the valve spindle. thus give the risk of a sticking valve spindle.

8) Repeat point 4 - 7 to remove the two other Too much clearance also means in­suf­fi­cient
valve spindles. guid-ance of the valve spindle, and thus bad
alignment between spind­le head and valve
seat ring. In con­nec­tion with overhaul of the
Inspection of Valves/Valve Seats cylinder head, the valve spindle guides should
be cleaned, inspected and measured for wear.
9) A slight grinding of valve/valve seat can be If the inner diameter of the valve spindle guide
carried out by means of the handle as shown, exceeds the tolerance, see page 600.35 the
see fig 4. valve spindle guide must be replaced. See
working card 605-01.20.
I f the valve seat is heavily burnt or scarred, it should
be ground using the valve seat grinder according to 11) For mounting of valve spindle follow the in-
working card 605-01.10. structions in point 4 - 7 in reversed order.

Fig 4 Fig 5

00.43 - ES0
MAN Diesel & Turbo

Working Card Reconditioning of Valve Spindle Seat 605-01.10


Page 1 (3) and Valve Seat Ring Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62005 40 Grinding machine
Shut-off fuel oil for valve spindle.
Shut-off cooling oil 62005 35 Grinding machine
Stopped lub. oil circul. for valve seat ring.
(Extra tools).

Description:

Reconditioning of valve spindle seat and valve


seat ring, with special grinding machine.
Hand tools:

All the hand tools and new stones, are included


in the tools box for grinding machine.
Starting position:

Valve spindle has been removed, 605-01.05

Related procedure:

Mounting of valve spindle, 605-01.05

Man power: Replacement and wearing parts:

Working time : 6 Hours Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel & Turbo

605-01.10 Reconditioning of Valve Spindle Seat Working Card


Edition 01H and Valve Seat Ring Page 2 (3)

L/V28/32H
Reconditioning of Valve Seat Ring. However when the seat "S" has been ground to such
an extent, that the recess "R" disappears, the valve
Reconditioning of valve seat rings by machining is seat ring has to be scrapped and a new one to must
carried out by means of a grinding machine, the installed, see working card 605-01.35
pilot spindle of which is to be mounted in the valve
spindle guide. For operation of the grinding machine,
see separate instructions. Reconditioning of Valve Spindle.

The grinding of the valve seat ring should be carried Reconditioning by machining is carried out with the
out according to the following sequence: valve spindle being rotated in a turning lathe and a
special grinding machine mounted on the tool post
1) The seating surface itself is ground with a feed of the turning latch.
at an angle "A" of 30° ± 0,10°.
0.
For operation of the grinding machine, see se­pa­ra­
The grinding should be continued until a clean and ted instructions.
uniform surface condition has been obtained.
1) The seating surface itself is ground with a feed
Carry out the final grinding with a feed in direction at an angel "A" of 30° ± 0.0,25°.
from inside to outwards, as normally the best surface
quality is obtained in this way. 2) The grinding shoud be continued until a clean
and uniform surface condition has been obtained.

3) After completing the grinding, the height "H"1


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

"S" If measured to be less, the spindle has to be scrap­


ped.

"H"1
Fig. 1.

"A" 30° ± 0,25°


0

2) Normally the valve seat ring can be re­con­di­


tion­ed several times.
Fig. 2.

91.45 - ES0S
MAN Diesel & Turbo

Working Card Reconditioning of Valve Spindle Seat 605-01.10


Page 3 (3) and Valve Seat Ring Edition 01H

L/V28/32H
After assembling the valves, check - on account of
the valve motion - that distance "H"2 between the
upper edge of the cylinder head and the upper edge
of the valve spindle does not exceed the maximum
value, see page 600.35.

"H"2

Fig. 3.

91.45 - ES0S
MAN Diesel & Turbo

Working Card 605-01.15


Page 1 (2) Valve Rotator Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62005 05
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Dismantling, inspection and mounting of valve


rotator. Hand tools:

Small screw driver.


Ring and open end spanner 24 mm.

Starting position:

Valve spindles has been removed, 605-01.05

Related procedure:

Mounting of valve spindles, 605-01.05

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel & Turbo

605-01.15 Working Card


Edition 01H Valve Rotator Page 2 (2)

L/V28/32H

Inspection of Rotocap. When inserting the balls and the tangential springs,
note that all balls on the inclined races of the ball
Dirt especially in the ball pockets due to residues in pockets point in the same direction, see fig. 1.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and hinder the
movement of the balls.

Rotocap valve rotators need no servicing under


normal operating conditions.

Unusual operating conditions may lead to di­stur­ban­


ces. Rotation of the valve should be checked at the
intervals specified in the "Maintenance program".
Rotator performance is satisfactory when the valve
rotates visibly and evenly.
Fig. 1.

Dismantling of Rotocap.

See working card 605-01.05, point 3 to 6. The inner ring of the spring washer should rest on
the retainer body.

Overhauls Note ! Having assembled the valve rotator in dry


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

91.45 - ESOS
MAN Diesel & Turbo

Working Card 605-01.20


Page1 (2) Replacement of Valve Guide Edition 05H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62005 60 Lytra tools
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Dismantling and mounting of valve guide, for inlet


and exhaust valve. Hand tools

Hammer.
Nitrogen (N2), or similar.

Starting position

Valve spindle has been removed, 605-01.05

Related procedure

Mounting of valve spindles, 605-01.05

Man power Replacement and wearing parts

Working time : 3/4 Hour Plate no. Item no. Qty. /


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

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

00.43 - ES0
MAN Diesel & Turbo

605-01.20 Working Card


Edition 05H Replacement of Valve Guide Page 2 (2)

L+V28/32H
If the clearance exceeds the shown max. limit, (see 3) Before mounting the new valve guide, it has to
page 600.35), the valve guide must be replaced. be cooled down to approx. -70°C with nitrogen
or similar.

Dismounting of valve guide When the new valve guide has been inserted
into the bore be sure that the shoulder bears
1) The valve guide is knocked out from the bot­tom against the cylinder head, by knocking slightly
of the cylinder head,by means of a mandrel, with the mandrel and a hammer.
which has a shoulder turning that fits into the
valve guide, see fig. 1. 4) Before mounting of the valve spindle insert a
new o-ring in the valve guide.

Valve seat ring

Mandrel

Fig 2.
Valve guide

Correct mounting can easily be done by the use of


two valve spindles as mounting tool, one spindle to
be used as support and the other spindle to be used
Fig 1 for pushing the o-ring downwards.

Screw drivers or other sharp tools should never be


2) After having knocked out the valve guide, ca- used for this purpose.
refully clean the bore of the cylinder head and
inspect for marks that can prvent mounting of 5) For mounting of valve spindle, see working
a new valve guide. card 605-01.05.

00.43 -ESO
MAN Diesel & Turbo

Working Card
Safety Valve 605-01.25
Page 1 (3) Edition 04H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62014 01 Pressure test
Shut-off fuel oil pump.
Shut-off cooling oil 62014 04 Pipe for fuel
Stopped lub. oil circul. injector

Description: Hand tools:

Dismantling, inspection, reassembling and Open end spanner, 32 mm.


pressure testing of safety valve. Small hammer.
Copaslip.

Starting position:

Related procedure:

Indicator valve 605-01.26

Man power: Replacement and wearing parts:

Working time : 1 hour Plate no Item no Qty. /


Capacity : 1 man
60508 14 1/cyl.

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.27 - ES0S
MAN Diesel & Turbo

605-01.25 Working Card


Edition 04H Safety Valve Page 2 (3)

L+V28/32H
Maintenance and Checking. 2. Reassembling.

During extended periods of standstill and at general 2.1 Lubricate the threads on valve housing (2)
engine overhauls, the safety valves should be tho­ with copaslip or similar.
rough­ly cleaned.
2.2 Reassemble the safety valve, reverse se-
Note: Do not attempt to stop a safety valve from quence of operations outlined above, point 1.1 to
leaking by increasing the spring load. 1.5.

The setting of the opening pressure is stamped onto


the cap nut (1), see fig 1. 3. Test of Safety Valve.

The valve is to be tested after each overhaul by


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

3.2 Vent the system by pumping until the oil


flows free of air bubbles through the valve ports (7)
in the valve housing (2).

Leakage Test

3.3 Increase the pressure to 135 bar.

3.4 Check that the pressure do not sink below


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

Fig 1. Safety valve


OK Continue with point 3.5.

below 135 bar Scrap the valve.


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

1.5 Inspect and carefully clean all parts and


con­di­tion valve, if necessary.

96.27 - ES0S
MAN Diesel & Turbo

Working Card 605-01.25


Page 3 (3) Safety Valve Edition 04H

L+V28/32H
Test of Opening Pressure 4. Adjustment of Opening Pressure

3.5 Increase the pressure to the opening pres- 4.1 Increase the pressure to the opening pres-
sure. sure.

4.2 Turn the cap nut (1) to the correct opening


pressure.
If the opening pressure is Then
4.3 Drill a new hole for mounting of split pin
(5).
OK The procedure is ended.

Not OK The valve must be 5. Mounting of Safety Valve


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

5.2 Mount the safety valve on the cylinder


head.

96.27 - ES0S
MAN Diesel & Turbo

Working Card 605-01.26


Page 1 (2) Indicator Valve Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate No Item No Note


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

Description:

Dismounting, inspection and mounting of indi-


cator valve. Hand tools:

Ring and open end spanner 10 mm


Ring and open end spanner 27 mm
Steel brush
Copaslip
Starting position:

Related procedure:

Safety valve 605-01.25

Man power:

Working time : 1/2 hour


Capacity : 1 man
Replacement and wearing parts:

Data: Plate No Item No Qty./

Data for pressure and tolerance (Page 600.35) 60508 16 1/Cyl.


Data for torque momen (Page 600.40)
Declaration of weight (Page 600.45)

94.26 - ES0S
MAN Diesel & Turbo

605-01.26 Working Card


Edition 02H Indicator Valve Page 2 (2)

L+V28/32H
Maintenance

By normal working conditions the indicator valve


require very little maintenance except an inspec-
tion in connection with the normal cylinder cover
overhaul.

Inspection of the Indicator Valve:

1. Disassemble the indicator valve.

2. Check the valve seat and the cone for "burning


through".

If the valve seat in the housing is "burned", the entire


valve is to be replaced. 1. Indicator valve, complete
2. Connecting piece
3. Clean and lubricate all components before
remounting.
Fig 1 Indicator valve.
4. Ensure that the spindle is in "OPEN" position
when assembling the valve.

NOTE: Otherwise cone and seat may be dama-


ged.

94.26 - ES0S
MAN Diesel & Turbo

Working Card 605-01.30


Page 1 (2) Replacement of Sleeve for Fuel Injector Edition 04H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note.


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

Description

Dismounting, inspection and mounting of sleeve


for fuel injector. Hand tools

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

Related procedure

Mounting of fuel valve, 614-01.10

Man power Replacement and wearing parts

Working time : 1 Hour Plate no. Item no. Qty./


Capacity : 1 man
60501 125 1/cyl.
Data 60501 137 1/cyl.
60501 149 1/cyl.
Data for pressure and tolerance (Page 600.35)
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

00.43 - ES0
MAN Diesel & Turbo

605-01.30 Working Card


Edition 04H Replacement of Sleeve for Fuel Injector Page 2 (2)

L+V28/32H
Dismounting of Sleeve for Fuel Injector 4) Coat the sealing ring zone in the bore with
grea­se or lub. oil.
1) Remove the snap ring by means of two screw
drivers.

2) The sleeve can now be driven out of the bo­ Snap ring
re by use of a brass mandrel and a hammer. O-ring
Sleeve
Loctite 572

Brass mandrel

Fig 2

5) Install new sealing rings on the sleeve.

6) Coat the sealing surfaces on the sleeve with


Fig 1 loctite 572.

7) Insert the sleeve in the bore.


Inspection of Bore in Cylinder Head and
mount­ing of the Sleeve: 8) Mount the snap ring.

3) Clean and inspect the bore in the cylinder head.


Any marks which could pre­vent mounting of
the sleeve, should be gent­ly smoothed.

00.43 - ES0
MAN Diesel & Turbo

Working Card 605-01.35


Page 1 (4) Replacement of Valve Seat Ring Edition 06H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62021 01
Shut-off fuel oil 62021 50 1 piece
Shut-off cooling oil 62005 45 Extra tools
Stopped lub. oil circul. 62005 50 Extra tools
62021 46 1 piece

Description

Replacement of valve seat ring, for inlet and


exhaust valve.

Starting position

Inlet and exhaust valves have been Hand tools


removed, 605-01.05
Ring and open end spanner 36 mm
Hammer.
Loctite, 648.
Lub. oil.
Related procedure

Mounting of valve spindles, 605-01.05

Man power Replacement and wearing parts

Working time : 1 1/2 Hours Plate no. Item no. Qty. /


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

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

00.43 - ES0
MAN Diesel & Turbo

605-01.35 Working Card


Edition 06H Replacement of Valve Seat Ring Page 2 (4)

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

9
3

5
10
6

1 Stud 6 Eye screw


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

2) The guide disc (3) is positioned so that it bears
against the bottom of the cylinder head, and the
hydraulic jack is clamped with the disc (4) and
Fig 1
collar nut hexagon (2), see fig 1. The hydraulic
jack is the one used for main bearing caps.

00.43 - ES0
MAN Diesel & Turbo

605-01.35
Working Card
Page 3 (4) Replacement of Valve Seat Ring Edition 06H

L+V28/32H
3) By pumping up the pack, see working card 3) To facilitate mounting of the valve seat ring it is
620-01.05 for the use of hydraulic tools, the cooled down, however to no more than -25°C
valve seat is pressed out max. 6 mm, and the or the O-ring can be damaged.
pressure is released again.The collar nut hexa-
gon is tightenied and the operation is continued 4) Place the O-ring on the valve seat ring and
until the valve seat ring can be removed. coat with oil/loctite as shown in fig 4, just before
positioning it in the bore.

Mounting of Valve Seat Rings

1) Prior to mounting of a new valve seat ring, the


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

Fig 4

5) The valve seat ring is positioned in the bore,


handle with stud inserted as shown in fig 5,
and washer with screw is screwed tight.
1

3
4

1 Handle 2 Stud
3 Washers 4 Hexagon nut
with collar

Fig 5

Fig 3

00.43 - ES0
MAN Diesel & Turbo

605-01.35 Working Card


Edition 06H Replacement of Valve Seat Ring Page 4 (4)

L+V28/32H

6) By knocking on the handle and at the same


time tightening the nut (4), the valve seat ring
slides in place in the bore and it is felt on the
knocks when it bears in the bore.

7) Prior to mounting of the valve spindle the valve


seat ring must be ground to ensure correct
centering of valve guide and valve seat ring.
This can be done according to working card
605-01.05 or 605-01.10.

00.43 - ES0
MAN Diesel & Turbo

Working Card 605-01.40


Page 1 (2) Mounting of Cylinder Head Edition 06H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62021 10
Shut-off fuel oil 62021 01
Shut-off cooling oil 62021 50 6 Pieces
Stopped lub. oil circul. 62021 51 1 Piece
62021 15
62005 01
62010 01
Description 62021 25
62014 15
Mounting of cylinder head after inspection and/or
overhaul.

Hand tools
Starting position
Ring and open end spanner, 14 mm.
Cylinder head is completely Ring and open end spanner, 17 mm.
assembled, 605-01.05 to 605-01.35 Ring and open end spanner, 24 mm.
Valve gear of respective cylinder is in right posi- Lub. oil and copaslip.
tion (valve closed).
Control of the surface on the
cylinder liner, 606-01.45

Related procedure

Adjustment of valve clearance 608-01.10

Replacement and wearing parts


Man power
Plate no. Item no. Qty. /
Working time : 1 1/2 Hour
Capacity : 2 men 60501 269 2/cyl.
60510 08 1/cyl.
Data 60610 01 2/cyl.
61202 31 1/cyl.
Data for pressure and tolerance (Page 600.35) 61625 01 2/cyl.
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

00.44 - ES0
MAN Diesel & Turbo

605-01.40 Working Card


Edition 06H Mounting of Cylinder Head Page 2 (2)

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

3) Attach the lifting tool to the cylinder head that


has been made ready for installation, and
position it carefully on the cylinder liner.

V28/32H
L28/32H

Fig 2

7) If new studs or nuts have been fitted, the nuts


must be tightened and loosened three times,
in order to compensate for deformation of the
thread and in order to ensure a safe minimum
load of the studs through the tightening.

8) Adjust the valve clearance, see working card


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

00.44 - ES0
MAN Diesel & Turbo

Working Card 605-01.45


Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Inspection of cylinder head cooling water


space. Hand tools:

Steel brush

Starting position:

The cylinder head dismantled


from engine, 605-01.00

Related procedure:

Man power:

Working time : ¼ Hour Replacement and wearing parts:


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

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

93.20 - ES0S
MAN Diesel & Turbo

605-01.45 Working Card


Edition 01H Inspection of Cylinder Head Cooling Water Space Page 2 (2)

L/V28/32H
Inspection of Cylinder Head Cool. Water Space.

1) Inspect the cooling water inlet at the bottom


and the cooling water outlet in the top of the cylinder Cooling water,
head, see fig. 1. outlet

2) Remove all possible deposits.

3) Pour water into the cooling water outlet and


make sure, that water is coming out of all the cooling
water inlet bores at the bottom of the cylinder
head.

4) Clean if necessary the cooling water inlet and


outlet by means of a steel brush. Flush the cooling
water space after cleaning.
Cooling
water, inlet
5) Should the cylinder head cooling water space
contrary to expectation be blocked with deposits,
contact MAN B&W Diesel, Holeby for further instruc- Fig. 1. Cylinder Head
tions.

93.20 - ES0S
MAN Diesel
Plate
Page 1 (2) Cylinder Head 60501-19H

L+V28/32H

091 125
101
137
113
149
101
017
113 029
054 162
174
066
186
078

198

208
270
221
233
245
030
042 257

269

304

282

294

03.44 - ES0
MAN Diesel

Plate
60501-19H Cylinder Head Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 4/C O-ring O-ring 304 Cylinder head (as 294) Cylinderdæksel (som
with brackets and 294) monteret med buk-
029 4/C Valve guide, inlet and Ventilstyr, indstr. og rockerarms installed ke og vippearne.
exhaust udstr.

030 6/C Plug screw Propskrue

042 6/C Gasket Pakning

054 2/C Nut Møtrik

066 2/C Distance pipe Afstandsrør

078 2/C Stud Tap

091 2/C Thrust collar Trykflange

101 4/C Plug screw Propskrue

113 4/C Gasket Pakning

125 1/C Snap ring Låsering

137 1/C Sleeve for fuel valve Foring for br. ventil

149 1/C O-ring O-ring

162 8/C Nut Møtrik

174 8/C Stud Tap

186 4/C Stud Tap

198 4/C Spring pin Fjederstift

208 2/C Plug screw Propskrue

221 2/C Screw Skrue

233 2/C Coupling Kobling

245 4/C O-ring O-ring

257 4/C Valve seat ring, Ventilsædering,


(inlet and exhaust) (indstr. og udstødning)

269 2/C O-ring O-ring

270 2/C Plug screw Propskrue

282 Cylinder head with Cylinderdæksel mon-


valve guide sleeve for teret med spindelstyr,
fuel valve and valve foring for br. ventil og
seat rings ventilsæderinge

294 Cylinder head (as 282) Cylinderdæksel (som


with valve spindles 282), monteret med
installed ventilspindler

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

03.44 - ES0
MAN Diesel

Plate
Page 1 (2) Valve Spindles and Valve Gear 60502-31H

L+V28/32H
19
20
21
32
03

27
28
29
01
34
30
02
35
36 31
38 13
19
04
14
05
06
06 07
07

15

16
08 17
08
09
09
10 10

11
11
33
08028-0D/H5250/94.08.12

22/23

25

26
12
12
37

08.28 - ES0
MAN Diesel

Plate
60502-31H Valve Spindles and Valve Gear Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 2/C Thrust piece Trykstykke 28 2/C Rocker arm Vippearm

02 2/C Nut Møtrik 29 2/C Thrust screw Trykskrue

03 4/C Plug screw Propskrue 30 2/C Bearing bush Lejebøsning

04 1/C Valve bridge, Ventilbro, 31 2/C Thrust pin Trykskrue


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

13 1/C Valve bridge,exhaust Ventilbro, udstødning 38 /I Loctite 243 Loctite 243

14 2/C Thrust piece Trykstykke

15 2/C Spring Fjeder

16 2/C Ball guide Kuglestyr

17 2/C Securing ring Sikring

19 4/C Rocker arm bracket Buk for vippearm inkl


incl spring pin spændstift

20 2/C Rocker arm shaft Aksel for vippearm

21 2/C Rocker arm, compl. Vippearm, komplet


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

22 24/C Spring Fjeder


08028-0D/H5250/94.08.12

23 24/C Ball Kugle

25 4/C Spring washer Fjederskive

26 4/C Retainer ring Låsering

27 2/C Nut Møtrik

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./ = Qty./Individual Antal/I = Antal/Individuelt

08.28 - ES0
MAN Diesel

Plate
Page 1 (2) Safety Valve and Indicator Valve 60508-11H

L+V28/32H

18

16

17

15

94.25 - ES0S
MAN Diesel

Plate
60508-11H Safety Valve and Indicator Valve Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

03* 1/C Valve cone Ventilkugle

06* 1/C Pressure spring Trykfjeder

13 1/C Safety valve, com- Sikkerhedsventil,


plete incl. item 03, komplet inkl. item 03,
06, 25, 26, 27, 28 06, 25, 26, 27, 28

14 1/C Gasket Pakning

15 1/C Gasket Pakning

16 1/C Gasket Pakning

17 1/C Connecting piece Forbindelsesstykke

18 1/C Indicator valve, Indikatorventil,


complete komplet

25* 1/C Valve housing Ventilhus

26* 1/C Valve spindle Ventilspindel

27* 1/C Cap nut Dækselmøtrik

28* 1/C Split pin Fjedernot

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

94.25 - ES0S
MAN Diesel

Plate
Page 1 (2) Cylinder Head, Top Cover 60510-12H

L+V28/32H

01

02

05, 16

06

07

15
13

08
09
10

11

06.32 - ES0S
MAN Diesel

Plate
60510-12H Cylinder Head, Top Cover Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 4/C Handle Håndtag

02 4/C O-ring O-ring

05 4/C Nut Møtrik

06 1/C Top cover Topdæksel

07 1/C Top cover, compl. Topdæksel, kompl.


incl. item Nos. inkl. pos. nr.
01, 02, 05, 06 01, 02, 05, 06

08 1/C Gasket Pakning

09 6/C Spring pin Fjederstift

10 1/C Coaming Karm

11 1/C Gasket Pakning

13 18/C Washer Skive

15 18/C Screw Skrue

16 /I Loctite 638 Loctite 638

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

06.32 - ES0S
Piston/connecting rod

506/606
MAN Diesel

Description
Piston, Connecting Rod and Cylinder Liner 606.01
Page 1 (1)
Edition 10H

L/V28/32H
Piston

The piston, which is oil-cooled and of the monobloc The big-end bearing is of trimetal type, i.e. steel shells
type made of nodular cast iron, is equipped with 3 lined with tin-aluminium or lead-bronze coated with
compression rings and 1 scraper ring. a running layer. Design as plain type or rillentype.
The bearing shells are of the precision type and are
By the use of a combination of compression rings therefore to be fitted without scraping or any other
with different barrel-shaped profiles and chrome- kind of adaption.
plated running surface on all rings, the piston ring
pack is optimized for maximum sealing effect and The small-end bearing is of trimetal type and is pres-
minimum wear rate. sed into the connecting rod.

The piston has a cooling oil space close to the piston


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

Connecting Rod Tell-tale borings in the frame, starting from a level


between the sealing rings and leading to the exterior
The connecting rod is die-forged. The big-end has an will reveal any sealing malfunction by sign of leaking
inclined joint in order to facilitate the piston and con- water or lubricating oil mist.
necting rod assembly to be withdrawn up through the
cylinder liner. The joint faces on connecting rod and
bearing cap are serrated to ensure precise location
and to prevent relative movement of the parts.
08028-0D/H5250/94.08.12

90.43 - ES0U
MAN Diesel
Working Card 606-01.00
Page 1 (3) Dismounting of Piston and Connecting Rod Edition 01H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 01
Shut-off fuel oil 62006 03
Shut-off cooling oil 62006 09 2 pieces
Stopped lub. oil circul. 62006 22
62006 28 140 - 760 Nm
62010 01

Description: Tool combination for dismounting of connecting


rod screw, see working card 620-01.20.
Dismounting of piston and connecting rod as-
sembly, for inspection and/or overhaul.

Starting position: Hand tools:

Cylinder head has been dismounted Threaded pin M16.


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

Separation of piston and connecting


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

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty./


Capacity : 2 men

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.06 - ES0S
MAN Diesel
606-01.00 Working Card
Edition 01H Dismounting of Piston and Connecting Rod Page 2 (3)

L28/32H
1) Clean the upper part of the cylinder, if not, the e) Turn the piston in top, in order to push the flame
piston may get stuck during removal in the carbon ring out of the cylinder by means of the tool.
deposited in this area.
Info: It is the used piston ring which pushes the flame
If the liner is mounted with a flame ring then start ring out of the cylinder, while the flame ring tool guides
with item No a to e. the piston ring out against the cylinder liner.

If the liner is not mounted with a flame ring then 2) Remove the gangway, if any installed, in order
continue with item No 2. to improve the access conditions.

a) Turn the piston to the buttom. 3) Turn the crankshaft to bring the crank throw
concerned into a position approx. 50 degrees before
b) Mount the tool for dismounting of the flame TDC.
ring in the cylinder at the top of the piston.
This position is identifiable by the connecting rod shaft
c) Place a used piston ring on top of the flame being very close to cylinder liner shirt, see fig. 1.
ring tool.
4) Clean the threaded hole in the piston top, and
d) Mount the tube (for holding down the cylinder mount the eye screw.
liner during the piston withdrawal) on one of the
cylinder head studs, screw on the nut and tighten it Mount the tube (for holding down the cylinder liner
slightly. during the piston withdrawal) on one of the cylinder
head studs, screw on the nut and tighten it slightly.

08028-0D/H5250/94.08.12

Fig. 2. Removal of bearing cap.

5) Attach a wire rope to the eye bolt by means of


Fig. 1. Mounting of tools. (placing). a shackle, hook the wire on to a tackle and pull the
wire rope tight.

96.06 - ES0S
MAN Diesel
Working Card 606-01.00
Page 3 (3) Dismounting of Piston and Connecting Rod Edition 01H

L28/32H

Fig. 3. Removal of upper big-end bearing shell.

If minor adjustment of the crank throw position ap-


pears necessary for acces to the connecting rod
screws, the wire rope must be slackened before
turning of the crankshaft and tightened up again in
the new crank throw position.

6) Unload the connecting rod screws and unscrew


one of the upper screws.

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

cap, and to facilitate easy handling when removing


10) Pull the piston and connecting rod assembly the bearing cap from the crankcase.
upwards and remove the upper big-end bearing shell,
see fig. 3.

96.06 - ES0S
MAN Diesel
Working Card 606-01.05
Page 1 (2) Separation of Piston and Connecting Rod Edition 03H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 01 L28/32H
Shut-off fuel oil 62006 03 L28/32H
Shut-off cooling oil 62006 05 V28/32H
Stopped lub. oil circul. 62006 20

Description:

Separation of piston and connecting rod for in-


spection or/and overhaul.
Assembly of the piston and connecting rod after
inspection or/and overhaul.

Starting position: Hand tools:

Piston and connecting rod are dismounted Open end spanner, 32 mm.
from engine, 606-01.00 Wooden wedge, 2 pieces.
Wooden support.
Wire.

Related procedure:

Inspection or/and overhaul of piston, 606-01.10


Inspection or/and overhaul of
connecting rod, 606-01.15
Inspection of connecting rod
big-end bearing, 606-01.16
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/4 hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

92.08 - ES0S
MAN Diesel

606-01.05 Working Card


Edition 03H Separation of Piston and Connecting Rod Page 2 (2)

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

6) Take out the securing ring, (seeger circlips),


push out the piston pin and lift the connecting rod
away.

Fig. 1. L28/32H

2) The bearing cap should be mounted with the


screws tightened only by hand, in order to protect the
serrated joint faces during handling of the assembly,
see fig. 1 or 2.

Fig. 3.

Assembly of the Piston and Connecting Rod.


08028-0D/H5250/94.08.12

Fig. 2. V28/32H

7) For assembly of the piston and connecting rod,


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

92.08 - ES0S
MAN Diesel

Working Card 606-01.10


Page 1 (4) Piston (with flame ring) Edition 09H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no Item no Note.


Shut-off starting air
Shut-off cooling water 62006 13
Shut-off fuel oil 62006 15
Shut-off cooling oil 62006 16
Stopped lub. oil circul.

Description Hand tools

Cleaning and inspection of piston. Control of piston Tools for cleaning of piston, steel brush,
ring, scraper ring and ring grooves. scraper etc.

Starting position

Piston has been dismantlet from


connecting rod 606-01.05

Related procedure

Mounting of piston and


connecting rod 606-01.20
08028-0D/H5250/94.08.12

Man power Replacement and wearing parts

Working time : 1/2 Hour Plate no Item no Qty. /


Capacity : 1 man

Data

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

01.16 - ES0
MAN Diesel

606-01.10 Working Card


Edition 09H Piston (with flame ring) Page 2 (4)

L+V28/32H
Removal of Piston Ring Inspection of Piston

For removal of piston rings, which are to be used 1) Remove the piston and scraper rings.
again, and for all mounting of rings, only the special
ring opener which prevents local over stressing of 2) Clean and examine the piston rings to determine
the rings should be used. if reuse is acceptable, see page 3.

Straps to expand the ring gap or tools working on 3) Clean the piston outside and inside.
the same principle must not be used, as this would
result in permanent deformation which might cause 4) Inspect the piston ring and scraper ring grooves
blow-by or broken rings. for wear, see page 3.

08028-0D/H5250/94.08.12

01.16 - ES0
MAN Diesel

Working Card 606-01.10


Page 3 (4) Piston (with flame ring) Edition 09H

L+V28/32H
The piston has to be scrapped if: Piston and oil New ring
Ring grooves.
scraper ring. grooves.
A) The wear limit on the testing mandrel is exceed- Nominal size. Tolerances.
Max. wear limit.
ed, see fig 1A
Piston ring New +0.18
or no 1 5.0 mm
5.0 mm
+0.16
5.43 mm

B) The clearance between the new piston/scraper Piston ring New +0.14
ring and ring groove is exceeded, see fig 1B. no 2 5.0 mm
5.0 mm
+0.12
5.43 mm

Piston ring New +0.14


Note: At each piston overhaul: no 3 4.95 mm
5.0 mm
+0.12
5.43 mm

- The piston and scraper ring must be ex- New +0.12


changed. Scraper ring 8.0 mm 8.43 mm
8.0 mm +0.10
- The cylinder liner must be honed according
to the instructions. Table 1 Nominal size, new ring groove tolerance and wear
limit for ring grooves

A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove

If the wear limit (2 mm mark) on the testing


mandrel is exceeded, the specified max. wear
limits are exceeded, and the piston must be
scrapped.

0.45

Wear limit line.

Maximum vertical clearance


between new piston ring/scraper
ring and ring groove: 0.45 mm.

The handle is marked


with the nominal size.
08028-0D/H5250/94.08.12

Fig 1 Wear limits for ring grooves

01.16 - ES0
MAN Diesel

606-01.10 Working Card


Edition 09H Piston (with flame ring) Page 4 (4)

L+V28/32H

Position of Piston and Scraper Rings

Piston Ring No 1:
marked with ident.
no "top 1619394-4"
or "1242".

Piston Ring No 2:
marked with ident.
no "top 1619394-4"
or "1242".

Piston Ring No 3:
marked with ident.
no "top 1600381-8"
or "0950".

Scraper ring:
marked with ident.
no "top 1600387-9"
or "0121".

Marking of Piston and Scraper Rings


08028-0D/H5250/94.08.12

Marking

Identification marks to face upwards against the piston crown when mounted.

Note: The marking may include other figures than mentioned above, for instance trade mark and
production codes.

01.16 - ES0
MAN Diesel

Working Card 606-01.15


Page 1 (4) Connecting Rod Edition 04H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 28 140-760 Nm
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Cleaning, inspection and test measurement of


connecting rod.

Hand tools:

Starting position: Inside micrometer (242 mm).


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

Related procedure:

Mounting of piston and


connecting rod, 606-01.20
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

97.24 - ES0S
MAN Diesel

606-01.15 Working Card


Edition 04H Connecting Rod Page 2 (4)

L/V28/32H
Cleaning and Inspection of Big-end Bore. Screws, which are damaged as mentioned above or
cannot be turned into the threaded holes by hand,
The connecting rod is cleaned on all machined must be renewed.
surfaces.

The serrated joint faces and threaded screw holes Measurement of Big-end Bore.
are to be degreased with a volatile solvent and blown
dry with working air.

The serrated joint faces are inspected.

The serration on the connecting rod may, due to


relative movements between the mating surfaces,
30 mm
show damages in form of wear marks and pittings CL of serration B

or even cracks in highly loaded zones. A B


x
x C
x
x C
Observed damages should be registered in the schem
D
"Connecting Rod Inspection". See page 4.

Wear marks are visible but not appreciable at a


fingernail. Pittings are not only visible but also noti-
ceable at a fingernail.

Single distinctly raised spots caused by pitting should


Fig. 1. Point of measurement
be gently smoothed by careful, local treatment with
a file.
For check of roundness the big-end bore has to be
The serration on the connecting rod and on the measured in a condition, where the connecting rod
bearing cap can be damaged by improper handling is mounted with the bearing cap but without bearing
during dismounting, transport and overhaul work. shells, and the connecting rod screws are tightened
up with the prescribed torque, see working card
Note ! The connecting rod and bearing cap must 606-01.25.
therefore be handled with care.
Note ! The ident no. on the connecting rod and the
Single dent marks caused by impact can be rectified bearing cap, must always be the same, see fig. 3.
by gentle and careful local treatment with a file.
Measurements must be taken 30 mm from seration
In case of damage of the serration, reuse must centerline. See fig. 1.
be rejected, and a new connecting rod assembly
including new bearing shells must be mounted in The measuring is executed with an inside micro-
the engine. meter.
08028-0D/H5250/94.08.12

The connecting rod screws are to be carefully clean- Five different diameters are measured in the middle
ed. of the boring, see fig. 1 and registered in the scheme
"Connecting Rod Inspection". See page 4.
The threads are inspected for seizures and tested
in the threaded holes in the connecting rod. The test The maximum ovalnees is calculated as the dif-
must confirm, that the screws can be turned into ference between biggest and smallest diamenter
bottom position by hand. The contact surface of the measured. For maximum allowable ovalness see
screw heads is inspected for seizure and pittings. page 600.35.

97.24 - ES0S
MAN Diesel
Working Card 606-01.15
Page 3 (4) Connecting Rod Edition 04H

L/V28/32H
If the ovalness exceeds this value, reuse must be Please note that squares for statement of information
rejected and a new complete connecting rod, inclu- and identification, should also be properly filled in.
ding new screws and new bearing shells has to be
mounted in the engine.
Connecting Rod Bush.

Inspect the surface of the piston pin and the connec-


ting rod bush. Measure the clearance between the
piston pin and bush, max. clearance between pin
and bush, see page 600.35.

In case the specified clearance is exceeded, contact


- 0,5 - 3,0 MAN B&W Diesel A/S, Holeby for replacement.
- 2,0 - 7,0
- 1,5 - 5,0
+ 5,0 + 5,5 Bearing Shells for Big-end.
+ 3,0 + 3,5
7,0 12,5 Criteria for replacement of connecting rod big-end
bearing, see working card 606-01.16.

to be to be
reused rejected

Fig. 2. "Connecting rod inspection".

The example, see fig. 2 shows measurements and


damage observations for two connecting rods, on the
scheme "Connecting Rod Inspection", (In case the
specified maximum ovalness is exceeded, contact
MAN B&W Diesel A/S, Holeby for overhaul).

For connecting rod no. 1 the maximum ovalness is


Connecting rod
0,07 mm and reuse thus acceptable. Ident no.
08028-0D/H5250/94.08.12

For connecting rod no. 2 the maximum ovalness is


0,125 mm and therefore the connecting rod is being
rejected. Fig. 3.

97.24 - ES0S
MAN Diesel

606-01.15 Working Card


Edition 04H Connecting Rod Page 4 (4)

L/V28/32H

08028-0D/H5250/94.08.12

97.24 - ES0S
MAN Diesel
Working Card Criteria for Replacement of 606-01.16
Page 1 (8) Connecting Rod Big-end and Main Bearing Shells Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air 62006 55
Shut-off cooling water
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Inspection of bearing shells.


Hand tools:

Magnifier (x30).

Starting position:

Bearing shells removed from engine:


Big-end bearing, 606-01.00 and 606-01.30
or
Main bearing, 610-01.05
Guide bearing, 610-01.10

Related procedure:

Mounting af bearing shells:


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

Man power: Replacement and wearing parts:

Working time : 1/4 Hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.41 - ES0S
MAN Diesel

606-01.16 Criteria for Replacement of Working Card


Edition 02H Connecting Rod Big-end and Main Bearing Shells Page 2 (8)

L+V28/32H
This paper gives information about the evaluation of Wear of the bearings running surface starts primarily
the connecting rod big-end and main bearing shells in the soft overlay, where the overlay in the slots is
when wear appears on the running surface under reduced approx. 0.001 mm. The difference between
normal operating conditions. the light-alloy metal and the overlay is by further wear
almost constant, i.e. approx. 0.005 mm.
Bearing damages caused by incorrect running con-
ditions, like The gravity of the running surface’s wear must be
determined with a magnifier (x30), hereby the over-
- Scoring of the running surface due to foreign lay can be seen as the dark area and the light-alloy
particles in the lubricating oil. metal as the light area.
- Cavitation.
- Corrosion The ratio between the width of the light-alloy metal
- Overloading, overheating a.s.o. and the width of the slot as well as the dimension
of the worn area are important for determining the
are not described in this paper. wear of the bearing.

In these cases, the bearing shells must be exchang- The bearing can also operate although part of the
ed, of course, and in order to avoid further bearing overlay is missing in the slots. Practice has shown, that
failures, the cause of the failure must be found and bearings with partly empty slots can run without any
eliminated. negative influence on the operation of the bearing.

By determining the condition of the bearing shell,


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

In case of a combination of the above mentioned


conditions, the lowest possible limits are valid.
Fig. 1. Running surface of the bearing shell.
08028-0D/H5250/94.08.12

A new bearing shell has a running surface with approx.


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

96.41 - ES0S
MAN Diesel
MAN Diesel
MAN Diesel
MAN Diesel

606-01.16 Criteria for Replacement of Working Card


Edition 02H Connecting Rod Big-end and Main Bearing Shells Page 6 (8)

L+V28/32H
3. Limit Case - Levelling Valuation: If the limits shown in fig. 11 and 12 are
exceeded the bearing shells must be exchanged.
Condition: The slots are locally totally levelled as
shown in fig. 10.
max. 10% of width

Fig. 10.

max. 5%
of extent
max. 10% of width or

max. 5 mm

Fig. 12.

Fig. 11.
08028-0D/H5250/94.08.12

96.41 - ES0S
MAN Diesel
MAN Diesel

606-01.16 Criteria for Replacement of Working Card


Edition 02H Connecting Rod Big-end and Main Bearing Shells Page 8 (8)

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

max. 10% of width or

max. 5 mm

Fig. 17.

max. 30% of width


extent

Fig. 19.
of
max. 15%

Fig. 18.
08028-0D/H5250/94.08.12

96.41 - ES0S
MAN Diesel
Working Card 606-01.20
Page 1 (4) Assembling of Piston and Connecting Rod Edition 01H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 01
Shut-off fuel oil 62006 03
Shut-off cooling oil 62006 11
Stopped lub. oil circul. 62006 13
62006 22

Description:

Mounting of piston and connecting rod assembly,


after overhaul and/or inspection.

Starting position: Hand tools:

Piston mounted on the connecting rod, crank-shaft Open end spanner 32 mm.
turned in the right position and the cylinder liner Clean lubricating oil.
is OK, see working card 606-01.35.

Related procedure:

Tightening of connecting rod screws,606-01.25


Mounting of cylinder head, 605-01.40
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 1/2 Hours Plate no. Item no. Qty./


Capacity : 2 men
60601 09 1/cyl.
Data: 60601 10 1/cyl.
60601 11 1/cyl.
Data for pressure and tolerance (Page 600.35) 60601 12 1/cyl.
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.49 - ES0S
MAN Diesel
606-01.20 Working Card
Edition 01H Assembling of Piston and Connecting Rod Page 2 (4)

L28/32H
1) Mount the lifting device comprising eye screw, A crank throw position of approx 50 degrees before
shackle and wire rope on the piston. TDC will ensure this and also be suitable for the
further mounting procedure.
2) Lift up the piston and connecting rod and
mount the piston and scraper rings, see point 14, 6) Lower the piston further down, lubricate the
and working card 606-01.10. ends of the bearing shells (a in fig. 2) with copaslip,
molycote pasta or similar and mount the upper shell
3) Remove the backstop for cylinder liner and of the big-end bearing.
place the piston guide ring on top of the cylinder
liner, see fig. 1.

4) When the piston approaches the guide ring,


stop the lowering, coat guide ring, piston, piston rings
and scraper ring, with clean lubricating oil in order
to minimize friction during the subsequent lowering
of the assembly.

Fig. 2.
08028-0D/H5250/94.08.12

7) Coat the crank journal with clean lubricating


Fig. 1. oil.

8) Now lower the piston and connecting rod slowly


5) Make sure that the crank throw is in a position into correct landing on the journal.
allowing the connecting rod to go clear of both crank
journal and cylinder liner skirt during further lower- During this the connecting rod must be guided by
ing. hand to ensure correct approach and landing on the
journal, see fig. 3.

91.49 - ES0S
MAN Diesel
Working Card 606-01.20
Page 3 (4) Assembling of Piston and Connecting Rod Edition 01H

L28/32H
9) Mount the bearing cap with inserted lower shell
of the big-end bearing, using the guide pin, see fig.
4.

10) Lubricate threads and contact face of the con-


necting rod screws with copaslip, molycote pasta or
similar.

11) Mount the screws and tighten them slightly


using an open end spanner.

12) Slacken the tackle and dismount the eye


screw/shackle from the piston.

Fig. 3.

Note ! The ident no. on the connecting rod and on the


bearing cap, must always be the same, see fig. 4.

Fig. 5.

13) Tighten the screws according to "Tightening


08028-0D/H5250/94.08.12

Procedure for Connecting Rod Screws", see working


card 606-01.25.

Fitting of Piston and Scraper Rings.

14) Piston rings should only be removed from and


Con. Rod - Ident No. fitted to the piston by the use of a special tool, the
socalled piston ring opener.
Fig. 4.

91.49 - ES0S
MAN Diesel
606-01.20 Working Card
Edition 01H Assembling of Piston and Connecting Rod Page 4 (4)

L28/32H
If the rings are opened further than necessary there Before fitting the coil spring loaded scraper ring, the
is a risk of overstressing, which means that rings will coil spring is dismantled from the ring by removal of
become permanently distorted and will not confirm the joint pin. The coil spring is placed and assembled
to the cylinder inner running surface. in the ring groove then the scraper ring is fitted in the
groove in such a way that the ring joint is approxima-
The piston rings should be installed with the identifi- tely 180° offset to the spring joint.
cation mark, which is stamped into the ring close to
the ring joints, facing upwords. Ascertain correct assembling by checking the back
clearance.The back clearance is suffient when the
face of the ring is below the groove edge, when the
ring is pressed against the bottom of the groove.

Joint pin for


When installed on the piston, the rings should be
Coil spring joint to be pla- pushed back and forth in the grooves to make sure
coil spring
ced opposite to ring joint that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring
and groove.

Adequate clearance is present of the feeler gauge


can be moved all the way round.

Ring joint To prevent gas leakage through coinciding ring joints


the piston rings should be turned into positions off-
setting the ring joint 180° to each other.

Fig. 6.

08028-0D/H5250/94.08.12

91.49 - ES0S
MAN Diesel

Working Card 606-01.25


Page 1 (2) Hydraulic Tightening of Connecting Rod Screws Edition 04H

L+V28/32H

Safety Precautions: Special Tools:

Stopped engine Plate No Item No Note


Shut-off starting air
Shut-off cooling water 62021
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Tightening procedure for connecting rod


screws. Hand Tools:
Check of connecting rod screws, tightening
condition.

Starting Position:

Piston, connecting rod, bearing shells and bearing


cap preassembled. 606-01.20

Related Procedure:

Man Power: Replacement and Wearing Parts:


08028-0D/H5250/94.08.12

Working time : 1/2 Hour Plate No Item No Qty./


Capacity : 2 men

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

97.43 -ES0S
MAN Diesel

606-01.25 Working Card


Edition 04H Hydraulic Tightening of Connecting Rod Screws Edition 2 (2)

L+V28/32H
1) Tighten the screw pos. 3 home to the connecting
rod by hand.

2) Mount the lower part pos. 2 and fasten the


lower part with the nuts, pos. 4.

3) Tighten the nuts by hand.

4) Mount the hydraulic tool, pos. 5.

Be aware of the max. lifting heigt of the tool and


adjust the distance between the piston and the
cylinder before adding pressure to the tool. Please
see Working Card 620-01.05

5) Connect the tool to the hydraulic tool.

6) Add the prescribed hydraulic pressure, (to both


screws simultaneously). Please see Description
600.40, and tighten the screws by using a handle,
pos 6.
2
7) Relieve the hydraulic pressure on the tool. 1 6

8) Add the hydraulic pressure to the tool.

9) Tighten the nuts again.

Note: The Points 7 to 9 are to be followed in order 5


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

11) Relieve the pressure on the tool and remove


Fig. 1
it from the screws.

Note: General instruction about hydraulic tightening.


Please see Working Card 620-01.10
08028-0D/H5250/94.08.12

97.43 - ES0S
MAN Diesel
Working Card 606-01.30
Page 1 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 01H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 07
Shut-off fuel oil 62006 22
Shut-off cooling oil 62006 28 140 - 760 Nm
Stopped lub. oil circul.

Tool combination for tightening of connecting


rod screw, see working card 620-01.20.
Description:

In-situ inspection and/or replacement of con-


necting rod big-end bearing, dismounting and
moun-ting.
Hand tools:

Open end spanner 32 mm.


Starting position:

Fuel injector dismounted, 614-01.00


Crankcase open.
Top cover for cylinder head removed.

Related procedure:

Inspection of connecting rod


big-end bearing 606-01.16
Tightening and check of connecting
rod screws, 606-01.25
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 1/2 Hours Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.22 - ES0S
MAN Diesel
606-01.30 Working Card
Edition 01H In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)

L28/32H
The big-end bearing shells can be inspected and/or
replaced in-situ i.e. without dismounting the piston
and connecting rod assembly from the engine.

Dismounting.

1) The crankshaft of the engine is turned into a


position allowing the connecting rod screws to be lo-
sened. Having loosened the connecting rod screws,
the crankshaft is turned until the piston in a position
thus allowing the connecting rod bearing cap to be
dismounted, see fig. 1.

Fig. 2.

3) Having tightened the tackle slightly, the con-


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

4) When connecting rod bearing cap and bearing


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

2) Before removing connecting rod bearing cap,


the especially long eye bolt is mounted. It is inserted
through the fuel injector sleeve and is screwed into
the thread hole in the piston, see fig. 2. Then by
means of a tackle it is slightly tightened.

91.22 - ES0S
MAN Diesel
Working Card 606-01.30
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 01H

L28/32H
While lowering the connecting rod, it must be guided
by hand to ensure correct approach and landing on
the journal, see fig. 4.

4) Mount the bearing cap with inserted lower


big-end bearing shell, using the guide pin.

5) Lubricate threads and contact face of the con-


necting rod screws with copaslip or similar.

6) Mount the screws and tighten them slightly


using an open-end spanner.

7) Slacken the tackle and dismount the eye screw


from the piston crown.

8) Tighten the screws according to "Tightening


Procedure for Connecting Rod Screw", see working
card 606-01.25.

Fig. 3.

5) For inspection of bearing shell, see working


card 606-01.16

Mounting.

Before remounting of inspected or new bearing, all


components must be cleaned.

Note: See also working card 606-01.20.

1) The bearing shell is placed in the bore, the


contact surfaces of the shells to be in parallel to the
08028-0D/H5250/94.08.12

contact surface of the connecting rod, the bearing


cap respectively.

2) Ascertain that the crank throw concerned is in


a position of approx 50 degrees before TDC. Fig. 4.

3) Coat the journal with clean lubricating oil and


lower the piston and connecting rod assembly slowly
into correct landing on the journal.

91.22 - ES0S
MAN Diesel
Working Card 606-01.35
Page 1 (4) Inspection and Honing of Cylinder Liner Edition 08H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 50 Extra tools
Shut-off fuel oil 62006 51 Extra tools
Shut-off cooling oil 62006 60 Extra tools
Stopped lub. oil circul.

Description:

Inspection and honing of cylinder liner with ho-


ning brush. Hand tools:

Drilling machine 60-180 rpm.


Honing oil.
Gas oil.
Starting position:

Piston and connecting rod is


removed, 606-01.00

Related procedure:

Mounting of piston and


connecting rod, 606-01.20
Replacement of cylinder liner, 606-01.40
Grinding of seal face on cylinder
head and cylinder liner, 606-01.45
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

05.28
MAN Diesel

606-01.35 Working Card


Edition 08H Inspection and Honing of Cylinder Liner Page 2 (4)

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

Note: After the honing process has taken place the


used flame ring is discarded. A new flame ring is
always mounted in the cylinder when replacing a
piston ring.

80-160 rpm.

Fig. 1.

The measurements should normally be taken in


transverse as well as in longitudinal direction.

When measuring, take care that the measuring tool


has the approximately same temperature as the liner.
When the wear of a cylinder liner exceeds the value
08028-0D/H5250/94.08.12

indicated on page 600.35, i.e. when it becomes


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

Honing the Cylinder Liner.


The honing is made by means of a flex-honer with
The renovation can be made either with dismantled finess grains 80-120. A revolution speed between
liner in the workshop or with liner mounted in the 80 and 160 rpm is chosen.
engine frame and by the use of the belonging fun-
nel.

05.28
MAN Diesel
Working Card 606-01.35
page 3 (4) Inspection and Honing of Cylinder Liner Edition 08H

L+V28/32H
In order to achieve the required angle between the
honing grooves, see fig. 2, the vertical speed is ad-
justed to about 1 m/sec. which corresponds to about
2 sec. for one double movement (the flex honer is
lead from below up and down in 2 sec.)

The procedure is to be continued until the cylinder 60°


wall is covered by honing grooves and the surface
has a slight matt appearance and without any signs
of glaze .

During the honing it is important to lubricate freely


with honing oil or cutting oil.
Fig. 3.
After the honing, the liner is carefully cleaned with
gas oil, and make sure that all abrasive particles
have been removed.
08028-0D/H5250/94.08.12

05.28
MAN Diesel
606-01.35 Working Card
Edition 08H Inspection and Honing of Cylinder Liner Page 4 (4)

L+V28/32H
Measurements of Cylinder Liner
Plant/ship: Engine Type: Engine No.:

Date: Sign.: Cyl. A-side B-side


no. Pos. A B C D
Running hours: 1

Fuel: cSt 1 2

Separator: Yes 3

2 2

3 2

4 2

5 2

6 2

7 2

3
08028-0D/H5250/94.08.12

8 2

Tem. of cyl. liner 25°C 3

Nom. diameter 280H8 1

Minimum 280.0 9 2

Maximum 280.60 3

05.28
MAN Diesel
Working Card 606-01.40
Page 1 (3) Replacement of Cylinder Liner Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 45
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Replacement of cylinder liner.


Dismounting and mounting of cooling water Hand tools:
guide jacket.
Allen key, 8 mm.
Adjustable spanner.

Starting position:

Cylinder head and piston/connecting rod dis-


mantled,working card 605-01.00 and 606-
01.00.

Related procedure:

Mounting of piston and


connecting rod, 606-01.20
Grinding of seal face on cylinder
head and cylinder liner, 606-01.45
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 2 Hours Plate no. Item no. Qty. /


Capacity : 2 men
60610 04 1/cyl.
Data: 60610 07 12/cyl.
60610 08 2/cyl.
Data for pressure and tolerance (Page 600.35) 60610 11 2/cyl.
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45) See also plate 60610.

91.22 - ES0S
MAN Diesel

606-01.40 Working Card


Edition 01H Replacement of Cylinder Liner Page 2 (3)

L/V28/32H
Dismounting of Cylinder Liner.

1) Dismount the cooling water guide jacket.


L28/32H
2) Prior to mounting of the lifting tool and dismoun- V28/32H
ting from the frame, it must be ensured that the liner
and frame have been marked to match, for the sake
of a posible remounting of the liner, see fig. 1.

Hole for charging air

Hole for roller guide house

Marking scratch frame

Marking scratch liner

Fig. 2.

Fig. 1.
5) Attach a tackle hook to the eye nut or the wire
and the cross bar, and lift the liner out from the engine
3) Mount the lifting tool as shown, see fig. 2. frame and stand it careful onto wooden supports.

4) Turn the lifting eye nut to pull out the liner, until 6) Clean all parts and inspect for damage and
the upper edge of the liner lie aligned against the wear, according to the description. For measurement
copper protecting pieces of the cross bar. of cylinder liner, see working card 606-02.00.
08028-0D/H5250/94.08.12

91.22 - ES0S
MAN Diesel

Working Card 606-01.40


Page 3 (3) Replacement of Cylinder Liner Edition 01H

L/V28/32H
Mounting of Cylinder Liner. 12) Mount the cooling water jacket, (for torque mo-
ment see page 600.40), piston/connecting rod and
7) Check that the sealing surfaces on engine, cylinder head according to working card 606-01.20
cylinder liner, and sealing rings are perfectly clean. and 605-01.40.

8) Mount the lifting tool, attach a tackle hook to 13) When preparing the start-up, check for possible
the eye nut or to the wire in the cross bar and lift the leakages of water and oil, including the inspection
liner. hole in the frame, see fig. 3.

9) Check that the o-ring grooves are clean. Mount


the o-rings and lubricate with a little oil. Place a new
sealing on top of the frame.

10) Lower the cylinder liner carefully into the engine


frame.

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


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

11) After having cleaned and inspected the cool-


ing water jacket, mount new o-rings on the cooling
water connections and change air connections.

Fit a new sealing ring and mount the jacket.

Fig. 3.
08028-0D/H5250/94.08.12

91.22 - ES0S
MAN Diesel
Working Card Grinding of Seal Face on 606-01.45
Page 1 (2) Cylinder Liner and Cylinder Head. Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62005 20
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Grinding of seal face on cylinder liner and cylinder


head by hand, with grinding tools and grinding Hand tools:
pasta.
Grinding pasta.

Starting position:

Cylinder head has been removed


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

Related procedure:

Mounting of cylinder head, 605-01.40


08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty. /


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

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel

606-01.45 Grinding of Seal Face on Working Card


Edition 01H Cylinder Liner and Cylinder Head Page 2 (2)

L/V28/32H
Note: The grinding tool is used for both grinding the
groove in the liner flange (1) and the seating surface
on the cylinder head (2), see fig. 1.

Fig. 3.
Fig. 1.

3) After grinding, remove all traces of abrasive


Grinding. and grinding compound.

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

08028-0D/H5250/94.08.12

y - z = 0,5 mm, min.


Fig. 2.

To do so, move the tool back and forth and lift it out
from time to time, to allow the grinding compound Fig. 4.
to distribute evenly.

91.45 - ES0S
MAN Diesel
Working Card Dismounting of Piston and Cylinder Liner 606-01.50
Page 1 (2) Edition 01H
at Low Overhaul Heights

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62050
Shut-off fuel oil 62006 05
Shut-off cooling oil 62006 09 2 pieces
Stopped lub. oil circul. 62006 22
62006 24
62006 28
62006 65
Description: 62010 01 If necessary

Dismounting of piston, connecting rod and cylinder Tool combination for dismounting of conncting
liner for inspection and/or overhaul. rod screw, 620-01.20

Starting position: Hand tools:

Cylinder head has been dismounting from the Inside micrometer (195 mm).
engine. Feeler gauge 0,15 - 0,20 mm.
Crankcase open.

Related procedure:

Separation of piston and connecting rod.


Inspection and honing of cylinder liner.

Manpower:

Working time : 2 ½ Hours


08028-0D/H5250/94.08.12

Capacity : 2 men
Replacement and wearing parts:

Data: Plate no Item no Qty/

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

94.38 - ES0S-G
MAN Diesel

606-01.50 Dismounting of Piston and Cylinder Liner Working Card


Edition 01H Page 2 (2)
at Low Overhaul Heights

L+V28/32H
Dismantling of Piston at Low Overhaul Dismantling of Cylinder Liner at Low Overhaul
Heights. Heights.

1) Lift up the piston and the connecting rod through 1) Mount normal lifting tool for cylinder liners.
the cylinder liner until the piston is clear of the
liner. 2) Carefully pull the cylinder liner half-way out of
the frame.
2) Mount collar on the connecting rod, see plate
62050, item 1896. 3) Mount special lifting tool for cylinder liners at
low overhaul heights, see plate 62050, item
3) Place the piston with the collar on the cylinder 1895.
liner.
4) Attach pull-lifts on the lifting tool for the cylinder
4) Mount pull-lifts on the collar. liner, see plate 62050, item 1895

If Then 5) Take out the liner over the camshaft side.

The overhaul height is Dismount the piston from


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

The overhaul height is Remove the piston and


sufficient to pull out the connecting rod by means
piston and the connect- of the pull-lifts.
ing rod in one piece.

08028-0D/H5250/94.08.12

94.38 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 60601-34H

L28/32H

07.01 - ES0
MAN Diesel
Plate
60601-34H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)

L28/32H
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse

01 1/C Piston pin incl. Stempelpind inkl.


item No 02 pos. nr. 02

02 4/C Socket screw Kraterskrue

03 2/C Retaining ring Sikringsring

04 1/C Plug screw Propskrue

05 1/C Bush for Plejlstangs-


connecting rod bøsning

06 1/C Connecting rod Plejlstang inkl.


incl. item Nos pos. nr.
04, 05, 14, 15, 16 04, 05, 14, 15, 16

08 1/C Piston Stempel

09 1/C Piston ring Stempelring

10 1/C Piston ring Stempelring

11 1/C Piston ring Stempelring

12 1/C Oil scraper ring Olieskrabering

13 1/C Connecting rod Plejlstangs-


bearing 2/2 leje 2/2

14 1/C Plug screw Propskrue

15 2/C Connecting rod stud Plejlstangsbolt

16 2/C Nut Møtrik

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

07.01 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Cylinder Liner and Water Guide Jacket 60610-09H

L28/32H

94.07 - ES0S
MAN Diesel & Turbo

Plate
60610-09H Cylinder Liner and Water Guide Jacket Page 2 (2)

L28/32H

Item Item
No Qty. Designation Beskrivelse No Qty Designation Beskrivelse

01 2/C O-ring O-ring

02 1/C Sleeve Muffe

03 1/C Water guide Kølekappe


jacket

04 1/C O-ring O-ring

05 6/C Sealing ring Tætningsring

06 6/C Plug screw Propskrue

07 12/C O-ring O-ring

08 1/C Sealing ring Tætningsring

09 6/C Cooling water Kølevands-


connection overgang

10 1/C Cylinder liner Cylinderforing

11 2/C O-ring O-ring

12 4/C Hexagon screw Unbracoskrue

13 4/C Washer Skive

14 4/C Sleeve Foring

15 1/C Water guide jacket Kølekappe inkl. item nr.


incl. item no. 05 and 05 og 06
06.

16 1/C Sealing ring Tætningsring

17 1/C Flame ring Flammering

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

94.07 - ES0S
Camshaft

507/607
MAN Diesel
Description
Camshaft and Camshaft Drive 607.01
Page 1 (1)
Edition 05H

L28/32H
General The lubricating oil pipes for the gear wheels are
equipped with nozzles which are adjusted to apply
The camshaft which controls the actuation of inlet the oil at the points where the gear wheels are in
valves, exhaust valves and fuel injection pumps is mesh. The position of the nozzles is determined by
driven by a gear wheel on the crankshaft through an direction of rotation of the engine.
intermediate wheel, and rotated by a speed which is
half of that of the crankshaft, see fig. 1.

The camshaft is placed in the engine frame at the Engine seen from aft - fly wheel end
control side, (left side, seen from the flywheel end)
and is carried in bearing bushes which are fitted in
bores in the engine frame, each bearing is replace-
able and locked in position in the engine frame by
means of lock screws.

The camshaft is built-up of sections, one for each


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

Except for the foremost and the aftmost ones, the


sections are identical and therefore interchangeable.
The foremost section is equipped with a clutch for
driving the fuel oil feed pump (if mounted). The gear
wheel for driving the camshaft as well as a gear
wheel connection of governor are screwed on the Clockwise rotation direction
aftmost section.

Fig. 1. Intermediate wheel


08028-0D/H5250/94.08.12

91.03 - ES0S
MAN Diesel

Working Card 607-01.00


Page 1 (2) Camshaft and Camshaft Drive Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 26 20 - 120 Nm.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Checking of gear wheels, bolted connections


and lubricating system. Hand tools:

Allen key, 12 mm.


Ring and open end spanner, 19 mm.
Socket spanner, 19 mm.
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 3 Hours Plate no. Item no. Qty./


Capacity : 1 man
60705 12 6/eng.
Data: 60705 24 3/eng.
61106 11 1/cyl.
Data for pressure and tolerance (Page 600.35) 61106 13 1/cyl.
Data for torque moment (Page 600.40) 61106 14 1/eng.
Declaration of weight (Page 600.45)

92.13 - ES0U
MAN Diesel

607-01.00 Working Card


Edition 01H Camshaft and Camshaft Drive Page 2 (2)

L/V28/32H

1) Dismount the covers which give access to the 3) Examine all lubricating oil spray pipe nozz-
gear wheels, camshaft and crankcase. les.

Examine all gear wheels for cracks, wear and defor- 4) Start the electrical lubricating oil pump and
mations. While turning the engine to enable inspec- check the oil flow everywhere. Be particularly careful
tion allover the circumference of the gear wheels. to check that the oil jet hits the gear wheels correctly
at the points where the wheels mesh.
2) Check all screws, nuts and bolted connections,
including locking devices everywhere in the gear
wheel housing, camshaft housing and crankcase to
check that they have not worked loose. Tightening
torques, see page 600.40.

08028-0D/H5250/94.08.12

92.13 - ES0U
MAN Diesel

Working Card 607-01.05


Page 1 (2) Inspection and Replacement of Camshaft Bearing Edition 01H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate No Item No Note


Shut-off starting air
Shut-off cooling water 62006 26 20 - 120 Nm.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Check of roller path of cams and check of cam-


shaft bearing. Hand tools
Replacement of camshaft bearing.
Ring and open end spanner, 19 mm.
Socket spanner, 19 mm.
Feeler gauge.
Starting position Big screw driver.

Cover for camshaft and gear wheel has been


removed.

Related procedure

Camshaft and camshaft drive, 607-01.00


08028-0D/H5250/94.08.12

Man power Replacement and wearing parts

Working time : 2 Hours Plate No Item No Qty. /


Capacity : 2 men
60705 01 1/eng.
Data 60705 03 1/cyl.
60705 21 1/cyl.
Data for pressure and tolerance (Page 600.35)
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

01.51 - ES0
MAN Diesel

607-01.05 Working Card


Edition 01H Inspection and Replacement of Camshaft Bearing Page 2 (2)

L+V28/32H
To Check Roller Path of Cams.

1) While turning the engine, examine the cam Camshaft bearing


discs and in particular, check the roller path of all Hole for lubricating oil
cams for cracks, crackles and ruffle. Also examine
the rollers of the roller guides.

Note: if there are flat spots on the roller and if some


of the rollers may be blocked, if so, the roller must
be replaced by a new one, see working card 608-
01.00.

To Check Camshaft Bearings.

2) The wearing surface of the camshaft bear- Locating screw


ings cannot be checked without dismounting the
Frame
camshaft. However, ab-normal wear of one or more
bearings will become apparent in the form of burrs
of white metal at the circumference of the camshaft
journal, and in that case the bearing will in no doubt Fig. 1.
be discoloured, as well.

The bearing clearance is measured with a feeler Mount a new camshaft bearing in the bore and make
gauge, see data sheet 600.35. sure that the hole for insertion of the locating screw
in the bearing is in a correct position. Lock the bea-
ring by means of the locating screw, which is to be
To Replace Camshaft Bearing. provided with a new gasket. To facilitate the fitting
of the bearing it can be cooled down with Co2.
3) If one or several of the camshaft bearings
should be replaced the camshaft must be wholly Inspect the camshaft journal for seizures.
or partly dismantled.
If necessary, the camshaft section must be entirely
Dismount the fuel oil feed pump, if mounted and removed from the engine, and the journal concerned
check that the camshaft sections are marked in must be polished.
relation to each other. Disassemble the camshaft
aft (toward flywheel) of the bearing that is to be Coat all the journals of the camshaft section with
replaced. Dismount all roller guides that are located clean lubricating oil and push the camshaft into
forward of the disassembling position, see working position, making sure that the marks on the flanges
card 608-01.00 and 608-01.05. coincide.
08028-0D/H5250/94.08.12

Pull the disconnected sections of the camshaft so Assemble the sections and fit the bolts (coated with
far a head that the bearing which is to be replaced Molycote or similar).
is free.
Tighten the nuts with a torque spanner, see data
Take out the locating screw of the camshaft bearing sheet 600.40.
concerned and push the bearing out of the bore in
the engine frame, see fig. 1. Mount all roller guides as well as the fuel oil feed
pump.
Check the lubricating oil ducts to the bearing for
free flow.

01.51 - ES0
MAN Diesel & Turbo

Working Card
Adjustment of Camshaft for Valve and Injection Timing 607-01.20
Page 1 (4) Edition 04H

L28/32H

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62006 26 20 - 120 Nm.
Shut-off fuel oil 62010 01
Shut-off cooling oil 62008 05
Stopped lub. oil circul.

Description

Adjustment of the injection timing.

Hand tools

Starting position Ring and open end spanner, 19 mm.


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

Related procedure

Manpower Replacement and wearing parts

Working time : 2-5 hours Plate no Item no Qty /


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

Data for pressure and tolerance (Page 500.35)


Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)

11.37 - ES0 - Tier II


MAN Diesel & Turbo

607-01.20 Adjustment of Camshaft for Valve and Injection Timing


Working Card
Edition 04H Page 2 (4)

L28/32H

Measure of fuel pump lead 4) Insert the dial gauge into the support.

1) Dismantle covers for fuel camshaft and fuel 5) Set the dial gauge to "Zero".
pump and covers for gear whell
6) Turn the engine until the TDC mark (ignition
2) Check the mobility of the regulating device. DC) for the actual cylinder is reached.
Turn engine to pos. cylinder No. 1 until the Read the dial gauge and note down the gauge
cambase circle is reached (approx. 40° BTDC). value.

3) Position the support of the measuring tool on 7) Determine the values for the other cylinders in
the two bolts of the camshaft covering. Slip on the same way.
the distance sleeves and fasten to the cylinder
crankcase by means of hexagon nuts. Calculate the average value of all measure-
ments.
Note: During attaching, pay attention to the correct
fitting position of the contact point, see fig 1.

1. Contact point
2 Lever
Fixing screws and
discs of enclosing
2 cover used

Fig 1 Fitting position of the contact point.

11.37 - ES0 - Tier II


MAN Diesel & Turbo

Working Card
Page 3 (4) Adjustment of Camshaft for Valve and Injection Timing 607-01.20
Edition 04H

L28/32H

8) Compare the calculated value determined with


the value mentioned below.

9) If the values exceeds the limits, an adjustment


must be done in order to correct the errors, on
the X-measure or reset the gear wheel, see
following text for changing "X"-measuring.

Cyl. kW/Cyl. rpm Average value

5-6-7-8-9 210 720 See section 600,


5-6-7-8-9 220 750 Desription
600.35

Fig 2 Plunger lift (average value)

To get a consistent lifting values on the plunger/


combustion pressure on the different cylinders the
"X"-measure can be changed. Fig 3 Gear wheel with engraved scale.

When changing “X” it must be ensured that the di-


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

After the adjustment the screws are fastened with


a torque wrench, please see description 500.40,
and secured.

11.37 - ES0 - Tier II


MAN Diesel & Turbo

607-01.20 Adjustment of Camshaft for Valve and Injection Timing Working Card
Edition 04H Page 4 (4)

L28/32H

The injection timing can be altered on each cylinders Thicker and/or more shims (reduction of the distance
by inserting or removing shims under the thrust piece “X”) results in an advanced injection.
on the roller guide, thus changing the measure “X”,
see Fig 4. If the distance “X” is to be changed the trigger (1) is
used for dismantling of the thrust piece (2), where-
Thinner and/or fewer shims (increase of the distance after the thickness and/or the number of shims (3)
“X”) results in a retarded injection timing. can be changed.

After replacement of shims the thrust piece is re-


mounted, see fig 5, in the roller guide (4) with a soft
hammer (5).
Measure "x"

1 5

1
2 2
3 2
Total height 3
3
4
4 4

1 Extractor 2 Thrust piece


3 Shims 4 Roller guide
5 Soft hammer

Fig 4 Measure "X" Fig 5 Remounting of thrust piece.

Action Results

Total height Distance Injection Max. combustion


on roller guide "x" timing pressure

increased ↑ Reduced ↓ Advanced ↑ increased ↑


Reduced ↓ increased ↑ Delayed ↓ Reduced ↓

Fig 6

10) Remove the complete measuring tool.

11) Mount all camshaft covers.

2) Plunger lift value, please see description


1
500.35.

11.37 - ES0 - Tier II


MAN Diesel
Plate
Page 1 (2) Intermediate Wheel 60701-06H

L28/32H

09

10

01
13

02

14

07

03 15 11

16

17

04

12+
05 08+

06

06.28 - ES0
MAN Diesel

Plate
60701-06H Intermediate Wheel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 6/E Screw Skrue

02 6/E Lock plate Sikringsplade

03 3/E Gasket Pakning

04 1/E Union Vinkelforskruning

05 1/E Pipe Rør

06 1/E Union Vinkelforskruning

07 1/E Spray pipe Sprøjterør

08+ 3/E Fitted bolt Pasbolt

09 3/E Self locking Selvlåsende


nut møtrik

10 1/E Cover Dæksel

11 1/E Gear wheel, Tandhjul, kompl.


complete

12+ 1/E Axle journal Lejetap

13 4/E Self locking nut Selvlåsende møtrik

14 1/E Spur gear Tandhjul

15 1/E Spur gear Tandhjul

16 4/E Bolt Bolt

17 1/E Bearing bush Lejebøsning

+ Item No. 08 and + Item nr. 08 og 12


12 require an indivi- kræver en individuel
dual matching, before tilpasning, før monte-
mounting, contact ring kontakt MAN B&W,
MAN B&W, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

06.28 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft and Camshaft Bearing 60705-22H

L28/32H

11
06

13

04

05 19

06
07
08
01 20
02, 29, 32, 33, 34 26
03 27 03
28
14 29

15 21
22
16 29 29 29 29
14
5 cyl.
16
03 03 01
03 03 03
35 20 20 20 20 02
6 cyl. 03
03 03 03 01
03 03 03
36 26 26 26 26 26 32 23
7 cyl. 06
03 03 03 01
03 03 03 03 25
37 27 27 27 27 27 27 33
8 cyl.
03 03 03 03 01
03 03 03 03
38 28 28 28 28 28 28 28 34
9 cyl.
03 03 03 03 01
03 03 03 03 03

06.43 - ES0
MAN Diesel
Plate
60705-22H Camshaft and Camshaft Bearing Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Camshaft bearing Styreakselleje 26 5/E Camshaft, Styreaksel,


intermediate, mellem
02 1/E Camshaft section Styreakselssektion 7 cyl. engine 7 cyl. motor
"aft", 6 cyl. engine "agter", 6 cyl. motor
27 6/E Camshaft, Styreaksel,
03 1/C Camshaft bearing Styreakselleje intermediate, mellem
8 cyl. engine 8 cyl. motor
04 1/E Hub Nav
28 7/E Camshaft, Styreaksel,
05 6/E Screw Skrue intermediate, mellem
9 cyl. engine 9 cyl. motor
06 24/E Disc spring Skivefjeder
29 4/E Camshaft section Styreakselsektion
07 1/E Guide ring Styrering "aft", 5 cyl. engine "agter", 5 cyl. motor

08 1/E Shaft pin Akseltap 32 1/E Camshaft section Styreakselssektion


"aft", 7 cyl. engine "agter", 7 cyl. motor
11 12/E Screw Skrue
33 1/E Camshaft section Styreakselssektion
13 1/E Gear wheel Tandhjul "aft", 8 cyl. engine "agter", 8 cyl. motor

14 Self locking nut Selvlåsende møtrik 34 1/E Camshaft section Styreakselssektion


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

Screw Skrue 36 1/E Camshaft "Fore" Styreaksel "For"


15 60/E 6 cyl. engine 6 cyl. motor 7 cyl. engine 7 cyl. motor
42/E 7 cyl. engine 7 cyl. motor
56/E 8 cyl. engine 8 cyl. motor 37 1/E Camshaft "Fore" Styreaksel "For"
82/E 9 cyl. engine 9 cyl. motor 8 cyl. engine 8 cyl. motor

16 1/E Camshaft "Fore" Styreaksel "For" 38 1/E Camshaft "Fore" Styreaksel "For"
5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor

19 10/E Screw Skrue

20 4/E Camshaft, Styreaksel,


intermediate, mellem,
6 cyl. engine 6 cyl. motor

21 Gasket Pakning
7/E 6 cyl. engine 6 cyl. motor
8/E 7 cyl. engine 7 cyl. motor
9/E 8 cyl. engine 8 cyl. motor
10/E 9 cyl. engine 9 cyl. motor

22 Guide screw Styreskrue


7/E 6 cyl. engine 6 cyl. motor
8/E 7 cyl. engine 7 cyl. motor
9/E 8 cyl. engine 8 cyl. motor
10/E 9 cyl. engine 9 cyl. motor

23 1/E Coupling flange Koblingssflange

25 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./E = Qty./Engine Antal/E = Antal/Motor

06.43 - ES0
Operating gear

508/608
MAN Diesel

Description
Operating Gear for Valve and Fuel Injection Pumps 608.01
Page 1(1)
Edition 12H

L/V28/32H
Roller Guides

The fuel injection pumps and the rocker arms for inlet
and exhaust valves are operated by the cams, on the
camshaft through roller guides. The roller guides for Valve bridge Rocker arm
fuel pump, inlet and exhaust valves are located in
bores in a common housing for each cylinder, this
housing is bolted to the engine frame.

The roller runs on a bush fitted on a pin that is pres-


sed into the roller guide and secured by means of
a lock screw.

Operating Gear for Fuel Injection Pumps


Valve spring
Valve spindle
The injection pumps which is mounted directly on
the roller guide housing is activated via thrust pieces Push rod
from the roller guide.
Protecting Tube

The roller is pressed down on to the cam by a spring, Roller guide


which is fixed between the roller guide and the foot housing
plate of the fuel injection pump.
Roller guide

Operating Gear for Inlet and Exhaust Valves Pin

The movment from the roller guides for inlet and Roller
exhaust is transmitted via the push rods the rocker
arms and spring-loaded valve bridges to each of
the two valve sets. The bridge is placed between Camshaft
the valve spindles and in the one end it is provided
with a pressed-on thrust shoe and in the other end
it is fitted with a thrust screw for adjustment of the
valve clearance. Fig. 1. Valve Operating Gear.

On its top the bridge is controlled by a spherical


thrust shoe on the rocker arm and at the bottom
by a guide which rests in a spherical socket in the
cylinder head.
08028-0D/H5250/94.08.12

91.13 - ES0S
MAN Diesel & Turbo

Working Card
Inspection of Valve Roller Guides 608-01.00
Page 1 (2) Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 26 20 - 120 Nm
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description: Hand tools:

Dismounting, inspection and/or overhaul, and Ring and open end spanner, 19 mm.
mounting of valve roller guides. Socket spanner, 19 mm.
Inspection of roller guide housing. Socket spanner, 24 mm.
Allen key, 3 mm.
Ratchet spanner.
Hammer.
Starting position: Drift.

Top cover for cylinder head and cover for fuel


injection pump removed.

Related procedure:

Inspection of fuel injection pump


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

Man power: Replacement and wearing parts:

Working time : 2 Hours Plate no. Item no. Qty. /


Capacity : 1 man
60801 04 4/cyl.
Data: 60801 08 2/cyl.
60801 09 1/cyl.
Data for pressure and tolerance (Page 600.35)
Data for torque moment (Page 600.40) See also plate 60801.
Declaration of weight (Page 600.45)

12.24 - ES0
MAN Diesel & Turbo

608-01.00 Working Card


Edition 01H Inspection of Valve Roller Guides Page 2 (2)

L/V28/32H
Dismounting of Roller Guide. 5) Dismount the screws (3) which secure the
roller guide top cover, take off the cover, and lift out
1) Turn the engine so that the roller, rests on the the roller guide (5).
circular part of the cam.
Disconnect any pipes that may be in the way (lub.
2) Unscrew the nuts which secure the rocket arm oil and fuel oil pipes).
brackets, and lift off the rocker arm with brackets.
6) If the roller guide housing is to be dismantled,
3) Remove the push rods (1), see fig. 1. the fuel injection pump and the fuel injection pump
roller guide are to be dismounted, see working card
614-01.05 and a number af lubricating oil and fuel
oil pipes are also to be disconnected.

1 The roller guide housing (6) cannot be dismantled


with the roller guides fitted.

7) If the event of any marks or scores from sezu-


2 res, these must be polished away.

8) Inspect the spherical stud for deformations


3 (replace as necessary).

4 Examine the surface of the roller for marks and other


deformations.
6
Make sure that there is free rotation between the
roller and the bush and the shaft pin, and replace
the bush, if necessary.

5 Replacement of Roller, Bush and Shaft Pin.

9) Remove the lock screw which secures the roller


guide shaft pin and push out the shaft pin.

The roller, shaft pin, and bush can now be replaced


as required.

0) Blow through the lubricating ducts in roller guide


1
and roller guide housing, and clean the lu­bri­ca­ting
grooves.

Mounting of Roller Guide.

Fig. 1. 1) When assembling the parts, which is carried


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

12.24 - ES0
MAN Diesel & Turbo

Working Card 608-01.05


Page 1 (2) Inspection of Fuel Injection Pump Roller Guide Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description: Hand tools:

Dismounting, inspection and/or overhaul, and Allen key, 3mm.


mounting af roller guide for fuel injection pump. Hammer.
Drift.

Starting position:

Cover for fuel injection pump removed.


Fuel injection pump has been
removed, 614-01.05

Related procedure:

Adjustment and/or check of max.


combustion pressure, 614-01.20

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

12.24 - ES0
MAN Diesel & Turbo

608-01.05 Working Card


Edition 01H Inspection of Fuel Injection Pump Roller Guide Page 2 (2)

L/V28/32H
Dismounting of Roller Guide. 3) Inspect the spherical stud for deformations
(replace as necessary).
1) Remove the support ring (1) and spring (2)
and take up the roller guide (3), see fig. 1. Examani the surface of the roller for marks and other
deformations.

Make sure that there is free rotation between the


roller and the bush and the shaft pin, and replace
the bush if necessary.

1
Replacement of Roller, Bush and Shaft Pin.
2
4) Remove the lock screw which secures the roller
guide shaft pin and push out the shaft pin.
3
The roller, shaft pin, and bush can now be replaced
as required.

5) Blow through the lubricating ducts in roller guide


and roller guide housing, and clean the lub­ri­ca­ting
grooves.

Mounting of Roller Guide.

6) When assembling the parts which is carried


out in the reverse order.
Fig. 1.
7) For adaption of the thrust piece of the roller
guide, see working card 614-01.20.
Inspection of Roller Guide.

2) If the event of any marks or scores from sezu-


res, these must be polished away.

12.24 - ES0
MAN Diesel & Turbo

Working Card 608-01.10


Page 1 (3) Control and Adjusting of Valve Clearance Edition 01H

L/V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62008 02 Exhaust
Shut-off fuel oil 62008 01 Inlet
Shut-off cooling oil 62010 01
Stopped lub. oil circul.

Description: Hand tools:

Control and/or adjusting of valve clearance. Ring and open end spanner, 30 mm.
Big screw driver.

Starting position:

Cover for rocker arm are removed.


All indicator valves open.

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/4 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35) See also plate 60502.
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel & Turbo

608-01.10 Working Card


Edition 01H Control and Adjusting of Valve Clearance Page 2 (3)

L/V28/32H
Adjusting of Inlet Valve Clearance.

1) Turn the engine so that the roller, rests on the


circular part of the cam, i.e. the inlet valves and the
exhaust valves are closed.

2) Loosen the adjustment screws on valve bridge


and rocker arm, see fig. 1.

Fig. 2.

8) Check that the clearance is correct si­mul­ta­neo­


us­ly at both valve spindles.

Adjusting af Exhaust Valve Clearance.


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

4) Place the feeler gauge marked with "correct"


o,4 mm above the valve spindle nearest to the rocker
arm bracket, see fig. 1.

5) Adjust the clearance between valve bridge and


valve spindle by means of the adjustment screw on
the rocker arm (above the push rod) and tighten the
lock nut.

The feeler gauge is to remain in this position when


adjusting the clearance of the other valve.

6) Place another feeler gauge, at the same size


o,40 mm above the other valve spindle, see fig. 2.
Fig. 3.
7) Adjust the clearance between valve bridge and
valve spindle by means of the adjusment screw on
the valve bridge, and tighten the lock nut, see fig.
2.

91.45 - ES0S
MAN Diesel & Turbo

Working Card 608-01.10


Page 3 (3) Control and Adjusting of Valve Clearance Edition 01H

L/V28/32H
0) The feeler gauges for checking the clearance
1
have two gauges which are marked "incorrect" and
"correct", the latter to be used when adjusting the
valve clearance, see fig. 4.

After tightening up the counter nuts on rocker arms


and valves bridge, be sure that the feeler gaugs mar-
ked "correct" can be inserted into the two clear­anc­es
simultaneously as where it must not be pos­si­ble to
insert the gauges marked "incorrect".

Fig. 4.

91.45 - ES0S
MAN Diesel & Turbo

Plate
Page 1 (2) Roller Guide and Push Rods 60801-17H

L28/32H

01
02*
38
04
03 01
04

16

05
17
06
18
07
19
08
20+

28
09

22
23

10
24
11 12
12
26 25 27
13 13
14 14
15 15

11.36 - ES0
MAN Diesel & Turbo

Plate
60801-17H Roller Guide and Push Rods Page 2 (2)

L28/32H
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse

01 4/C Thrust piece Trykstykke 27 1/C Roller guide for fuel Rullestyr for brændsels­
injection pump, com- pumpe, komplet inkl.
02* 2/C Pipe Rør plete incl. item 12, 13, item 12, 13, 14, 15,
14, 15, 24, 25 24, 25
03 2/C Protecting tube Skærmrør
28 4/C Screw Skrue
04 4/C Sealing ring Tætningsring
38 2/C Push rod, complete Stødstang, komplet inkl.
05 4/C Screw Skrue incl. item 01, 02 item 01, 02

06 2/C Cover Dæksel

07 2/C Screw Skrue


+ Item no 20 require + Item nr. 20 kræver
08 2/C Gasket Pakning an individual match­ en individuel tilpasning
ing before mounting, før montering, kontakt
09 1/C Gasket Pakning contact MAN Diesel & MAN Diesel & Turbo,
Turbo, Holeby Holeby
10 2/C Ball pin Kugletap

11 2/C Roller guide Rullestyr

12 3/C Pin Tap

13 3/C Stop screw Stopskrue

14 3/C Bush Foring

15 3/C Roller Rulle

16 1/C Washer for spring Skive for fjeder

17 1/C Spring Fjeder

18 2/C Guide pin Styrestift

19 8/C Screw Skrue

20+ 1/C Housing for Hus for


roller guides rullestyr

22 1/C Thrust piece Tryktap

23 1/C 1 set shims (0.1, 0.3, 1 sæt shims (0,1, 0,3,


0.5 and 1.0 mm) 0,5 og 1,0 mm)

24 1/C Thrust piece Tryktap

25 1/C Roller guide Rullestyr

26 2/C Roller guide for Rullestyr for ventil­be­


valve gear, complete vægelse, komplet inkl.
incl. item 10, 11, 12, item 10, 11, 12, 13,
13, 14, 15 14, 15

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

11.36 - ES0
Control/safety

509/609
MAN Diesel

Description
Control and Safety Systems 609.01
Page 1 (2)
Edition 20H

L+V28/32H

Governor Should a fuel pump plunger seize in its barrel, thus


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

Pick-up for Engine RPM


Mechanical Overspeed (SSH 81)
The pick-up for transfer of signal to the tachometer
instrument for engine RPM is mounted on the fly The engine is protected against overspeeding in the
wheel end cover of the engine. event of, for instance, governor failure by means of
an overspeed trip.
A signal varying proportionally to engine RPM is
created in the pick-up by the rotating toothed im- The engine is equipped with a stopping device
pulse wheel mounted on the camshaft end. which starts to operate if the maximum permissible
revolution number is exceeded.

Pick-up for Turbocharger RPM The overspeed tripping device is fitted to the end
cover of the lubricating oil pump and is driven
See turbocharger instruction book, section 612. through this pump.

If the pre-set tripping speed is exceeded, the spring-


Regulating Shaft loaded fly weight (1), see fig. 1, will move outwards
and press down the arm (2).
The governor movements are transmitted through a
spring-loaded pull rod to the fuel pump regulating The arm is locked in its bottom position by the lock
shaft which is fitted along the engine. pin (3) which is pressed in by the spring (4).

The spring-loaded pull rod permits the governor to At the same time the arm (2) presses down the
give full deflection even if the stop cylinder of the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keep the fuel pump regulating whereby compressed air will be led to the Lambda
shaft at "no fuel" position. cylinder , see Description 609.10, in which the
piston is pressed forward and turns the fuel pump
Each fuel pump is connected to the common, lon- regulating rod to STOP position, thereby the engine
gitudinal regulating shaft by means of a two-piece, stops, the spring-loaded pull rod connection to the
spring-loaded arm. governor being compressed.

08.43 - ES0
MAN Diesel

609.01 Description
Edition 20H
Control and Safety Systems Page 2 (2)

L+V28/32H

The engine can be stopped manually by pressing The overspeed alarm (SAH 81) is activated by means
down the button (7), see fig. 1, which will activate the of the micro switch (9).
spring-loaded fly weight (1) through the lever (8).

If the overspeed has been activated the overspeed


must be reset before the engine can be started.
Reset is done by means of the button (10).

3 8
1

5
2

6
1. Flyweight
1
2. Arm
3. Lock pin
9
4. Spring
5. Spindle
6. Pneumatic valve
Normal Overspeed
poisition activated 7. Button
8. Lever
9. micro switch
10. Button
2 5 3 4 10 10

Fig 1 Mechanical overspeed (SSH 81).

08.43 - ES0
MAN Diesel
Description
Instruments and Automatics 609.05
Page 1 (3)
Edition 11H

L28/32H
Main instrument panel

As standard the engine is equipped with an instru- The instrument panel is mounted flexibly on rubber
ment panel, comprising instruments for visual indi- elements and all manometer connections are con-
cation of the most essential pressures. nected to the panel by means of flexible hoses, as
Illustrated on fig. 1. shown on fig. 2.

Flexible hose

Rubber element

Valves

Push button

On the engine is as standard mounted an instrument


panel.

The following incorporating pressure gauges for the most Fig. 2. Cross section of instrument panel
essential pressures.
08028-0D/H5250/94.08.12

Pressure gauge for:

PI 01 LT fresh water, inlet to air cooler


PI 10 HT fresh water, inlet engine The connecting pipes to the manometers are equip-
PI 21/22 Lubricating oil, inlet/outlet to filter ped with valves which make it possible to replace
PI 23 Lub. oil, inlet to turbocharger the manometers during operation.
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
PI 50 (*) Nozz. cool. oil, inlet to fuel valves In the charging air and nozzle oil piping damping
Switch for PI 21/22 filters are inserted for levelling out pressure fluctua-
(*) If nozzle cooling oil applied only. tions.

Fig. 1. Lay-out of instrument panel

94.28 - ES2S
MAN Diesel
609.05 Instruments and Automatics Description
Page 2 (3)
Edition 11H

L28/32H
Instrumentation - too high press. drop across lub. oil filter
- too high HT FW temperature - outlet engine
As standard the engine is supplied with the following - too low starting air pressure - inlet engine
instrumentation mounted local on the engine: - too high engine speed (overspeed)

Thermometer TI 01 LT water - inlet air cooler The actual number and type of the alarm- and shut-
Thermometer TI 02 LT water - outlet from air cooler down switches for the plant can be seen in the list
Thermometer TI 03 LT water - outlet from lub. oil cooler "Engine Automatic part list" in this section.
Thermometer TI 10 HT fresh water - inlet to engine
Thermometer TI 11 HT fresh water - outlet each cylinder
Thermometer TI 20 Lubricating oil - inlet to cooler Leakage Alarm (LAH 42)
Thermometer TI 22 Lubricating oil - outlet from filter
Thermometer TI 30 Charge air - inlet to cooler Waste and leak oil from the comparement, for the
Thermometer TI 31 Charge air - outlet from cooler injection equipment, fuel valves, high-pressure pipes
Thermometer TI 40 Fuel oil - inlet to engine and engine feed pump (if mounted) is led to a fuel
Thermometer*) TI 51 Nozz. cool. oil - outlet from fuel valves leakage alarm unit.
Thermometer TI 60 Exhaust gas - outlet each cylinder
Thermometer TI 61 Exhaust gas - outlet turbocharger

*) If nozzle cooling oil applied only. Normal leakage

C
The actual number of the instrumentation for the
plant can be seen on the diagrams for the specific
plant in the sections 612-613-614-615-616.
For code identification see 600.20. B
Leak alarm
Normal level

Pressostates and Thermostates

The engine is supplied with a number of alarm- and


shut-down functions. The alarms shall via the alarm
panel worn against an abnormal working condition, A
which can lead to break down and the shut-down
functions shall stop the engine before a break down.
I.e. a shut-down is "worse" than an alarm because High level
a shut-down is given if the engine could be severe
damage by running on these conditions.
Leakoil
As standard the engine is equipped with:
08028-0D/H5250/94.08.12

Alarm
Shut-down Switches for Normal

- too low lubricating oil pressure - inlet engine


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

Alarm Switches for


Waste oil outlet
- leaking fuel oil
- too low lubricating oil pressure - inlet engine
- too low prelubricating oil pressure Fig. 4. Fuel oil leakage alarm.
(level alarm)

94.28 - ES2S
MAN Diesel
Description
Instruments and Automatics 609.05
Page 3 (3)
Edition 11H

L28/32H
The alarm unit consist of a box with a float switch Alarm for Prelubricating (LAL 25)
for level monitoring, see fig. 4.
Alarm for missing prelubricating, when the engine
The supply fuel oil to the engine is led through the is stopped is given by means of a level switch (LAL
unit in order to keep heated up, thereby ensuring 25) mounted in the main lubricating oil pipe.
free drainage passage even for high-viscous wa-
ste/leak oil.
Alarm and Shut-down for Overspeed
Under normal conditions there will always be a smal-
ler amount of waste/leak oil from the comparement, When the mechanical overspeed is activated, see
this will be led out through the bore "A" in the pipe 609.01 fig. 2, a micro-switch will release the alarm
"B" as illustrated. for overspeed (SAH 81) and activate the shut-down
solenoid in the governor.
In case of a larger then normal leakage, the level
in the box will rise and the level switch "C" will be The latter function is a back-up for the mechanical
activated. The larger amount of leak oil will be lead overspeed.
out through the top of the pipe "B".
08028-0D/H5250/94.08.12

94.28 - ES2S
MAN Diesel

Description
Lambda Controller 609.10
Page 1 (2)
Edition 15H

L28/32H

Purpose Thus the solenoid valve (4) opens. The jet system is
activated, the turbocharger accelerates and increases
The purpose with the lambda controller is to prevent the charge air pressure, thereby pressing the piston
injection of more fuel in the combustion chamber than (3) backwards in the lambda cylinder (5). When the
can be burned during a momentary load in-crease. lambda ratio is satisfactory, the jet system will be
This is carried out by controlling the relation between de-activated.
the fuel index and the charge air pressure.
At a 50% load change the system will be activated
The Lambda controller is also used as stop cylin- for about 3-8 seconds.
der.
If the system is activated more than 10 seconds,
the solenoid valve will be shut off and there will be
Advantages a remote signal for "jet system failure".

The lambda controller has the following advan-


tages: Fuel oil limiting during start procedure

- Reduction of visible smoke in case of sudden During the start procedure the lambda controller is
momentary load increases. used as an index limiter.

- Improved load ability. Hereby heavy smoke formation is prevented during


start procedure and further the regulating device
- Less fouling of the engine's exhaust gas ways. cannot over-react.

- Limitation of fuel oil index during starting


procedure. Air Consumption

At 50% step load the air consumption will be as


Principles for functioning follows:

Figure 1 illustrates the controller's operation mode.


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

04.15 - ES0
MAN Diesel

609.10 Lambda Controller Description


Page 2 (2)
Edition 15H

L28/32H

1. Regulating arm
2. Switch (Pick-up)
3. Piston
4. Solenoid valve
5. Lambda controller
6. Overspeed device
(mecanical activated 3/2 valve)

5 Charge air
receiver

3
2
1
~
4 Engine's
compression
air system

Fig 1 Lambda controller incl. start limitation

04.15 - ES0
MAN Diesel & Turbo

Description
Starting Box 609.35
Page 1 (1) Edition 06H

L28/32H
Description Engine / Turbocharger RPM

The starting box is mounted on the engine's control By activating the "Engine RPM/TC RPM" button, the
side. On front of the box there are the following in- indication is changed.
dications/pushbuttons:
Engine RPM indication is green light-emitting diodes
– Indication of engine or turbocharger RPM and turbocharger RPM indication is red light-emitting
– Indication of electronic overspeed diodes.
– Pushbutton for "Manual Start"
– Pushbutton for "Manual Stop" External Indications
– Pushbutton for "Remote" *
– Pushbutton for "Local" * There are output signals for engine RPM and tur-
– Pushbutton for "Blocking" * bocharger RPM.
– Pushbutton for change-over between engine Engine: 0 - 1200 RPM ~ 4-20 mA
and turbocharger RPM TC: 0 - 60000 RPM ~ 4-20 mA

* The function chosen is indicated in the pushbutton. The pushbuttons for "Remote", "Local" and "Blocking"
See fig. 1. have potential free switches for external indication.

Manual Start All components in the starting box are wired to the
built-on terminal box.
The engine can be started by means of the start
button, but only if the button "Local" is activated.

The manual, local start is an electrical, pneumatic


start, i.e. when activating the start button a solenoid
valve opens for air to the air starter, thereby engaging
the starter and starting the diesel engine.Throughout
the starting cycle the start button must be activated.

The air starter is automatically disengaged when the


diesel engine exceeds 110 RPM. If the start button is
disengaged before the diesel engine has exceeded
110 RPM, further starting cycles are blocked, until
5 sec. after the engine is at standstill.

Remote Start

Remote start can only take place if the pushbutton


for "Remote" is activated.

Manual Stop

The "Manual Stop" button is connected to the stop


coil on the governor.

Blocking

If "Blocking" is activated, it is not possible to start


the diesel engine.
Fig 1 Starting box.

12.01 - ES1
MAN Diesel

Description 609.40
Page 1 (1) Converter for Engine- and Turbocharger RPM Signal Edition 01H

L+V28/32H
Engine RPM signal The "engine run" signals will be given through a relay.
One for synchronizing and one for start/stop of pre.
For measuring the engine's RPM, a pick-up mounted lub. oil pump or alarm blocking at start/stop.
on the engine is used giving a frequency depending
on the RPM. To be able to show the engine's RPM
on an analogue tachometer, the frequency signal Safe start
is sent through an f/I converter (frequency/current
converter), where the signal is transformed into a When the safe start signal is activated the engine
proportional 4-20 mA ~ 0-1200 RPM signal. can start. When the engine reach 140 RPM the air
starter will be shut-off.
Further, the converter has following signals:
Further, the safe start signal is a blocking function
- overspeed for the air starter during rotation.
- engine run
- safe start
- tacho fail Tacho fail

The tacho fail signal will be on when everything is


normal. If the pick-up or the converter failes the
signal will be deactivated. E.g. if there is power
supply failure.

The converter for engine RPM signal is mounted in


the terminal box on the engine.

Turbocharger RPM signal

For measuring the turbocharger RPM, a pick-up


mounted on the engine is used giving a frequency
depending on the RPM. To be able to show the
Fig 1. Converter for engine RPM. turbocharger's RPM on an analogue tachometer,
the frequency signal is sent through a f/I converter
(frequency/current converter), where the signal is
Overspeed transferred into a proportional 4-20 mA ~ 0-60000
RPM.
When the engine speed reach the setpoint for elec-
tronic overspeed the converter gives a shutdown
signal and a alarm signal through a relay.
08028-0D/H5250/94.08.12

Engine run

When the engine speed reach 710 RPM or 200


RPM + 10 seconds, the converter gives a "engine
run" signal.
Fig 2. Converter for TC RPM.
The engine run signal will be deactivated when
the speed is 640 RPM. If the engine speed haven't
been over 710 RPM the signal will be deactivated The converter is mounted in the terminal box on
at 200 RPM. engine.

96.30 - ES2S
MAN Diesel
Working Card Functional Test and Adjustment of Safety, 609-01.00
Page 1 (2) Edition 01H
Alarm and Monitoring Equipment

General

Safety precautions Special tools

Stopped engine Plate No Item No Note.


Shut-off starting air
Shut-off cooling water See Related Procedure
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description

Function test and adjustment of safety, alarm and


monitoring equipment. Hand tools

See Related Procedure

Starting position

Related procedure

Overspeed trip 609-01.05


Pressostate 609-05.00
Thermostate 609-05.01
Level switch (LAL 25) 609-05.02
Analog pressure transmitter 609-05.03
Analog temperature transmitter 609-05.04
08028-0D/H5250/94.08.12

Man power Replacement and wearing parts

Working time : hours Plate No Item No Qty. /


Capacity : man

Data

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

03.32 - ES0U
MAN Diesel
609-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 01H Page 2 (2)
Alarm and Monitoring Equipment

General
Maintenance of monitoring and safety sy- For check of these functions use the working cards
stems mentioned under related procedure on page 1.

One of the most important parameters in the pre-


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

The extent of the alarm and safety functions is vari-


able from plant to plant.

08028-0D/H5250/94.08.12

03.32 - ES0U
MAN Diesel
Working Card 609-01.05
Page 1 (2) Functional Test and Adjustment of Overspeed Trip Edition 01H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62009 01
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Functional test and adjustment of overspeed


trip. Hand tools:

Allen key, 4 mm.


Allen key, 2 mm.

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel
609-01.05 Working Card
Edition 01H Functional Test and Adjustment of Overspeed Trip Page 2 (2)

General
1) The engine is run up manually, (on governor Turn the engine until the adjusting screw is opposite
"synchronizer") and at no load, while watching the the opening on the side of the housing. Now loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular pin spanner supplied, se fig. 2.
On reaching the revolution number indicated on
page 600.30 or in "Test Report", the overspeed trip-
ping device must function, thus actuating the stop
cylinders. The fuel injection pump control rods are
now moved to zero index, and the engine stops.

2) If the overspeed divice trip at a revolution


number different from that stated on page 600.30
or in the "Test Report" the overspeed device must
be adjusted.

Fig. 2.

Turn the adjusting screw outwards (slacken flyweight


spring) to reduce the revolution number. Be careful
not to screw the adjusting screw so far out that it
may touch the release arm. Tighten the lock screw
and test the overspeed device again.

4) Refit the covers when the overspeed device


functions at correct revolution number.

5) The overspeed device can be tested manually


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

3) Remove both covers on the housing of the


overspeed tripping device, see fig. 1. 6) It is recommended now and then, while the
engine is at a standstill, to move the flyweight by
means of the push button to ensure that the flyweight
can always move with sufficient ease.

91.45 - ES0S
MAN Diesel
Working Card 609-05.00
Page 1 (2) Adjustment and Test of On/Off Pressostate Edition 02H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Adjustment and test of on/off pressostate. (lub.


oil,fuel oil, water etc.). Hand tools:

Screw driver.
Testing pump.
Ring and open end spanner, 10 mm.
Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel
609-05.00 Working Card
Edition 02H Adjustment and Test of On/Off Pressostate Page 2 (2)

General
Adjustment:

1) When the pressostate cover is removed and


locking screw pos. 5, fig. 1 is loosened, the range
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read.

1. Trial flange.
2. Drain screw.
3. Valve.
1. Range spindle.
2. Range scale.
3. Differential spindle.
4. Differential scale. Fig. 2.
5. Locking screw.

4) Remove the screw pos. 2.


Fig. 1.
5) Mount the testing pump on the trial flange pos.
1.
2) In pressostates having an adjustable differen-
tial, the spindle pos. 3 must be used to make the
adjusment. The differential obtained can be read Alarm for Falling Pressure:
directly on the scale pos. 4.
6) Pump up the pressure until the switch has
Set points, see page 600.30. changed. The pressure will slowly be relieved and
it must be checked that the switch change back to
the pressure stated as the alarm point.
08028-0D/H5250/94.08.12

Test:

It is possible to make a functional test of the pres- Alarm for Rising Pressure:
sure switch. This is to be carried out according to
the following procedure. 7) Pump up the pressure until the switch chang-
es, and check that it happens at the stated alarm
3) Shut off system pressure with the valve pos. point.
3, fig. 2.
8) After the final check and adjustment, remove
the testing pump, mount the screw pos. 2 and open
the valve pos. 3.

91.45 - ES0S
MAN Diesel

Working Card 609-05.01


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

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Adjustment and test of on/off thermostate. (lub.


oil, fuel oil, water etc.). Hand tools:

Screw driver.
Special testing devices.

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.26 - ES0S
MAN Diesel

609-05.01 Working Card


Edition 02H Adjustment and Test of On/Off Thermostate Page 2 (2)

L+V28/32H
Adjustment: Test:

1) When the thermostate cover is removed and 3) The funcional test of the thermostate is to be
locking screw pos. 5, fig. 1 is loosened, the range carried out according to the following procedure.
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read. 4) Take out the sensor of the pocket.

5) Test the sensor in a water bath, where the


temperature can be controlled.

Alarm for Falling temperature:

6) Raise the temperature until the switch has


changed.

Then the temperature must slowly be reduced, and


check that the switch changes back at the tempera-
ture stated in the list page 600.30.

Alarm for Rising temperature:


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

9) The sensor is mounted again.


Fig. 1.

2) Thermostates having an adjustable differential,


the spindle pos. 3 can be used while the scale pos.
4 is read.

Set points, see page 600.30.

96.26 - ES0S
MAN Diesel
Working Card 609-05.02
Page 1 (2) Function and Test of Level Switch (LAL 25) Edition 02H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Function and test of level switch, LAL 25, in


lubricating oil system. Hand tools:

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.03 - ES0S
MAN Diesel
609-05.02 Working Card
Edition 02H Function and Test of Level Switch (LAL 25) Page 2 (2)

General

The level switch LAL 25, which is mounted on the


main lubricating oil pipe of the engine, gives alarm
for missing prelubricating oil. Vent pipe

Function.

1) By starting the prelubricating oil pump the main


lubricating oil pipe will be filled with lubricating oil,
which means that the level switch is lifted and the
alarm is disconnected.
Level switch
2) When the prelubricating is interrupted, the lub.
oil will run out of the system through the bearings, Main lubricating oil pipe
which means that level switch is lowered and the
alarm starts.
Fig. 1.

Test:

The test is carried out when the engine is stop-


ped.

3) Start the lubricating oil pump, and let the pump


run about 5 min.

4) Stop the prelubricating oil pump. The alarm


must be released after 0 - 5 min., depending of the
oil viscosity.

08028-0D/H5250/94.08.12

91.03 - ES0S
MAN Diesel
Working Card 609-05.03
Page 1 (2) Adjustment and Test of Analogous Pressure Transmitter Edition 02H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Adjustment and test of analogous pressure


transmitter. Hand tools:

Ring and open end spanner, 10 mm.


Testing pump.

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.45 - ES0S
MAN Diesel
609-05.03 Working Card
Edition 02H Adjustment and Test of Analogous Pressure Transmitter Page 2 (2)

General

The pressure transmitter registers the actual pres- Adjustment:


sure and marks the change to an electrical signal,
which adjusts the pressure. 1) The pressure transmitter shall not be adjust-
ed, but the alarm limit must be set on the alarm
plant. Kindly see the instruction book for the alarm
plant.

Set points, see page 600.30.

Test:

2) It is possible to make a functional test of the


pressure transmitter. This is carried out according
to the following procedure:

3) Shut off system pressure with the valve pos. 3.

4) Remove the screw pos. 2.

5) Mount the testing apparatus on the trial flange


pos. 1. and pump on a pressure within the working
area of the transmitter.

If the alarm plant has an instrument unit, the pres-


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

91.45 - ES0S
MAN Diesel

Working Card Adjustment and Test of 609-05.04


Page 1 (2) Analogous Temperature Transmitter Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Adjustment and test of analogous temperature


transmitter, (PT 100 sensor). Hand tools:

Special testing devices.

Starting position:

Functional test and adjustment of safety


alarm and monitoring equipment, 609-01.00

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty./


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.26 - ES0S
MAN Diesel

609-05.04 Adjustment and Test of Working Card


Edition 02H Analogous Temperature Transmitter Page 2 (2)

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

Adjustment:

1) The PT 100 sensor connot be adjusted, but


the alarm limit must be set on the alarm plant.

Set point, see page 600.30.

Test:

2) The functional trial of the PT 100 sensor can be


carried out according to the following procedure.

3) Take out the sensor of the pocket.

4) Test the sensor by diving the sensor in the


water. Compare the signal from the sensor with the
water temperature.

If the alarm plant has an instrument unit, the tempe- Fig. 1.


rature can be read on this.

96.26 - ES0S
MAN Diesel
Working Card 609-10.00
Page 1 (2) Lambda Controller Edition 16H

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


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

Description: Hand tools:

Adjustment of lambda controller. Allen key.

Starting position:

Related procedure:

Manpower: Replacement and wearing parts:

Working time : 1 hour Plate no Item no Qty /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

10.23 - ES0
MAN Diesel
609-10.00 Working Card
Edition 16H
Lambda Controller Page 2 (2)

L28/32H

Adjustment of the Lamda Controller

All adjustments are made when the engine is in 1. Compressed air from
overspeed device
1
standstill position. 2. Lambda cylinder
3. Charge air pressure
4. Piston of the
2
1. Check that the free space between the pick- lambda cylinder
5. Regulating arm
up and the band steel on the regulating arm 6. Adjustment screw
is min. 1 mm, see fig 1.

6
5

Fig 3.

2. Turn the lever (fig 2) of the governor a few


times to full load with an adjustable spanner
(spring between governor and fuel rack full
com-pressed). Check that the fuel index is 24
mm at the fuel pump.

Note: Be sure that the fuel index is 24 mm at the fuel


pump when the engine is started.
Fig 1.
3. In case of large deviation from index 24 ad-
justment is done by turning the regulating arm
(5), fig 3. Finally adjustment is done at the
adjustment screw (6), fig 3.

4. Adjustment completed.

Adjustment of the stop screw

5. Remove pipe for charge air pressure, see fig 3.

6. Supply air pressure until the piston rod reaches


its upper position.

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


according to the test bed, plus 1.5 index.
Use the index arm on the fuel pump nearest to the
lambda controller as control for the index.

Fig 2. 8. Adjustment finished.

10.23 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 60901-13H

L28/32H

For actuator,
see special
instruction book
10

11

12
13
14
16 15
17
02
18
03
20
19+

04
05 21

06 22
07 23

08 24
25

26
27

30
29

06.33 - ES0
MAN Diesel
Plate
60901-13H Governor and Governor Drive Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

02 1/E Plug screw Propskrue


29 1/E Wear disc Slidskive
03 1/E Gasket Pakning
30 1/E Key Feder
04 4/E Nut Møtrik

05 2/E Stud Tap + Item No. 19 require + Item nr. 19 kræver


an individual match- en individual tilpasning
06 1/E O-ring O-ring ing (by shims) before (med shims) før monte-
mounting, contact, ring, kontakt MAN B&W,
07 1/E Castle nut Kronemøtrik MAN B&W, Holeby Holeby.

08 1/E Split pin Split

10 1/E Actuator Aktuator

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 -


0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)

13 1/E Disc Skive

14 1/E Ball bearing Kugleleje

15 1/E Bevel gear wheel Konisk tandhjul

16 1/E Key Feder

17 1/E Castle nut Kronemøtrik

18 1/E Split pin Split

19+ 1/E Housing Hus

20 2/E Stud Tap

21 2/E Pin Stift

22 1/E Plug Prop

23 1/E Plug Prop

24 1/E Axle journal Akseltap

25 1/E Bush Bøsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

06.33 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 60901-14H

L28/32H

01 09

For governor, 10
see special
instruction book

11

12
13
14
16 15
17
02
18
03
20
19+

04
05 21

06 22
07 23

08 24
25

26
27

30
29

06.33 - ES0
MAN Diesel
Plate
60901-14H Governor and Governor Drive Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Synchronnizing Synchroniserings- 29 1/E Wear disc Slidskive


motor motor
30 1/E Key Feder
02 1/E Plug screw Propskrue

03 1/E Gasket Pakning + Item No. 19 require + Item nr. 19 kræver


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

06 1/E O-ring O-ring

07 1/E Castle nut Kronemøtrik

08 1/E Split pin Split

09 1/E Shut down Shut-down


solenoid spole

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


item 01, 09 and 12 item 01, 09 og 12

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 -


0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)

13 1/E Disc Skive

14 1/E Ball bearing Kugleleje

15 1/E Bevel gear wheel Konisk tandhjul

16 1/E Key Feder

17 1/E Castle nut Kronemøtrik

18 1/E Split pin Split

19+ 1/E Housing Hus

20 2/E Stud Tap

21 2/E Pin Stift

22 1/E Plug Prop

23 1/E Plug Prop

24 1/E Axle journal Akseltap

25 1/E Bush Bøsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

06.33 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 60901-15H

L28/32H

09

31 For governor,
see special
instruction book
10
11

12

13
14
16 15
17
02
18
03
20
19+

04
05 21

06 22
07 23

08 24
25

26
27

30
29

06.47 - ES0
MAN Diesel
Plate
60901-15H Governor and Governor Drive Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

02 1/E Plug screw Propskrue 30 1/E Key Feder

03 1/E Gasket Pakning 31 1/E Shutdown solenoid Shutdown spole

04 4/E Nut Møtrik


+ Item No. 19 require + Item nr. 19 kræver
05 2/E Stud Tap an individual match- en individual tilpasning
ing (by shims) before (med shims) før mon-
06 1/E O-ring O-ring mounting, contact, tering, kontakt MAN
MAN Diesel A/S. Diesel A/S.
07 1/E Castle nut Kronemøtrik

08 1/E Split pin Split

09 1/E Synchronizing motor Synkroniseringsmotor

10 1/E Governor, Europa Regulator, Europa


(720/750 rpm) (720/750 rpm)

11 4/E Screw Skrue

12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 -


0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)

13 1/E Disc Skive

14 1/E Ball bearing Kugleleje

15 1/E Bevel gear wheel Konisk tandhjul

16 1/E Key Feder

17 1/E Castle nut Kronemøtrik

18 1/E Split pin Split

19+ 1/E Housing Hus

20 2/E Stud Tap

21 2/E Pin Stift

22 1/E Plug Prop

23 1/E Plug Prop

24 1/E Axle journal Akseltap

25 1/E Bush Bøsning

26 1/E Bevel gear wheel Konisk tandhjul

27 1/E Gear wheel Tandhjul

29 1/E Wear disc Slidskive

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./E = Qty./Engine Antal/E = Antal/Motor

06.47 - ES0
MAN Diesel
Plate
Page 1 (3) Regulation Mechanism 60902-18H

L28/32H

Governor Plate 60901

17
15, 70
18
01 13
19 16
02
03

04
05 14

19
06 25 20
07 26 18
08 27 17
09 28 21
24 22
10
25 23
11
12
64
13
65
02

66

67

56, 92, 93, 94, 95


68

48
49 69
57 50
58 51
52
55 53

61 54
62 59
63
60

06.35 - ES0
MAN Diesel

Plate
60902-18H Regulation Mechanism Page 2 (3)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/R Split pin Split 28 2/R Spring pin Fjederstift

02 2/R Pull rod head Trækstangshoved 48 1/C Linkage Lænkeled

03 1/R Pull rod end Trækstangsende 49 1/C Pin Stift

04 1/R Cylindrical pin Cylindrisk stift 50 1/C Spring Fjeder

05 1/R Spring housing Fjederhus 51 1/C Spring arm Fjederarm

06 1/R Pointed screw Pinolskrue 52 3/C Spring pin Fjederstift

07 1/R Spring Fjeder 53 1/C Arm holder Armholder

08 1/R Pull rod Trækstang 54 1/C Screw Skrue

09 1/R Cylindrical pin Cylindrisk stift 55 1/C Spring loaded Fjederbelastet


lever, complete arm, komplet
10 1/R Guide ring Styrering
56 1/E Regulating shaft Reguleringsaksel
11 1/R Guide ring Styrering 5 cyl. engine 5 cyl. motor

12 1/R Nut Møtrik 57 1/C Split pin Split

13 2/R Locking plate Låseblik 58 1/C Pin Stift

14 1/R Spring loaded pull Fjederbelastet træk- 59 1/C Bush Bøsning


rod, complete stang, komplet
60 1/C Bearing bracket Lejeblik
15 1/R Governor arm, Regulator arm, incl. item 59 inkl. item 59
Woodward Woodward
61 2/C Screw Skrue
16 1/R Screw Skrue
62 2/C Washer Skive
17 2/R Split pin Split
63 2/C Spring pin Fjederstift
18 2/R Self locking nut Selvlåsende møtrik
64 1/E Stop ring Stopring
19 2/R Screw for ball head Skrue for kuglehoved
65 1/E Screw Skrue
20 1/R Arm Arm
66 2/E Screw Skrue
21 1/R Spring pin Fjederstift
67 2/E Screw Skrue
22 1/R Locking plate Låseblik
68 1/E Bracket Konsol
23 1/R Screw Skrue
69 2/E Nut Møtrik
24 1/R Bearing housing Lejehus
incl. item 25 inkl. item 25 70 1/E Governor arm, Regulator arm,
Europa Europa
25 2/R Bush Bøsning
92 1/E Regulting shaft Reguleringsaksel
26 2/R Screw Skrue 6 cyl. engine 6 cyl. motor

27 2/R Washer Skive 93 1/E Regulating shaft Reguleringsaksel


7 cyl. engine 7 cyl. motor

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme

06.35 - ES0
MAN Diesel

Plate
Page 3 (3) Regulation Mechanism 60902-18H

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

94 1/E Regulating shaft Reguleringsaksel


8 cyl. engine 8 cyl. motor

95 1/E Regulating shaft Reguleringsaksel


9 cyl. engine 9 cyl. motor

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme

06.35 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Overspeed Device 60903-38H

L+V28/32H
01
02
03
04
05
06
07
09
08 10
11
12
13

16 14
17 15
18
21 46 19
20

24 48
22
25
23

30
26
33
27 31
32
34
37 35
39 36
38
40

41

42

43

47 44

45

11.02 - ES0
MAN Diesel & Turbo

Plate
60903-38H Overspeed Device Page 2 (2)

L+V28/32H

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

01 1/E Socket Muffe 32 1/E Button Knap

02 1/E Button Knap 33 1/E Nipple Nippel

03 1/E Spring pin Fjederstift 34 1/E Spindle Spindel

04 1/E Spring Fjeder 35 1/E Spring (left) Fjeder (venstre)

05 4/E Screw Skrue 36 1/E Spindle Spindel

06 1/E Screw Skrue 37 2/E Washer Skive

07 1/E Cover Dæksel 38 2/E Screw Skrue

08 1/E Spindle Spindel 39 1/E Ball bearing Kugleleje

09 1/E Spring pin Fjederstift 40 1/E Elastic coupling Elastisk kobling

10 1/E Cylindrical pin Cylindrisk stift 41 1/E Spring (right) Fjeder (højre)

11 1/E Lever Arm 42 1/E Valve attachment Ventilholder

12 1/E Screw Skrue 43 4/E Screw Skrue

13 1/E Flyweight housing Hus for svingvægt 44 1/E Pneumatic valve Pneumatisk ventil

14 1/E Adjusting screw Justeringsskrue 45 1/E Silencer Lyddæmper

15 1/E Spring Fjeder 46 1/E Overspeed device, Overspeed anordning,


complete excl. item 27, komplet eksl. item 27,
16 1/E Circlip Sikringsring 37, 38, 44 37, 38, 44

17 1/E Flyweight Svingvægt 47 1/E Spare parts kit for Reservedelskit for
item 44 item 44
18 1/E Key Not
48 1/E Limit switch (optinal) Afbryder (option)
19 1/E Ball bearing Kugleleje

20 1/E Housing Hus

21 1/E Cover Dæksel

22 4/E Washer Skive

23 4/E Screw Skrue

24 1/E Pin Stift

25 1/E Lever Arm

26 1/E Nut Møtrik

27 1/E Gasket Pakning

30 1/E Spindle Spindel

31 1/E Spring Fjeder

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

11.02 - ES0
MAN Diesel
Plate
Page 1 (2) Instrument Panel 60905-20H

L28/32H

33 33A 04 04 03

01
16

09
10

03 04

07

04 29
08
24-26
13

05 05
14

06 19
20
25
12

30
28 15
02
06 11 18 02A

PI 01 LT fresh water, inlet to air cooler


PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
PI 23 Lub. oil, inlet to turbocharger
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
PI 50 Nozz. cool. oil, inlet to fuel valves

06.35 - ES0S
MAN Diesel

Plate
60905-20H Instrument Panel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Housing for instru- Hus for instrument pa- 28 1/E Washer Skive
ment panel nel
29 1/E Pressure gauge 0-10 Manometer 0-10 bar,
02 1/E Bracket for instrument Konsol for instrument bar, PI 40 PI 40
panel , L23/30H panel, L23/30H
30 4/E Packing ring Pakningsring
02A 1/E Bracket for instrunent Konsol for instrument
panel, L28/32H panel, L28/32H 33 1/E Instrument panel, Instrument panel, kom-
complete, L23/30H plet, L23/30H
03 2/E Pressure gauge 0-3 Manometer 0-3 bar (PI
bar (PI 31 and PI 23) 31 og PI 23) 33A 1/E Instrument panel, Instrument panel, kom-
complete, L28/32H plet, L28/32H
04 4/E Pressure gauge 0-6 Manometer 0-6 bar,
bar, PI 01, PI 10, PI 50, PI 01, PI 10, PI 50, PI
PI 21-22 21-22

05 8/E Needle valve Nåleventil

06 1/E 3-way valve for PI 3-vejsventil for PI 21-


21-22 22

07 3/E Pressure gauge hose Manometer slange


195 mm 195 mm

08 2/E Pressure gauge hose Manometer slange


140 mm 140 mm

09 1/E Pressure gauge hose Manometer slange


300 mm 300 mm

10 2/E Pressure gauge hose Manometer slange


340 mm 340 mm

11 1/E Damper Dæmper


(charging air) (ladeluft)

12 1/E Damper (fuel oil) Dæmper (fuel oil)

13 4/E Rubber clutch Gummikobling

14 2/E Union Forskruning

15 1/E Screwed connection Skrue forbindelse

16 8/E Packing ring Pakningsring

18 2/E Union Forskruning

19 2/E Union Forskruning

20 3/E Screw Skrue

24 8/E Nut Møtrik

25 4/E Serrated washer Stjerneskrue

26 8/E Washer Skive

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

06.35 - ES0S
MAN Diesel
Plate
Page 1 (2) Instrument Panel 60905-27H

L28/32H

PI 01 LT fresh water, inlet to air cooler


PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
PI 23 Lub. oil, inlet to turbocharger
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
PI 50 Nozz. cool. oil, inlet to fuel valves

94.28 - ES0S
MAN Diesel
Plate
60905-27H Instrument Panel Page 2 (2)

L28/32H
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse

01 1/E Housing for instru- Hus for instrument- 23 1/E Damper (charging air) Dæmper (ladeluft)
ment panel panel
43 4/E Screw Skrue
02 1/E Bracket for instru- Konsol for instrument-
ment panel panel 44 4/E Serrated lock washer Stjernefjederskive

03 4/E Rubber clutch Gummikobling 45 2/E Screw Skrue

04 8/E Nut Møtrik 46 2/E Serrated lock washer Stjernefjederskive

05 8/E Spring lock Fjederskive 47 8/E Screw Skrue

06 2/E Pressure gauge Manometer 48 1/E Side plate Sideplade


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

08 1/E Pressure gauge Manometer


0-10 bar (PI 40) 0-10 bar (PI 40)

09 7/E Needle valve Nåleventil

10 1/E 3-way valve for 3-vejsventil for


PI 21-22 PI 21-22

11 1/E Washer Skive

12 1/E Pipe Rør

13 1/E Angle union Vinkelforskruning

14 2/E Straight union Ligeforskruning

15 2/E Pressure gauge hose Manometer slange


195 mm 195 mm

16 2/E Pressure gauge hose Manometer slange


140 mm 140 mm

17 2/E Pressure gauge hose Manometer slange


300 mm 300 mm

18 1/E Pressure gauge hose Manometer slange


340 mm 340 mm

19 7/E Packing ring Pakningsring

20 2/E Reduction Reduktion

21 1/E Damper (fuel oil) Dæmper (fuel oil)

22 2/E Coupling for mano- Kobling for manometer


meter

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

94.28 - ES0S
MAN Diesel
Plate
Page 1 (2) Instrument Panel 60905-32H

L28/32H

49 19 07 06 07

01
17

18

47 07 08

16

48 07 06

15

04-05
03 02
14
09

10

11
43-44-45 20 20
12 23 21
13
14 22 22

PI 01 LT fresh water, inlet to air cooler


PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
PI 23 Lub. oil, inlet to turbocharger
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
PI 50 Nozz. cool. oil, inlet to fuel valves

95.20 - ES0S
MAN Diesel

Plate
60905-32H Instrument Panel Page 2 (2)

L28/32H
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse

01 1/E Housing for instru- Hus for instrument- 23 1/E Damper (charging air) Dæmper (ladeluft)
ment panel panel
43 4/E Screw Skrue
02 1/E Bracket for instru- Konsol for instrument-
ment panel panel 44 4/E Lock washer Låseskive

03 4/E Rubber clutch Gummikobling 45 4/E Nut Møtrik

04 8/E Nut Møtrik 47 8/E Screw Skrue

05 8/E Spring lock Fjederskive 48 1/E Side plate Sideplade

06 2/E Pressure gauge Manometer 49 1/E Instrument panel, Instrument panel,


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

07 4/E Pressure gauge Manometer


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

08 1/E Pressure gauge Manometer


0-10 bar (PI 40) 0-10 bar (PI 40)

09 7/E Needle valve Nåleventil

10 1/E 3-way valve for 3-vejsventil for


PI 21-22 PI 21-22

11 1/E Washer Skive

12 1/E Pipe Rør

13 1/E Angle union Vinkelforskruning

14 2/E Straight union Ligeforskruning

15 2/E Pressure gauge hose Manometer slange


195 mm 195 mm

16 2/E Pressure gauge hose Manometer slange


140 mm 140 mm

17 2/E Pressure gauge hose Manometer slange


300 mm 300 mm

18 1/E Pressure gauge hose Manometer slange


340 mm 340 mm

19 7/E Packing ring Pakningsring

20 2/E Reduction Reduktion

21 1/E Damper (fuel oil) Dæmper (fuel oil)

22 2/E Coupling for mano- Kobling for manometer


meter

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

95.20 - ES0S
MAN Diesel
Plate
Page 1 (3) Thermometer 60907-19H

L28/32H
Scale Length Item
Fig. Code
°F °C L L1 No

40-240 0-120 110 100 TI 01 01

TI 02

TI 31

L 40-240 0-120 110 63 TI 22 02

TI 20

40-600 0-300 150 100 TI 30 03


L1

40-400 0-200 110 40 TI 40 04

TI 51

40-220 0-120 110 100 TI 03 05

TI 10

TI 11

L1

04.11 - ES0
MAN Diesel
Plate
60907-19H Thermometer Page 2 (3)

L28/32H
Scale Length Item
Fig. Code
°F °C L L1 No.

100-
1300 50-650 100 115 TI 60 06

°C°F

L1

L1

Pocket 115 07

100-
1300 50-650 65 215 TI 61 08

° C° F

Pocket 215 09

04.11 - ES0
MAN Diesel
Plate
Page 3 (3) Thermometer 60907-19H

L28/32H
Scale Length Item
Fig. Code
°F °C L L1 No.

120-1200 50-650 140 215 TI 61 10

TI 62

Thermo-
meter 11

Feeler
NiCr-Ni 12

Pocket 100 13

120-1200 50-650 165 115 TI 60 14

120-1200 50-650 190 115 TI 60 15

Feeler
NiCr-Ni 16

Thermo-
meter 17

Pocket 200 18

04.11 - ES0
MAN Diesel
Plate Pressostate, Thermostate
Page 1 (2)
Difference Pressostate and Pressure Transmitter 60907-02H

General

Fig. and Description Range Code L Item No.

0-8 bar PSL 22 01


PAL 10
PAL 22

6-18 bar PAL 70 02


PAL 24

10-35 bar 03

1-10 bar PAL 40 04


Pressostate

20-60°C TAL 10 2m 05
5m 06

50-100°C 2m 07
5m 08
8m 09

70-120°C TAH 12 2m 10
TSH 12 5m 11
TAH 20 8m 12
L TSH 22
TSH 12
Thermostate

0.2-2.5 bar PDAH 21-22 13

Difference Pressostate

99.33 - ES0S
MAN Diesel

Pressostate, Thermostate Plate


60907-02H Difference Pressostate and Pressure Transmitter Page 2 (2)

General

Fig. and Description Range Code L Item No.

0-2.5 bar PT 31 14

0-4 bar PT 10 15

0-6 bar PT 22 16

0-10 bar PT 40 17

0-16 bar PT 70 18

0-40 bar 19

0-400 bar 20
Pressure Transmitter

Needle Valve with 3/8" pipe thread 25

Needle valve with 1/2" pipe thread 26

Needle Valve

99.33 - ES0S
MAN Diesel

Plate
Page 1 (2) Prelubricating Oil Alarm (LAL 25) 60919-01H

L+V28/32H

01

02

03

Switch point

04
08028-0D/H5250/94.08.12

07.11 - ES0
MAN Diesel
Plate
60919-01H Prelubricating Oil Alarm (LAL 25) Page 2 (2)

L+V28/32H

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

01 1/E Plug screw Propskrue

02 1/E Packing ring Pakningsring

03 1/E Loctite 577 Loctite 577

04 1/E Level switch Niveauafbryder

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.11 - ES0
MAN Diesel
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 60920-01H

L28/32H

09 10

05 04

07 02

13 03

16
MAX

06
15
13
08

15
MIN

08

01

04
08028-0D/H5250/94.08.12

07.12 - ES0
MAN Diesel
Plate
60920-01H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)

L28/32H

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

01 1/E Level alarm Niveaualarm

02 1/E Flange Flange

03 1/E Packing Pakning

04 4/E Screw Skrue

05 4/E Nut Møtrik

06 1/E Pipe, LAL Rør, LAL

07 1/E Pipe, LAH Rør, LAH

08 2/E Level switch Niveaukontakt

09 2/E Reduction adaptor Reduktionsadapter

10 1/E Dipstick complete Pejlestok komplet

13 2/E Reduction adaptor Reduktionsadapter

15 /I Loctite 577 Loctite 577

16 1/E O-ring O-ring

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.12 - ES0
MAN Diesel

Plate
Page 1 (2) Local Starting Box - No 1 60935-13H

L+V28/32H

07.45 - ES0
MAN Diesel

Plate
60935-13H Local Starting Box - No 1 Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0
MAN Diesel

Plate
Page 1 (2) Local Starting Box - No 1 60935-16H

L28/32H

600
OVERSPEED 720
750
30000

20000 40000
300 900 029
10000 50000

140 TC
0 60000
ENG. 0 1200

RPM

ENGINE RPM
START STOP
TC RPM

REMOTE LOCAL BLOCKING

017
08028-0D/H5250/94.08.12

07.45 - ES0 - TCR lader


MAN Diesel

Plate
60935-16H Local Starting Box - No 1 Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0 - TCR lader


MAN Diesel

Plate
Page 1 (2) Local Starting Box - No 2 60935-14H

L+V28/32H

07.45 - ES0
MAN Diesel

Plate
60935-14H Local Starting Box - No 2 Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0
MAN Diesel

Plate
Page 1 (2) Local Starting Box - No 2 (incl. high lub. oil temp.) 60935-15H

L+V28/32H

07.45 - ES0
MAN Diesel

Plate
60935-15H Local Starting Box - No 2 (incl. high lub. oil temp.) Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/E Panel Panel

029 1/E Starting box Startboks

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor

07.45 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Engine Control Box 60936-08H

General

ELECTRONICS
Beijer
T70
EXTER
536

727 715 703

345 345

0 4 0 4
1 5 1 5
OUTPUT
AC/DC OUT

AC/DC OUT

OK OK
INPUT

2 6 2 6

095 585
3 7 3 7

DC INPUTS ANALOG ANALOG


ISOLATED RELAY ISOLATED RELAY
Allen-Bradley 0
1
4
5
8 12
9 13
2 6 10 14
3 7 11 15

DC/RELAY OUT

573 -K6.6
0

2
1
4
5
6 10
8
9 333
3 7 11

-K8.0 -K7.0 -K9.0 -K9.6

644

656

404 -K9.2
11 12 13 14

394 GND 0 GND 274


GND 0 GND
-F3.0.1
-F3.0

416 561
GND 0 GND

142 548
41 42 43 44

10.51 - ES0
MAN Diesel & Turbo

Plate
60936-08H Engine Control Box Page 2 (2)

General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

095 1/E Safety system, Sikkerhedssystem,


Base unit Base unit

142 1/E Terminal, earth Jordklemme

274 3/E End stop Endestop

333 1/E Analog Analog


output module outputmodul

345 2/E Digital Digital


output module outputmodul

394 2/E Fuse terminal Sikringsklemme

404 1/E End plate Endeplade

416 4/E Fuse Sikring

536 1/E Panel Panel

548 50/E Terminal double Klemme, dobbelt

561 1/E End plate Endeplade

573 1/E Processor unit (CPU) Processor unit (CPU)

585 1/E End cap Endestykke

644 1/E Analog Analog


input module inputmodul

656 1/E Converter Konverter

668 1/E Cable Kabel

703 8/E Cable union Kabelforskruning

715 3/E Cable union Kabelforskruning

727 2/E Cable union Kabelforskruning

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/E = Qty/Engine Qty/E = Qty/Motor

10.51 - ES0
MAN Diesel

Plate
Page 1 (2) Terminal Box 60936-07H

L28/32H

619
607 620 250
)
SSH 81
SAH 81

597 X:2
UX 95

632
(

5K6

3K2
3K3
3K9
4K2
4K3
4K4
4K5
4K6
4K7
5K4
5K9
4P1

274
644
225 668
F1/1
F1/2

394 X:1
416

536
681
693 490 477 453 274
500 489 465 656
08028-0D/H5250/94.08.12

07.45 - ES0
MAN Diesel

Plate
60936-07H Terminal Box Page 2 (2)

L28/32H
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

225 1/E Conduit Ledningskanal

250 1/E Conduit Ledningskanal

274 4/E End stop Endestop

394 2/E Fuse terminal Sikringsklemme

416 2/E Fuse 2A Sikring 2A

453 2/E Cable union M16 Kabelunion M16

465 2/E Nut M16 Møtrik M16

477 2/E Cable union M20 Kabelunion M20

489 2/E Nut M20 Møtrik M20

490 2/E Cable union M25 Kabelunion M25

500 2/E Nut M25 Møtrik M25

536 1/E Panel Panel

597 1/E Speed converter, Speed converter,


engine 720 rpm motor 720 omdr

607 1/E Timer Timer

619 11/E Aux. relay Hjælperelæ

620 11/E Socket Sokkel

632 1/E Speed converter, Speed converter,


engine 750 rpm motor 750 omdr

644 12/E Terminal Klemme

656 54/E Terminal Klemme

668 2/E Diode terminal Diode klemme

681 3/E Cable union M32 Kabelunion M32

693 3/E Nut M32 Møtrik M32


08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor

07.45 - ES0
MAN Diesel

Plate
Page 1 (2) Converter 60956-01

General

(RS-232)
021

ADAM ADAM-4520
RS-232 TO RS-422/RS-485
CONVERTER
(B) GND 10

(RS 485)
(RS 422)
(R) +Vs
DATA +
DATA -

RX +
TX +

RX -
TX -

033
045
08028-0D/H5250/94.08.12

07.37 - ES0
MAN Diesel
Plate
60956-01 Converter Page 2 (2)

General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

021 1/E Coverter Converter

033 1/E Cable, length 1.8 m Kabel, længde 1.8 m

045 1/E Cable, length 10 m Kabel, længde 10 m

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor

07.37 - ES0
Crankshaft

510/610
MAN Diesel

Description
Crankshaft and Main Bearings 610.01
Page 1 (1)
Edition 12H

L/V28/32H
Crankshaft Vibration Damper

The crankshaft, which is a one-piece forging with In special cases a vibration damper is mounted on
ground main bearing and crankpin journals, is sus- the crankshaft to limit torsional vibrations.The damper
pended in inderslung bearings. The main bearings consists essentially of a heavy flywheel totally en-
are equipped with insertion-type shells, which are closed in a light casing. A small clearance is allowed
coated with a wearing surface. To attain a suitable between the casing and the flywheel, and this space
bearing pressure the crankshaft is provided with is filled with a highly viscous fluid.The casing is rigidly
counterweights, which are attached to the crank- connected to the front end of the engine crankshaft
shaft by means of dovetail joints and secured with and the only connection between the crankshaft
a centrally placed screw. and the damper flywheel is through the fluid. Under
conditions of no vibration, the casing and damper
At the flywheel end the crankshaft is fitted with a gear flywheel tend to rotate as one unit, since the force
wheel which through an intermediate wheel drives required to shear the viscous film is consi-derable.
the camshaft. Also fitted here is the flywheel and a As the torsional vibration amplitudes increase, the
coupling flange for connection of a reduction gear or casing follows the movement of the crankshaft but
a alternator. At the opposite end there is a claw-type the flywheel tends to rotate uniformly by virtue of
coupling for the lub. oil pump or a flexible gear wheel its inertia, and relative motion occurs between the
connection for lub. oil and water pumps. flywheel and the casing. The viscous fluid film there-
fore undergoes a shearing action, and vibration
energy is absorbed and appears as heat.
08028-0D/H5250/94.08.12

91.45 - ES0U
MAN Diesel

Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00


Page 1 (6) Edition 10H
(Hydraulic Tightened Connecting Rod)

L28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62010 01
Shut-off fuel oil 62010 05
Shut-off cooling oil 62010 35 Angle for
Stopped lub. oil circul. mounting on
crank web

Description:

Checking of main bearings alignment (deflec-


tion). Hand tools:

Starting position:

Turning gear in engagement. (If mounted).


Cover for crankshaft has been removed from
frame.
All indicator valves open.

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 1/2 hours Plate no. Item no. Qty. /


Capacity : 2 men

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

99.25 - ES0S
MAN Diesel

610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card


Edition 10H Page 2 (6)
(Hydraulic Tightened Connecting Rod)

L28/32H
Alignment of Main Bearings.

The lower main bearing shells should be positioned


so that they keep the main bearing journals of the
crankshaft centered in a straight (ashore horizon-
tal) line. Deviations from this centre line cause the
crankshaft to bend and increase the load on some
main bearings.

If two adjacent main bearings are placed too low, the


crankshaft centre line will in this place be lowered to
form an arc, causing the intermediate crank throw to
bend in such a way that it "closes" when turned into
bottom position and "opens" in top position.

As the magnitude of such axial lengthening and


shor tening during the turning of the throw increases Fig. 1 Placing of dial gauge
in proportion to the difference in the height of the
bearing, it is measured as a check on the alignment
and condition of the bearing.
Checking The Deflection Measurement.
As the crankshafts of medium speed engines are very
stiff, any great deviations in the alignment will result The reading is entered in the table page 6, see
in clearance at the bottom shell of the bearings. example in fig. 2 - 6.

The cause of incorrect main bearing position may As "bottom" reading is used the mean value of the
be wear of the bearings or misalignmnet of the two "near bottom" readings X and Y, fig. 3.
engine.
The total deflection ("opening-closing") of the throw
during the turning from bottom to top position is
Effecting The Deflection Measurement. entered in fig. 4.

The deflection measurement is effected by placing a These figures are due to vertical misalignment of
springloaded dial gauge in the centre punch marks the main bearings.
provided for this purpose, see fig. 1.
Similarly, horizontal misalignment procedures the
"Closing" of the throw in top dead centre is regarded figures in the table fig. 5.
as negative, (compression of the gauge).
Besides misalignment of the bearings, the readings
In the example, page 3, the deflection reading is can be influenced by ovality or eccentricity of the
therefore negative. journals.
08028-0D/H5250/94.08.12

As during the turning of the throw, the gauge and the


connecting rod will meet near the bottom position of Engines Equipped with Turning Gear.
the throw, the measurement for the bottom position
is to be replaced by the average of the two near by When taking these deflection readings for the three
positions on either side. aftmost cylinders, the turning gear should at each
stoppage be turned a little backwards to ease off
The dial gauge is set to zero, when the crank throw the tangential pressure on the teeth of the turning
is in the near-bottom (x in fig. 8) and during the wheel as this pressure may otherwise falsify the
turning the throw is stopped in the position horizon- readings.
tal-top-horizontal-near bottom (P-T-S-Y in fig. 8) for
reading of the gauge.

99.25 - ES0S
MAN Diesel

Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00


Page 3 (6) (Hydraulic Tightened Connecting Rod) Edition 10H

L28/32H
Deflection of crankshaft in 1/100 mm. (0.01 mm).
Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig. 4.
Left side P 2 0 2 0 -1 2

Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment

Bottom stop Y 2 -1 0 1 0 2 Right side - left side


or P - S = H -1 2 0 0 -1 1

Fig. 2. Fig. 5.

Bottom (0,5 x Y) = B 1 -0.5 0 -0.5 0 1 Check on T+B= C 4 -2.5 4 5.5 -2 4


gauge
readings P+S= D 5 -2 4 0 -1 3
Fig. 3.

Fig. 6.

C and D should be nearly the same, reading for cylinder 4 to be repeated.

S P
08028-0D/H5250/94.08.12

Y X

Front end view.


"Closing" of the crankthrow is considered Start in position X.
negative. Turn anti clockwise

Fig. 7. Fig. 8.

99.25 - ES0S
MAN Diesel

610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card


Pagee 4 (6)
Edition 10H (Hydraulic Tightened Connecting Rod)

L28/32H

Measurement of Crank Throw Deflections by Means of Dial Indicator (Autolog)

Crank throw deflection = Difference in dial indicator readings in two diametrically


opposite crank throw positions, i.e. two positions displa-
ced 180°.

Vertical deflection = Difference in top-bottom readings.

Horizontal deflection = Difference in side-side readings.

Vertical and Horizontal Deflections of Crank Throws

Unless otherwise stated the values refer to cold engine.

For new or realigned aggregate Aim for + or - 4/100 mm


Acceptable + or - 6/100 mm

For aggregate in service realignment


is recommended if deflections exceed + or -10/100 mm

Vertical Deflection of Crank Throw at Flywheel

Unless otherwise stated the values refer to cold engine.

Rigid coupling between Flexible coupling between


diesel engine and driven machine diesel engine and driven machine
08028-0D/H5250/94.08.12

For new or realigned For new or realigned


aggregate 0 to + 4/100 mm aggregate Aim for - 7/100 mm
Acceptable - 10/100 mm

For aggregate in service realignment is For aggregate in service


recommended if deflection measured realignment recommendable
on warm engine exceeds - 10/100 mm if deflection exceeds - 14/100 mm

99.25 - ES0S
MAN Diesel

Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00


Page 5 (6) Edition 10H
(Hydraulic Tightened Connecting Rod)

L28/32H

Process/Proces I.D. no.

Plant/Anlæg Page of/Side af

Engine Type/Motortype Engineer/Operatør Date/Dato

Instruction/Instruktion

Top

Right side Left side

Bottom end/ Bottom start/


1/100 mm Bund slut Bund start

Right side Right side

Cyl. no 1 2 3 Cyl. no 1 2 3

Left side Cyl. no 1 2 3

Left side

Remarks/Bemærkninger
08028-0D/H5250/94.08.12

99.25 - ES0S
MAN Diesel

610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card


Edition 10H (Hydraulic Tightened Connecting Rod) Page 6 (6)

L28/32H

Component/Komponent Type I.D. no.

Process/Proces Page of/Side af

Test place/ Test bed/prøvehal Cold/Kold


Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal

Engine no.:
Motornr.:

Cyl. no. 1 2 3 4 5 6 7 8 9

Bottom X 0 0 0 0 0 0 0 0 0

Left side P

Top T

Right side S

Bottom Y

Bottom
(0.5xY)=B

Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V

Deflection from
horizontal mis-
alignment.
08028-0D/H5250/94.08.12

Left side - Right


side or P - S = H

Check on gauge
readings.

T+B= C

P+S= D

99.25 - ES0S
MAN Diesel
Working Card 610-01.05
Page 1 (3) Inspection of Main Bearing Shells Edition 05H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62010 10 2 pieces
Shut-off fuel oil 62010 20
Shut-off cooling oil 62010 01
Stopped lub. oil circul. 62010 15 2 pieces
62010 30 Extra tools
62021 40 Hydraulic tools
62021 50 2 pieces
Description: 62021 51
62021 20
Dismantling, inspection and/or replacement and
mounting of main bearing shells.
Hand tools:

Allen key, 12 mm.


Socket spanner, 36 mm.
Starting position: Lead hammer.
Silastene.
Copaslip.

Related procedure:

Inspection of guide bearing shell, 610-01.10


Criteria for replacement of bearings, 606-01.16

Manpower:
08028-0D/H5250/94.08.12

Working time : 2 hours Replacement and wearing parts:


Capacity : 2 men
Plate no Item no Qty/
Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.30 - ES0S-G
MAN Diesel

610-01.05 Working Card


Edition 05H Inspection of Main Bearing Shells Page 2 (3)

L+V28/32H
Make Ready for Dismantling of the Main Bear-
ing

1) Dismount crankcase covers in front and oppo-


site the bearing concerned.

2) Turn the engine until the crank is in a conveni-


ent position for carrying out the work.

3) Dismount the bracing screw (side screw).

4) Mount the hydraulic tools and loosen the main


bearing stud nuts. For operation of the hydraulic tools,
see working card 620-01.05.
Fig 2. Mounting of Wire Straps.

8) Lift the main bearing cap a little and unscrew


the bearing stud nut.

9) Fit guide tubes on the threads of the bearing


studs and lower the bearing cap to make it rest on
the collar of the guide tubes.

Dismantling of the Main Bearing Shells

10) Remove the locking piece from the bearing


cap and take out the bearing shell.

11) Fit the tool for upper main bearing, for dis-mant-
ling of upper main bearing shell, in the lubricating
Fig 1. Mounting of Hydraulic Tools.
hole in the crankshaft and turn out the upper bearing
shell by turning the crankshaft, see fig 3.

5) Dismount the hydraulic tools and slacken the


nuts somewhat.

Dismantling of the Main Bearing Cap


08028-0D/H5250/94.08.12

6) Fit the eye screws, diagonally, in the threaded


holes in the main bearing cap, see fig 2.

Pass the wire supplied through the eye screw and at-
tach it as shown, so as to keep the bearing cap in place
when the main bearing stud nuts are removed. Tool for upper main
bearing

7) Work the main bearing cap loose from the


engine frame with a lead hammer or similar. Fig 3. Mounting of tool for upper main bearing.

96.30 - ES0S-G
MAN Diesel
Working Card 610.01-05
Page 3 (3) Inspection of Main Bearing Shells Edition 05H

L+V28/32H
Cleaning 17) Insert the lower bearing shell in the bearing
cap and mount the locking piece.
12) Clean all machined surfaces, on frame, bearing
cap, stud, nuts and bearing shells. Lubricate the bearing shell and journal with clean
lubricating oil.

Inspection of Main Bearing Shells


Mounting of the Main Bearing Cap
13) Inspect the main bearing shells according to
working card 606-01.16. 18) Raise the bearing cap into position, dismount
the guide tubes, coat the bearing studs with molycote
Note: The bearing is marked according to size and pasta or similar and fit the bearing stud nuts.
when replaced it must be by a new bearing of the
same size. Make sure that the bearing cap and bearing shell
are in their correct position.

Mounting of the Main Bearing Shells 19) Dismantle the wire straps.

14) Push the upper bearing shell as far into position 20) Mount the hydraulic tools, see working card
as possible. 620-01.05, and tighten the nuts as prescribed on
page 600-40.
15) Fit the tool for upper main bearing in the lub-
ricating hole in the crankshaft and turn in the upper 21) Coat the back side of the bracing screws' (side
bearing shell by turning the crankshaft. screws') hexagonal head with a thin coat of silastene
or similar.
Make sure that the shell enters its correct position
then remove the tool for upper main bearing. 22) Mount the screws and tighten with a torque
spanner as indicated on page 600.40.
16) Lubricate the end of the bearing shells with
molycote pasta or similar.
08028-0D/H5250/94.08.12

96.30 - ES0S-G
MAN Diesel
Working Card 610-01.10
Page 1 (4) Inspection of Guide Bearing Shells Edition 08H

L+V28/32H

Safety precautions Special tools

Stopped engine Plate no Item no Note


Shut-off starting air
Shut-off cooling water 62006 28 140 - 760 Nm
Shut-off fuel oil 62010 10 2 pieces
Shut-off cooling oil 62010 20
Stopped lub. oil circul. 62010 01
62010 25
62010 15 2 pieces
62010 30 Extra tools
Description 62021 40 Hydraulic tools
62021 50 2 pieces
Dismantling, inspection and/or replacement 62021 51
and mounting of guide bearing shells and thrust 62021 20
washer.

Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Molycote

Related procedure

Inspection of main bearing shells. 610-01.05


Criteria for replacement of bearing
shells. 606-01.16
08028-0D/H5250/94.08.12

Manpower

Working time : 2 hours


Capacity : 2 men Replacement and wearing parts

Data Plate no Item no Qty/

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

02.47 - ES0
MAN Diesel
610-01.10 Working Card
Edition 08H Inspection of Guide Bearing Shells Page 2 (4)

L+V28/32H

Make Ready for Dismantling of the Guide


Bearing

1) Dismount the crankcase covers opposite the


bearing concerned.

2) Turn the engine until the crank is in a convenient


position for carrying out the work.

3) Dismount the bracing screw (side screw).

4) Mount the hydraulic tools, see fig 1, and


loosen the guide bearing stud nuts. For ope-
ration of the hydraulic tools, see working card
620-01.05. Fig 2 Mounting of Wire Straps

8) Lift the guide bearing cap a little and unscrew


the bearing stud nut.

9) Fit guide tubes on the threads of the bearing


studs and lower the bearing cap to make it rest
on the collar of the guide tubes.

Dismantling of the Guide Bearing Shells

10) Remove the locking piece from the bearing


cap and take out the bearing shell.
To pump

Fig 1 Mounting of Hydraulic Tools Thrust washer

5) Dismount the hydraulic tools and slacken the


nuts somewhat.
08028-0D/H5250/94.08.12

Dismantling of the Guide Bearing Cap

6) Fit the eye screws, diagonally, in the threaded


holes in the guide bearing cap, see fig 2.
Fig 3 Guide Bearing with Thrust Washer
Pass the wire supplied through the eye screw
and attach it as shown, so as to keep the
bearing cap in place when the guide bearing The thrust washer of the guide bearing is partially
stud nuts are removed. countersunk into the engine frame and attached by
means of four screwed-on clamps which are visible
7) Work the guide bearing cap loose from the after lowering the bearing cap, see fig 3.
engine frame with a lead hammer or similar.

02.47 - ES0
MAN Diesel
Working Card 610-01.10
Page 3 (4) Inspection of Guide Bearing Shells Edition 08H

L+V28/32H
In case the guide shell tool is locked between guide
bearing and bearing studs, use the bolt on the back
of the guide shell tool to dislodge it.

Cleaning of Components

14) Clean all machined surfaces, on frame, bearing


cap, stud, nuts and bearing shells.

Inspection of Guide Bearing Shells

15) Inspect the guide bearing shells according to


working card 606-01.16.

Guide for mounting of upper shell.

Fig 4 Dismounting of Upper Shell


Fig 5 Mounting of Upper Shell in Guide Bearing

11) Unscrew the clamns and push out the thrust Mounting of the Guide Bearing Shells
washers.
The bearing shells of the guide bearing, which are
12) Fit the tools for dismantling of upper guide identical to those of the main bearings, are narrower
bearing shell, see fig 4, in the bearing cap and than the bore for the guide bearing and it is therefore
raise the bearing cap into position, making sure essential that the shells are positioned perfectly cor-
that the guide shell is not being damaged. rect in the bore.
08028-0D/H5250/94.08.12

After that, dismount the guide tubes, fit and For this purpose a guide tool is supplied for positio-
tighten the nuts slightly. ning on the engine frame when the upper bearing
shell is to be fitted, see fig 5.
13) With the guide shell tool, which is guided by
the bearing cap, the upper bearing shell is 16) Push the bearing shell as far as possible into
carefully turned out into the bearing cap. Then position through this guide tool.
dismount the nuts and lower the bearing cap
on the collar of the guide tubes. Take out the 17) Insert the guide shell tool in the bearing cap,
bearing shell and the guide shell tool. which is resting on the collar of the guide tu-
bes.

02.47 - ES0
MAN Diesel

610-01.10 Working Card


Edition 08H Inspection of Guide Bearing Shells Page 4 (4)

L+V28/32H
18) Raise the bearing cap with the guide shell tool Bearing Cap
into its correct position, dismount the guide
tubes, fit and tighten the bearing stud nuts Lubricate the bearing shell and journal with clean
slightly. lubricating oil.

19) Now push the bearing shell into its correct 24) Raise the bearing cap into position, dismount
position with the guide shell tool.Make sure the guide tubes, coat the bearing stud with
that the shell enters its correct position. molycote pasta or similar and fit the bearing
stud nuts.
20) Then unscrew the bearing stud nuts, fit the guide
tubes and lower the bearing cap again. Make sure that the thrust washers, bearing shell
and bearing cap are in their correct position.
21) Fit the thrust washers and clamps.
25) Dismantle the wire straps.
Note: Clearance in guide bearing axially, see page
600.35. 26) Mount the hydraulic tools, see working card
620-01.05, and tighten the nuts as prescribed
22) Lubricate the end of the bearing shells with on page 600-40.
molycote pasta or similar.
27) Coat the back side of the bracing screws' (side
23) Insert the lower bearing shell in the bearing screws') hexagonal head with a thin coat of
cap, and mount the locking piece. silastene or similar.

28) Mount the screws and tighten with a torque


spanner as indicated on page 600.40.

08028-0D/H5250/94.08.12

02.47 - ES0
MAN Diesel
Working Card 610-04.00
Page 1 (3) Vibration Damper Edition 01H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Taking a silicone oil sample


Hand tools:

Ring and open end spanner, 19 mm.

Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 2-4 hours Plate no. Item no. Qty. /


Capacity : 1 man
See plate 61004
Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

10.15 - ES0
MAN Diesel
610-04.00 Working Card
Edition 01H Vibration Damper Page 2 (3)

General
The vibration damper is equipped with extraction
plugs which provide the opportunity of testing the 3. Rotate the engine in order to bring the extraction
viscosity of the silicone oil inside the damper without plugs (6) of the damper in optimal position, see fig.
having to dismantle it. 2A.

Corresponding to the condition of the silicone oil an


approximate assessment of the damper efficiency
is possible. A
6
A silicone oil sample should be extracted as follows
by means of a special tube that can be required
from MAN Diesel & Turbo, PrimeServ Holeby, see
plate 61004.

1. After the engine is stopped let damper cool


down to approximately 40°C.

2. For access to the damper remove the blank 6


flange (A) on the front end cover (B) see fig. 1.
B
In some cases it is necessary to dismount the lub.
oil pump or the cooling water pump, for access to 5
the damper.
6

C
E

F
C
D

10 5 11
B

A
3
08028-0D/H5250/94.08.12

A. Blank flange or cooling water pump.


B. Front end cover.
C. Damper.
D. Gearwheel (if mounted) Fig. 2. Vibration Damper
E. Main bearing (Frame)
F. Crankshaft.

4. Prepare the sample container (10) by removing


Fig. 1. Mounting of Vibration Damper. one of its caps (11), see fig. 2 C.

10.15 - ES0
MAN Diesel

Working Card 610-04.00


Page 3 (3) Vibration Damper Edition 01H

General

5. Unscrew and remove one of the extraction 9. Send the sample container to:
plugs (6) and replace it with the sample container
(10). MAN Diesel & Turbo
PrimeServ Holeby
If meeting the inertia ring (3) unscrew the container Østervej 2
one revolution. 4960 Holeby
Denmark
6. Remove the second cap from the sample
container and wait until silicone fluid (5) begins to The sample must be marked in such a way that we
flow out from the free end. Depending on the silicone can forward the result of the analysis correctly.
viscosity the process needs a certain amount of time.
If possible it, can be speeded up by means of: - Name of ship.
- Engine type.
A Turning the damper until the sample contai- - Engine no.
ner is underneath the crankshaft. - Running hours.
B Temporarily removing the second extraction - Data for vibration damper.
plug too.
10. For hours between taking new samples, see
7. As soon as the silicone fluid begins to flow, page 600.25.
close the sample container by the cap. Remove
the container from the damper casing, wipe off the The quantity of silicone oil removed its so small that
sealing jace round the extraction hole and screw in up to 10 such samples can be taken without risk.
the plugs together with new sealing washers (7).
Now close the second side of the container.

8. Tighten both extraction plugs with thumb and


forefinger then turn them further 45° (about 20 Nm).
Seal both plugs by caulking their grooves.
08028-0D/H5250/94.08.12

10.15 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 61001-15H

L28/32H

10

11

12
13
09

06
05

04

03

02+
15+

01
16
17
18

07-14

08-14

06.33 - ES0
MAN Diesel
Plate
61001-15H Crankshaft Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Crankshaft Krumtapaksel


6 cyl. engine 6 cyl. motor

02+ /I Counterweight Kontravægt


6,7,9 cyl. engine 6,7,9 cyl. motor

03 1/W Locking plate Sikringsplade

04 1/W Locking plate Sikringsplade

05 2/W Screw Skrue

06 1/W Screw for Skrue for


counterweight kontravægt

07 1/C Plug screw Propskrue

08 1/E Plug screw Propskrue

09 12/E Screw Skrue

10 12/E Self locking nut Selvlåsende møtrik

11 12/E Washer Skive

12 1/E Oil throw ring Olieafslyngningsring

13 1/E Gear wheel Tandhjul


(crankshaft) (krumtap)

14 /I Loctite 242 Loctite 242

15+ /I Counterweight Kontravægt


8 cyl. engine 8 cyl. motor

16 1/E Crankshaft Krumtapaksel


7 cyl. engine 7 cyl. motor

17 1/E Crankshaft Krumtapaksel


8 cyl. engine 8 cyl. motor

18 1/E Crankshaft Krumtapaksel


9 cyl. engine 9 cyl. motor

+ Item No. 02 and 15 + Item nr. 02 og 15


require an indivi- kræver en individuel
dual matching tilpasning før
before mounting montering, kontakt
contact MAN Diesel, MAN Diesel, Holeby
Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./W = Qty./Counterweight Antal/W = Antal/Kontravægt
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

06.33 - ES0
MAN Diesel
Plate
Page 1 (2)
Crankshaft 61001-21H

5L28/32H

10

11

15+ 12
13
03 09
04

06
05

06
05

04

03

02+

01

07-14

08-14

06.33 - ES0
MAN Diesel
Plate
61001-21H Crankshaft Page 2 (2)

5L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Crankshaft Krumtapaksel

02+ /I Counterweight Kontravægt

03 1/W Locking plate Sikringsplade

04 1/W Locking plate Sikringsplade

05 2/W Screw Skrue

06 1/W Screw for Skrue for


counterweight kontravægt

07 1/C Plug screw Propskrue

08 1/E Plug screw Propskrue

09 12/E Screw Skrue

10 12/E Self locking nut Selvlåsende møtrik

11 12/E Washer Skive

12 1/E Oil throw ring Olieafslyngningsring

13 1/E Gear wheel Tandhjul


(crankshaft) (krumtap)

14 /I Loctite 242 Loctite 242

15+ /I Counterweight Kontravægt

+ Item No. 02 and 15 + Item nr. 02 og 15


require an indivi- kræver en individuel
dual matching tilpasning før
before mounting montering, kontakt
contact MAN Diesel, MAN Diesel, Holeby
Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./W = Qty./Counterweight Antal/W = Antal/Kontravægt
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder

06.33 - ES0
MAN Diesel

Plate
Page 1 (2) Resilient Gear Wheel 61002-07H

L28/32H

01

Crankshaft 19+
(Plate 61001)

02

05 03

06

07
18

08
04
09

10 10

11

17 16

15

14

13

12

96.01 - ES0S
MAN Diesel

Plate
61002-07H Resilient Gear Wheel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul,


wheel, compl. komplet

02 1/E Axle journal Akseltap

03 4/E Screw Skrue

04 6/E Self locking nut, for Selvlåsende møtrik,


Item No. 03 and 19 for Item nr. 03 og 19

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for


for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for


for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

19+ 2/E Fitted bolt Pasbolt

+ Item 19 require an + Item 19 kræver en


individual matching individuel tilpasning
during mounting, før montering, kontakt
contact MAN Diesel, MAN Diesel, Holeby
Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

96.01 - ES0S
MAN Diesel
Plate
Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-11H

6-7-8-9L28/32H

Crankshaft
(Plate 61001)

01

02

03

07.02 - ES0
MAN Diesel
Plate
61002-11H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

6-7-8-9L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling flange Koblingsflange

02 3/E Locking plate Låseplade

03 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.02 - ES0
MAN Diesel
Plate
Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-12H

5L28/32H

06

05

Crankshaft
(Plate 61001)

04
01

02

03

07.02 - ES0
MAN Diesel
Plate
61002-12H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

5L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling flange Koblingsflange

02 3/E Locking plate Låseplade

03 6/E Screw Skrue

04 1/E Flyweight Svingklods

05 6/E Nut Møtrik

06 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.02 - ES0
MAN Diesel
Plate
Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-13H

5L28/32H

06

05

Crankshaft
(Plate 61001)

04
01

07.03 - ES0
MAN Diesel
Plate
61002-13H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

5L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling flange Koblingsflange

04 1/E Flyweight Svingklods

05 6/E Nut Møtrik

06 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0
MAN Diesel
Plate
Page 1 (2) Coupling for Central Driven Lub. Oil Pump 61002-14H

L28/32H

06

05

Crankshaft
(Plate 61001)

01

02

03

07.03 - ES0
MAN Diesel
Plate
61002-14H Coupling for Central Driven Lub. Oil Pump Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Coupling flange Koblingsflange

02 3/E Locking plate Låseplade

03 6/E Screw Skrue

05 6/E Nut Møtrik

06 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0
MAN Diesel
Plate
Page 1 (2) Resilient Gear Wheel 61002-15H

L28/32H

01

Crankshaft
(Plate 61001)

02

05 03

06

07
18

08
09 04

10 10

11

17 16

15

14

13

12

07.03 - ES0
MAN Diesel
Plate
61002-15H Resilient Gear Wheel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul,


wheel, compl. komplet

02 1/E Axle journal Akseltap

03 6/E Stud Tap

04 12/E Self locking nut, Selvlåsende møtrik,


for Item No. 03 for Item nr. 03

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for


for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for


for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0
MAN Diesel
Plate
Page 1 (2) Resilient Gear Wheel 61002-16H

L28/32H

01

Crankshaft 19+
(Plate 61001)

02

05 03

06

07
18

08
04
09

10 10

11

17 16

15

14

13

12

07.03 - ES0
MAN Diesel
Plate
61002-16H Resilient Gear Wheel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul,


wheel, compl. komplet

02 1/E Axle journal Akseltap

03 4/E Screw Skrue

04 6/E Self locking nut,for Selvlåsende møtrik,


Item No. 03 and 19 for Item nr. 03 og 19

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for


for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for


for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

19+ 2/E Fitted bolt Pasbolt

+ Item 19 require an + Item 19 kræver en


individual matching individuel tilpasning
during mounting, før montering, kontakt
contact MAN diesel, MAN Diesel, Holeby
Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0
MAN Diesel
Plate
Page 1 (2) Resilient Gear Wheel 61002-17H

L28/32H

01

Crankshaft 19+
(Plate 61001)

02

05 03

06

07
18

08
04
09

10 10

11

17 16

15

14

13

12

07.03 - ES0
MAN Diesel
Plate
61002-17H Resilient Gear Wheel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Resilient gear Fjedrende tandhjul,


wheel, compl. komplet

02 1/E Axle journal Akseltap

03 4/E Screw Skrue

04 6/E Self locking nut,for Selvlåsende møtrik,


Item No. 03 and 19 for Item nr. 03 og 19

05 1/E Hub Nav

06 6/E Slide shoe Glidesko

07 3/E Distance piece Afstandsstykke

08 1/E Gear wheel Tandhjul

09 12/E Locking washer Låseblik for


for item No. 10 item nr. 10

10 12/E Nut Møtrik

11 4/E Cylindrical pin Cylindrisk stift

12 6/E Spring guide Fjederstyr

13 6/E Spring Fjeder

14 3/E Distance piece Afstandsstykke

15 6/E Screw Skrue

16 6/E Locking washer, Låseblik for


for Item No. 15 Item nr. 15

17 1/E Side plate Sideplade

18 2/E Cylindrical pin Cylindrisk stift

19+ 2/E Fitted bolt Pasbolt

+ Item 19 require an + Item 19 kræver en


individual matching individuel tilpasning
during mounting, før montering, kontakt
contact MAN Diesel, MAN Diesel, Holeby
Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.03 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 61003-02H

5L28/32H

10

04

11
05

01
Crankshaft
(plate 61001)
03 02

07.02 - ES0
MAN Diesel
Plate
61003-02H Flywheel with Gear Rim Page 2 (2)

5L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Gear rim 2/2 Tandkrans 2/2

02 18/E Screw Skrue

03 12/E Self locking nut, for Selvlående møtrik for


item no. 04 item nr. 04

04 12/E Screw Skrue

05 1/E Flywheel Svinghjul

10 2/E Screw Skrue

11 1/E Guide pin Styrestift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

Qty./E = Qty./Engine Qty./E = Antal/Motor

07.02 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 61003-05H

L28/32H

10

04

11
05

01
Crankshaft
(plate 61001)
03 02

07.02 - ES0
MAN Diesel
Plate
61003-05H Flywheel with Gear Rim Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Gear rim 2/2 Tandkrans 2/2

02 18/E Screw Skrue

03 12/E Self locking nut, for Selvlående møtrik for


item no. 04 item nr. 04

04 12/E Screw Skrue

05 1/E Flywheel Svinghjul

10 2/E Screw Skrue

11 1/E Guide pin Styrestift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

Qty./E = Qty./Engine Qty./E = Antal/Motor

07.02 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 61003-06H

L28/32H

10

04

11
05

01
Crankshaft
(plate 61001)
03 02

07.02 - ES0
MAN Diesel
Plate
61003-06H Flywheel with Gear Rim Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Gear rim 2/2 Tandkrans 2/2

02 18/E Screw Skrue

03 12/E Self locking nut, for Selvlående møtrik for


item no. 04 item nr. 04

04 12/E Screw Skrue

05 1/E Flywheel Svinghjul

10 2/E Screw Skrue

11 1/E Guide pin Styrestift

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

Qty./E = Qty./Engine Qty./E = Antal/Motor

07.02 - ES0
MAN Diesel

Plate
Page 1 (2) Torsional Vibration Damper 61004-05H

L28/32H

01

04*
05
02*

03*

10.14 - ES0
MAN Diesel

Plate
61004-05H Torsional Vibration Damper Page 2 (2)

L28/32H

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

01 1/E Torsional vibration Svingningsdæmper


damper, with 30 mm med 30 mm monte-
mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings-


beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving-


onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort


card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0
MAN Diesel
Plate
Page 1 (2) Torsional Vibration Damper 61004-12H

L28/32H

01

04*
05
02*

03*

10.14 - ES0
MAN Diesel
Plate
61004-12H Torsional Vibration Damper Page 2 (2)

L28/32H

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

01 1/E Torsional vibration Svingningsdæmper


damper, with 30 mm med 30 mm monte-
mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings-


beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving-


onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort


card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0
MAN Diesel
Plate
Page 1 (2) Torsional Vibration Damper 61004-13H

L28/32H

01

04*
05
02*

03*

10.14 - ES0
MAN Diesel
Plate
61004-13H Torsional Vibration Damper Page 2 (2)

L28/32H

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

01 1/E Torsional vibration Svingningsdæmper


damper, with 30 mm med 30 mm monte-
mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings-


beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving-


onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort


card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0
MAN Diesel
Plate
Page 1 (2) Torsional Vibration Damper 61004-14H

L28/32H

01

04*
05
02*

03*

10.14 - ES0
MAN Diesel
Plate
61004-14H Torsional Vibration Damper Page 2 (2)

L28/32H

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

01 1/E Torsional vibration Svingningsdæmper


damper, with 30 mm med 30 mm monte-
mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings-


beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving-


onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort


card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0
MAN Diesel
Plate
Page 1 (2) Torsional Vibration Damper 61004-15H

L28/32H

01

04*
05
02*

03*

10.14 - ES0
MAN Diesel
Plate
61004-15H Torsional Vibration Damper Page 2 (2)

L28/32H

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

01 1/E Torsional vibration Svingningsdæmper


damper, with 30 mm med 30 mm monte-
mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings-


beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving-


onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort


card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0
MAN Diesel
Plate
Page 1 (2) Torsional Vibration Damper 61004-16H

L28/32H

01

04*
05
02*

03*

10.14 - ES0
MAN Diesel
Plate
61004-16H Torsional Vibration Damper Page 2 (2)

L28/32H

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

01 1/E Torsional vibration Svingningsdæmper


damper, with 30 mm med 30 mm monte-
mounting flange rings-flange

02* 1/E Plug screw Propskrue

03* 1/E Sample container Prøveudtagings-


beholder

04* 1/E O-ring O-ring

05+ Sampling kit for torsi- Prøvesæt for sving-


onal vibration damper ningsdæmper
(the kit includes an (Sættet er inklusiv en
analysis of the sample analyse af prøven. Alle
taken. All information informationer er til-
is available in the kit) gængelige i sættet)

+ See also working + Se også arbejdskort


card 610-04.00 610-04.00

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

10.14 - ES0
MAN Diesel

Plate
Page 1 (2) Tuning Wheel 61004-06H

L28/32H

01

94.23 - ES0S
MAN Diesel

Plate
61004-06H Tuning Wheel Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Tuning wheel with, Afstemningshjul med


30 mm mounting flan- 30 mm monterings-
ge flan-ge

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

94.23 - ES0S
Engine frame/Oil pan

511/611
MAN Diesel
Description
Engine Frame and Base Frame 611.01
Page 1 (1)
Edition 07H

L28/32H

Frame The crankshaft guide bearing is located at the fly-


wheel end of the engine.
The engine frame is made of cast iron, and is at-
tached to the top of the base frame by means of On the sides of the frame there are covers for acces
bolts. The cross girders of the frame are provided to the camshaft, the charge air receiver and crank-
with bores for the main bearings in which the crank- case. Some of the covers are fitted with relief valves
shaft is underslung, i.e. it is carried by the main which will act, should oil vapours in the crankcase be
bearing caps. ignited, for instance in the event of a hot bearing.

The main bearing caps are attached by means of


studs and nuts, which are loosened and tightened Base Frame
with the aid of hydraulic tools. After mounting, the
main bearing caps are further secured by means Engine and alternator (gear, pump) are mounted on
of bracing screws, which are screwed horizontally a common base frame which is in welded design.
into the sides of the caps and tightened against the
sides of the engine frame. The main bearings are The base frame is used as lubricating oil reservoir
equipped with replaceable shells which are fitted "wet sump".
without scraping.
08028-0D/H5250/94.08.12

91.13 - ES0U
MAN Diesel
Working Card 611-01.00
Page 1 (2) Functional Test of Crankcase Safety Relief Valves Edition 04H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Functional test of crankcase safety relief val-


ves. Hand tools:

Starting position:

Related procedure:
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
61106 13 1/cyl.
Data: 61106 39 12/relief valve
61106 45 1/relief valve
Data for pressure and tolerance (Page 600.35)
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

06.46 - ES0
MAN Diesel
611-01.00 Working Card
Edition 04H Functional Test of Crankcase Safety Relief Valves Page 2 (2)

General

Functional Testing

Functional testing of the crankcase safety relief Cover


valves cannot be performed during operation of the
engine, but it must be checked during overhauls that
the valve flap is movable. Relief
valve

When Painting

When painting the engine, take care not to block up


the safety relief valves with paint.

Check of Opening Pressure

To check the proper opening pressure, proceed as


follows:

1) Remove the relief valve cover from the engi-


ne.

2) Place the cover on the floor with the pressure Fig 1 Cover with relief valve
area upwards.

3) Apply a weight at 18 kg on the pressure


area.

The relief valve must open under this pres-


sure.

4) Remount the relief valve cover of the engine.

If the safety relief valves are actuated, the


engine must be stopped immediately, and it
must not be restarted until the cause is detected
and the fault is detected, see also description
503.04, Ignition in Crankcase.
08028-0D/H5250/94.08.12

06.46 - ES0
MAN Diesel

Plate
Page 1 (2) Frame with Main Bearings 61101-11H

01
L28/32H
02
03 05
04 06
03
10 04
11
09
12

13

16 14
17 15
18
21+
19+

20 10
22
23
13 25
27

24
15
14

10
26+
23 22
21+
24

Cover
( Plate 61102)

06.49 - ES0
MAN Diesel

Plate
61101-11H Frame with Main Bearings Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/C Wear ring Slidring 27 1/C Cylindrical pin Cylindrisk stift

02 3/C Protective cap, Beskyttelseshætte,


plastic plastik
+ Item No. 19, 21 and + Item nr. 19, 21 og 26
03 6/C Nut for Møtrik for 26 require an indi- kræver en individuel
cylinder cover cylinderdæksel vidual tilpasning før monte-
matching before ring,
04 6/C Cylinder cover Tap for mounting, contact kontakt MAN B&W,
stud cylinderdæksel MAN B&W, Holeby Holeby

05 3/C Protective cap, Beskyttelseshætte,


metal metal

06 3/C O-ring O-ring

09 6/C Sealing kit Tætningssæt for


for cap dæksel

10 Loctite 243 Loctite 243

11 Silicone oil Silikoneolie

12 1/E Frame Stativ

13 1/B Main bearing Hovedleje-


shell 2/2 skaller 2/2

14 1/B Locking piece Låsestykke

15 2/B Screw Skrue

16 4/E Safety sleeve Sikkerhedsbøsning

17 4/E Screw Skrue

18 1/E Cylindrical pin Cylindrisk stift

19+ 1/E Guide bearing cap Styrelejedæksel

20 2/E Thrust bearing Trykleje

21+ 2/B Distance piece Afstandsstykke

22 6/B Screw Skrue

23 2/B Main bearing stud Hovedleje tap

24 2/B Nut for main Møtrik for


bearing stud hovedlejetap

25 2/B Bracing screw Sideskrue

26+ 1/C Main bearing cap Hovedlejedæksel

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty/Cylinder Antal/C = Antal/Cylinder
Qty./B = Qty/Bearing Antal/B = Antal/Leje

06.49 - ES0
MAN Diesel

Plate Front Cover for


Page 1 (2)
Lubricating Oil Pump 61102-09H

L28/32H

01

02
For lubricating
oil pump, see
Plate 61501

05

03

06 04
07

91.45 - ES0S
MAN Diesel

61102-09H Front Cover for Plate


Page 2 (2)
Lubricating Oil Pump

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Cover Dæksel

02 40/E Screw Skrue

03 2/E Guide pin Styrestift

04 2/E Nut Møtrik

05 1/E Gasket Pakning

06 1/E Cover Dæksel

07 6/E Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

91.45 - ES0S
MAN Diesel

Plate Front Cover for


Page 1 (2)
Lubricating Oil Pump and Cooling Water Pump 61102-07H

L28/32H

Fresh water cooling pump


(Plate 61610)

13
01
14
02
03

12
04 11
10

09
08 04

05+

06
07

08

10
09
10 04

Lub. oil pump


(Plate 61501)

91.40 - ES0S
MAN Diesel

61102-07H Front Cover for Plate


Page 2 (2)
Lubricating Oil Pump and Cooling Water Pump

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 4/E Screw Skrue

02 4/E Locking plate Låseskive

03 2/E Spray pipe Sprøjterør

04 52/E Screw Skrue

05+ 1/E Cover Dæksel

06 2/E Guide pin Styrestift

07 2/E Nut Møtrik

08 2/E Gasket Pakning

09 2/E Cover Dæksel

10 18/E Screw Skrue

11 1/E Gasket Pakning

12 1/E Cover Dæksel

13 2/E Guide pin Styrestift

14 2/E Nut Møtrik

+ Item No. 05 + Item nr. 05 kræver


require an individual en individuel til-
matching before pasning før montering,
mounting, contact kontakt MAN B&W,
MAN B&W, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

91.40 - ES0S
MAN Diesel

Plate Front Cover for


Page 1 (2)
Lubricating Oil Pump and Cooling Water Pumps 61102-10H

L28/32H

Fresh water cooling pumps


(Plate 61610)

13
01
14
02
03

04

04
12
11 05+

10
06
07

08

09
10 04

Lub. oil pump


(Plate 61501)

92.38 - ES0S
MAN Diesel

61102-10H Front Cover for Plate


Page 2 (2)
Lubricating Oil Pump and Cooling Water Pumps

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 6/E Screw Skrue

02 6/E Locking plate Låseskive

03 3/E Spray pipe Sprøjterør

04 58/E Screw Skrue

05+ 1/E Cover Dæksel

06 2/E Guide pin Styrestift

07 2/E Nut Møtrik

08 1/E Gasket Pakning

09 1/E Cover Dæksel

10 12/E Screw Skrue

11 1/E Gasket Pakning

12 1/E Cover Dæksel

13 4/E Guide pin Styrestift

14 4/E Nut Møtrik

+ Item No. 05 + Item nr. 05 kræver


require an individual en individuel til-
matching before pasning før montering,
mounting, contact kontakt MAN B&W,
MAN B&W, Holeby Holeby

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

92.38 - ES0S
MAN Diesel & Turbo

Plate
Page 1 (2) Covers on Frame 61106-20H

L28/32H

06.06 - ES0
MAN Diesel & Turbo

Plate
61106-20H Covers on Frame Page 2 (2)

L28/32H

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

01 1/E Guard end aft Skærm, agter 27 /I Cover Dæksel

02 12/E Washer Skive 28 /I Gasket Pakning

03 12/E Screw Skrue 39 12/D Washer Skive

04 1/C Intermediate guard Mellemskærm 40 1/D Flange Flange

05 1/C Handle, upper Håndtag, øverst 45 1/D O-ring O-ring

06 1/C Handle, lower Håndtag, nederst

07 1/E Guard end fore Skærm, for + Item 14, 15 and 16 + Item 14, 15 og 16 er
are only mounted if kun monteret hvis mo-
08 1/C Intermediate gauge Mellemskærm, the engine is delive- toren er leveret uden
complete, Item 04, komplet, Item 04, red without fuel oil fuel olieforpumpe
05 and 06 05 and 06 feed pump

09 12/C Screw Skrue

10 1/C Cover for camshaft Dæksel for


housing Kamakselhus

11 1/C O-ring O-ring

12 Cover for Dæksel for


crankcase krumtaphus
7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
10/E 7 cyl. engine 7 cyl. motor
11/E 8 cyl. engine 8 cyl. motor
12/E 9 cyl. engine 9 cyl. motor

13 2/C O-ring O-ring

+14 6/E Screw Skrue

+15 1/E Cover Dæksel

+16 1/E Gasket Pakning

17 6/D Self locking nut Selvlåsende møtrik

19 6/D Screw Skrue

24 Cover with safety Dæksel med sikker-


valve complete hedsventil komplet
3/E 5 cyl. engine 5 cyl. motor
4/E 6 cyl. engine 6 cyl. motor
4/E 7 cyl. engine 7 cyl. motor
5/E 8 cyl. engine 8 cyl. motor
6/E 9 cyl. engine 9 cyl. motor

25 1/D Safety valve Sikkerhedsventil,


complete komplet

26 /I Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./D = Qty./Safety cover Antal/D = Antal/Sikkerhedsdæksel
Qty./I = Qty./Individual Antal/I = Antal/Individuelt

06.06 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Covers on Frame 61106-14H

L28/32H

01 04

15 05
02

03

14
06 12
07
08
13
16
09

11
10
11

07.08 - ES0
MAN Diesel & Turbo

Plate
61106-14H Covers on Frame Page 2 (2)

L28/32H

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

01 12/E Screw Skrue

02 1/E Sealing ring 2/2 Tætningsring 2/2

03 2/E Guide pin Styrestift

04 2/E Cylindrical pin Cylindrisk stift

05 2/E Screw Skrue

06 6/E Screw Skrue

07 1/E Flange Flange

08 1/E Gasket Pakning

09 4/E Guide pin Styrestift

10 39/E Screw Skrue

11 1/E Cover 2/2 Dæksel 2/2

12 18/E Screw Skrue

13 1/E Cover Dæksel

14 1/E Gasket Pakning

15 2/E Nut Møtrik

16 4/E Nut Møtrik

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

07.08 - ES0
Turbocharger

512/612
MAN Diesel

Description
Turbocharger System 612.01
Page 1 (2) Edition 28H

L28/32H

Fig. 1. Diagram for Turbocharger System

Turbocharger System The charging air cooler is of the compact tube-type


with a large cooling surface. The cooling water is pas-
The turbocharger system of the engine, which is a sed twice through the cooler, the end covers being
constant pressure system, consists of an exhaust designed with partitions which cause the cooling
gas receiver, a turbocharger, a charging air cooler water to turn.
and a charging air receiver, the latter being integrated
in the engine frame. The cooling water tubes are fixed to the tube plates
by expansion.
The turbine wheel of the turbocharger is driven by
the engine exhaust gas, and the turbine wheel drives From the exhaust valves, the exhaust is led through
the turbocharger compressor, which is mounted on water cooled intermediate pieces to the exhaust gas
the same shaft. receiver where the pulsatory pressure from the indi-
vidual exhaust valves is equalized and passed to the
Turbocharger, see separate manual. turbocharger as a constant pressure, and further to
the exhaust outlet and silencer arrangement.
The turbocharger pumps the air through the char-
ging air cooler to the charging air receiver. From the The exhaust gas receiver is made of pipe sections,
charging air receiver, the air flows to each cylinder one for each cylinder.The pipe sections are connected
through the inlet valves. to each other with compensators.This prevents exces-
sive stress in the pipes due to heat expansion.

03.26 - EO2S
MAN Diesel

612.01 Turbocharger System Description


Page 2 (2)
Edition 28H

L28/32H
In the cooled intermediate piece a thermometer for The purpose is to increase the compressor perfor-
reading the exhaust gas temperature is fitted. It is mance. With this system the engine can take up a
also possible to fit a sensor for remote reading. large momentary load increase.

To avoid excessive thermal loss and to ensure a The system is activated automatically and only when
reasonably low surface temperature, the exhaust the engine is exposed to a large momentary load
gas receiver is insulated. increase, see section 609.

The turbocharger is equipped with a jet system for


supply of extra driving torque to the compressor.

03.26 - EO2S
MAN Diesel
Description Cleaning the Turbocharger In Service 612.05
Page 1 (1)
Water Washing of Compressor Edition 07H

General
Compressor Chemical cleaning will not improve the cleaning
process as this primarily is based on the mechanical
Fouling of the airways depends primarily on the pu- effect from the impact of the water droplets.
rity of the inlet air and thus, in turn, on the general
maintenance condition of the machinery, i.e. mainly Certain types of fluid solvents can give formation
of the gas and oil tightness of the engines and on the of deposits on the compressor wheel, and should
fresh air ventilation system of the engine room. under no circumstances be used.

Fouling of air filter, compressor or charging air cooler The intervals between cleaning by injection of water
may be observed as changes in performance para- should be adjusted after assessing the degree and
meters: rate of fouling in the particular plant, i.e. based on
observations and experience.
- Decreasing charging air pressure.
- Decreasing turbocharger rotor speed.
- Increasing exhaust gas temperature.
- Severe fouling of airways may even result in
compressor surge.

Regular cleaning during operation by injection of


water before the compressor wheel will reduce the
fouling rate considerably, and consequently prolong
the intervals between dismantling necessary for
mechanical cleaning.
08028-0D/H5250/94.08.12

94.01 - ES0U
MAN Diesel

Description Cleaning the Turbocharger in Service 612.10


Page 1 (3)
Dry Cleaning - Turbine Edition 09H

L+V28/32H
Description Cleaning System

The tendency to fouling on the gas side of turbo- The cleaning system consists of a cleaning agent
chargers depends on the combustion conditions, container (2) with a capacity of approx. 0.5 liters and
which are a result of the load and the maintenance a removable cover. Furthermore the system consists
condition of the engine as well as the quality of the of an air valve (3), a closing valve (1) and two snap
fuel oil used. on connectors.

Fouling of the gas ways will cause higher exhaust The position numbers (2) and (3) indicate the system's
gas temperatures and higher wall temperatures of "blow-gun". Only one "blow-gun" is used for each
the combustion chamber components and will also engine plant. The blow-gun is working according to
lead to a higher fuel consumption rate. the ejector principle with pressure air (working air)
at 5-7 bar as driven medium. Injection time approx.
Tests and practical experience have shown that radi- 2 min. Air consumption approx. 5 Nm3/2 min.
al-flow turbines can be successfully cleaned by the
dry cleaning method.

This cleaning method employs cleaning agents con-


sisting of dry solid bodies in the form of granules. A
certain amount of these granules, depending on the
turbocharger size, is, by means of compressed air,
blown into the exhaust gas line before the gas inlet
casing of the turbocharger.

The injection of granules is done by means of wor-


king air with a pressure of 5-7 bar.

On account of their hardness, particularly suited


blasting agents such as nut-shells, broken or artifi-
cially shaped activated charcoal with a grain size of
1.0 mm to max. 1.5 mm should be used as cleaning
agents.
1 Closing valve 2 Container
The solid bodies have a mechanical cleaning effect 3 Air valve 4 working air inlet
which removes any deposits on nozzle vanes and 5 Exhaust pipe 6 Snap coupling
turbine blades.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine.
Dry cleaning can be executed at full engine load and
does not require any subsequent operating period of
the engine in order to dry out the exhaust system.

Experience has shown that regular cleaning intervals


are essential to successful cleaning, as ex-cessive
fouling is thus avoided. Cleaning every second day
during operation is recommended.

The cleaning intervals can be shorter or longer based


on operational experience.

97.08 - ES2S
MAN Diesel

612.10 Cleaning the Turbocharger in Service Description


Page 2 (3)
Edition 09H Dry Cleaning - Turbine

L+V28/32H
Dry cleaning of turbochargers

Suppliers of cleaning agents:

1. "Solf Blast Grit, Grade 14/25"

TURCO Products B.V.


Verl. Blokkenweg 12, 617 AD EDE - Holland
Tel.:08380 - 31380, Fax.: 08380 - 37069

2. Designation unknown

Neptunes Vinke B.V.


Schuttevaerweg 24, 3044 BB Rotterdam
Potbus 11032, 3004 E.A. Rotterdam, Holland
Tel.: 010 - 4373166 Fax.: 4623466

3. "Grade 16/10"

FA. Poul Auer GmbH


Strahltechnik
D-6800 Mainheim 31, Germany

4. "Granulated Nut Shells"

Eisenwerke Würth GmbH + Co.


4107 Bad Friederichshall, Germany
Tel.: 0 71 36-60 01

5. "Soft Blasting Grade 12/3a"

H.S. Hansen Eftf. Kattegatvej 2


2100 Copenhagen Ø, Denmark
Tel.:(31) 29 97 00 Telex: 19038

6. "Crushed Nutshells"

Brigantine, Hong Kong

7. "Turbine Wash"

Ishikawajima-Harima Heavy Industries Co.


Ishiko Bldg., 2-9-7 Yassu, Chuo-Ku
Tokyo 104, Japan
Tel.: 03-2 77-42 91

97.08 - ES2S
MAN Diesel

Description Cleaning the Turbocharger in Service 612.10


Page 3 (3)
Dry Cleaning - Turbine Edition 09H

L+V28/32H

8. "A-C Cleaner" (Activated Coal)

Mitsui Kozan Co. Ltd. (Fuel Dept.)


Yamaguchi Bldg., 2-1-1 Nihonbashi
Muromachi, Chuo-Ku
Tokyo 103, Japan

9. "OMT-701"

Marix KK
Kimura Bldg., 6-2-1 Shinbashi
Minato-Ku, Tokyo 105, Japan
Tel.: 03-4 36-63 71, Telex: 242-7232 MAIX J

10. "OMT-701"

OMT Incorporated
4F, Kiji Bldg., 2-8 Hatchobori,
4-chome, Chuo-Ku, Tokyo 104, Japan
Tel.: 03-5 53-50 77, Telex: 252-2747 OMTINC J

11. "Marine Grid No. 14" (Walnut)

Hikawa Marine
Kaigan-Dori 1-1-1, Kobe 650, Japan
Tel.: 0 78-3 21-66 56

12. "Marine Grid No. 14"

Mashin Shokai
Irie-Dori, 3-1-13, Hyogo-Ku
Kobe 652, Japan
Tel.: 0 78-6 51-15 81

13. Granulate

MAN B&W Diesel A/S


Teglholmsgade 41 2450 København SV, Danmark
Tel.: +45 33 851100 Fax.: +45 33 851030

The list is for guidance only and must not be considered complete. We under-
take no responsibility that might be caused by these or other products.

97.08 - ES2S
MAN Diesel
Description Cleaning the Turbocharger in Service 612.15
Page 1 (1)
Water Washing - Turbine Side Edition 02H

General
Description Heavily contaminated turbines, which where not
cleaned periodically from the very beginning or after
The tendency to fouling on the gas side of turbo- an overhaul, cannot be cleaned by this method.
chargers depends on the combustion conditions,
which are a result of the load on and the maintenance If vibration in the turbocharger occur after water-wa-
condition of the engine as well as the quality of the shing has been carried out, the washing should be
fuel oil used. repeated. If unbalance still exists, this is presumably
due to heavy fouling, and the engine must be stop-
Fouling of the gas ways will cause higher exhaust ped and the turbocharger dismantled and manually
gas temperatures and higher surface temperatures cleaned.
of the combustion chamber components and will
also lead to a lower performance. The washing water should be taken from the fresh
water system and not from the fresh cooling water
Tests and practical experience have shown that system or salt water system. No cleaning agents are
radial-flow turbines can be successfully cleaned solvents need to be added to the water.
by injection water into the inlet pipe of the turbine.
The cleaning effect is based on the water solubility To avoid corrosion during standstill, the engine must,
of the deposits and on the mechanical action of the upon completing of water washing run far at least 1
impinging water droplets and the water flow rate. hour before stop so that all parts are dry.

The necessary water flow is dependent on the gas


flow and the gas temperature. Enough water must be Water Washing System
injected per time unit so that, not the entire flow will
evaporate, but about 0.25 l/min. will flow off through The water washing system consists of a pipe system
the drainage opening in the gas outlet.Thus ensuring equipped with a regulating valve, a manoeuvring
that sufficient water has been injected. valve, a 3-way cock and a drain pipe with a drain
valve from the gas outlet, see illustration on work
Service experience has shown that the above card 612-15.00.
mentioned water flow gives the optimal reduced or
disappear. If the recommended water flow is exceed, The water for washing the turbine, is supplied from
there is a certain risk of a accumulation of water in the external fresh water system through a flexible
the turbine casing, which can result in damage on hose with couplings. The flexible hose must be
the turbocharger. disconnected after water washing.

The best cleaning effect is obtained by cleaning at By activating the manoeuvring valve and the regu-
low engine load approx. 20% MCR. Cleaning at low lating valve, water is led through the 3-way cock to
load will also reduce temperature shocks. the exhaust pipe intermediate flange, equipped with
a channel to lead the water to the gas inlet of the
Experience has shown, that washing at regular inter- turbocharger.
vals is essential to successful cleaning, as excessive
08028-0D/H5250/94.08.12

fouling is thus avoided. Washing at intervals of 100 The water which is not evaporated, is led out through
hours is therefore recommended. Depending on the the drain pipe in the gas outlet.
fuel quality these intervals can be shorter or longer.
However, the turbine must be washed at the latest
when the exhaust gas temperature upstream of the
turbine has risen about 20° C above the normal
temperature.

92.01 - ES0U
MAN Diesel
Working Card 612-01.00
Page 1 (2) Overhaul of Charging Air Cooler Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Overhaul of charging air cooler.


Hand tools:

Ring and open end spanner, 13 mm.


Ring and open end spanner, 19 mm.
Ring and open end spanner, 24 mm.
Starting position: Allen key, 10 mm.
Wire rope.
Tackle.

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 3-4 Hours Plate no. Item no. Qty. /


Capacity : 2 men
61203 14 8/cooler
Data: 61203 35 1/cooler
61203 37 1/cooler
Data for pressure and tolerance (Page 600.35) 61203 39 1/cooler
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.30 - ES0S-G
MAN Diesel

612-01.00 Working Card


Edition 02H Overhaul of Charging Air Cooler Page 2 (2)

L+V28/32H
The charging air cooler is normally cleaned and 4) Clean the cooler element of the water and air
overhauled at the intervals indicated in the "Planned sides.
Maintenance Program", or if observations prove that
the cooler does not work satisfactory, see section After using cleaning agents the manufacting recom-
602. mendting must be followed.

The greatest care must be exercised when dismant-


Overhaul of Charging Air Cooler. ling cleaning and mounting the cooler element, as
the thin fins of the tubes cannot stand impacts and
1) Close the cooling water inlet and outlet valves pressure.
and disconnect the pipes.
If nevertheless, the metal is damaged, it should be
2) Remove the screw (1), fig. 1, which secure the carefully straightened, as bent fins will increase the
end cover of the cooler element to the cooler hous- pressure drop across the cooler considerably.
ing, and pull the cooler element half-way out.
Should one ore more cooler tubes become leaky
Place a wire rope round the cooler element and at- it/they must immediately be made tight, either by
tach a tackle hook, after which the elements are lifted expending the tube ends into the tube plates or by
and pulled out of the cooler housing and landed on blanking of the tube(s) concerned with plugs.
a couple of wooden planks on the floor.
It is important that the charging air cooler is not leaky
as any sea water that leaks in will be carried along
with the air to the cylinders where the salt contained
in the water will damage valves, piston rings, and
cylinder liners.

5) Also clean end cover and coat it on the inside


5 with an anti-corrosion blocks agent. Inspect the anti-
corrosion (6) and renew if necessary.
4
Note: That paint or similar must not be applied to
6 these blocks.

6) Fouling and deposite in the pipes can be remo-


ved by using a hand or machine operated circular
steel brush. The pipe inner diameter is 13 mm.

3 7) When mounting the air cooler, renew all gas-


kets.
2
08028-0D/H5250/94.08.12

1
Out of Service Periods.

At longer periods out of service the air cooler is


Fig. 1. drained if the coolant is sea water followed by flushing
with fresh water and left with drain and venting cocks
open.
3) Remove screws (2) and end cover (3) reversal
chamber (4) and side plates (5). At fresh water coolant systems recommendations
for the entire system is followed.

96.30 - ES0S-G
MAN Diesel
Working Card 612-01.05
Page 1 (2) Charge Air Cooler Housing - Draining Edition 02H

L+V28/32H

Safety Precautions: Special Tools:

Stopped engine Plate No Item No Note


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

Description:

Check of drain from charge air cooler housing.


Hand Tools:

Starting Position:

Related Procedure:

Replacement and Wearing Parts:

Plate No Item No Qty. /


08028-0D/H5250/94.08.12

Man Power:

Working time :
Capacity : 1 person

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

97.08 - ES0S
MAN Diesel

612-01.05 Working Card


Edition 02H Charge Air Cooler Housing - Draining Page 2 (2)

L+V28/32H
In order to prevent water from collecting at the bottom
of the gas outlet of the turbocharger, the charge air
cooler and the charge air receiver, the charge air
cooler is equipped with a drain and an automatic
water discharger.

This installation will prevent water from the charge


air to be sucked into the engine, where it will destroy
the lubricating oil film on the cylinder walls, resulting
in increasing wear. Further, the water will cause
corrosion of the intake components.

Therefore, frequent control of the drain and the water


discharger has to take place to secure that these
components are free of foreign substances which
could foul them.

1) The drain screw at the bottom of the water


discharger has to be loosened and cleaned of im-
purities, if any.

Fig 1 Placement of Steam Trap

If, with the drain screw dismounted If, with the drain screw dismounted

- a constant air flow is present: - no constant air flow is present:

1. Everything is all right. 1. Dismount the drain pipe and blow-through the
pipe by means of compressed air.
2. Mount the drain screw at the bottom of the Clean the discharge hole in the charge air
water discharger. cooler in order to secure a clear passage of
water.

2. Mount the drain pipe and check with your hand


08028-0D/H5250/94.08.12

that a constant air flow is present.

3. Mount the drain screw at the bottom of the


water discharger.

97.08 - ES0S
MAN Diesel
Working Card Water Washing of Compressor Side 612-05.00
Page 1 (3) Edition 03H
Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R.

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no Item no Note


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

Description:

Water washing of compressor side.


Turbocharger cleaning with engine in service. Hand tools:

Starting position:

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/4 hour Plate no Item no Qty. /


Capacity : 1 man
See the special instructions for turbocharger.
Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

96.30 - ES0S
MAN Diesel

612-05.00 Water Washing of Compressor Side Working Card


Edition 03H Page 2 (3)
Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R

L+V28/32H
Before Cleaning

The cleaning process is only to be carried out when 3) Fill the container with 2 litres fresh water (see
the engine is at operating temperature (see Opera- the scale on the container).
ting Data 600.30) and when it is loaded as close as
possible to full load (see Main Data 600.00).
Warning: Do not use sea water or cooling water.
See also "Description for Water Washing of Com-
pressor side", 612.05.
4) Mount the top cover on the container.

Cleaning Procedure 5) Blow air into the container by means of a blow


gun, until an operation pressure of 3 bar is reached
1) Run the engine with as high a load as pos- (see fig 2).
sible.

2) Discharge the excesspressure in the container The safety valve will open at a pressure of 4 bar.
by drawing out the spindle in the safety valve (see
fig. 1) before loosening the top cover. Excesspressure will discharge through the safety
valve.
The spindle returns automatically by means of a
built-in spring.

Fig 1 Fig 2

96.30 - ES0S
MAN Diesel

Working Card Water Washing of Compressor Side 612-05.00


Page 3 (3) Edition 03H
Turbocharger Type NR15/R - NR20/R - NR24/R - NR26/R.

L+V28/32H
6) Connect the plug-in coupling of the lance to
the snap coupling on the pipe (see fig 3).

7) Depress the handle on the hand valve until


the water is completely injected into the compressor
(approx. 30 seconds).

The water will enter the compressor in atomized


condition, impinge the vanes of the compressor
wheel with high velocity and thus wash off the dirt
deposited.

8) Release the plug-in coupling and vent the


container by drawing the spindle out of the safety
valve.

After Cleaning

9) Run the engine for minimum 10 minutes at


1 Injection tube 5 Hand valve with handle unaltered high load.
2 Pipe 6 Container
3 Snap coupling 7 Charge air line
4 Plug-in coupling 10) Compare the measurements of the operating
data (see fig 4) before and after the cleaning proce-
dure (see Operating Data 600.30).
Fig 3

IF THEN

the comparison indicates success of the the water washing of the compressor side
washing procedure is finished

the comparison indicates lack of the wa- carry out the washing procedure from step
shing procedure 1 with 10 minutes interval from the initial
washing

severe dirt is being deposited in the com- dismantling of the compressor components
pressor for manual cleaning is necessary (see spe-
cial turbocharger manual in section 612).

Fig 4

96.30 - ES0S
MAN Diesel
Working Card 612-10.00
Page 1 (2) Dry Cleaning of Turbocharger - Turbine Side Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water Blow gun with container.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Dry cleaning of turbine side, cleaning with engine


in service. Hand tools:

Starting position:

Related procedure:

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /


Capacity : 1 man
See the special instruction for turbocharger.

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

97.07 - ES0S
MAN Diesel

612-10.00 Working Card


Edition 02H Dry Cleaning of Turbocharger - Turbine Side Page 2 (2)

L+V28/32H
Cleaning Procedure.

1) The cleaning is carried out during high engine 2) Before connecting the "blow-gun" open the
load minimum 75 % at full load. closing valve (1), see fig 1 and check whether there
is free passage.

3) Fill cleaning granulated substance into the


container (2) for turbocharger type:

NR20/R - NR20S: 0.2 - 0.3 liters.


NR24/R - NR26/R: 0.3 - 0.4 liters.

Connect to the working air system (4), 5 -7 bar.

4) Connect the "blow-gun" to valve (1). Open air


valve (3).

Then open valve (1) slowly until a whisling sound


indicates that blowing-in of granulated substance
takes place.

1 Closing valve 2 Container Injection time approx. 2 min.


3 Air valve 4 working air inlet
5 Exhaust pipe 6 Snap coupling For dry cleaning of turbine side, see also description
612.10 "Cleaning the Turbocharger in Service, Dry
Cleaning - Turbine Side.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine.

97.07 - ES0S
MAN Diesel
Working Card 612-15.00
Page 1 (2) Water Washing of Turbine Side Edition 01H

General

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Water washing of turbine side, cleaning with


engine in service. Hand tools:

Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1/2 Hour Plate no. Item no. Qty. /


Capacity : 1 man
See the special instruction for turbocharger.
Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.04 - ES0S
MAN Diesel
612-15.00 Working Card
Edition 01H Water Washing of Turbine Side Page 2 (2)

General
Cleaning Procedure. 3) Turn the 3-way cock to position 2 "Open", see
fig. 2 and check for free passage. If ok turn to the
1) Adjust the engine load to approx. 20 % and let water wash position 3 "Wash".
the engine stabilize for 10 min.
4) Connect the water supply to the water wash
2) Open the drain cock at the turbocharger outlet system.
and check for free passage, see fig. 1.
5) Activate the manoeuvring valve, see fig. 1.

Then open the regulating valve and adjust the water


flow until the drain flow is approx. 0,25 l/min.
3-way cock
6) Continue the water washing 5 - 10 min. or until
the drain water is free of particles.
Plate with clean-
ing instruction 7) Release the manoeuvring valve and disconnect
the water supply.
Manoeuvering
valve
Turn the 3-way cock to position 1, "Closed" and check
Regulating valve that the water drain flow has stopped.
Cleaning water
inlet 8) Continue at this load at least 5 min. before
Drain cock increasing the load to the normal condition.

9) After the water washing, the engine should run


for at least 1 hour before stop.

Fig. 1. Arrangement for water washing. Note: The regulating valve has to be opened
slowly.

The manoeuvring valve must not be locked in open


position.

The water injection time mentioned in item 6 must


be not exceeded.

For water washing of turbine side, see also descrip-


tion for water washing.
08028-0D/H5250/94.08.12

Fig. 2. 3-way cock.

91.04 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-12H

5-6L28/32H
08028-0D/H5250/94.08.12

97.06 - ES0S
MAN Diesel
Plate
61201-12H Charging Air Cooler - Freshwater Page 2 (2)

5-6L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/K Crossmember Travers

029 1/K Crossmember Travers

030 2/K Pipe Rør

042 1/K Cooler block Kølerblok

054 1/K Gasket end cover Pakning endedæksel

066 4/K Plug screw Propskrue

078 4/K Cu-washer Cu-skive

091 1/K End cover Endedæksel

101 4/K Nut Møtrik

113 8/K Screw Skrue

125 1/K Side plate right Sideplade højre

137 1/K Gasket reversing Pakning vendekam-


cover mer

149 1/K Reversing cover Vendekammer

150 32/K Screw Skrue

162 1/K Crossmember Travers

174 5/K Screw Skrue

186 5/K Cu-washer Cu-skive

198 5/K Screw Skrue

208 1/K Side plate left Sideplade venstre

221 4/K Screw Skrue

233 1/K O-ring O-ring

245 1/K Plug Prop

257 1/K Gasket Pakning

282 22/K Screw Skrue

304 1/E Charging air cooler, Ladeluftkøler, komplet,


complete, incl. item inkl. item 017, 029, 030,
017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
08028-0D/H5250/94.08.12

125, 137, 149, 150, 162, 150, 162, 174, 186, 198,
174, 186, 198, 208, 221, 208, 221, 233 og 245
233 and 245

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler

97.06 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-13H

7-8-9L28/32H
08028-0D/H5250/94.08.12

97.06 - ES0S
MAN Diesel
Plate
61201-13H Charging Air Cooler - Freshwater Page 2 (2)

7-8-9L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/K Crossmember Travers

029 1/K Crossmember Travers

030 2/K Pipe Rør

042 1/K Cooler block Kølerblok

054 1/K Gasket end cover Pakning endedæksel

066 4/K Plug screw Propskrue

078 4/K Cu-washer Cu-skive

091 1/K End cover Endedæksel

101 4/K Nut Møtrik

113 8/K Screw Skrue

125 1/K Side plate right Sideplade højre

137 1/K Gasket reversing Pakning vendekam-


cover mer

149 1/K Reversing cover Vendekammer

150 32/K Screw Skrue

162 1/K Crossmember Travers

174 5/K Screw Skrue

186 5/K Cu-washer Cu-skive

198 5/K Screw Skrue

208 1/K Side plate left Sideplade venstre

221 4/K Screw Skrue

233 1/K O-ring O-ring

245 1/K Plug Prop

257 1/K Gasket Pakning

282 22/K Screw Skrue

304 1/E Charging air cooler, Ladeluftkøler, komplet,


complete, incl. item inkl. item 017, 029, 030,
017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
08028-0D/H5250/94.08.12

125, 137, 149, 150, 162, 150, 162, 174, 186, 198,
174, 186, 198, 208, 221, 208, 221, 233 og 245
233 and 245

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler

97.06 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-14H

5-6L28/32H
08028-0D/H5250/94.08.12

97.06 - ES0S
MAN Diesel
Plate
61201-14H Charging Air Cooler - Freshwater Page 2 (2)

5-6L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/K Crossmember Travers

029 1/K Crossmember Travers

030 2/K Pipe Rør

042 1/K Cooler block Kølerblok

054 1/K Gasket end cover Pakning endedæksel

066 4/K Plug screw Propskrue

078 4/K Cu-washer Cu-skive

091 1/K End cover Endedæksel

101 4/K Nut Møtrik

113 8/K Screw Skrue

125 1/K Side plate right Sideplade højre

137 1/K Gasket reversing Pakning vendekam-


cover mer

149 1/K Reversing cover Vendekammer

150 32/K Screw Skrue

174 5/K Screw Skrue

186 5/K Cu-washer Cu-skive

198 5/K Screw Skrue

208 1/K Side plate left Sideplade venstre

221 8/K Screw Skrue

233 1/K O-ring O-ring

257 1/K Gasket Pakning

269 1/K Ring Ring

270 1/K Drain pipe for WMC Drænrør for WMC

282 22/K Screw Skrue

294 1/K Water mist catcher Vandudskiller

304 1/E Charging air cooler, Ladeluftkøler, komplet,


complete, incl. item inkl. item 017, 029, 030,
08028-0D/H5250/94.08.12

017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
125, 137, 149, 150, 174, 150, 174, 186, 198,
186, 198, 208, 221, 233, 208, 221, 233, 269, 270
269, 270 and 294 og 294

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler

97.06 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-15H

7-8-9L28/32H
08028-0D/H5250/94.08.12

97.06 - ES0S
MAN Diesel
Plate
61201-15H Charging Air Cooler - Freshwater Page 2 (2)

7-8-9L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/K Crossmember Travers

029 1/K Crossmember Travers

030 2/K Pipe Rør

042 1/K Cooler block Kølerblok

054 1/K Gasket end cover Pakning endedæksel

066 4/K Plug screw Propskrue

078 4/K Cu-washer Cu-skive

091 1/K End cover Endedæksel

101 4/K Nut Møtrik

113 8/K Screw Skrue

125 1/K Side plate right Sideplade højre

137 1/K Gasket reversing Pakning vendekam-


cover mer

149 1/K Reversing cover Vendekammer

150 32/K Screw Skrue

174 5/K Screw Skrue

186 5/K Cu-washer Cu-skive

198 5/K Screw Skrue

208 1/K Side plate left Sideplade venstre

221 8/K Screw Skrue

233 1/K O-ring O-ring

257 1/K Gasket Pakning

269 1/K Ring Ring

270 1/K Drain pipe for WMC Drænrør for WMC

282 22/K Screw Skrue

294 1/K Water mist catcher Vandudskiller

304 1/E Charging air cooler, Ladeluftkøler, komplet,


complete, incl. item inkl. item 017, 029, 030,
08028-0D/H5250/94.08.12

017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
125, 137, 149, 150, 174, 150, 174, 186, 198,
186, 198, 208, 221, 233, 208, 221, 233, 269, 270
269, 270 and 294 og 294

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler

97.06 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Seawater 61201-16H

5-6L28/32H
08028-0D/H5250/94.08.12

97.45 - ES0S
MAN Diesel
Plate
61201-16H Charging Air Cooler - Seawater Page 2 (2)

5-6L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/K Crossmember Travers 304 1/E Charging air cooler, Ladeluftkøler, komplet,
complete, incl. item inkl. item 017, 029, 030,
029 1/K Crossmember Travers 017, 029, 030, 042, 042, 054, 066, 078, 091,
054, 066, 078, 091, 101, 101, 113, 125, 137, 149,
030 2/K Pipe Rør 113, 125, 137, 149, 150, 150, 174, 186, 198, 208,
174, 186, 198, 208, 221, 221, 233, 269, 270, 294,
042 1/K Cooler block Kølerblok 233, 269, 270, 294, 316, 316, 328, 341
328, 341
054 1/K Gasket Pakning
end cover endedæksel 316 12/K Nut Møtrik

066 4/K Plug screw Propskrue 328 6/K Anti-corrosion block Anode

078 4/K Cu-washer Cu-skive 341 12/K Stud Tapskrue

091 1/K End cover Endedæksel

101 4/K Nut Møtrik

113 8/K Screw Skrue

125 1/K Top plate Topplade

137 1/K Gasket Pakning


reversing cover vendekammer

149 1/K Reversing cover Vendekammer

150 32/K Screw Skrue

174 5/K Screw Skrue

186 5/K Cu-washer Cu-skive

198 5/K Screw Skrue

208 1/K Bottom plate Bundplade

221 8/K Screw Skrue

233 1/K O-ring O-ring

257 1/K Gasket Pakning

269 1/K Ring Ring

270 1/K Drain pipe for Drænrør for


water mist catcher vandudskiller

282 22/K Screw Skrue

294 1/K Water mist catcher Vandudskiller


08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler

97.45 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Seawater 61201-17H

7-8-9L28/32H
08028-0D/H5250/94.08.12

97.45 - ES0S
MAN Diesel
Plate
61201-17H Charging Air Cooler - Seawater Page 2 (2)

7-8-9L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

017 1/K Crossmember Travers 304 1/E Charging air cooler, Ladeluftkøler, komplet,
complete, incl. item inkl. item 017, 029, 030,
029 1/K Crossmember Travers 017, 029, 030, 042, 042, 054, 066, 078, 091,
054, 066, 078, 091, 101, 101, 113, 125, 137, 149,
030 2/K Pipe Rør 113, 125, 137, 149, 150, 150, 174, 186, 198, 208,
174, 186, 198, 208, 221, 221, 233, 269, 270, 294,
042 1/K Cooler block Kølerblok 233, 269, 270, 294, 316, 316, 328, 341
328, 341
054 1/K Gasket Pakning
end cover endedæksel 316 12/K Nut Møtrik

066 4/K Plug screw Propskrue 328 6/K Anti-corrosion block Anode

078 4/K Cu-washer Cu-skive 341 12/K Stud Tapskrue

091 1/K End cover Endedæksel

101 4/K Nut Møtrik

113 8/K Screw Skrue

125 1/K Top plate Topplade

137 1/K Gasket Pakning


reversing cover vendekammer

149 1/K Reversing cover Vendekammer

150 32/K Screw Skrue

174 5/K Screw Skrue

186 5/K Cu-washer Cu-skive

198 5/K Screw Skrue

208 1/K Bottom plate Bundplade

221 8/K Screw Skrue

233 1/K O-ring O-ring

257 1/K Gasket Pakning

269 1/K Ring Ring

270 1/K Drain pipe for Drænrør for


water mist catcher vandudskiller

282 22/K Screw Skrue

294 1/K Water mist catcher Vandudskiller


08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler

97.45 - ES0S
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-29H

L28/32H

318

081 176 056


296
306 081
007

235

019

247

103

115 044

068

188 330

139
272
164
176
223 032

176
211

284
08028-0D/H5250/94.08.12

260
127
140
093
259 152 020

093

07.12 - ES0
MAN Diesel
Plate
61201-29H Charging Air Cooler - Freshwater Page 2 (2)

L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

007 1/K End cover Endedæksel 306 4/K Gasket Pakning

019 1/K Gasket for Pakning for 318 1/E Charge air cooler, Ladeluftkøler,
end cover endedæksel complete komplet

020 2/K Reversing chamber Vendekammer 330 1/K Gasket Pakning

032 1/K Gasket for Pakning for


reversing chamber vendekammer

044 1/K Cooler block Kølerblok

056 5/K Screw Skrue

068 5/K Gasket ring Pakningsring

081 5/K Screw Skrue

093 32/K Screw Skrue

103 1/K Ring by drain pipe Ring ved drænrør

115 1/K O-ring O-ring

127 1/K Side cover- right Sidedæksel - højre

139 1/K Side cover- left Sidedæksel - venstre

140 2/K Crossmember Travers

152 2/K Distance pipe Afstandsrør

164 4/K Nut Møtrik

176 /I Locktite Locktite

188 8/K Screw Skrue

211 8/K Screw Skrue

223 8/K Washer Skive

235 1/K Water mist catcher Vandudskiller

247 1/K Drain pipe for Drænrør for


water mist catcher vandudskiller

259 8/K Spring, straight pin Spændestift


slotted

260 8/K Spring, side cover Fjeder, sideplade

272 4/K Lock, side cover Lås, sideplade


08028-0D/H5250/94.08.12

284 8/E Screw Skrue

296 4/K Plug screw Propskrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler
Qty./I = Individual Antal/I = Individuelt

07.12 - ES0
MAN Diesel

Plate
Page 1 (2) Exhaust Pipe Arrangement 61202-23H

5,6L28/32H

11 08 05 05
06 10 08 10
11 07 05 10 04
09
11

16
14 13
15 12

23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34

91.18 - ES0S
MAN Diesel

Plate
61202-23H Exhaust Pipe Arrangement Page 2 (2)

5,6L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag 30 1/C Gasket Pakning

05 Exhaust pipe Udstødsrør 31 1/C Gasket Pakning


4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor 32 1/C O-ring O-ring

06 1/E Exhaust pipe, Udstødsrør, tilgang 33 1/C Cooling water Kølevandsnippel


inlet TC. turbolader nipple

07 1/E Exhaust pipe for Udstødsrør for 34 1/C O-ring O-ring


cyl. 1 cyl. 1

08 Compensator Kompensator
4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor

09 1/E Compensator Kompensator

10 Gasket Pakning
9/E 5 cyl. engine 5 cyl. motor
11/E 6 cyl. engine 6 cyl. motor

11 3/E Gasket Pakning

12 Screw Skrue
108/E 5 cyl. engine 5 cyl. motor
132/E 6 cyl. engine 6 cyl. motor

13 Nut Møtrik
108/E 5 cyl. engine 5 cyl. motor
132/E 6 cyl. engine 6 cyl. motor

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

91.18 - ES0S
MAN Diesel

Plate
Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-32H

5,6L28/32H

17
06
11 07 08 04
09 05
11

16
14
15
23 28
22
29
30
20 31
21
22
23
24
25
26 32
27 33
34

92.38 - ES0S
MAN Diesel

Plate
61202-32H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)

5,6L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 Exhaust pipe Udstødsrør


4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor

06 1/E Exhaust pipe, Udstødsrør, tilgang


inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for


cyl. 1 cyl. 1

08 Compensator Kompensator
4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor

09 1/E Compensator Kompensator

11 2/E Gasket Pakning

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water Kølevandsnippel


nipple

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

92.38 - ES0S
MAN Diesel

Plate
Page 1 (2) Exhaust Pipe Arrangement 61202-26H

7,8L28/32H

17 08 05 05
06 10 08 10
11 07 05 10 04
09
11

16
14 13
15 12

23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34

91.18 - ES0S
MAN Diesel

Plate
61202-26H Exhaust Pipe Arrangement Page 2 (2)

7,8L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag 29 1/C Plug screw Propskrue

05 Exhaust pipe Udstødsrør 30 1/C Gasket Pakning


6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor 31 1/C Gasket Pakning

06 1/E Exhaust pipe, Udstødsrør, tilgang 32 1/C O-ring O-ring


inlet TC. turbolader
33 1/C Cooling water Kølevandsnippel
07 1/E Exhaust pipe for Udstødsrør for nipple
cyl. 1 cyl. 1
34 1/C O-ring O-ring
08 Compensator Kompensator
6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor

09 1/E Compensator Kompensator

10 Gasket Pakning
13/E 7 cyl. engine 7 cyl. motor
15/E 8 cyl. engine 8 cyl. motor

11 2/E Gasket Pakning

12 Screw Skrue
156/E 7 cyl. engine 7 cyl. motor
180/E 8 cyl. engine 8 cyl. motor

13 Nut Møtrik
156/E 7 cyl. engine 7 cyl. motor
180/E 8 cyl. engine 8 cyl. motor

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

91.18 - ES0S
MAN Diesel

Plate
Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-28H

7,8L28/32H

17
06
11 07 08 04
09 05
11

16
14
15
23 28
22
29
30
20 31
21
22
23
24
25
26 32
27 33
34

92.07 - ES0S
MAN Diesel

Plate
61202-28H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)

7,8L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 Exhaust pipe Udstødsrør


6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor

06 1/E Exhaust pipe, Udstødsrør, tilgang


inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for


cyl. 1 cyl. 1

08 Compensator Kompensator
6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor

09 1/E Compensator Kompensator

11 2/E Gasket Pakning

14 8/E Screw Skrue

15 8/E Nut Møtrik

16 16/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water Kølevandsnippel


nipple

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

92.07 - ES0S
MAN Diesel

Plate
Page 1 (2) Exhaust Pipe Arrangement 61202-27H

9L28/32H

16 08 05 05
06 10 08 10
11 07 05 10 04
09
11

15
14
12 13
13 12

23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34

91.18 - ES0S
MAN Diesel

Plate
61202-27H Exhaust Pipe Arrangement Page 2 (2)

9L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 8/E Exhaust pipe Udstødsrør

06 1/E Exhaust pipe, Udstødsrør, tilgang


inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for


cyl. 1 cyl. 1

08 8/E Compensator Kompensator

09 1/E Compensator Kompensator

10 17/E Gasket Pakning

11 2/E Gasket Pakning

12 216/E Screw Skrue

13 216/E Nut Møtrik

14 12/E Screw Skrue

15 12/E Screw Skrue

16 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water nipple Kølevandsnippel

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

91.18 - ES0S
MAN Diesel

Plate
Page 1 (2) Exhaust Pipe Arrangement with Welded Compensator 61202-42H

9L28/32H

17
06
11 07 08 04
09 05
11

16
14
15
23 28
22
29
30
20 31
21
22
23
24
25
26 32
27 33
34

97.08 - ES0S
MAN Diesel

Plate
61202-42H Exhaust Pipe Arrangement with Welded Compensator Page 2 (2)

9L28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

04 1/E End cover, aft Endeplade, bag

05 8/E Exhaust pipe Udstødsrør

06 1/E Exhaust pipe, Udstødsrør, tilgang


inlet TC. turbolader

07 1/E Exhaust pipe for Udstødsrør for


cyl. 1 cyl. 1

08 8/E Compensator Kompensator

09 1/E Compensator Kompensator

11 2/E Gasket Pakning

14 12/E Screw Skrue

15 12/E Nut Møtrik

16 24/E Screw Skrue

17 1/E Gasket Pakning

20 4/C Screw Skrue

21 1/C Gasket Pakning

22 4/C Gasket Pakning

23 4/C Plug Prop

24 2/C Screw Skrue

25 2/C Washer Skive

26 1/C Intermediate piece Mellemstykke

27 1/C Plug screw Propskrue

28 4/C Screw Skrue

29 1/C Plug screw Propskrue

30 1/C Gasket Pakning

31 1/C Gasket Pakning

32 1/C O-ring O-ring

33 1/C Cooling water Kølevandsnippel


nipple

34 1/C O-ring O-ring

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder

97.08 - ES0S
MAN Diesel & Turbo

Plate
Page 1 (2) Water Washing of Compressor Side 61205-02H

L+V28/32H

26*
23
25*

24*
27 01*

02*

03*
07
04*
08
05*
09
06*
10
22

21 11

20 12

19 13*

09

10

18

16

14*

17

15*

94.01 - ES0S
MAN Diesel & Turbo

Plate
61205-02H Water Washing of Compressor Side Page 2 (2)

L+V28/32H

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

01* 1/E Top cover with non- Topdæksel med kon- 25* 1/E Straight male stud Ligeforskruning
return valve traventil coupling

02* 1/E O-ring for top cover O-ring for topdæksel 26* 1/E Plug in coupling Kobling

03* 1/E O-ring for non-return O-ring for kontraventil 27 1/E Lance complete, incl. Lanse komplet, inkl.
valve item 24-25 and 26 item 24-25 og 26

04* 1/E Valve seat Ventilsæde 28 1/E Container complete, Beholder komplet, som
as shown on plate vist på plate
05* 1/E Spring for non-return Fjeder for kontraventil
valve

06* 1/E Cap screw for non- Omløber til


return valve kontraventil

07 1/E Top cover with non- Topdæksel med kontra-


return valve complete, ventil komplet, inkl. item
incl. item 01-02-03-04- 01-02-03-04-05 og 06
05 and 06

08 1/E Safety valve Sikkerhedsventil

09 2/E O-ring O-ring

10 2/E Finger nut Fingermøtrik

11 1/E Cap Top

12 1/E Gasket for the cap Pakning for top

13* 1/E Cable binder Kabelbinder

14* 1/E Strap Gjord

15* 1/E Eye for strap Øje for gjord

16 1/E Strap complete, incl. Gjord komplet, inkl. item


item 13-14 and 15 13-14 og 15

17 1/E Container Beholder

18 1/E Flexible pipe Fleksibel slange

19 1/E Handle with flexible Håndtag med fleksibel


pipe and cap screw slange og omløber

20 1/E Filter insert Filterinsats

21 1/E Gasket for handle Pakning til håndtag

22 1/E Hand valve Håndventil

23 1/E Gasket for Pakning til


hand valve håndventil

24* 1/E Lance Lanse

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor

94.01 - ES0S
MAN Diesel

Plate
Page 1 (2) Steam Trap 61208-01H

L+V28/32H

01

05
02

06
03

04

07

97.07 - ES0S
MAN Diesel

Plate
61208-01H Steam Trap Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01 1/E Steam trap, Vandudlader,


complete komplet

02 1/E Packing Pakning

03 1/E Clip Klemme

04 1/E House, bottom Hus, bund

05 1/E House, top Hus, top

06 1/E Swimmer Svømmer

07 1/E Valve Ventil

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor

97.07 - ES0S
MAN Diesel

Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 61210-02H

General

053
016 112 028 041 028 065 077

089 148

100

136
08028-0D/H5250/94.08.12

01.12 - ES0
MAN Diesel

Plate
61210-02H Blowgun for Dry Cleaning of Turbocharger Page 2 (2)

General
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

016 1/E Snap coupling Snapkobling

028 2/E Nipple Nippel

041 1/E Tee T-stykke

053 1/E Ball valve Kugleventil

065 1/E Snap coupling Snapkobling

077 1/E Snap coupling Snapkobling

089 1/E Packing ring Pakningsring

100 1/E Container, complete beholder, komplet

112 1/E Socket Muffe

136 1/E Blowgun, complete Rensepistol, complete

148 /I Granulate Granulat

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor
Qty./I = Qty./Individual Qty./I = Qty./Individuelt

01.12 - ES0
Compressed air system

513/613
MAN Diesel
Description
Compressed Air System 613.01
Page 1 (2)
Edition 20H

L28/32H

On-off valve
for jet-system

K1
Main
starting
valve

Overspeed
device
Starting
valve

Stop cylin- Emergency


der starting valve
Air starter

Cyl. 1

Fig. 1. Diagram for Compressed Air System

General Starting System

The compressed air system on the engine contains The engine is started by means of a built-on air
a starting system, starting control system and safety starter, which is of the turbine starter motor type
system. Further, the system supplies air to the jet with gear box, safety clutch and drive shaft with
system. pinion. Further, the starting system consists of a
main starting valve.
The compressed air is supplied from the starting air
receivers (30 bar) through a reduction station, where
from compressed air is supplied to the engine. Control System

To avoid dirt particles in the internal system, a dirt se- The air starter is activated electrically with a pneu-
08028-0D/H5250/94.08.12

parator is mounted in the inlet line to the engine. matic 3/2 way solenoid valve (starting valve).

The intervals between cleaning and draining will The valve can be activated manually from the star-
depend on the condition of the air in the main sup- ting box on the engine, and it can be arranged for
ply system, and has therefore to be determined remote control, manual or automatic.
according to service experience gained with the
particular plant. For remote activation, the starting spool must be
connected so that every starting signal to the starting
Note: Due to the safety system, the air supply to spool goes through the converter for engine RPM
the engine must not be interrupted during operation signal or via the engine control box if supplied.
of the engine.

94.23 - ES0S
MAN Diesel

613.01 Compressed Air System Description


Page 2 (2)
Edition 20H

L28/32H
Further, the system is equipped with an emergency Safety System
starting valve which makes it possible to activate the
air starter manually in case of a power failure. As standard the engine is equipped with a pneu-
matically/mechanically overspeed device, which
starts to operate if the maximum permissible RPM
Emergency Starting Valve is exceeded. This device is fitted to the end cover
of the engine driven lubricating pump and is driven
The emergency starting valve is activated by means from the pump through a resilient coupling, see
of a screw-driver or similar as illustrated in fig. 2. section 609.

When the maximum permissible RPM is exceeded,


the overspeed device will activate a pneumatically
controlled stop cylinder, which will bring the fuel
index to zero and stop the engine.

Pneumatic Start Sequence


Press down Emergency
start valve
⇓ When the starting valve is opened, air will be supplied
to the drive shaft housing of the air starter.

The air supply will - by activating a piston - bring


the drive pinion into engagement with the gear rim
on the engine fly wheel.

When the pinion is fully engaged, the pilot air will


flow to, and open the main starting valve, whereby
air will be led to the air starter, which will start to
Fig. 2. Emergency start valve turn the engine.

Simultaneously with air supply for the air starter, air


will be supplied to the fuel limitating cylinder, thus
limiting the fuel supply during the start sequence.

When the RPM exceeds approx. 110, at which firing


has taken place, the starting valve is closed whereby
the air starter is disengaged.
08028-0D/H5250/94.08.12

94.23 - ES0S
MAN Diesel
Working Card 613-01.21
Page 1 (2) Air Filter Edition 02H

General

Safety precautions Special tools

Stopped engine Plate no Item no Note


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

Description Hand tools

Cleaning and/or maintenance of air filter.

Starting position

Related procedure
08028-0D/H5250/94.08.12

Manpower Replacement and wearing parts

Working time : hours Plate no Item no Qty/


Capacity : man

Data

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

02.46 - ES0
MAN Diesel
613-01.21 Working Card
Edition 02H Air Filter Page 2 (2)

General
Cleaning Air Filter To replace filter element

1) Depressurize unit. 7) Depressurize unit.

2) Remove bowl and bowl guard assembly by 8) Remove bowl and bowl assembly by turning
turning counter-clockwise. counter-clockwise.

3) Inspect bowl for damage seals and replace, if 9) Unscrew baffle by turning counter-clockwise.
nessesary.
10) Remove filter element and discard.
4) If bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth or mild detergent. 11) Install new filter element and reassemble in
reverse order.
5) Before returning to service, insure that all seals
have been reinstalled or replaced. 12) Before returning to service, insure that all seals
have been reinstalled or replaced.
6) Reinstall bowl and bowl guard assembly and
rotate bowl guard clockwise to securely lock in 13) Reinstall bowl and bowl guard assembly and
place. Align arrow on bowl guard with arrow on filter rotate bowl guard clockwise to securely lock in
body. place. Align arrow on bowl guard with arrow on filter
body.

08028-0D/H5250/94.08.12

Fig 1 Air Filter

02.46 - ES0
MAN Diesel

Working Card 613-01.30


Page 1 (9) Overhaul, Test and Inspection of Turbine Starter Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


Shut-off starting air
Shut-off cooling water 62006 xx 20 - 120 Nm.
Shut-off fuel oil
Shut-off cooling oil
Stopped lub. oil circul.

Description:

Disassembly, overhaul and assembly of the air


starter. Hand tools:

Allen key, 4 mm.


Allen key (long), 8 mm.
Screwdriver.
Starting position: Big screwdriver.
Chisel.
All connection to the air starter have been re- Retaining ring pliers.
moved, and air starter is removed. Plastic hammer.
Lubricating oil.
Copaslip or similar.
Sleeve.
Bearing puller.
Related procedure: Impact Wrench
Bearing pressing tool.
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 4 Hours Plate no. Item no. Qty./


Capacity : 1 man
See plate 61309.
Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

03.47 - ES0-G
MAN Diesel

613-01.30 Working Card


Edition 02H Overhaul, Test and Inspection of Turbine Starter Page 2 (9)

L+V28/32H
General Information

1. Always mark adjacent parts on the housing


exhaust cover (1), motor housing (8), intermediate
gear case (13), gear case (28) and drive housing
(38) so these members can be located in the same
relative position when the starter is reassembled.

Note: Do not disassemble the starter any further than


necessary to replace worn or damaged parts.
Never reuse old seals or o-rings.
Never wash the inertia drive in a solvent.

2. Do not remove any part which is a press fit in


or on a subassembly unless the removal of that part
is necessary for replacement or repairs.

3. Always have a complete set of seals and o-rings


on hand before starting any overhaul of the turbine Fig 1.
starter.

4. When grasping a part in a vise, always use 5. Remove the deflector retaining screw (5), de-
copper-covered vise jaws to protect the surface of the flector retai-ning spring (4) and the splash deflector
part and help prevent distortion. This is particularly (3) from the housing exhaust cover (1), See fig 2.
true of threaded members.

Housing Exhaust Cover, Motor Assembly, and


Motor Housing

1. If replacing the motor assembly (12), remove


both housing plugs (10) and drain the oil from the
gearing before beginning disassembly of the starter.
Inspect the magnetic housing plugs (10) for metal
particles. Very fine metal particles are normal. Re-
move particles and reinstall plugs. Large particles or
chips are an indication of a problem. Disassemble
gear case (28) and inspect.

2. Using a screw driver, unscrew the exhaust


08028-0D/H5250/94.08.12

cover (67) from the housing exhaust cover (1).


Fig 2.

3. Using an 8 mm hex-head wrench, unscrew


and remove the starter assembly cap screws (6) 6. Tap the motor housing with a plastic hammer
and washers (7), See fig 1. to dislodge it from the intermediate gear case (13).

4. Pull the housing exhaust cover (1) from the 7. Grasp the rear of the motor assembly (12) and
motor housing (8). To dislodge the housing exhaust pull it from the rear of the motor housing (8).
cover, rotate it until the ears clear the motor housing. If the motor assembly (12) is difficult to remove, lightly
Using a plastic hammer, tap the ears alternately until push the motor pinion which is on the front of the
the housing cover can be removed from the motor motor assembly toward the exhaust side of the motor
housing. housing in order to free the motor assembly.

03.47 - ES0-G
MAN Diesel

Working Card 613-01.30


Page 3 (9) Overhaul, Test and Inspection of Turbine Starter Edition 02H

L+V28/32H
8. Tap the intermediate gear case (13) with a 13. Remove the planet gear frame assembly from
plastic hammer to dislodge it from the gear case the intermediate gear case. Using a sleeve that con-
(28). tacts the outer race of the front gear frame bearing
(17), press the planet gear frame shaft seal (16) and
9. Position the intermediate gear case (13) on a the front gear frame bearing (17) from the front end
bench in a copperfaced vise so that the intermediate and out of the rear of the intermediate gear case.
pinion (26) is secured in the jaws of the vise. Tighten
the vise only enough to hold the intermediate pinion 14. Remove the rear gear frame bearing (24) from
securely. the planet gear frame (18), using a bearing puller
and remove the gear shaft retaining washer (23),
10. Loosen the intermediate pinion retaining screw See fig. 4.
(27) 1-1/2 turns only. Do not remove. Remove the planet gear shafts (22), planet gears
(19), planet gear bearings (20) and bearing spac-
Warning: If the intermediate gear case is not sup- ers (21).
ported on a bench and if the intermediate pinion
retaining screw is completely removed, the interme- 15. Remove the front bearing spacer (25), using
diate gear case and compoments could fall causing a bearing puller and the gear shaft retaining washer
injury. (23) from the front of the planet gear frame by press-
ing on the front of the planet gear frame shaft.
11. Tap the intermediate pinion lightly to back the Remove the gear shaft retaining washer only if the
planet gear frame assembly out of the intermediate washer or front bearing spacer is damaged.
gear case.

12. Remove the intermediate gear case assembly


from the vise and remove the intermediate pinion
(26). Remove the rear gear case o-ring (14) and
front gear case o-ring (15) from the intermediate
gear case (13), See fig 3.
08028-0D/H5250/94.08.12

Fig 4.

Drive Housing

1. Grasp the drive pinion (63) in a copper-faced


vise with the starter supported on the workbench.
Fig 3.

03.47 - ES0-G
MAN Diesel

613-01.30 Working Card


Edition 02H Overhaul, Test and Inspection of Turbine Starter Page 4 (9)

L+V28/32H
2. Remove the drive pinion retaining screw (61) ment is necessary and new parts are available. The
which has a right-hand thread. bearing and/or the seal will always be damaged when
removed from the drive housing.
3. Remove the starter from the vise.
15. Remove the piston ring (55) from the piston
4. Remove the drive pinion washer (62) and the (54).
drive pinion (63).
16. Press the clutch spring cup (50) down and
5. Slide the pinion spring sleeve (64) and the remove the clutch spring cup retainer (49).
pinion spring (65) off the drive shaft (57).
17. Remove the clutch spring cup and clutch spring
6. Unscrew the drive gear screw (34). Using an (51).
impact wrench with a 5/16" (8 mm) x 8" (203 mm)
log hex inserted into the end of the drive shaft. 18. Remove the two clutch jaws (52).

7. Unscrew and remove the drive housing cap 19. Remove the front drive gear bearing (30), drive
screws (38) and lock washers (39). gear cup (36), drive gear lock washer (35), drive gear
screw ring (37) and drive gear screw (34).
8. Tap the drive housing (40) with a plastic ham-
mer to help dislodge it from the gear case (28). 20. Remove the large drive shaft bearing retainer
(53) using a screwdriver.
Warning: Failure to follow this procedure could result
in injury to personnel. 21. Press the rear drive shaft bearing and drive
shaft (57) out of the piston. If the rear drive shaft
9. Place the drive housing (40) in an arbor press, bearing needs to be replaced, proceed as follows:
piston end up. Apply a load to the piston (54) using
the arbor press to compress the piston return spring a. Cut and remove the small drive shaft bear-
(59) before removing the bulkhead retainer (45). Do ing retained in the drive shaft, using a small
not use compressed air to load the piston. chisel.
b. Press the rear drive shaft bearing (58) off
10. Remove the bulkhead retainer (45). Using a the drive shaft.
screwdriver and the arbor press.
22. Place the gear case (28) on a workbench.
Caution: Make sure the tension of the spring pushes
the bulkhead out of the drive housing before removing 23. Remove the drive gear bearing retainer (32),
the drive housing from the arbor press. using retaining ring pliers and working through the
access holes in the gear web, See fig 5.
11. Remove the bulkhead (46) from the piston
(54). 24. Pull the drive gear (29) out of the gear case.
08028-0D/H5250/94.08.12

12. Remove the outer bulkhead ring (47) and the Note: Do not disassemble the drive gear and clutch
inner bulkhead ring (48). parts of the turbine powered starters. If the drive shaft
is defective, install a new or factory-rebuilt unit.
13. Slide the drive shaft (57) from the drive housing
(40). 25. Remove the drive gear shaft bearing retainer
(33), using retaining ring pliers.
14. Pull the piston return spring (59) off the drive
shaft. 26. Remove the rear drive gear bearing (31) from
the drive gear.
Note: Do not remove the front drive shaft bearing
(42) or the drive housing seal (43) unless replace-

03.47 - ES0-G
MAN Diesel

Working Card 613-01.30


Page 5 (9) Overhaul, Test and Inspection of Turbine Starter Edition 02H

L+V28/32H
5. Install the drive gear bearing retainer, using
retaining ring pliers and working through the access
holes in the gear web.

6. Lubricated the drive gear with approximately


240 ml of SHELL ALVANIA EPO grease.

7. Press the rear drive shaft bearing (58) onto


the drive shaft.

8. Slide the small bearing retainer convex side


first, onto the drive shaft. Press it into position in
accordance with the in-structions packaged with the
new retainer.

9. Assemble the drive gear Schrew (34), drive


Fig 5. gear lock washer (35), drive gear cup (36) and drive
gear screw o-ring (37).

Assembly of the Starter 10. Grasp the drive shaft (57) in a vise, external
splined end down. Place assembled drive shaft screw
1. Always press on the inner ring of a ball bearing Unit into the drive shaft, screwhead down. Lubricate
when installing the bearing on a shaft. the inside diameter of the drive shaft with SHELL
ALVANIA EPO grease.
2. Always press on the outer ring of a ball bearing
when pressing the bearing in a bearing recess. 11. Slide the drive gear bearing (30) into the drive
shaft.
3. Whenever grasping a part in a vise, always use
leather-covered, copper-covered vise jaws to protect 12. Lubricate with SHELL ALVANIA EPO grease
the surface of the part and help prevent distortion. and install the driving clutch jaw teeth facing up and
This is particularly true of threaded members. driven clutch jaw teeth facing down into the drive
shaft.
4. Always clean every part, and wipe every part
with a thin film of oil before installation. 13. Insert the clutch spring (51) into the drive
shaft.

Gear Case 14. Insert the clutch spring cup (50) into the drive
shaft.
1. Place the drive gear bearing retainer over the
rear end of the drive gear. 15. Press the inserted parts into the drive shaft,
08028-0D/H5250/94.08.12

and install the clutch spring cup retainer (49).


2. Press the rear drive gear bearing (31) onto the
rear end of the drive gear, using an arbor press. Note: If it is necessary to replace the drive hous-
ing (40) and drive components, make sure that the
3. Seat the rear drive gear bearing into the gear piston seal has been removed from the rear of the
case by tap-ping the opposite end of the drive gear, new piston (54).The piston seal must be removed
using a plastic hammer. to prevent pressure build-up which will cause move-
ment of the planet gear frame shaft seal (16). If this
4. Install the drive gear shaft bearing retainer conditions occurs, the piston cannot retract and the
(33), using retaining ring pliers. drive pinion (63) will remain in engagement with the

03.47 - ES0-G
MAN Diesel

613-01.30 Working Card


Edition 02H Overhaul, Test and Inspection of Turbine Starter Page 6 (9)

L+V28/32H
flywheel, causing damage to the starter drive train 26. Install the bulkhead retainer (45), using a
and/or starter motor. To remove the piston seal, in- screwdriver.
sert a screwdriver inside the lip of the seal and pry
it loose from the piston. Warning: Make sure the bulkhead retainer is properly
seated in the motor housing groove before easing off
16. Install the piston (54) onto the drive shaft until the arbor press. Failure to do so will allow improperly
the rear drive shaft bearing seats into the piston. retained parts to separate when removed from the
arbor press resulting in injury to personnel.
17. Coil the large drive shaft bearing retainer (53)
into the groove of the piston to retain the outer race 27. Remove the drive housing from the arbor
of the drive shaft bearing, using a thin flat blade press.
screwdriver to assist in this operation.
28. Lubricate and install the drive housing o-ring
18. Lubricate the piston o-ring (55) and install it in (41) in the groove of the drive housing.
the groove of the piston.
29. Position the assembled gear case on a work-
19. Position the drive housing in an arbor press, bench.The as-sembled unit must be upright to accept
pinion-end down and install the drive housing seal the drive housing.
(43) into the drive housing. Using a pressing sleeve of Carefully position the assembled drive housing (40)
the proper size, press the seal into the drive housing onto the gear case so as not to damage the piston
so that the lip of the seal faces away from the drive seal. Align the punch marks of the gear case and
pinion. drive housing.

20. Press the bearing into the drive housing until 30. Install the drive housing cap screw lock wash-
it seats, using a sleeve that contacts the outer race ers (39) and the drive housing cap screws (38) and
of the front drive shaft bearing (42). Drop the piston tighten to 28 Nm torque.
return spring seat (60) on top of front drive shaft
bearing. 31. Tighten the drive gear screw (34) 77.3 Nm
torque, using an impact wrench with a 8 mm x 203
21. Slide the piston return spring (59) onto the mm long hex inserted into the end of drive shaft.
drive shaft and snap it into the front of the piston so
that it is against the large drive shaft bearing retainer 32. Grease and slide the pinion spring (65) and
(53). the pinion spring sleeve (64) over the pinion end of
the drive shaft.
22. Lubricate and insert the assembled drive shaft
into the drive housing. 33. Grease the pinion end of the drive shaft and
install the drive pinion (63).
23. Lubricate and install the outer bulkhead o-
ring (47) and the Inner bulkhead o-ring (48) on the 34. Grasp the drive pinion in a copper-covered
bulkhead (46). vise with the starter supported on a workbench.
08028-0D/H5250/94.08.12

24. Slide the bulkhead onto the piston. 35. Place the drive pinion washer (62) onto drive
pinion retaining screw (61).
25. With the drive housing in the arbor press, press
down on the rear face of the piston. Note: The thread on the drive pinion retaining screw
is right-hand thread.
Note: Feel the underside of the drive housing to make
sure the drive shaft passes through the bearing. 36. Install the drive pinion retaining screw into
the end of the drive shaft and tighten it to 108.5 Nm
torque.

03.47 - ES0-G
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Working Card 613-01.30


Page 7 (9) Overhaul, Test and Inspection of Turbine Starter Edition 02H

L+V28/32H
Intermediate Gear Case, Motor Housing, Motor 6. Install the other planet gear shaft retaining
Assembly and Housing Exhaust Cover washer over the shaft at the rear of the planet
gear.
1. Press the front gear frame bearing (17) into
the rear of the intermediate gear case (13), using a 7. Press the rear gear frame bearing (24) on the
bearing pressing tool of the proper size. shaft at the rear of the planet gear frame, using the
proper size bearing inserting tool.
2. Press the planet gear frame shaft seal (16) into
the rear of the intermediate gear case over the front 8. Slide the planet gear frame assembly, coupling
gear frame bearing, using a sleeve which contacts end first, into the rear of the intermediate gear case
the outer ring of the seal. (13), making sure that the planet gears mesh with the
ring gear. Use care so as to not damage the seal.
Note: Make sure the flat side of the seal is installed
against the bearing. 9. Install the intermediate pinion (26), making
sure that the notches at the rear of the pinion align
3. Install the rear gear case o-ring (14) in the with the notches and tangs in the shaft of the planet
groove at the rear of the intermediated gear case gear frame.
and the front gear case o-ring (15) in the groove at
the front of the intermediate gear case. coat both 10. Clean the threads of the intermediate pinion
o-rings. retaining screw (27) and apply 2-3 drops of Perm-
abond HM 118 to the threads approximately 3 mm
4. Install one gear shaft retaining washer (23) on from the end of the screw. Install screw and tighten
the front of the planet gear frame (18). Press the front enough to hold assembly together.
bearing spacer (25) on the front shaft of the planet
gear frame to hold the gear shaft retaining washer 11. For final tightening, position the intermediate
snugly in position. gear case so the intermediate pinion is secured in
the jaws of the copperfaced vise. Tighten the inter-
Note: Coat the front bearing spacer with gear Lube mediate pinion retaining screw to 122 Nm torque.
before installing it. Be careful not to gouge or scratch
the front bearing spacer during installation as this 12. Remove the intermediate gear case from the
could result in leakage between the planet gear vise and set it on a bench.
frame and gear case.
Note: The intermediate gear case will work in only
5. Place planet gear frame on a bench, shaft side one orientation.
down. Place the planet gear bearing (20) inside of
planet gear (19). Place bearing spacers (21) on top Align the punch marks on the intermediate gear
and bottom of bearing and gear. Slide the components case and gear case and tap the intermediate gear
into the slots in the side of the planet gear frame. case with a plastic hammer until it seats in the rear
Align holes in spacers and bearing with holes in of the gear case. Make sure the intermediate pinion
planet gear frame and insert planet gear shaft (22), meshes with the drive gear.
08028-0D/H5250/94.08.12

integral keyed end down, through the spacers and


bearing so that the larger portion of the keyed end Coat the o-rings on the motor assembly and the
of the shaft contacts the planet gear shaft retain- inside of the cylinder before installing the motor
ing washer (23). Repeat the procedure for the two assembly.
remaining planet gears and components.
13. Install the motor assembly through the rear of
Note: Do not move or turn over the planet gear frame the motor housing with the geared end of the rotor
until step 6 and 7 have been completed. Movement toward the front.
of the planet gear frame assembly could dislodge
assembled components, making it necessary to
repeat step 5.

03.47 - ES0-G
MAN Diesel

613-01.30 Working Card


Edition 02H Overhaul, Test and Inspection of Turbine Starter Page 8 (9)

L+V28/32H

Fig 6. Turbine Starter.

Note: Turn the intermediate pinion so that the gear 17. Align the punch marks on the housing exhaust
on the rotor meshes with the planet gears. Make cover with the punch marks on the motor housing
sure that the rear of the motor assembly is installed and tap the housing exhaust cover with a plastic
flush with the rear of the cylinder. hammer until it seats.

14. Align the punch marks on the motor housing 18. Install the housing exhaust cover on the rear
with the punch marks on the intermediate gear case of the motor housing using the starter assembly cap
and tap the motor housing with a plastic hammer until screws (6) and cap screw washers (7). Use an 8 mm
it seats on the rear of the intermediate gear case. hex-head wrench to tighten each a little at a time to
a final torque of 61 to 68 Nm increments.
15. Install the splash deflector (3), deflector retain-
08028-0D/H5250/94.08.12

ing spring (4) and deflector retaining screw (5) in the 19. Mount the exhaust cover (68) on the housing
rear of the housing exhaust cover. exhaust cover (1).

Note: Coat the threads of the deflector retaining Note: Use Intersoll-Rand SMB-441 pipe sealant on
screw with Ingersoll-Rand SMB-441 sealant. all plugs.

16. Coat the exhaust cover seal (2) and install it 20. Install the bottom housing plug (10) and the
in the groove on the housing exhaust cover. housing plug inlet boss (11). Put the starter on its
side with the side plug hole upward. Add 175 ml
automatic transmission fluid fulfilling DEXRON II D
specification, e.g. SHELL DONAX TA, through the
side plug hole.

03.47 - ES0-G
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Working Card 613-01.30


Page 9 (9) Overhaul, Test and Inspection of Turbine Starter Edition 02H

L+V28/32H
Caution: Do not overfill. Remove the pressure from the “IN” port. Measure
Install the side housing plug (10) and tighten all plugs the distance form the face of the drive shaft pinion
to 6.8 to 13.6 Nm torque. the the face of the mounting flange. It should be
45.0 +2.0 mm.

Test and Inspection Procedure 4. Motor Action: Secure starter in a vise and ap-
ply 90 psig (6.2 bar/620 kPa) pressure using a 3/8"
1. Clutch Ratcheting: Turn the drive shaft pinion (9 mm) supply line to the inlet of the motor. starter
(63) by hand in the direction of the starter rotation. should run smoothly.
The clutch should rachet smoothly with a slight click-
ing action. 5. Motor Seals: Plug the exhaust and slowly apply
20 psig (1.38 bar/138 kPa) pressure to the inlet of
2. Motor and Gearing Freeness: Turn the the motor. Immerse the starter for 30 seconds in o
drive shaft pinion (63) opposite the direction of the non-flammable, bubble-producing liquid. If the starter
starter rotation. The drive shaft pinion should turn by is properly sealed, no bobbles will appear.
hand.
6. Gear Case Seals: Plug the exhaust and slowly
Note: Inadvertent application of air pressure to the apply 20 psig (1.38 bar/138 kPa) pressure to the inlet
“OUT” port will result in drive malfunction (pinion will of the motor. Immerse the starter for 30 seconds in
fail to retract). If this condition occurs, loosen the drive o non-flammable, bubble-producing liquid.
housing cap screws (38) to vent gear case (28). Also,
loosen housing plugs (10) and (11) to vent motor. There should be no leakage in the housing joints
in the gear case area or in the shaft seal in the
3. Pinion Engagement: Apply 50 psig (3.4 intermediate gear system. If the starter is properly
bar/345 kPa) pressure to the engagement “IN” port. sealed, no bubbles will appear.
drive shaft pinion (63) should move outward and air
should escape from the “OUT” port. 7. Confirm Drive Rotation: Apply low pressure
to the motor and observe rotation. drive pinion (63)
Plug the “OUT” port and apply 150 psig (10.3 bar/1034 must rotate in the direction stamped on the nameplate.
kPa) pressure to the “IN” port. Check and make sure Chamfer on pinion teeth should be on the trailing
that no air is escaping. edge of the gear tooth.

Measure the dimension from the face of the drive


shaft pinion (63) to the face of the mounting flange.
It should be 69.0 +2.0 mm).
08028-0D/H5250/94.08.12

03.47 - ES0-G
MAN Diesel

Working Card 613-01.40


Page 1 (2) Main Starting Valve Edition 01H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Lubricating, disassembly and reassembly of main


starting valve in starting system. Hand tools:

Soft hammer.
Locking ring plier.
Allen key, 1/4".
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time : 1 Hour Plate no. Item no. Qty. /


Capacity : 1 man
61310 02 1/eng.
Data: 61310 03 1/eng.
61310 04 1/eng.
Data for pressure and tolerance (Page 600.35) 61310 07 1/eng.
Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

91.08 - ES0S-G
MAN Diesel

613-01.40 Working Card


Edition 01H Main Starting Valve Page 2 (2)

L+V28/32H
Warning: Disassembly:

Do not attempt any maintenance on the main start- 4) Clamp the main starting valve, in a vice with
ing valve before the starting air system has been the locking ring (9) end up.
bled off.
5) Carefully remove the locking ring (9). The end
plug (3) should spring out. If it does not, tap the valve
Important: housing (1) lightly with a soft hammer until it does.

The main starting valve should be periodically lub- 6) Remove the end plug (3), spring (8) and piston
ricated as follows: (2) assembly.

1) Blend off the air pressure. 7) Remove and discard all used o-rings, o-rings
retainer (5), bumper (7) and spring (8).
2) Remove the plug screw (A) , see fig. 1. and
squirt about 30 g of 10 w oil into the valve through 8) Wash all other parts in a clean, nonflammable
the plug opening. solvent.

3) Reinstall the plug.


Reassembly:

9) Using o-ring lubricant, lubricate and install the


new piston o-ring (4) and the new upper piston o-ring
B (6) on the piston (2).
6
Note: The upper piston o-ring (6) is slightly larger in
1
diameter than the end plug o-ring (11).
2 C
10) Turn the piston over and insert the new bumber
(7).
4

D 11)Using o-ring lubricant, lubricate and install the


7 5 new end plug seal o-ring (10) and the new end plug
8 o-ring (11) on the end plug (3).
11
A
12) Lubricate the lower small bore of the valve
9 housing (1) with o-ring lubricant.
10
3
13) Insert the piston assembly into the valve hou-
sing. Push on the piston until the piston o-ring seats
against the bevelied face.
08028-0D/H5250/94.08.12

A Plug screw B Pilot air


C Starting air outlet D Starting air inlet
14) Install the new o-ring retainer (5) with the large
1 Valve housing 2 Piston opening over the piston o-ring.
3 End plug 4 Piston o-ring
5 O-ring retainer 6 Piston o-ring
7 Bumper 8 Spring 15) Place the new piston spring (8) on the piston.
9 Retaining ring 10 O-ring
11 O-ring 16) Place the end plug assembly on the piston
spring.

17) Using a press to hold down the end plug as-


Fig. 1. Main starting valve.
sembly, install the end plug locking ring (9).

91.08 - ES0S-G
MAN Diesel

Working Card 613-01.90


Page 1 (2) Check of Compressed Air Piping System Edition 02H

L+V28/32H

Safety precautions: Special tools:

Stopped engine Plate no. Item no. Note.


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

Description:

Check of compressed oil piping system.


Hand tools:

Screwdriver.

Starting position:

Compressed air connected to the engine.

Related procedure:
08028-0D/H5250/94.08.12

Man power: Replacement and wearing parts:

Working time: ½ hour Plate no. Item no. Qty. /


Capacity : 1 man

Data:

Data for pressure and tolerance (Page 600.35)


Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)

94.21 - ES0U-G
MAN Diesel

613-01.90 Working Card


Edition 02H Check of Compressed Air Piping System Page 2 (2)

L+V28/32H
With air connected. With air disconnected and stopped engine.

1) Examine the piping system for leaks. 6) Move all valves and cocks in the piping system.
Lubricate valve spindles with graphite or similar.
2) Retighten all bolts and nuts in the piping system.
7) Connect the air supply and make a function test
3) Drain the system for condensed water. - This of the emergency valve. See description 613.01.
should be based on observations.

4) Check flexible connections for leaks and dama-


ges.

5) Check manometers.

08028-0D/H5250/94.08.12

94.21 - ES0U-G
MAN Diesel
Plate
Page 1 (3) Turbine Starter 61309-05H

L+V28/32H

96.26- ES0S-G
MAN Diesel
Plate
61309-05H Turbine Starter Page 2 (3)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

1 1/S Housing exhaust Hus for udstøds-dæk- 22 1/S Planet gear shaft. Planetgearaksel.
cover. sel.
23 2/S Gear shaft retainer Spænderingsskive for
2 1/S Exhaust cover seal. Tætningsring for ud- washer. gearaksel.
stødsdæksel.
24 1/S Rear gear frame Bagerste gearstelleje.
3 1/S Splash deflector. Stænk deflektor. bearing.

4 1/S Deflector return Returfjeder for de- 25 1/S Front bearing spa- Forreste gearstelleje.
spring. flektor. cer.

5 !/S Deflector retaining Spændeskive for 26 1/S Intermediate pinion. Mellemtandhjul.


screw. deflektor.
27 1/S Intermediate pinion Spændeskrue for mel-
6 4/S Starter assembly cap Dækselskrue for mon- retaining screw. lemtandhjul.
screw. tage af starter.
28 1/S Gear case. Gearkasse.
7 4/S Cap screw washer. Skive for dækselskrue.
29 1/S Drive gear. Drivgear.
8 1/S Motor housing. Motorhus.
30 1/S Front drive gear Forreste drivgearleje.
10 1/S Housing plug. Prop til motorhus. bearing.

11 1/S Housing plug inlet Tilgangsknast for prop 31 1/S Rear drive gear Bagerste drivgearleje.
boss. til motorhus. bearing.

12 1/S Motor assembly. Motor samling. 32 1/S Drive gear bearing Spændskrue for driv-
retainer. gearleje.
12A 2/S Cylinder o-ring seal. O-ringstætning for
cylinder. 33 1/S Drive gear shaft Spændskrue for driv-
bearing retainer. gearakselleje.
12B 2/S Housing o-ring seal. O-ringstætning for
motorhus. 34 1/S Drive gear screw. Drivgearskrue.

13 1/S Intermediate gear Mellem gearkasse. 35 1/S Drive gear lock Skive for drivgear.
case. washer.

14 1/S Rear gear case o- Bagerste gearkasse 36 1/S Drive gear cup. Dæksel for drivgear.
ring. o-ring.
37 1/S Drive gear screw O-ring for drivgear-
15 1/S Front gear case Forreste gearkasse o-ring. skrue.
o-ring. o-ring.
38 8/S Drive housing cap Dækselskrue for driv-
16 1/S Planet gear frame Tætningsring for pla- screw. gear.
shaft seal. netgearakselstel.
39 8/S Drive housing cap Skive for dækselskrue
16A 1/S Spacer ring. Afstandsring. screw lock washer. til drivgearhus.

17 1/S Front gear frame Forreste gearstelleje. 40 1/S Drive housing kit. Drivgearhus.
bearing.
41 1/S Drive housing o-ring O-ring for drivgearhus.
18 1/S Planet gear frame. Planetgearstel.
42 1/S Front shaft bearing. Forreste akselleje.
19 1/S Planet gear. Planetgear.
43 1/S Drive housing seal. Tætningsring for driv-
20 1/S Planet gear needle Nålevalse for planet- gearhus.
roller. gear.
44 1/S Drive housing vent Afluftningsprop for
21 1/S Bearing spacer. Ligemellemstykke. plug. drivgearhus.

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty.//E = Qty./Engine Qty./E = Qty./Motor
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter

96.26 - ES0S-G
MAN Diesel
Plate
Page 3 (3) Turbine Starter 61309-05H

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

45 1/S Bulkhead retainer. Skotholder 69A 2/E Turbine star- Turbinestar-


ter, complete. ter, komplet.
46 1/S Bulkhead kit. Skotsæt V28/32H. V28/32H.

47 1/S Outer bulkhead Ydre skot o-ring. 70 Spare parts Reservedels-


o-ring. kit, incl. item sæt incl. item
2, 12A, 12B, 2, 12A, 12B,
48 1/S Inner bulkhead o- Indre skot o-ring. 14, 15, 16, 14, 15, 16,
ring. 16A, 17, 21, 16A, 17, 21,
23, 24, 25, 41, 23, 24, 25, 41,
49 1/S Clutch spring cup Fjedertallerken holder. 45, 47, 48, 55, 45, 47, 48, 55,
retainer. 61 and 62 61 og 62.

50 1/S Clutch spring cup. Fjedertallerken.

51 1/S Clutch spring. Koblingsfjeder.

52 1/S Clutch jaw kit. Koblingssæt.

53 1/S Large drive shaft Stor lejespændering


bearing retainer. for drivaksel.

54 1/S Piston kit. Stempelsæt.

55 1/S Piston o-ring. Stempel o-ring.

57 1/S Drive shaft kit. Drivakselsæt.

58 1/S Rear drive shaft Bagerste drivakselleje.


bearing.

59 1/S Piston return spring. Stempel returfjeder.

60 1/S Seat. Sædering.

61 1/S Drive pinion retain- Tandhjulsspænde-


ing screw. skrue.

62 1/S Drive pinion washer. Tandhjulsskive.

63 1/S Drive pinion. Tandhjul. L28/32H.


L28/32H

63A 1/S Drive pinion. Tandhjul. V28/32H.


V28/32H

64 1/S Pinion spring sleeve. Tandhjulsbøsning.

65 1/S Pinion spring. Tandhjulsfjeder.

66 1/S Inlet flange kit. Tilgangsflangesæt.

67 3/S Cover Dæksel

68 1/S Self drilling screws Selvborende skruer

69 1/E Turbine starter, com- Turbinestarter, kom-


plete. L28/32H plet. L28/32H.

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter

96.26 - ES0S-G
MAN Diesel

Plate
Page 1 (2) Main Starting Valve 61310-03H

L+V28/32H

03*

01*

04* 02*
05
07*

08
06*

08.03 - ES0-G
MAN Diesel

Plate
61310-03H Main Starting Valve Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

01* 1/V O-ring O-ring

02* 1/V O-ring retainer O-ring holder

03* 1/V O-ring O-ring

04* 1/V Bumper Stødfanger

05 1/V Spring Fjeder

06* 1/V O-ring O-ring

07* 1/V O-ring O-ring

08 1/E Main starting valve, Hovedstartventil,


complete komplet

09 1/V Spare part kit Reservedelssæt


Item No. 01, 02, 03, Item nr. 01, 02, 03,
04, 06 and 07 04, 06 og 07

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./V = Qty./Valve Antal/V = Antal/Ventil

08.03 - ES0-G
MAN Diesel

Plate
Page 1 (2) Muffler 61312-02H

L+V28/32H

01

91.20 - ES0S-G
MAN Diesel

Plate
61312-02H Muffler Page 2 (2)

L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty Designation Benævnelse

01 1/S Muffler Dæmper

When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./S = Qty./Starting air motor Antal/S = Antal/Startemotor

91.20 - ES0S-G

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