Professional Documents
Culture Documents
Man B&W L1624 - Marine Diesel Engine
Man B&W L1624 - Marine Diesel Engine
GenSet Index
L16/24
Index GenSet
L16/24
Quality of lube oil (SAE40) for heavy fuel oil operation (HFO) Description 504.01-10
Quality of lube oil (SAE40) for operation on gas oil and diesel oil Description 504.01-11
(MGO/MDO) and biofuel
Lubricating points Description 504.05 (03)
Lubricating oil in base frame Description 504.06 (08H)
Specific lubricating oil consumption - SLOC Description 504.07 (03)
Quality of heavy fuel oil (HFO) Description 504.20-08
Quality of marine diesel fuel (MDO) Description 504.20-09
Quality of gas oil / diesel fuel (MGO) Description 504.20-10
Analysis data Description 504.27 (02)
Fuel oil cleaning Description 504.30 (01)
Fresh water system treatment Description 504.40 (02)
Camshaft 507/607
MAN Diesel
GenSet Index
L16/24
Operating gear for valves and fuel injection pumps Description 508.01 (02H)
Inspection of valve roller guide Working card 508-01.00 (03H)
Control of valve clearance Working card 508-01.10 (09H)
Safety valve adjustment Working card 508-01.10 (10H)
Roller guide and push rods Plate 50801-02H
Control/safety 509/609
Crankshaft 510/610
Index GenSet
L16/24
Turbocharger 512/612
GenSet Index
L16/24
Index GenSet
L16/24
Tools 520/620
500/600
MAN Diesel
Description
Page 1 (1) Warning A500
General
Warning !
08.16 - ES0
MAN Diesel
Description
Main Data for Engine 500.00
Page 1 (1) Edition 17H
L16/24
Cycle : 4-stroke
Configuration : In-line
Bore : 160 mm
Stroke : 240 mm
05.45 - ES1
MAN Diesel
Description
Introduction 500.01
Page 1 (1)
Edition 02
General
Description
This instruction book serves the purpose to provide Reliable and economical operation of the plant is
general information for operation and maintenance, conditional upon its correct operation and mainte-
and to describe the design. It can also be used as nance in accordance with MAN B&W Diesel A/S'
a reference when ordering spare parts. instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in MAN
B&W Diesel A/S' instructions and any additional
instructions to that effect included in the Technical
File. Consequently, it is essential that the engine
room personnel are fully acquainted with the con-
tents of this book and, in respect of instructions on
emissions related maintenance of the diesel engine,
also the additional instructions to that effect set out
Section 505-519
Spare parts plates in the Technical File.
03.36 - ES0
MAN Diesel
Description
Safety 500.02
Page 1 (2)
Edition 02
General
General Spares
Proper maintenance, which is the aim of this book, Large spare parts should, as far as possible, be placed
is a crucial aspect of achieving optimum safety in well strapped near the area of use and should be
the engine room. The general measures mentioned accessible by crane. The spare parts should be well-
here should, therefore, be a natural routine for the preserved against corrosion and protected against
entire engine room staff. mechanical damage. Stock should be checked at
intervals and replenished in time.
Cleanliness
Light
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the Ample working light should be permanently installed
engine room while the ship is in port, the ventilation at appropriate places in the engine room, and port-
should be stopped and ventilating ducts, skylights, able working light in explosion-proof fittings should
and doors in the engine room should be closed. be available everywhere.
Order
01.32 - ES0
MAN Diesel
General
Whenever repairs or alterations have been made After prolonged out-of-service periods or overhaul
to the running gear, apply the "feel-over sequence" work which may involve a risk of accumulation of liquid
until it is ensured that there is no undue heating, oil- in the combustion spaces, turning should always be
mist formation, blow-by, or failure of cooling water or effected through at least two complete revolutions.
lubricating oil systems.
08028-0D/H5250/94.08.12
01.32 - ES0
MAN Diesel
Description
Cross Section 500.05
Page 1 (1) Edition 05H
L16/24
08028-0D/H5250/94.08.12
99.40 - ES1
MAN Diesel
Description
Cross Section 500.05
Page 1 (1)
Edition 05H
L16/24
08028-0D/H5250/94.08.12
99.40 - ES1
MAN Diesel
Description 500.10
Page 1 (1) Key for Engine Designation Edition 02
General
The engine types of the MAN B&W programme are identified by the following figures:
6 L 28/32 H MCR
No of cylinders
5, 6, 7, 8, 9
12, 16, 18
Engine Type
L : In-line
V : V-built
Cyl. diam/stroke
16/24 : 160/240
21/31 : 210/310
23/30 : 225/300
27/38 : 270/380
28/32 : 280/320
32/40 : 320/400
Design Variant
08028-0D/H5250/94.08.12
Rating
04.08 - ES1
MAN Diesel
Description 500.11
Page 1 (1) Designation of Cylinders Edition 03
General
08028-0D/H5250/94.08.12
98.19 - ES1
MAN Diesel
Description 500.12
Page 1 (1) Engine Rotation Clockwise Edition 02
General
Engine
08028-0D/H5250/94.08.12
Alternator
98.18 - ES1
MAN Diesel
Description
Code Identification for Instruments 500.20
Page 1 (2) Edition 03
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
Measureing device
PT Sensor mounted on engine/unit
22 Reading/identification in a panel on the engine/unit and reading/indication outside
the engine/unit
Pressure Transmitting
No. 22 *
* Refer to standard location and text for instruments on the following pages.
04.36 - ES1
MAN Diesel
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
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
04.36 - ES1
MAN Diesel
Description
Introduction to Planned Maintenance Programme 500.24
Page 1 (2)
Edition 03
General
The overhaul intervals are based on operation on 1) Safety regulations, which MUST be carried out
a specified fuel oil quality at normal service output, before the maintenance work can start.
which means 70-100% of MCR.
2) A brief description of the work.
In the long run it is not possible to achieve safe and
optimum economical running without an effective 3) Reference to any work which must be carried
maintenance system. out before the maintenance work can start.
The structure and amount of information in the main- 4) Related procedures - indicates other works,
tenance programme mean that it can be integrated in depending on the present work - or works
the entire ship's/power station's maintenance system which it would be expedient to carry out.
or it can be used separately.
5) Indicates x number of men in x number of hours
The core of the maintenance system is the key dia- to accomplish the work.
gram, see pages 500.25 and 500.26, indicating the
inspection intervals for the components/systems, The stated consumption of hours is only intended
so that the crew can make the necessary overhauls as a guide.
based on the engines' condition and/or the time
criteria.
98.19 - ES0
MAN Diesel
500.24 Description
Edition 03
Introduction to Planned Maintenance Programme Page 2 (2)
General
Experience with the specific station/personnel may 8) Various requisite hand tools.
lead to updating.
9) Indicates the components/parts which it is
6) Refers to data required to carry out the work. advisible to replace during the maintenance
work. Please note that this is a condition for
7) Special tools which must be used. Please note the intervals stated.
that not all tools are standard equipment.
08028-0D/H5250/94.08.12
98.19 - ES0
MAN Diesel
Description 500.25
Page 1 (3) Planned Maintenance Programme Edition 08H
L16/24
Major overhaul/inspection
Time Between Overhauls
overhauled parts
Working
Observations
3rd month
Description ●
after - hours
= Overhaul to be carried out Card
Check new/
Monthly
Weekly
200
6000
12000
24000
50
2000
Daily
■ = Check the condition No
Cylinder Unit:
02.31 - ES0
MAN Diesel
500.25 Description
Edition 08H Planned Maintenance Programme Page 2 (3)
L16/24
Major overhaul/inspection
Time Between Overhauls
overhauled parts
Working
Observations
● = Overhaul to be carried out
3rd month
Description
after - hours
Card
Check new/
Monthly
Weekly
■
200
6000
12000
24000
50
2000
Daily
= Check the condition
No
Turbocharger System
02.31 - ES0
MAN Diesel
Description 500.25
Page 3 (3) Planned Maintenance Programme Edition 08H
L16/24
Major overhaul/inspection
Time Between Overhauls
overhauled parts
Working
Observations
● = Overhaul to be carried out
3rd month
Description
after - hours
Card
Check new/
Monthly
Weekly
■
200
6000
12000
24000
50
2000
Daily
= Check the condition
No
02.31 - ES0
MAN Diesel
Description 500.26
Page 1 (2) Planned Maintenance Programme Edition 12H
L16/24
Duties during Operation
Time Between Overhauls
overhauled parts
Working
Observations
●
3rd month
= Overhaul to be carried out
after - hours
Description
Check new/
Monthly
200
6000
12000
24000
Weekly
50
2000
Card
Daily
■ = Check the condition
No
Operating of Engine
Cylinder Head
Turbocharger System
07.12
MAN Diesel
500.26 Planned Maintenance Programme Description
Edition 12H Page 2 (2)
L16/24
Overhauled parts
Working
Observations
●
3th month
= Overhaul to be carried out
Description
Check new/
after -hours
50
2000
6000
200
24000
Weekly
12000
Card
Montly
Daily
■ = Check the condition
No
07.12
MAN Diesel
Description
Operation Data & Set Points 500.30
Page 1 (4) Edition 57
L16/24
Press. LT system, inlet engine PI 01 1.5-4.5 bar >1.8 bar PAL 01 0.4 + (B) bar 3
Press. HT system, inlet engine PI 10 1.5-4.0 bar >1.8-<6 bar PAL 10 0.4 + (B) bar 3
Temp. HT system, outlet engine TI 12 75-85°C <85° C TAH 12 90° C 3 TSH 12 95° C
TAH 12-2 93° C 3 (TSH 12) (100° C) (D)
Temp. LT system, inlet engine TI 01 10-45°C
Exhaust Gas and Charge Air
Press. inlet engine (start/stop) PI 70 7-10 bar >7.5-<10 bar PAL 70 6.5 bar 15
08.40 - ES1
MAN Diesel
L16/24
Engine speed elec. SI 90 1200 rpm SAH 81 1380 rpm 0 SSH 81 1356 rpm
(SSH 81) (1380 rpm) (D)
SI 90 1000 rpm SAH 81 1150 rpm 0 SSH 81 1130 rpm
(SSH 81) (1150 rpm) (D)
Turbocharger speed SI 89 (L) SAH 89 (J) 3
Alternator
For these alarms (with underscore) there are alarm cut-out at engine standstill.
08028-0D/H5250/94.08.12
08.40 - ES1
MAN Diesel
Description
Operation Data & Set Points 500.30
Page 3 (4) Edition 57
L16/24
A. Fuel Oil Pressure, HFO-operation The following signals are used for start interlock/
blocking:
When operating on HFO, the system pressure must
be sufficient to depress any tendency to gasification 1) Turning must not be engaged
of the hot fuel. 2) Engine must not be running
3) "Remote" must be activated
The system pressure has to be adjusted according 4) No shutdowns must be activated.
to the fuel oil preheating temperature. 5) The prelub. oil pressure must be OK, 20 min.
after stop.
B. Cooling Water Pressure, Alarm Set Points 6) "Stop" signal must not be activated
The read outs of lub. oil pressure has an offset H. Alarm Hysterese
adjustment because of the transmitter placement.
This has to be taken into account in case of test and On all alarm points (except prelub. oil pressure) a
calibration of the transmitter. hysterese of 0.5% of full scale are present. On prelub.
oil pressure alarm the hysterese is 0.2%.
D. Software Created Signal
I. Engine Run Signal
Software created signal from PI 22, TI 12, SI 90.
The engine run signal is activated when engine
E. Set Points depending on Fuel Temperature rpm >1130 or lube oil pressure >3.0 bar or TC rpm
>5000 rpm.
If engine rpm is above 210 rpm but below 1130
rpm within 30 sec. the engine run signal will be
activated.
(SAH 89)
08.40 - ES1
MAN Diesel
L16/24
The exhaust gas temperature deviation alarm is Normal value at full load of the turbocharger is de-
normally ±50° C with a delay of 1 min., but at start- pendent on engine type (cyl. no) and engine rpm.
up the delay is 5 min. Furthermore the deviation The value given is just a guide line. Actual values
limit is ±100° C if the average temperature is below can be found in the acceptance test protocol.
200° C.
08028-0D/H5250/94.08.12
08.40 - ES1
MAN Diesel
Description
"Green Passport" 500.33
Page 1 (1) Edition 01
General
List of potentially hazardous materials of MAN four-
stroke diesel engines that are relevant to be delivered
to recycling facilities according to IMO resolution
A.962(23) Adopted on 5 december 2003.
Asbestos
Type of asbestos Materials Location Approximate quantity/volume
- - None
Plastic Materials
Type Location Approximate quantity/volume
Copolymer, based on acrylnitrile and O-rings (Inside engine) *)
butadiene: NBR
Copolymer, based on vinylidene-fluoride O-rings (Inside engine) *)
and hexafluoro-propene: FPM
FPI 155, Flame retardant according to Cable jacket < 100 m
IEC 332-3 cat. 3
Chemicals in engine
Type Location Approximate quantity/volume
Anti-seize Compounds Used on high temperature screws *)
Engine Additives None
Water Treatment: Nitrite-borate inhibitor Fresh water system See instruction manual
*) The component is most likely bound in an alloy or present at a very low concentration
1
) only valid for GenSets
2
) only valid for Propulsion engines
07.36 - ES0
MAN Diesel
Description
Data for Pressure and Tolerance 500.35
Page 1 (1)
Edition 30H
L16/24
c) Minimum height of valve head, inlet valve and exhaust valve, "H" 1 5.0 mm
d) Maximum height of spindle above cylinder head, "H" 2 66.5 mm
506 a) Piston and piston ring grooves (see working card 506-01.10)
509 a) Free spand between pick-up and band steel (Lambda controller) 1 mm
08.17 - ES0
MAN Diesel
Description 500.40
Page 1 (8) Data for Tightening Torque Edition 24H
L16/24
Lubricant
XX Screw in with Loctite 243 until it Re-tightening procedure for hydraulic tool:
sits squarely 1) Pressurize the hydraulic tool to specified
hydraulic pressure.
° Angle when slackening
2) Check if nut is loose. If loose, then tighten.
L Number of holes by which the 3) De-pressurize the hydraulic tool.
nut must be turned back
Tab. 1.
012-1
Cap main bearing / 1200 HAND/hand-M M 510-01.05
Cylinder crankcase Loctite 243
012-2
Cap main bearing / 200 HAND/hand-M MH 510-01.05
Cylinder crankcase 1200 HAND/hand-M MH 510-01.05
012-3
Crankcase / 1200 MH 505-01-55
Cylinder head
012-4
Crankcase / Baseframe 340
020 Crankshaft
020-1
08028-0D/H5250/94.08.12
020-2
Gear wheel 100-M
(two parts)
020-3
Gear wheel / 100-M
Crankshaft
08.20 - ES0
MAN Diesel
500.40 Description
Edition 24H Data for Tightening Torque Page 2 (8)
L16/24
027-1
Gear wheel / Damper 1. step 210-O 510-04.00
2. step +60°
027-2
Side / Disc 55-O
030-1
Connecting rod shaft / Con- 1200 M 506-01.25
necting rod cover 506-01.15
506-01.30
034 Piston
034-1
Piston 506-01.10
08028-0D/H5250/94.08.12
034-2
Piston 506-01.10
08.20 - ES0
MAN Diesel
Description 500.40
Page 3 (8) Data for Tightening Torque Edition 24H
L16/24
056-1
Clamp / Cylinder head 6-O 32-O 514-01.10
073-1
Crankcase covers / 8-M 511-01.00
Cylinder crankcase
100-1
Cylinder crankcase / 1200 HAND/hand-M 507-01.20
Stepped spur gear
101-1
Camshaft part piece / 55-M 507-01.00
08028-0D/H5250/94.08.12
Bearing disk
101-2
Bearing plate / Housing 55-M 507-01.00
507-01.05
101-3
Damper (9 cyl.) / Gear wheel 55-M 507-01.00
507-01.05
101-4
Spur gear / Bearing disk 55-M 507-01.05
08.20 - ES0
MAN Diesel
500.40 Description
Edition 24H Data for Tightening Torque Page 4 (8)
L16/24
101-5
Camshaft part piece / 55-M 507-01.00
Bearing disk
Spur wheel / Bearing disk 507-01.05
101-6
Bearing plate / Housing 55-M 507-01.00
507-01.05
101-7
Damper (9L) / Gear wheel 55-M 507-01.00
507-01.05
111-1
Valve bridge / Settting screws 40-M
111-2
Rocker arm / Setting screws 40-M
112 Tappet
112-1
Housing / Axle 8-M 505-01.05
200-1
Connection socket / 4-MH 39-MH 514-01.06
Front-end box Loctite 638
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
Description 500.40
Page 5 (8)
Data for Tightening Torque Edition 24H
L16/24
200-2
Plugs on the side of the fuel
injection pump:
Woodward 45 M
L'Orange 100-120 M 514-01.90
289-1
Pipe piece / Compensator 80-MH
289-2
Clamping strap 34-MH 505-01.55
289-3
Cover / Pipe piece 80-MH
289-4
Pipe piece / Turbocharger 34-MH
289-5
Pipe piece 80-MH
311 Casing
311-1
Oil separator (closing cover)
/ Housing 7-MH 68-MH
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
500.40 Description
Edition 24H Data for Tightening Torque Page 6 (8)
L16/24
350-1 350-2
Water pump shaft/spur gear 80-O 350-1
350-2
Water pump shaft/impeller 40-O
434-1
2 clamps / Cylinder head 4-MH 28-MH 514-01.05
434-2
3 clamps / Cylinder head
434-1
434-2
447-1
Flange / Bearing 4-MH 39-MH 505-01.55
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
Description 500.40
Page 7 (8) Data for Tightening Torque Edition 24H
L16/24
701-2
Crankshaft / Flywheel 1.step 150-MH
2. step +90°
08.20 - ES0
MAN Diesel
500.40 Description
Edition 24H Data for Tightening Torque Page 8 (8)
L16/24
Tightening of Screwed Connections by the
Strength class 5.6 6.8 10.9 12.9
Torque
Conversion factor x 0.47 0.75 1.40 1.7
If screwed connections other than those listed are
to be tightened using a torque wrench, see tab. 3,
Tab. 2. Conversion factors for tightening torques as a function of
should be looked up for approximate tightening the bolt strength class.
torques. The following should be observed:
M5 4 6 M 24 475 690
M6 7 10 M 24 x2 500 750
m8 17 25 M 27 700 1020
M 10 34 50 M 27x2 730 1100
M 12 60 85 M 30 950 1380
M 14 95 135 M 30x2 1015 1540
M 14x1.5 100 145 M33 1270 1870
M 16 140 205 M 33x2 1350 2060
M 16x1.5 150 220 M 36 1640 2400
M 18 200 280 M 36x3 1710 2550
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
Description
Declaration of Weight 500.45
Page 1 (1) Edition 06H
L16/24
08.05 - ES0
MAN Diesel
Description
Ordering of Spare Parts 500.50
Page 1 (2)
Edition 02
General
When spare parts are ordered (or referred to in These data are necessary to ensure supply of the
correspondence, etc.) the following data must be correct spare parts for a particular engine, even
indicated for the engine concerned: though the spare part illustrations contained in this
book may not always be in complete accordance with
• Name of customer/ship the individual components of a specific engine.
• IMO number
• Engine Type Note: For ordering of spare parts for governor, turbo-
• Engine no charger and alternator, please see the special chapter
• Built by in the instruction book for these components.
• Plate number
• Item no
• Description
• Qty.
Pla
Page te
1 (2)
Piston
and Conn
ecting
Rod
60601-
13H
L/V28/
08
32H
09
10
11
12
01
02
03
04
05
7
60
8
60
9
60
06
0
61
611
08028-0D/H5250/94.08.12
13
2
61
07
3
61
4
91.4
61
6 - ES
0S
14
5
61
6
61
7
61
8
61
9
61
0
62
07.04
MAN Diesel
Description
Ordering of Spare Parts 500.50
Page 2 (2)
Edition 02
General
07.04
MAN Diesel
Description
Service Letters 500.55
Page 1 (1)
Edition 01
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.
97.40 - ES0
MAN Diesel
Description
Conversion Table 500.60
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
Area (m2)
04.37 - ES0
MAN Diesel
General
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)
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
04.37 - ES0
MAN Diesel
Description
Conversion Table 500.60
Page 3 (3) Edition 01
General
Volume (1 m3 = 1000 l)
Mass (kg)
Pressure
(1 N/m2 = 1 Pa, 1 bar = 105 Pa, 1 mbar = 10-3 bar)
* Mercury. 1 mm Hg = 1 Torr
Values in table provided gn = 9.80665 m/s2
** Water column (WC)
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
04.37 - ES0
MAN Diesel
Description
Page 1 (3) Basic Symbols for Piping 500.65
Edition 01
General
1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint
1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere
2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight
05.02 - ES0
MAN Diesel
General
3.19 Suction valve chest with non-return valves 4.2 Remote control
3.27 Cock with bottom connection 4.10 Manual (at pneumatic valves)
3.28 Cock, straight through, with bottom conn. 4.11 Push button
3.35 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
05.02 - ES0
MAN Diesel
Description
Basic Symbols for Piping 500.65
Page 3 (3) Edition 01
General
05.02 - ES0
Operation of engine
501/601
MAN Diesel
Description
Operation 501.01
Page 1 (3)
Edition 03H
L16/24
Preparations for Starting 4) Check pre. lub. oil pressure at inlet to filter, inlet
of the engine and inlet turbocharger on the
The following describes what to do before starting monitoring box display according to the data
when the engine has been out of service for a period and setpoints sheet.
of time.
2) Check the oil level in the governor, see Fig. 2, Note: To avoid shock effects owing to large tem-
with the level indicator on the governor. perature fluctuations just after start, it is recom-
mended:
3) Start up the prelubricating pump.
a) to preheat the engine. Cooling water at least
Note: The engine must be prelubricated for at least 60°C should be circulated through the frame
30 minutes prior to start-up (at the first starting-up, or and cylinder head for at least 2 hours before
if the engine is cold, the engine must be prelubricated start:
for at least 60 minutes)
or - by means of cooling water from engines which
check that there is oil coming out at bearings, pistons are running or by means of a preheater (if
and rocker arms. installed).
08028-0D/H5250/94.08.12
02.49 - ES0
MAN Diesel
501.01 Description
Edition 03H
Operation Page 2 (3)
L16/24
b) When starting without preheated cooling
water, the engine may only be started on MDO
(Marine Diesel Oil).
HFO System
13) Start the engine by activating the start button 19) Check that all cylinders are firing, see exhaust
on the operation box; push the button until the gas temperatures.
engine ignites, see Fig. 3.
Note: Check the stop cylinder (Lambda controller) for
regulating the shaft works properly, both when stop-
Testing during Running ping normally and at overspeed and shut down.
02.49 - ES0
MAN Diesel
Description
Operation 501.01
Page 3 (3)
Edition 03H
L16/24
Check that all shutdowns are connected and func- 29) To ensure full operational reliability, the con-
tion satisfactory. dition of the engine should be continuously
observed so that order for preventive mainte-
20) Test the overspeed, see Working Card nance work can be carried out before serious
509-01.05. breakdowns occur, see also section 502.
23) The lubricating oil temperature must be kept Before starting on HFO the engine must be properly
within the stated limits indicated on the data preheated as described in "Preparations for Starting"
and setpoints sheet. and as described below.
24) The fuel oil pressure must be kept at the stated Stopping the engine on HFO is no problem, but it
value. should be ensured that the temperature of fuel pipes
is not reduced to a level below the pour point of the
25) The cylinder cooling water temperature must fuel. Otherwise reestablishing the circulation might
be kept within the limits indicated on the data cause problems.
and setpoints sheet.
08028-0D/H5250/94.08.12
02.49 - ES0
MAN Diesel
Description
Operation 501.01
Page 1 (4)
Edition 08
L16/24 L27/38
V28/32S L21/31
Preparations for Starting V28/32S
The following describes what to do before starting Note: The engine must be prelubricated for at least
when the engine has been out of service for a period 5 minutes prior to start-up
of time. or
check that there is oil coming out at bearings, pistons
and rocker arms.
Lubricating Oil System
1) Check the oil level in the base frame with the L16/24, L27/38, L21/31
dipstick.
Note: The engine must be prelubricated for at least
2) Check the oil level in the governor, see Fig 2, 30 minutes prior to start-up (at the first starting-up, or
with the level indicator on the governor. if the engine is cold, the engine must be prelubricated
for at least 60 minutes)
3) Start up the prelubricating pump. or
check that there is oil coming out at bearings, pistons
and rocker arms.
Synch. motor
Manuel
raise/lower speed
Droop
setting
Manuel
Oil level
emergency
stop
08028-0D/H5250/94.08.12
Compensation
02.49 - ES0
MAN Diesel
501.01 Description
Edition 08
Operation Page 2 (4)
L16/24 L27/38
V28/32S L21/31
4) Check prelubricating oil pressure at inlet to
filter, inlet of the engine and inlet turbocharger
on the monitoring box display according to the
data and setpoints sheet.
7) Open the fuel oil supply. 10) Drain the starting air system.
Starting on HFO: circulate preheated fuel through the 11) Open the starting air supply.
08028-0D/H5250/94.08.12
- that all fuel injection pumps are set at index Turning of Engine (not valid for L16/24
"0" when the regulating shaft is in STOP posi- engine)
tion.
13) Open the indicator valves and turn the engine
- that each fuel injection pump can be pressed some few revolutions, check that no liquid is
by hand to full index when the regulating shaft flowing out from any indicator valves during
are in STOP position, and that the pumps return the turning.
automatically to the "0" index when the hand
is removed.
02.49 - ES0
MAN Diesel
Description
Operation 501.01
Page 3 (4)
Edition 08
L16/24 L27/38
V28/32S L21/31
14) Slow turning must always be carried out, be- 23) Test the overspeed, see Working Card
fore the engine is started after prolonged out 509-01.05.
of-service-periods and after overhauls, which
may involve a risk of liquid having collected in 24) Check that all alarms are connected.
the cylinders.
21) Check that the prelubricating oil pump stops sea trials.
automatically.
30) Keep the charging air pressure and tempera-
22) Check that all cylinders are firing, see exhaust ture under control. For normal values, see the
gas temperatures. test report from shop and sea trials.
Note: Check the stop cylinder (Lambda controller) for 31) Recharge the starting air receivers to the de-
regulating the shaft works properly, both when stop- scribed value.
ping normally and at overspeed and shut down.
32) To ensure full operational reliability, the con-
Check that all shutdowns are connected and func- dition of the engine should be continuously
tion satisfactory. observed so that order for preventive mainte-
nance work can be carried out before serious
breakdowns occur, see also section 502.
02.49 - ES0
MAN Diesel
501.01 Description
Edition 08
Operation Page 4 (4)
L16/24 L27/38
V28/32S L21/31
Stopping Before starting on HFO the engine must be properly
preheated as described in "Preparations for Starting"
33) Before stopping, it is recommended to run the and as described below.
engine at reduced load, max. 2 min.
Stopping the engine on HFO is no problem, but it
34) The engine is stopped by activating the stop should be ensured that the temperature of fuel pipes
button on the operating box. Please note that is not reduced to a level below the pour point of the
the push button must be activated at least 3 fuel. Otherwise reestablishing the circulation might
sec. before stop will be activated. cause problems.
Starting and stopping of the engine should take Initial ignition may be difficult if the engine and ambient
place on HFO in order to prevent any incompatibility temperatures are lower than 5°C and 15°C cooling
problems on changeover to MDO. water temperature.
08028-0D/H5250/94.08.12
02.49 - ES0
MAN Diesel
Description
Operation 501.01
Page 1 (4)
Edition 14
L16/24 L27/38
V28/32S L21/31
Preparations for Starting L16/24, L27/38, L21/31
The following describes what to do before starting Note: The engine must be prelubricated for at least
when the engine has been out of service for a period 30 minutes prior to start-up (at the first starting-up, or
of time. if the engine is cold, the engine must be prelubricated
for at least 60 minutes)
or
Lubricating Oil System check that there is oil coming out at bearings, pistons
and rocker arms.
1) Check the oil level in the base frame with the
dipstick.
4) Check prelubricating oil pressure at inlet to
2) Check the oil level in the governor, see Fig 2, filter, inlet of the engine and inlet turbocharger
with the level indicator on the governor. on the monitoring box display according to the
data and setpoints sheet.
3) Start up the prelubricating pump.
Filler cup
Oil level
UG-Actuator
08028-0D/H5250/94.08.12
06.19 - ES0
MAN Diesel
501.01 Description
Edition 14
Operation Page 2 (4)
L16/24 L27/38
V28/32S L21/31
Note: To avoid shock effects owing to large tem-
perature fluctuations just after start, it is recom-
mended:
HFO System
10) Drain the starting air system. 15) Close the indicator valves.
06.19 - ES0
MAN Diesel
Description
Operation 501.01
Page 3 (4)
Edition 14
L16/24 L27/38
V28/32S L21/31
Starting Operation
16) Start the engine by activating the start button The engine should not be run up to more than 50%
on the operation box; push the button until the load to begin with, and the increase to 100% should
engine ignites, see Fig 3. take place gradually over 5 to 10 minutes.
Note: If the engine have been without prelubrica- Note: When the engine is running the planned
tion for more than 20 min. it will not be possible maintenance programme and the following should
to start the engine (either remote or local). be checked:
The only possibility in this case is to activate
the emergency start, located directly on the 25) The lubricating oil pressure must be within the
starter. stated limits and may not fall below the stated
minimum pressure. The paper filter cartridges
must be replaced before the pressure drop
Testing during Running across the filter reaches the stated maximum
value, or the pressure after the filter has fallen
See Description 509.05 before operating the control below the stated minimum value. Dirty filter
panel. cartridges cannot be cleaned for re-use.
Check the following on the monitoring box according 26) The lubricating oil temperature must be kept
to the data and setpoints sheet. within the stated limits indicated on the data
and setpoints sheet.
17) Check the lubricating oil pressure.
27) The fuel oil pressure must be kept at the stated
18) Check the cooling water pressure. value.
19) Check the fuel oil feed pressure. 28) The cylinder cooling water temperature must
be kept within the limits indicated on the data
20) Check that the turbocharger is running. and setpoints sheet.
21) Check that the prelubricating oil pump stops 29) The exhaust gases should be free of visible
automatically. smoke at all loads. For normal exhaust tem-
peratures, see the test report from shop and
22) Check that all cylinders are firing, see exhaust sea trials.
gas temperatures.
30) Keep the charging air pressure and tempera-
Note: Check the stop cylinder (Lambda controller) for ture under control. For normal values, see the
regulating the shaft works properly, both when stop- test report from shop and sea trials.
08028-0D/H5250/94.08.12
06.19 - ES0
MAN Diesel
501.01 Description
Edition 14
Operation Page 4 (4)
L16/24 L27/38
V28/32S L21/31
Stopping Before starting on HFO the engine must be properly
preheated as described in "Preparations for Starting"
33) Before stopping, it is recommended to run the and as described below.
engine at reduced load, max. 2 min.
Stopping the engine on HFO is no problem, but it
34) The engine is stopped by activating the stop should be ensured that the temperature of fuel pipes
button on the operating box. Please note that is not reduced to a level below the pour point of the
the push button must be activated at least 3 fuel. Otherwise reestablishing the circulation might
sec. before stop will be activated. cause problems.
Starting and stopping of the engine should take For starting on MDO there are no restrictions except
place on HFO in order to prevent any incompatibility that lubricating oil viscosity may not be higher than
problems on changeover to MDO. 1500 cSt (10°C SAE 40).
MDO should only be used in connection with mainte- Initial ignition may be difficult if the engine and ambient
nance work on the engine or before a longer period temperatures are lower than 5°C and 15°C cooling
of engine standstill. water temperature.
08028-0D/H5250/94.08.12
06.19 - ES0
MAN Diesel
Description
Out of Service 501.05
Page 1 (2)
Edition 05
L16/24 L27/38
V28/32S L21/31
Stand-by Mode 3) A lubricating oil sample should be sent to a
laboratory for immediate analysis.
During engine standstill in stand-by position the me-
dia cooling water and fuel oil should be continuously 4) The installed drain fasilities in the exhaust gas
circulated at temperatures similar to the operating system must be open.
conditions.
The prelubricating pump must always run in stand- Work during Repairs
by mode.
The following should be carried out during major
repairs.
Maintenance during Standstill
5) Retighten all bolts and nuts in the crankcase.
In periods during standstill of the engine (not in
stand-by position) it is recommended to start the 6) Check the various gearwheel drives for the
prelubricating oil pump for minimum 20 minutes camshafts.
once every week and to turn the engine during the
prelubricating period by 2-3 revolutions. 7) Remedy leakages of water and oil in the engine,
and blow through blocked-up drain pipes.
During the lay-up period we recommend that our 9) Empty the oil sump of lubricating oil and check
special instructions for preservation of the engines the bottom of the oil sump for fragments of
are followed. babbitt from bearings. Remove the sludge, if
not done within a period of one year. Clean the
sump very thoroughly and subsequently coat
Work before Major Repairs with clean lubricating oil.
After overhaul of pistons, bearings, etc. this check The differential pressure across the lubricating oil
should be repeated before starting the engine. filter must be watched very carefully after cleaning
and star ting-up the engine. Be sure to replace filter
2) Open up all filters to check that filter elements cartridges in due time.
are intact. Filter cartridges in the lub. oil filter
are to be replaced before start, after repair, 11) After restoring normal prelubricating oil circula-
or after excessive differential pressure. After tion, turn the engine at least two revolutions
removal, dirty elements can be examined for by means of the turning device to check the
particles of bearing metal at the bottom of the movability of the relevant parts of the engine.
paper lamella (the elements cannot be used
again). 12) Close drain cocks in the exhaust gas system
if mounted.
02.47 - ES0
MAN Diesel
501.05 Description
Edition 05
Out of Service Page 2 (2)
L16/24 L27/38
V28/32S L21/31
Lubrication of Manoeuvering Gear b) Adjustment speed: switch in the alternator
on the switchboard and set the load to about
13) Lubricate the bearings and rod connections 40%. On reaching normal oil temperatures in
in the manoeuvering gear. Move the rod con- governor and engine increase the load instantly
nections by hand to check that the friction in to about 80% (by starting a major pump or
bearings and fuel injection pumps is sufficiently compressor).This must not cause the frequency
low. to fall by more than some 8%, and the engine
must return to a constant no. rpm after about 3
14) Checks to be made just before starting the seconds (although this rpm will be a little lower
engine are described under 501.01. than before owing to the speed drop of the
governor). If the engine is operated in parallel
with other engines, an even sharing of the load
Check of Governor must be established within about 3 seconds.
If the governor reacts too slowly, compensat-
Note: At starting-up after an overhaul the overspeed ing adjustment is effected as indicated in the
shutdown must be testet at correct setpoint after the governor's instruction manual (Compensating
following has been done: Adjustment).
a) Start the engine and keep it at no load. Note: It is a condition for this test that the engine
and turbocharger are in perfect operating condition,
b) Turn the speed setting on governor until the so that possible sources of error can be eliminated
overspeed is released. Check that it is released immediately.
at correct rpm according to "Operation data
& set points", 500.30 and working card 509- c) Hunting: run the engine at synchronous rpm,
01.05. and without load. Provided that the governor oil
is warm, the regulating lever must not perform
Note: If both overspeed shutdown (SSH 81) are ac- any major periodical movements, and neither
tivated, nuts and bolts have to be retightened before must there be any variation in the engine speed.
the engine is started, (Nuts and bolts according to the If that is the case, repeat the compensating
colomn "Check new/overhauled parts after - hours" adjustment according to the governor's instruc-
in the planned maintenance program). tion manual.
15) Check the governor as follows: start up the d) Speed drop: in case of unsatisfactory load
engine and run it at the synchronous number sharing between two or more engines this can
of revolutions. be rectified by increasing the speed drop of the
engine that is subject to the greatest load (or
a) Speed-setting: before switching-in the alterna- by reducing the setting of the other engines).
tor on the switchboard please check that the
The setting should normally not be increased be-
08028-0D/H5250/94.08.12
Woodward Europa
Max. 70 100
Normal range 45-60 70-90
Default 52 80
02.47 - ES0
MAN Diesel
Description
Starting-up after Repair 501.10
Page 1 (1)
Edition 03
General
The following enumerated checks are to be made im- feel-over on the surfaces of all moving parts where
mediately after starting and during load increase. friction may arise and cause undue heating.
Note: In the following it is assumed that the engine has Feel: main bearings, big-end bearings, alternator
been out of service for some time due to repairs and bearings, and camshaft bearings, cylinder liners,
that checks during out of service periods have been roller guides and gear wheels.
carried out as described in the previous chapter.
After the last feel-over, repeat check 1) on page
When starting up after repair, the following checks 501.05, see also "Ignition in Crankcase" on page
must be made, in the order stated in addition to 503.04 in section 503.
normal surveillance and recording.
After repair or renewal of cylinder liners, piston rings
or bearings, allowance must be made for a running-
To be Checked Immediately after Starting in period, i.e. the engine load should be increased
gradually as indicated in the tables below.The engine
1) Check that the turbocharger is running. output is determined on the basis of the fuel index
and the load on the electric switchboard. The turbo-
2) Check that the lubricating oil pressure is in charger speed gives some indication of the engine
order. output, but is not directly proportional to the output
throughout the service period.
3) Check that all cylinders are firing (see exhaust
temperatures). Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for cer-
4) Check that everyting is normal for the engine tain that there are no hot spots in the engine. Then
speed, fuel oil, cooling water and system oil. increase the speed to the normal rpm and connect
to the switchboard and put on load.
5) Check by simulation of the overspeed shutdown
device that the engine stops, see working card The load increase during the starting-up sequence
509-01.05. may, for instance, be:
known, especially after repairs or alterations, After completing the starting-up sequence, make
the "feel-over sequence" should always be sure that all fuel injection pumps are set at the same
followed, i.e.: index and that the governor can cause all fuel pumps
to move to "0" index.
After 5-15 and 30 minutes' idle running, open the
crankcase and the camshaft housing and perform
02.40 - ES0
MAN Diesel
Description
Guidelines for Longterm Low-Load Operation on HFO 501.15
Page 1 (1) Edition 03
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
Admissible low-load operation Necessary operating period
(load percent/period) on HFO. with min. 70% load after low-
load operation on HFO.
a b 70% load
10 HFO or MDO
08028-0D\H5250\94.08.12
5
a b
08.20 - ES1
MAN Diesel
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
plications. This guideline covers the engine related cause problems, but please notice the following
aspects of the use of such fuels. restrictions:
Low sulphur HFO In order to avoid seizure of the fuel oil injection
pump components the viscosity at engine fuel oil
From an engine manufacturer’s point of view there inlet must be > 1.5 cSt (except for L32/40 - required
is no lower limit for the sulphur content of HFO. We viscosity at engine fuel oil inlet > 2.0 cSt). In order
have not experienced any trouble with the currently achieve this it may be necessary to install a fuel oil
available low sulphur HFO, that are related to the cooler, when the engine is running on MGO. This is
sulphur content or specific to low sulphur HFO. This both to ensure correct viscosity and avoid heating
may change in the future if new methods are applied up the service tank, which is important as the fuel
for the production of low sulphur HFO (desulphuriza- oil injection pumps are cooled by the fuel.
tion, uncommon blending components). MAN Diesel
will monitor developments and inform our customers When operating on MDO/MGO a larger leak oil
if necessary. amount from fuel oil injection pumps and fuel oil
injection valves can be expected compared to op-
If the engine is not operated permanently on low eration on HFO.
sulphur HFO, then the lubricating oil should be se-
lected according to the highest sulphur content of In order to carry out a quick change between HFO
the fuels in operation. and MDO/MGO the change over should be carried
out by means of the valve V1-V2 installed in front
of the engine.
07.12 - ES1
Performance and
condition
502/602
MAN Diesel
Description
Engine Performance and Condition 502.01
Page 1 (3) Edition 04H
L16/24
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 of gas temperature.
deposits, wear, corrosion, etc. If continuously record-
ed, these changes in the condition can give valuable Reduction of the charge air pressure results in
information about the operational and maintenance a corresponding reduction of the compression
condition of the engine. Continuous observation can pressure and max. combustion pressure.
contribute to forming a precise and valuable basis for
evaluation of the optimum operation and maintenance
programmes for the individual plant. Fuel Injection Pump
98.48 - ES0
MAN Diesel
502.01 Engine Performance and Condition Description
Edition 04H Page 2 (3)
L16/24
Fouling of the turbine side of the turbocharger will, The overhaul intervals for exhaust valves is one of
in its first phase, manifest itself in increasing turbo- the key parameters when the reliability of the entire
charger revolutions on account of increased gas engine is to be judged. The performance of the ex-
velocity through the narrowed nozzle ring area. In haust valves is therefore extremely informative.
the long run, the charging air quantity will decrease
on account of the greater flow resistance through the Especially under unfavourable conditions, fuel quali-
nozzle ring, resulting in higher wall temperatures in ties with a high vanadium and sodium content will
the combustion chambers. promote burning of the valve seats. Combinations of
vanadium and sodium oxides with a corrosive effect
Service experience has shown that the turbine side will be formed during combustion. This adhesive ash
is exposed to increased fouling when operating on may, especially in the event of increased valve tem-
HFO. peratures, form deposits on the seats. An increasing
sodium content will reduce the melting point and
The rate of fouling and thereby the influence on thereby the adhesive temperature of the ash, which
the operation of the engine is greatest for small will involve a greater risk of deposits. This condition
turbochargers where the flow openings between the will be especially unfavourable when the na weight
va
guide vanes of the nozzle ring are relatively small. ratio increases beyond 1:3.
Deposits occur especially on the guide vanes of the
nozzle ring and on the rotor blades. In the long run, The exhaust valve temperature depends on the actual
fouling will reduce the efficiency of the turbocharger maintenance condition and the load of the engine.
and thereby also the quantity of air supplied for the With correct maintenance, the valve temperature is
combustion of the engine. A reduced quantity of air kept at a satisfactory low level at all loads. The air
will result in higher wall temperatures in the combus- supply to the engine (turbocharger/air cooler) and the
tion spaces of the engine. maximum pressure adjustment are key parameters
in this connection.
If, for any reason, the surface temperature of the fuel Air Inlet Valves
valve nozzle is lower than the condensation tempera-
ture of sulphuric acid, sulphuric acid condensate The operational conditions of the air inlet valves are
can form and corrosion take place (cold corrosion). not altered substantially when using residual fuel.
08028-0D/H5250/94.08.12
98.48 - ES0
MAN Diesel
Description 502.01
Page 3 (3) Engine Performance and Condition Edition 04H
L16/24
The occurrence of increasing abrasive wear of plunger The fresh air supply (ventilation) to the engine room
and barrel can be a consequence of insufficient should correspond to approximately 1.5 times the
purification of the fuel oil, especially if a fuel which air consumption of the engines and possible boilers
contains residues from catalytic cracking is used. in operation. Sub-pressure in the engine room will
Water in the fuel oil increases the risk of cavitation in involve an increased exhaust temperature level.
connection with pressure impulses occurring at the
fuel injection pump cut-off. A fuel with a high asphalt The exhaust back-pressure measured after the tur-
content has deteriorating lubricating properties and bochargers at full load must not exceed 250-300 mm
can, in extreme cases, result in sticking of the fuel water column. An increase in the exhaust back-pres-
injection pump plungers. sure will also cause an increased exhaust valve tem-
perature level, and increased fuel comsumption.
98.48 - ES0
MAN Diesel
General
PRESSURE DROP
INCREASING
(limit 50%)
Air filters
fouled.
PRESSURE DROP
INCREASING
(limit 50%)
Air side of
cooler fouled.
ALL CYLINDERS
Exhaust temp. increasing:
TEMP. DIFFERENCE
Air system fouled
TOO LARGE
(Air filter-blower-cooler).
Water flow too small
Exhaust system fouled
(nozzle ring, turbine wheel).
TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.
See also:
Engine Performance
and Condition 502.01
98.19 - ES0
MAN Diesel
Description
Condensate Amount 502.05
Page 1 (2) Edition 03
General
the diagram. The ability to absorb water depends on the diagram can be used.
the pressure and temperature of the air.
Example:
04.31 - ES2
MAN Diesel
General
As a guidance, an air consumption of 8.2 kg/kWh (Le) Amount of Condensate Water in Air Tanks
at full load can be used for MAN B&W engines.
The volume of condensate in the air tank is determi-
Solution according to diagram: ned by means of the curve at the bottom to the right
of the diagram, representing an operating pressure
Water content of air (I) 0.033 kg/kg of 30 bar.
Max. water cont. of air (II) 0.021 kg/kg
Example:
Amount of condensate in charge air receiver.
Amount of condensate in air tank.
= (I-II) x le x P
= (0.033 - 0.021) x 8.2 x 1000 = 123 kg/h Volumetric capacity of tank (V) 4000 dm³
Temperature in tank (T) 40 °C=313K
Internal press. of tank (p) 30 bar
Draining of Condensation Water = 31 x 105 N/m²(abs.)
Gas constant for air (R) 287 Nm/kg.K
This phenomenon will occur on all turbocharged Ambient air temperature 35 °C
engines. For MAN B&W Four-stroke engine, there Relative air humidity 90 %
is no risk with a small amount of water in the charge Weight of air in tank
air receiver. But if the charge air receiver is filled with
water, there is a risk of getting water into the cylinder. pxV 31 x 105 x 4
This water have to be drained away. As standard a m= = = 138 kg
RxT 287 x 313
valve is mounted on the charge air receiver/cooler
on the engine. This valve is to be used for draining
of the water. If there is a great amount, the valve can Solution acc. to above diagram:
be left half-open. If the amount is small, the charge
air receiver can be drained periodically. Water content of air (l) 0.033 kg/kg
Max. water cont. of air (lll) 0.0015 kg/kg
= (I - III) x m
= (0.033 - 0.0015) x 138 = 4.35 kg
08028-0D/H5250/94.08.12
04.31 - ES2
MAN Diesel
Working Card 502-01.00
Page 1 (1) Engine Performance Data Edition 03H
L16/24
Starting position
Engine is running.
Related procedure
Data
99.03 - ES0
MAN Diesel MAN Diesel
Performance L16/24
M/V
Eng. type: Eng. No:
T/C type: Serial No:
Fuel type: Viscosity:
Density:
Load
Air temp °C
Date
Time
Run hours
RPM 1/min
T/C rpm 1/min
HT temp. °C
HT press. bar
LT temp. °C
LT press. bar
LO temp. °C
LO press. b. filt. bar
LO press. a. filt. bar
LO press. T/C bar
FO temp. °C
FO press. bar
CA temp. °C
CA press. bar
Exh. cyl. 1 °C
Exh. cyl. 2 °C
Exh. cyl. 3 °C
Exh. cyl. 4 °C
Exh. cyl. 5 °C
Exh. cyl. 6 °C
Exh. cyl. 7 °C
Exh. cyl. 8 °C
Exh. cyl. 9 °C
Exh. b. T/C °C
Exh. a. T/C °C
L1 °C
L2 °C
L3 °C
Gov. IDX
IDX 1 mm
IDX 2 mm
IDX 3 mm
IDX 4 mm
IDX 5 mm
IDX 6 mm
IDX 7 mm
IDX 8 mm
IDX 9 mm
Power kW
08028-0D/H5250/94.08.12
Voltage V
Current A
Cos phi / kvAr
Signature:
10029-0EX/H5810/98.07.03
MAN Diesel
Working Card 502-05.00
Page 1 (3) Check of Leakages from Inspection Holes Edition 01H
L16/24
Description
Check of leakages from inspection holes.
Hand tools
Starting position
Related procedure
Data
98.22 - ES0
MAN Diesel
502-05.00 Working Card
Edition 01H Check of Leakages from Inspection Holes Page 2 (3)
L16/24
Description
If Then
Water leaks from the inspection hole The O-ring on the top of the liner has to be
replaced
Gas leaks from the inspection hole The sealing ring cylinder head/liner has to be
replaced
98.22 - ES0
MAN Diesel
Working Card 502-05.00
Page 3 (3) Check of Leakages from Inspection Holes Edition 01H
L16/24
2) Leakages from HT cooling water pump, see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing
If Then
Water leaks from the inspection hole Check the rotating sealing
If Then
Air leaks from the inspection holes The inner O-ring on the charge air cooler has
to be replaced
Water leaks from the inspection hole The O-rings on the cooling water connecting
has to be replaced
08028-0D/H5250/94.08.12
98.22 - ES0
Trouble shooting
503/603
MAN Diesel
Description
Starting Failures 503.01
Page 1 (1)
Edition 02
General
Engine turns as soon as shut- Faults in electrical system. Check electrical parts.
off valve is opened, without
start button being activated.
Engine does not turn when Air pressure in starting air Start compressors, re-charge
start button is activated. receiver too low. air receiver.
Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing or clutch
jaws,
see Working Card 513-01.30.
Engine turns too slowly or ir- Worn air motor parts. Remove and disassemble the
regularly when start button is air motor. Examine all parts
activated. and replace any that are worn
or damaged. Use the guidelines
for determining unserviceable
parts, see Working Card 513-
01.30.
Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.
08028-0D/H5250/94.08.12
04.31 - ES0
MAN Diesel
Description
Faults in Fuel Oil System 503.02
Page 1 (2)
Edition 05
L16/24 L27/38
V28/32S L21/31
Engine turns, but ignition fails. Fuel Sluggish movement of manoeuvering Lubricate and mobilize rod connections
pumps are not actuated. gear. in manoeuvering gear.
Incorrect adjustment of manoeuver- Check rod connec. Check that fuel pump
ing gear. index corresponds to "Adjustments after
trials" in testbed chart.
Piston in Lambda controller is ac- Check that piston is not sticking. Check
tuated. that pressure in cylinder is relieved.
Check that the shutdown trip is not
actuated.
Engine turns, but no fuel is injected Fuel oil service tank empty. Pump oil into the tank.
owing to failure in fuel system.
If Then
Air in fuel pumps. Loosen hexagon
socket screw on
fuel pumps until air
disappears.
Engine runs, but does not ignite on Air in fuel valves. Ignition fails on Vent the respective
08028-0D/H5250/94.08.12
Cont.
02.40 - ES0
MAN Diesel
L16/24 L27/38
V28/32S L21/31
If Then
Pressure before Clean fuel filter.
pumps is too low. Check that by-pass
valve for feed pump
is not open.
Engine turns, fuel is injected, but Water in the fuel. Drain off water and repeat venting of fuel
ignition fails. pumps by loosening the hexagonal socket
screw until air disappears.
Fuel valves or nozzles defective. Change defective fuel valves, see working
card 514-01.10.
If Then
Compression Check intake and
during start too exhaust valve for
low. tight closing.
Check piston rings.
First ignitions are too violent. Engine Sluggish movement of manoeuvering Lubricate and mobilize rod connections
runs erratically. gear. and bearings in manoeuvring gear.
02.40 - ES0
MAN Diesel
Description
Disturbances During Running 503.03
Page 1 (3)
Edition 03H
General
Exhaust gas temperatures Increased charging air temperature Clean air coolers, see working card 512-01.00.
increased on all cylinders. due to ineffective air coolers.
Fouling of air and gas passages. Clean air and gas passages, see working cards in section
512.
Wrong maximum combustion pres- Check camshaft adjustment, see working card
sure. 507-01.20.
Exhaust gas temperature Fuel valve or valve nozzle defective. Overhaul fuel valve, see working card 514-01.10.
increased on one cylinder.
Leaky exhaust valves. Check the valve clearance, see working card 514-01.10
or
change the leaky valve and recondition the exhaust valve,
see working card 505-01.05.
Blow-by = leaky combustion cham- Check piston rings, see working card 506-01.35.
ber.
Blow-by means a serious danger of piston seizure, and
the engine must if possible be stopped and the piston in
question pulled. Leaky piston rings will normally result in
heavy excess pressure in the crankcase.
If Then
Stopping of the The fuel pump of the cylinder con-
engine is not cerned should be put out of opera-
possible or tion by moving the index to stop
convenient. and locking it in this position.
Damaged fuel pump cam. Replace camshaft section, working card 507-01.05.
08028-0D/H5250/94.08.12
Exhaust gas temperature Decreased charging air temperature. Check the thermostatic valve in the cooling water system,
decreases on all cylinders. see working card 516-04.00.
Exhaust gas temperature Spindle in fuel valve is sticking. Change and overhaul defective fuel valve, see working
decrease on one cylinder. card 514-10.00.
Fuel pump plunger is sticking or Change fuel pump plunger/barrel assembly, see working
leaking. card 514-10.00.
Cont.
98.19 - ES0
MAN Diesel
General
Engine speed decreases. Pressure before fuel pumps too low. Raise fuel oil feed pump pressure to normal.
or
check filter, see working card 514-01.15.
Fuel valve defective. Change defective valve, see working card 514-01.10.
Water in the fuel. Drain off water from service and setting tanks. Check fuel
oil centrifuge.
Engine stops. Shut-down for overspeed. Check fuel pumps, see working card 514-10.00.
Check governor, see governor manual.
Check movement of regulating mechanism.
Shut-down for low lubricating Check pressostat, see working card 509-05.00.
oil pressure. Check lubricating oil filter, see working card 515-01.10.
Check lubricating oil pump, see working card 515-01.00.
Shut-down for high lubricating Check lub. oil flow and pressure,
oil pressure. see working card 515-01.20.
Clean lubricating oil cooler, see working card 515-06.00.
Smoky exhaust. Turbine speed lagging behind engine Clean turbine(s), see working card 512-15.00.
speed.
Air supply too low. Clean air cooler, see working card 512-01.00.
Clean air filter, see working card 512-35.00.
Clean compressor, see working card 512-05.05.
Clean turbine, see working card 512-15.00.
Fuel valves or nozzles defective. Check fuel valves, see working card 514-01.10.
Exhaust valve knocking. Adjusting screw for valve setting loose. Inspect and replace defective parts, see working card
Push rod thrust disc damaged. 508-01.00.
08028-0D/H5250/94.08.12
If Then
The cooling water Open the test cocks (if
fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-100°C.
Cont.
98.19 - ES0
MAN Diesel
Description
Disturbances During Running 503.03
Page 3 (3)
Edition 03H
General
Lubricating oil pressure Lubricating oil pump defective. Check lubricating oil pump, see working card 515-01.00.
fails.
Filters fouled. Clean filter, see working card 515-01.10.
If Then
The lubricating oil Stop the engine: find the
pressure drops below cause of the pressure drop
the minimum stated and remedy the defect
before
in the Data sheet. restarting the engine.
98.19 - ES0
MAN Diesel
Description 503.04
Page 1 (1) Ignition in Crankcase Edition 03
General
During running the atmosphere in the crankcase 2) Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of oil drops is slung around everywhere. If
undue friction, and thus heating, arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is otherwise transmitted to after stopping the engine. When opening up, keep
the crankcase, the heated surface will cause eva- clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed onto it. When do not smoke.
the oil vapours condense they form milky white oil
mist which can ignite. Such ignition may be caused 3) Cut off starting air.
by the same "hot spot" that produced the oil mist. Set the control panel in "Blocking Mode" see
If a large quantity of oil mist has developed before description 501.01.
ignition, the burning may cause considerable pres- Take off all doors on one side of the crank-
sure rise in the crankcase, forcing the relief valves case.
to open. In a few cases, presumably when the whole
crankcase has been filled with oil mist, a subsequent 4) Locate the hot spot. Powerful lamps should be
explosion has thrown off the crankcase doors and employed at once (in explosion-proof fittings).
caused fire in the engine room. Feel over all sliding surfaces (bearings, liners,
pistons, roller guides, etc.).
Every precaution should therefore be taken to (A)
avoid "hot spots" and (B) discover oil mist in time. Look for squeezed-out bearing metal and discol-
oration by heat (blistered paint, burnt oil, heated
steel).
"Hot spots" in Crankcase
5) Prevent further heating, preferably by making
Overheating of bearings is a result of inadequate or a permanent repair. Special attention should be
failing lubrication, possibly caused by pollution of paid to ensuring lubricating oil supply and the
the lubricating oil. satisfactory condition of the frictional surfaces
involved. It is equally important to replace filter
It is therefore important that the lubricating oil filtration elements in time.
equipment is in perfect condition. Filter cartridges may
not be used again if they have been removed from 6) Start electrically driven lubricating oil pump
the filter. Checking of the oil condition by analysis is and check oil flow from all bearings and spray
recommended. pipes in crankcase while turning the engine
through at least two revolutions.
The presence of oil mist may be noted at the vent Especially the frictional surfaces that caused the
pipe which is usually fitted to the top of the engine heating should be felt over (5-15-30 minutes after
frame. starting, and again when full load is obtained). Sec-
tion 501.10.
Measures (in case of white oil mist).
8) If it has not been possible to locate the hot spot,
Warning: Keep away from doors and relief valves on step 7 should be intensified and repeated until
crankcase. Do not stay unnecessarily in doorways the cause of the oil mist has been found and
near the doors of the engine room casing. remedied. In very rare cases oil mist could be
due to "atomization" of lubricating oil by the
action of an air jet (for instance blow-by, or
blow-by through cracked piston).
00.12 - ES0
MAN Diesel
Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 02H
General
Tabulated below are the remedial actions to be taken
if the following faults are observed:
Oil leakage through cover nut. Missing or damaged O-ring Replace O ring.
(see Item 158, Plate 51515).
Dirt deposit not completely removed. Clean and bring to notice of maintenance
staff.
Bushes loose or worn in tube as- Fit new bearing tube assembly.
sembly.
08028-0D/H5250/94.08.12
98.20 - ES0
MAN Diesel
Description 503.06
Page 1 (1) Trouble Shooting Guide for Air Starter Edition 07H
L16/24
Pinion revolves and advances, but - Ring gear and/or pinion burrs or Clean burrs or replace if necessary
does not engage the ring gear. damage
- Lack of clearance between pinion Replace pinion by a more adequate one.
and ring gear Check for distortion of ring gear
Pinion revolves but does not advance. - Push-rod Item 531 inoperative Disassemble, check, smoothen guide dia-
meter, clean or replace if rusted
- Insufficient air pressure Increase pressure in receiver
- Splined shaft Item 511 sticking Disassemble, clean, check spring Item 513
and reassemble
- Excessive length of control pipe Approach push-button to the starter or
install a solenoid valve near the latter
Pinion advances but does not revolve. - Pneumatic motor inoperative Disassemble, inspect rotor for foreign mat-
ters between teeth and for possible wear of
gears.
- Check valve Item 578 Clean and reassemble. Replace worn parts
Disassemble, clean and reassemble
Pinion engages gear ring, but will not - Main valve Item 557 blocked Disassemble, clean and reassemble or
turn the engine. replace
- Rotors worn or blocked Disassemble, clean and reassemble or
replace rotors
- Insufficient air pressure Increase pressure in receiver
- Main air pipework restricted or of Check all pipework and replace if necessary
insufficient bore
Starter starts working upon opening - Incorrect connection of control pipes Connect control pipes as per installation
the flow valve of the feed line, although (with separate solenoid- valve) instruction.
push-button (or solenoid valve) are not - Main valve Item 557 blocked and Disassemble, clean and replace joint if
actuated. open needed
08028-0D/H5250/94.08.12
Lack of starter power. - Main pipework choked or bore is Check entire pipework for correct bore and
less than stipulated for the starter replace if incorrect.
- Insufficient air pressure Increase pressure in receiver.
- Badly worn rotors Disassemble, replace and reassemble.
After starting the engine, pinion tries to - Incorrect bore of main pipework Chcek entire pipework for correct bore and
re-engage and hits the ring gear which replace if incorrect.
results in damage to both. - Starting period unnecessarily long Check and adjust timer (if fitted) or press
starter pushbutton for shorter period.
- Idling of main valve item 557 Disassemble, clean, oil and reassemble.
Starter motor will not stop. - Main valve 557 blocked Disassemble, clean, oil and reassemble.
- Check valve 578 keeps open or Disassemble, check for correct closing of
does not seat properly the ball and that plug presses the valve
against is seat.
- Splined shaft 511 sticking Disassemble, clean, check spring 513 and
reassemble.
03.14 - ES0
MAN Diesel
Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1)
Edition 03
General
Oil or water flows out of the inspec- Worn rotating sealing. See working card 502-05.00.
tion holes.
The pump does not work after start. Pump draws in air at suction side. Check packings and pipes for tightness.
The system is not filled-up. Check the level in the expansion tank.
Pump capacity drops after normal Air leakages from shaft seal. Overhaul the shaft seal.
operation.
Fouled impeller. Clean the impeller.
Pump does not give maximum Suction valve not fully open. Open the suction valve.
delivery.
Defective seals. Replace the seals.
98.20 - ES0
MAN Diesel
Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01
General
Trouble Shooting Fatigue fracture will normally necessitate replace-
ment of all plates and gaskets as there may be a
It is necessary to replace damaged plates or ga- risk of fatigue fracture in all the material.
skets. In case of corrosion, all plates must be examined
carefully!
First examine the external conditions around the Concerning the work to be carried out see Working
plate heat exchanger in order to localize the cause card 515-06.00.
of the damage. Do this very carefully.
Visible Leakage
Leakage. Too high pressure. Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operating
Data & Set Points".
Leakage. Fouled or deformed plates. Separate the plate heat exchanger and
(Phase 2) Inelastic or deformed gaskets. check if the plates are deformed or
fouled.
Check that the gaskets are elastic and
non-deformed, and that the faces of the
joints are clean.
Replace deformed plates and gaskets,
if any.
Before assembling clean all plates and
gaskets very carefully.
Assemble the plate heat exchanger and
start it up again.
Note: Even tiny impurities such as sand
grains may cause leakage.
Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the gas- plate. Replace defective plates and gaskets,
kets.) if any.
Assemble the plate heat exchanger and
start it up again.
98.20 - ESO
MAN Diesel
503.10 Description
Edition 01 Troubleshooting for Lubricating Oil Cooler Page 2 (2)
General
Non-Visible Leakage
Reduced heat transmission and/or Fouled plates or choked plate chan- Separate the plate heat exchanger and
increasing pressure drop. nels. check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger and
start it up again.
98.20 - ES0
MAN Diesel
Description 503.20
Page 1 (6) Trouble Shooting / Electrical Failures Edition 08
L16/24
L21/31
Trouble Shooting Safety System
This description is a trouble shooting guide for the The safety system is an independent system and
automation system on the diesel engine type L16/24 consists of maker ABB PLC hardware modules and
and L21/31. MAN B&W software. Fig 1 describes the hardware
modules.
06.22 - ES0
MAN Diesel
503.20 Description
Edition 08 Trouble Shooting / Electrical Failures Page 2 (6)
L16/24
L21/31
Table 1.1
Engine will not start. Supply voltage polarity, or no Check the supply voltage on the green diode on 3P1. If it is alight
Start motor is not engaged. supply voltage. the power supply for the PLC modules are OK.
RUN/STOP change-over switch Put the RUN/STOP change-over switch in RUN position. Check
on 3P1 in wrong position. RUN LED on 3P1.
No software in the module. If all diodes on 3P1 and 4P1 are alight after having switched
on the power supply, the module is without software. The mod-
ule must be replaced with a module incl. software. Note! After
switch-on of the power supply the initialization takes app. 3 sec.
Please wait these seconds before observation.
Output relay on 5P1 out 5 is in Check that diode on 5P1 OUT 5 is alight.
failure or loose connections. If on 5P1 out 5 is not alight check that IN 0 is alight and is
stable (continuous on or continuous off) Check for loose wires
on terminals 5 + C5 on 5P1.
All or some of the shutdown Connector is not correctly Check the connector J29 on the base module. Check the con-
LED are alight on the monitor- connected, internal failure in nector on the 3P1 unit. No red LED must be alight on 3P1.
ing box and the engine is run- 3P1 or connector on 3P1 is not Activate the change-over switch RUN/STOP. Exchange the 3P1
ning without a critical situation, correctly connected. module. Please note that in case that connections from PLC
only LED’s are alight. to base module is in failure it will be possible that the engine
is starting and running even there are one or more indications
of shutdown on the operation box. This observation will only
be possible with base module software version below 2.30 for
engine L16/24 and 4.10 for engine L21/31.
Low lub. oil shutdown oc- Damaged or wrong adjustment Check the pick-up for correct adjustment.
curs when normal stop is of the rpm pick-up. Sensing distance = app. 2 mm.
activated. Check that the connector is plugged correctly. Be aware that
no counternuts prevent from plugging the connector correctly.
Replace the pick-up.
Note! Diode 3 on 4P1 will be alight if actual speed is above
nominal speed. If actual speed is below, it will be dark.
08028-0D/H5250/94.08.12
The alarm „System & Power The internal bus connection Check that the bus connection between 3P1, 4P1, 5P1 is OK.
failure“ is activated. is disconnected or internal Check that power supply is OK. (Green diode must be alight).
Diode 0 or diode 1 are not component failure. Switch on the RUN/STOP change-over switch.The problem could
alight. be related to an internal component failure and the module must
be replaced. Observe that no red diode is alight on 3P1.
The shutdown functions are Wiring or sensor problem. Check the wiring for shutdown sensors.
not working. Internal component failure. Replace the module.
Overspeed set point is not Missing jumper or wrong Check that input 7 is alight for 1000 rpm engines, and OFF for
correct. software. 900 rpm (L21/31) and 1200 rpm (L16/24) engines. Check the
software version (see page 1)
06.22 - ES0
MAN Diesel
Description 503.20
Page 3 (6) Trouble Shooting / Electrical Failures Edition 08
L16/24
L21/31
The Monitoring System Interface to the alarm and monitoring system in the
control room is made by MODBUS or Interlink to the
The monitoring system monitors shows all relevant output module.
pressures, temperatures and rpm on the engine.
The software can be read by pushing the lamp test
The monitoring system consists of four hardware button for 3 seconds. The software version number
modules as standard and a module as option for will be displayed in the operation box display.
bearing temp. monitoring. The monitoring system
hardware and software is developed by MAN B&W. The software for the engine type L21/31 will start
Fig 2 describes the hardware. with 4.xx f.ex. 4.11. Please make sure that the dip
switches SW1, SW2, SW5 and SW3 are in correct
All sensors are connected to the base module and position acc. to the plant related schematic. See
the Operation Box (OB), Monitor for Temp. and section 509.
Pressure Module (MTP) and Monitor for Exh. Gas
Temp. Module (MEG) are connected via interlink
bus connection.
Failure LED
2.5 A
Fuses
OB ENGINE RPM.
0 1400
SI90
MTP H.T. WATER TEMP.
OUTLET ENGINE
TI12
switches LED
START AIR PI70 L.T. WATER PRESS.
PRESS. PI01
INLET AIR COOL.
ALT. RPM.
LUB. OIL PRESS.
PI22
OVERSPEED INLET ENGINE
INLET TC
PI23
0 80
OUTLET COOL.
TI31
Software version
08028-0D/H5250/94.08.12
0 4
BLOCKING CHARGE AIR PRESS.
REMOTE LOCAL PI31
OUTLET COOL.
RESET
will be indicated
in the display
AP HIGH H.T. WATER TEMP.
TAH 12.
LOW FUEL OIL PRESS.
PAL 40.
MEG 200 400 600
X
CYL.
1 TI60
H
HIGH/LOW EXH. GAS TEMP. OVERSPEED.
TDAH 60. SAH 81.
A CYL.
2 TI60
S
HIGH ALTERNATOR WINDING COMMON SHUTDOWN.
TEMP. TAH98 SS 86. T
CYL.
5 TI60
E
LOW L.T. WATER PRESS. START FAILURE.
PAL 01. SX 83.
M CYL.
6 TI60
A
LOW LUB. OIL PRESS. FUEL LEAKAGE.
PAL 22. LAH 42.
T CYL.
8 TI60
06.22 - ES0
MAN Diesel
503.20 Description
Edition 08 Trouble Shooting / Electrical Failures Page 4 (6)
L16/24
L21/31
Table 1.2
Engine will not start. Power supply is not correct. Check that the power supply is correct 24 V ± 20%
Start motor is not engaged. Interlock activated. on terminals J3; 132, 133.
Internal component failure. Check that no interlocks are activated
– Turning gear not engaged
– No start failure activated
– No engine run signal
– Remote mode is activated
– No shutdown activated
– Stop valve not activated
– No lub. oil pressure
– Prelub. oil pressure is OK
Check that LED on base module is steadily green
alight. See also table 1.3
Check that wirings from terminals J20; 98, 99 are
correct.
Check the safety system (see table 1.1)
Check that the ON/OFF switch on the base module
is working properly.
Note! After having switched on the power supply,
the system initializes app. 3 seconds. Please wait
with observations until initializing is finished.
Replace the base module.
Start motor engaged and engine Pick-up failure on both safety- and Check monitor pick-up and safety system. If system
started but stopped again after few monitor pick-up. failure or cable failure is activated on safety system
minutes. and the monitor pick-up is out of order the engine
will be stopped again.
Data communication failure. EMC problem or loose connec- Check that the green LED on the base module is
tions. alight. See also table 1.3
Check that all cable screens are connected correctly
in the EMC cable glands.
Check that the data communiation cable (MODBUS)
is the twisted pair type.
No RPM indication Defect pick-up or incorrect adjust- Check the pick-up for correct adjustment.
ment. Sensing distance = app. 2 mm.
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly.
08028-0D/H5250/94.08.12
The engine suddenly starts or Two or more earth failures on the Check for earth failures on all sensors.
stops. engine and yard installation. Special attention should be made to the exh. gas sen-
sors. Check for earth failures in the yard system.
Replace the base module.
LED flashing green, yellow or red. Internal component failure or EMC See table 1.3. Switch the power ON/OFF.
problem. Exchange the base module.
Cont.
06.22 - ES0
MAN Diesel
Description 503.20
Page 5 (6) Trouble Shooting / Electrical Failures Edition 08
L16/24
L21/31
Cont. Table 1.2
All or some of the red diodes on the No power supply or software in the Check the safety system accoding to table 1.1.
operation box are alight. safety system or bad connection
between safety system and base
module.
Jet system activated under no The band steel on the lambda arm Adjust the band steel to app. 2-3 mm above the
load condition and/or jet alarm is adjusted incorrectly. jet pick-up.
activated.
„Frozen“ operation box, MTP and Internal software failure. See table 1.3. Switch the power supply on/off.
MEG box. Exchange the base module.
Instable behaviour of the output Too high voltage on the output circuit Check that the voltage is below 48 VDC.
signals for start/stop of prelubricat- terminals J20, 108, 109 120 VAC or 220 VAC is not allowed.
ing pump. Note! The voltage must be checked in the prelubri-
cating pump starter panel.
Temp. indication is too high acc. Internal component failure. Replace the base module.
to calibrated values, or values are
abnormal.
Change-over switch between LO- Internal failure in the operation See table 1.3 and 1.4. Replace the operation box.
CAL - REMOTE - BLOCKING is box.
not working. Damaged flat cable between print
card and front panel.
The alarm „System & Power failure“ This alarm consists of different alarm 1) Check diode out 1 on the safety system module
is activated. possibilities 4P1. If it is alight, it is OK. No red LED must be alight
1) Power & system failure in the on 3P1. See also table 1.1. SUPPLY LED and RUN
safety system. LED must be alight.
2) Power supply failure to the pres- 2) Check green diode J29/J30 and fuse 2.5 AT. If
sure sensors. green diode is alight, it is OK.
3) Cable/wire failure for monitor 3) Check if any analog signals are missing. If all
sensors. signals are present, it is OK. Remember to check
4) Cable/wire failure for safety also the spare exh. gas input channels. A jumper
system sensors. must be present. See also table 1.4
5) Communication link failure. 4) Check diode out 0. If it is alight, it is OK. If it is
6) Tacho failure. not alight, check the safety system for cable break
or loose connections.
5) Check if rpm pick-up is OK, and/or lub. oil
08028-0D/H5250/94.08.12
OB display indicates OFFLN or Cable break on data communication See table 1.3. Check cable installation for sensor(s)
ERR-1 or fault. or sensor(s). and/or data communication
06.22 - ES0
MAN Diesel
503.20 Description
Edition 08 Trouble Shooting / Electrical Failures Page 6 (6)
L16/24
L21/31
Table 1.3
Base Module LED indications
On the Base Module printed circuit board a two-coloured lamp (light diode, LED) is located , which indicates the current state of the
Base Module central processor.
Observations Description
GREEN flash One or more Interlink modules are offline (disconnected) or incorrect setup on SW2.
RED permanent light BM internal hardware error (or lockup caused by EMC disturbances).
YELLOW permanent light BM internal hardware error (or lockup caused by EMC disturbances).
RED flash BM software or hardware fault. The number of flashes indicates an internal error code which must be
reported when returning the module. (It may also be caused by EMC disturbances)
Yellow 4x flash MODBUS address error (SW1): Incorrectly set to an illegal address (0 or 255, all switched ON or
OFF).
Other yellow flashes BM internal software fault. The number of flashes indicates an internal error code which must be reported
when returning the module. (It may also be caused by EMC disturbances)
Table 1.4
Display indications on the Operation Box (OB)
Observations Description
Ready Shown for a few seconds when the OB module is powered on, indicating that the internal selftest of the module
was successfully passed.
OFFLN The OB module is OFFLINE. There is no communication from the base module to the OB module. This message
will appear shortly when powering on the system, indicating that the base module has been reset.
FAULT Indicates that the BM module has entered failsafe mode either because of a fatal software or hardware fault.
06.22 - ES0
MAN
MAN Diesel
Diesel
Date: Signature:
Adjustment F
Mechanical G
Water Damage H
Repair
Software Update I
Updating J
K
08050-1EX/H5810/00.12.18
Media specification
504/604
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
The specific power output offered by today’s Die- Bright stocks, if contained, must neither adversely
sel engines and the use of fuels which more and affect the thermal nor the oxidation stability.
more often approach the acceptable limit in quality
increase the requirements placed on the lube oil The base oil must meet the limit values given in
and make it imperative that the lube oil is chosen Table 1, particularly as concerns its ageing tenden-
carefully. Medium-alkaline lube oils have proven cies.
to be suitable for lubricating the running gear, the
cylinders, the turbocharger and for the cooling of Medium-alkaline lube oil
the pistons. Medium-alkaline oils contain additives
which, amongst other things, provided them with a The finished oil (base oil with additives) must dem-
higher neutralising capacity than blended (HD) en- onstrate the following characteristics.
gine oils have.
Additives
No international specifications exist for medium-al-
kaline lube oils. An adequately long trial operation The additives must be dissolved in the oil and must
in compliance with the manufacturer’s instructions be of such a composition that an absolute minimum
is therefore necessary. of ash remains as residue after combustion, even
though the engine were run on distillate fuel tem-
Only lube oils, which have been approved by MAN porarily. The ash must be soft. If this prerequisite
Diesel, are to be used. These are listed in Table 5. is not complied with, increased deposits are to be
expected in the combustion spaces, especially the
Requirements exhaust valves and the inlet housing of the turbo-
chargers. Hard additive ash promotes pitting on
Base oil the valve seats, as well as burnt-out valves and in-
creased mechanical wear in the cylinder liners.
The base oil (medium-alkaline lube oil = base oil +
additives) must be a narrow distillation cut and must Additives must not facilitate clogging of the filter el-
be refined in accordance with modern procedures. ements, neither in their active nor in their exhaust-
ed state.
Weight
nheptane insolubles ASTMD4055 or
% < 0.2
DIN 51592
Evaporation loss <2
Drop test (filter paper) Must not allow to recognize precipitation of
MAN Diesel test
resinous or asphaltlike ageing products
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
Detergency Lube oil selection
The neutralisation capacity (ASTM-D2896) must In order to meet the emission regulations, fuels
be so high that the acidic products of combustion with different sulphur content are used today. In en-
are neutralised at the lube oil consumption rate that vironmental sensitive areas (SECA) a low sulphur
is specific for the engine. The reaction time of the fuel must be used. Outside the SECA a fuel with
additives must be matched to the process in the a high sulphur content can be used. In this case
combustion chamber. Hints concerning the selec- the lube oil BN should be selected to meet the re-
tion of the BN are given in Table 3. quirements of the operation on high sulphur fuel.
Only for permanent operation on low sulphur fuel,
Evaporation tendency the lube oil with the lower BN should be selected.
Ultimately, the operating results are the decisive
The tendency to evaporate must be as low as pos- criterium as to which content of additives ensures
sible, otherwise the oil consumption is adversely the most economic mode of engine operation.
affected.
Cylinder lube oil
Further conditions
In the case of engines with separate cylinder lubri-
The lube oil must not form a stable emulsion cation, the pistons and the cylinder liner are sup-
08028-0D/H5250/94.08.12
with water. Less than 40 ml emulsion are ac- plied with lube oil by means of a separate oil pump.
ceptable in the ASTM-D1410 test after one hour. The oil supply rate is factory-set to conform to both
The foaming behaviour (ASTM-D892) must meet the quality of the fuel to be used in service and to
the following conditions: after 10 minutes < 20 ml. the anticipated operating conditions.
The lube oil must not contain agents to improve vis-
cosity index. Fresh oil must not contain any water or A lube oil as specified above is to be used for the
other contamination. cylinder and the lubricating circuit.
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
approx. BN (mg Engines / Operating conditions
KOH/g oil)
Marine Diesel Oil (MDO) of poor quality (ISOFDMC) or heavy fuel oil with a sulphur content
20
of <0.5 %.
23/30H and 28/32H in general. 23/30A, 28/32A and 28/32S under normal operating
conditions.
30 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 and 58/64 and 51/60DF in pure HFO
mode only if fuel sulphur content is < 1.5 %.
51/60DF in alternating mode (HFO/Gas).
23/30A, 28/32A and 28/32S in case of severe operating conditions and in case of necessity
regarding oil life and engine cleanliness.
40
16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 and 58/64 and 51/60DF in pure HFO
mode generally, provided the sulphur content is >1.5%.
32/40, 32/44CR, 40/54, 48/60, and 58/64 if BN 40 is inadequate in terms of oil life or engine
50
cleanliness (high sulphur content of the fuel, very low lube oil consumption.
In case of mechanic-hydraulic governors with sep- It is not allowed to add additives to the lube oil, or
arate oil sump, multi grade oil 5W-40 is preferably mixing the different makes (brands) of the lube oil,
used. If this oil is not available as refill, an oil 15W- as the performance of the carefully matched pack-
40 may exceptionally be used. In this context it is age of additives which is suiting itself and adapted
not important, if multi grade oils based on synthetic to the base oil, may be upset. Also, the lube oil
or mineral oil are used. company (oil supplier) is no longer responsible for
the oil.
The oil quality specified by the manufacturer is to
be used for the remaining equipment fitted to the Selection of lube oils / warranty
engine. For the engine L27/38 (propulsion) service
experience have shown that the operation temper- Most of the mineral oil companies are in close and
ature of the Woodward governor UG10MAS and permanent consultation with the engine manufac-
the corresponding actuator for UG723+ can ex- turers and are therefore in a the position to quote
ceed 93° C. In such case we recommend to use a the oil from their own product line that has been
synthetic oil like Castrol Alphasyn HG150. Engines approved by the engine manufacturer for the given
delivered later than March 2005 are already filled application. Independent of this release, the lube
08028-0D/H5250/94.08.12
with this oil. oil manufacturers are in any case responsible for
quality and performance of their products. If you
have further questions, we are more than willing to
provide you with further information.
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
Oil in service
Water Content max. 0.2% (for a short period max. 0.5%) ISO 3733 or ASTM D1744
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
Examinations
We carry out the investigations on lube oil in our
laboratories for our customers. A representative
sample of about 0.5 litre is required for the exami-
nation.
20 30 40 50
BP Energol ICHFX 204 Energol ICHFX 304 Energol ICHFX 404 Energol IC-HFX 504
CASTROL TLX Plus 204 TLX Plus 304 TLX Plus 404 TLX Plus 504
CEPSA Troncoil 3040 Plus Troncoil 4040 Plus Troncoil 5040 Plus
TOTAL Lubmarine Aurelia XL 4025 Aurelia XL 4030 Aurelia XL 4040 Aurelia XL 4055
Aurelia TI 4030 Aurelia TI 4040 Aurelia TI 4055
Table 5 Lubricating oils (SAE40), which have been approved for the use in MAN Diesel
fourstroke engines running on heavy fuel oil
Note!
MAN Diesel SE do not take any responsibility
for difficulties that might be caused by these
oils!
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
The specific power output offered by today’s Die- Bright stocks, if contained, must neither adversely
sel engines and the use of fuels which more and affect the thermal nor the oxidation stability. The
more often approach the limit in quality increase base oil must meet the limit values as specified in
the requirements placed on the lube oil and make Table 1, particularly concerning the ageing stabil-
it imperative that the lube oil is chosen carefully. ity.
Blended lube oils (HD oils) have proven to be suit-
able for lubricating the running gear, the cylinder, Blended lube oils (HD-oils)
the turbocharger and for the cooling of the pistons.
Blended lube oils contain additives which, amongst The base oil for which additives have been mixed
other things, provide them with sludge carrying, (blended lube oil) must demonstrate the following
cleaning and neutralisation capabilities. characteristics:
The base oil (blended lube oil = basic oil + addi- Additives must not facilitate clogging of the filter el-
tives) must be a narrow distillation cut and must ements, neither in their active nor in their exhaust-
be refined in accordance with modern procedures. ed state.
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
Detergency Blended grade
The detergency must be so high that coke and tar- Blended lube oils (HD oils) corresponding to inter-
like residues from fuel combustion must not build- national specifications MIL-L 2104 or API-CD, and
up. having a Base Number (BN) of 10 – 16 mg KOH/g
are recommended by us (Designation for armed
Dispersancy forces of Germany: O-278).
The dispersancy must be selected such that com- The content of additives included in the lube oil de-
mercially available lube-oil cleaning equipment can pends upon the conditions under which the engine
remove the detrimental contamination from the is operated, and the quality of fuel used. If marine
used oil, i.e. the oil must have good separating and Diesel fuel is used, which has a sulphur content of
filtering properties. up to 2.0 weight % as per ISO-F DMC, and coke
residues of up to 2.5 weight % as per Conradson,
Neutralisation capacity a BN of approx. 20 is preferred. Ultimately, the op-
erating results are the decisive criterion as to which
The neutralisation capacity (ASTM-D2896) must content of additives ensures the most economic
be so high that the acidic products which result dur- mode of engine operation.
ing combustion are neutralised. The reaction time
of the additives must be matched to the process in Cylinder lube oil
the combustion chamber.
In the case of engines with separate cylinder lubri-
Evaporation tendency cation, the pistons and the cylinder liner are sup-
plied with lube oil by means of a separate oil pump.
The tendency to evaporate must be as low as pos- The oil supply rate is factory-set to conform to both
sible, otherwise the oil consumption is adversely the quality of the fuel to be used in service and to
affected. the anticipated operating conditions.
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
For the engine L27/38 (propulsion) service experi-
Approved SAE40 lube oils
ence have shown that the operation temperature of
the Woodward governor UG10MAS and the corre- Manufacturer Base Number
sponding actuator for UG723+ can exceed 93° C. In 10161) [mgKOH/g]
such case we recommend to use a synthetic oil like
AGIP Cladium 120 SAE 40
Castrol Alphasyn HG150. Engines delivered later
Sigma S SAE 40 2)
than March 2005 are already filled with this oil.
BP Energol DS 3154
Lube-oil additives
CASTROL Castrol MLC 40
Castrol MHP 154
It is not allowed to add additives to the lube oil, or
Seamax Extra 40
mixing the different makes (brands) of the lube oil,
as the performance of the carefully matched pack- CHEVRON Taro 12 XD 40
age of additives which is suiting itself and adapted (Texaco, Caltex) Delo 1000 Marine SAE 40
to the base oil, may be upset. Also, the lube oil
EXXON MOBIL Exxmar 12TP40
company (oil supplier) is no longer responsible for
Mobilgard 412 / MG 1SHC
the oil. Mobilgard ADL 40 2)
Delvac 1640
Selection of lube oils / warranty
PETROBRAS Marbrax CCD410
Most of the mineral oil companies are in close and
Q8 Mozart DP40
permanent consultation with the engine manufac-
turers and are therefore in a position to quote the oil REPSOL Neptuno NT 1540
from their own product line that has been approved
by the engine manufacturer for the given applica- SHELL Gadinia 40
Sirius FB 40 2)
tion. Independent of this release, the lube oil manu-
Sirius/Rimula X40 2)
facturers are in any case responsible for quality and Gadinia AL40
performance of their products. If any questions, we
are more than willing to provide you with further in- STATOIL MarWay 1540
formation. MarWay 1040
if the oil is cleaned by an appropriate device (e.g. 2) If the sulphur content of the fuel is < 1 %.
separator).
MAN Diesel SE do not take any reponsibility for dif-
Examinations ficulties that might be caused by these oils.
08.19 - ES1
MAN Diesel
L16/24, L21/31
L27/38, V28/32S
Limit value Method
Water Content max. 0.2% (for a short period max. 0.5%) ISO 3733 or ASTM D1744
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description
Page 1 (1) Lubricating Points 504.05
Edition 03
General
Lubricating Oil Types Used in the Engine
Engine system lubricating oil SAE 40 oil according to lubricating oil specification on page 504.01.
Alternator (only for GenSet) See special instructions in section 518 or separate instructions.
Hydraulic tools Hydraulic oil or turbine oil (with a viscosity of about SAE 20).
08028-0D/H5250/94.08.12
04.35 - ES0
MAN Diesel
Description
Page 1 (1) Lubricating Oil in Base Frame 504.06
Edition 08H
L16/24
99.27 - ES1
MAN Diesel
Description 504.07
Page 1 (2) Specific Lubricating Oil Consumption - SLOC Edition 03
General
run.hrs period * PMCR [kW] ρlubricating oil @15°C [kg/m3] – 0,64 * (tlubricating oil [°C] – 15)
In order to evaluate the correct engine SLOC, The engine maximum continuous design rating (PMCR)
the following circumstances must be noticed and must always be used in order to be able to compare
subtracted from the engine SLOC: the individual measurements, and the running hours
since the last lubricating oil adding must be used
A1: in the calculation. Due to inaccuracy *) at adding
08028-0D/H5250/94.08.12
Desludging interval and sludge amount from the lubricating oil, the SLOC can only be evaluated
lubricating oil separator (or automatic lubricating oil after 1,000 running hours or more, where only the
filters). The expected lubricating oil content of the average values of a number of lubricating oil addings
sludge amount is 30%. are representative.
06.25 - ES0
MAN Diesel
Description 504.07
Page 2 (2) Specific Lubricating Oil Consumption - SLOC Edition 03
General
Plant / Ship
Lube oil consumption
Engine type:___________________ Engine # :__________________
06.25 - ES0
MAN Diesel
Description
Quality of Heavy Fuel Oil (HFO) 504.20
Page 1 (10) edtion 08
General
Prerequisites Several international specifications for heavy fuel
oils are existing. The most important specifications
MAN Diesel four-stroke engines can be operated are ISO 8217-2005 and CIMAC-2003. These two
on any crude-oil based heavy fuel oil meeting the specifications are more or less equivalent. Table
requirements listed in Table 3-24, Page 3-37 , pro- 2 CIMAC Recommendations for residual fuels for
vided the engine and the fuel treatment plant are diesel engines (as bunkered) shows the specifi-
designed accordingly. In order to ensure a well-bal- cations CIMAC-2003. All qualities of these specifi-
anced relation between the costs for fuel, spare cations up to K700 can be used provided the fuel
parts and maintenance and repair work, we recom- treatment system is designed for these fuel grades
mend bearing in mind the following points. e.g. fuels with a maximum density of 1010 kg/m3
can only be used with modern separation.
Heavy fuel oil (HFO)
Important
Provenance/refining process
Fuel oil characteristics as stated in analysis results
The quality of the heavy fuel oil is largely deter- - even if they meet the above mentioned require-
mined by the crude oil grade (provenance) and the ments - may be not sufficient for estimating the
refining process applied. This is the reason why combustion properties and the stability of the fuel
heavy fuel oils of the same viscosity may differ con- oil. This means that service results depend on oil
siderably, depending on the bunker places. Heavy properties which cannot be known beforehand.
fuel oil normally is a mixture of residue oil and distil- This especially applies to the tendency of the oil to
lates. The components of the mixture usually come form deposits in the combustion chamber injection
from state-of-the-art refining processes such as system, gas passages and turbines. It may, there-
visbreaker or catalytic cracking plants. These proc- fore, be necessary to rule out some oils that cause
esses may have a negative effect on the stability of difficulties.
the fuel and on its ignition and combustion proper-
ties. In the essence, these factors also influence the Blends
heavy fuel oil treatment and the operating results of
the engine. The admixing of engine oils (ULO:used lube oil), of
non-mineral oil constituents (such as coal oil) and
Bunker places where heavy fuel oil grades of stand- of residual products from chemical or other proc-
ardised quality are offered should be given prefer- esses (such as solvents, polymers or chemical
ence. If fuels are supplied by independent traders, waste) is not permitted. The reasons are, for ex-
it is to be made sure that these, too, keep to the ample: the abrasive and corrosive effects, the ad-
international specifications. The responsibility for verse combustion properties, a poor compatibility
the choice of appropriate fuels rests with the en- with mineral oils and, last but not least, the nega-
gine operator. tive environmental effects. The order letter for the
fuel should expressly mention what is prohibited,
Specifications as this constraint has not yet been incorporated in
the commonly applied fuel specifications.
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
General
A fuel shall be considered to be free of used lube The admixing of chemical waste materials (such as
oil (ULO) if one or more of the elements Zn, P and solvents) to the fuel is for reasons of environmen-
Zn are below the specific limits (Zn: 15 ppm; P: tal protection prohibited by resolution of the IMO
15 ppm; Ca: 30 ppm). Marine Environment Protection Committee of 1st
January 1992.
Vanadium mg/kg
600 »Heavy fuel oil treatment«
Water % vol.
1 »Heavy fuel oil treatment«
Sediment % wt.
0.1
(potential)
Supplementary characteristic values
Aluminium mg/kg max.
08028-0D/H5250/94.08.12
08.19 - ES1
08028-0D/H5250/94.08.12
Characteristics Unit Limit CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC Test method
A30 B30 D80 E 180 F 180 G 380 H 380 K 380 H 700 K 700 reference
08.19 - ES1
Table 2
Description
Page 3 (10)
Density at 15 ûC kg/m3 max. ISO 3675 or
MAN Diesel
Ash % max.
0.10 0.10 0.10 0.15 0.15 0.15 ISO 6245
(m/m)
Water % max.
(V/V) 0.5 0.5 0.5 0.5 0.5 ISO 3733
CIMAC Recommendations for residual fuels for diesel engines (as bunkered)
or IP 501
Total sediment % max. ISO
potential (m/m) 0.10 0.10 0.10 0.10 0.10
Quality of Heavy Fuel Oil (HFO)
103072
Aluminium plus mg/kg max.
silicon 80 80 80 80 80 ISO 10478
Used lubricating The fuel shall be free of ULO. A fuel shall be considered to be free of ULO if one ore more of the elementsl Zinc,
oil (ULO) Phosphorus and Calcium are below or at the specified limits. All three elements must exceed the same limits
before a fuel shall be deemed to contain ULO.
1) 1 mm2/s = 1cSt
2) Fuels with density close to the maximum, but with very low viscosity, may exhibit poor ignition quality.
edtion 08
504.20
3) A sulphur limit of 1,5% mm will apply in SOx Emission Control Areas designated by the IMO, when its relevant Protocol comes into force. There may be local variations.
General
MAN Diesel
General
Leaked oil collectors The specified injection viscosity of 12-14mm2/s (for
GenSets 16/24, 21/31, 23/30H, 27/38 and 28/32H:
Leaked oil collectors into which leaked oil and resi- 12 - 18 cSt) and/or fuel oil temperature upstream
due pipes as well as overflow pipes of the lube oil of the engine should be adhered to. Only then will
system, in particular, must not have any connection an appropriate atomisation and proper mixing,
to fuel tanks. Leaked oil collectors should empty and hence a low-residue combustion be possible.
into sludge tanks. Besides, mechanical overloading of the injection
system will be prevented. The specified injection
Supplementary remarks viscosity and/or the necessary fuel oil temperature
upstream of the engine can be seen from the vis-
The following remarks are thought to outline the re- cosity/temperature diagram.
lations between heavy fuel oil grade, heavy fuel oil
treatment, engine operation and operating results. Heavy fuel oil treatment
08.19 - ES1
MAN Diesel
Description
Quality of Heavy Fuel Oil (HFO) 504.20
Page 5 (10) edtion 08
General
• Separators pable of separating water up to a heavy fuel oil density
of 1.01 g/ml at 15° C.
A centrifugal separator is a suitable device for ex-
tracting material of higher specific gravity, such as Table 3, shows the demands made on the separa-
water, foreign particles and sludge. The separators tor. These limit values which the manufacturers of
must be of the self-cleaning type (i.e. with automati- these separators take as a basis and which they
cally induced cleaning intervals). also guarantee.
Separators of the new generation are to be used ex- The manufacturer’ specifications have to be ad-
clusively; they are fully efficient over a large density hered to in order to achieve an optimum cleaning
range without requiring any switchover, and are ca- effect.
1 separator for
100% throughput
Layout of the separators is to be in accordance with lected, it can be expected that the results given in
the latest recommendations of the separator manu- Table 3, for water and inorganic foreign particles in
facturers, Alfa Laval and Westfalia. In particular, the the heavy fuel oil are reached at the entry into the
density and viscosity of the heavy fuel oil are to be engine.
taken into consideration. Consulting MAN Diesel is
required if other makes of separators come up for The results obtained in practical operation reveal
discussion. that adherence to these values helps to particularly
keep abrasive wear in the injection system and in
If the cleaning treatment prescribed by MAN Die- the engine within acceptable limits. Besides, opti-
sel is applied, and if the correct separators are se- mal lube oil treatment must be ensured.
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
General
• Water • Ash
Attention is to be paid to very thorough water sep- Heavy fuel oils with a high ash content in the form
aration, since the water is not a finely distributed of foreign particles such as sand, corrosion and
emulsion but in the form of adversely large droplets. catalyst residues, promote the mechanical wear in
Water in this form promotes corrosion and sludge the engine. There may be catalyst fines (catfines)
formation also in the fuel system, which has an ad- in heavy fuel oils coming from catalytic cracking
verse effect on the delivery and atomisation and processes. In most cases, these catfines will be
thus also on the combustion of the heavy fuel oil. aluminium silicate, which causes high wear in the
If the water involved is sea water, harmful sodium injection system and in the engine. The aluminium
chloride and other salts dissolved in the water will content found multiplied by 5 - 8 (depending on
enter the engine. the catalyst composition) will approximately cor-
respond to the content of catalyst materials in the
The water-containing sludge must be removed from heavy fuel oil.
the settling tank prior to each separating process,
and at regular intervals from the service tank. The • Homogeniser
venting system of the tanks must be designed in
such a way that condensate cannot flow back into If a homogeniser is used, it must not be installed
the tanks. between the settling tank and the separator on any
account, since in that case, harmful contaminants,
• Vanadium/sodium and in particular seawater, cannot be separated out
sufficiently.
Should the vanadium/sodium ratio be unfavour-
able, the melting temperature of the heavy fuel oil Flash point (ASTMD-93)
ash may drop into the range of the exhaust valve
temperature which will result in high-temperature National and international regulations for transport,
corrosion. By precleaning the heavy fuel oil in the storage and application of fuels must be adhered to
settling tank and in the centrifugal separators, the in respect of the flash point. Generally, a flash point
water, and with it the water-soluble sodium com- of above 60° C is specified for fuels used in Diesel
pounds can be largely removed. engines.
If the sodium content is lower than 1/3 of the vadi- Low temperature behaviour (ASTM D-97)
um content, the risk of high-temperature corrosion
will be small. It must also be prevented that sodium • Pourpoint
in the form of sea water enters the engine together
with the intake air. The pour point is the temperature at which the fuel
is no longer fluid (pumplike). Since many of the low-
If the sodium content is higher than 100 mg/kg, an viscosity heavy fuel oils have a pour point greater
increase of salt deposits is to be expected in the than 0° C, too, the bunkering system has to be pre-
combustion space and in the exhaust system. This heated unless fuel in accordance with CIMAC A30
08028-0D/H5250/94.08.12
condition will have an adverse effect on engine op- is used. The entire bunkering system should be de-
eration (among others, due to surging of the turbo- signed so as to permit preheating of the heavy fuel
charger). oil to approx. 10° C above the pour point.
08.19 - ES1
MAN Diesel
Description
Quality of Heavy Fuel Oil (HFO) 504.20
Page 7 (10) edtion 08
General
Pump ability Preheating of the charge-air in the part-load range
and output reduction for a limited period of time
Difficulties will be experienced with pumping if the are possible measures to reduce detrimental influ-
fuel oil has a viscosity higher than 1,000mm2/s (cSt) ences of fuel of poor ignition qualities. More effec-
or a temperature less than approx. 10° C above the tive, however, are a high compression ratio and the
pour point. Please also refer to “Low temperature in-service matching of the injection system to the
behaviour (ASTM D-97)”. ignition qualities of the fuel oil used, as is the case
in MAN Diesel trunk piston engines.
Combustion properties
The ignition quality is a key property of the fuel. The
An asphalt content higher than 2/3 of the carbon reason why it does not appear in the international
residue (Conradson) may lead to delayed combus- specifications is the absence of a standardised
tion, which involves increased residue formation, testing method. Therefore, parameters such as the
such as deposits on and in the injection nozzles, Calculated Carbon Aromaticity Index (CCAI) are
increased smoke formation, reduced power and in- resorted to as an aid, which are derived from de-
creased fuel consumption, as well as a rapid rise of terminable fuel properties. We have found this to
the ignition pressure and combustion close to the be an appropriate method of roughly assessing the
cylinder wall (thermal overloading of the lube oil ignition quality of the heavy fuel oil used.
film). If the ratio of asphaltenes to carbon residues
reaches the limit value 0.66, and the asphaltene A test instrument utilising a constant-volume
content also exceeds 8 %, additional analyses of combustion technology (FIA fuel ignition analy-
the heavy fuel oil by means of thermogravimetric ser) has been developed and is currently be-
analysis (TGA) must be performed by MAN Diesel ing evaluated at a number of testing laboratories.
to evaluate the usability. This tendency will also be The ignition quality of a fuel is determined as an ig-
promoted by the blend constituents of the heavy nition delay in the instrument that is converted to an
fuel oil being incompatible, or by different and in- instrument-related cetan number (FIA-CN or ECN).
compatible bunkering being mixed together. As a It has been observed that fuels with a low FIA ce-
result, there is an increased separation of asphalt tan number or ECN could, in some cases, lead to
(also see “Compatibility”). operational problems.
Ignition quality As the fluid constituent in the heavy fuel oil is the
determining factor for its ignition quality and the vis-
Cracked products which nowadays are preferred as cous constituent is decisive for the combustion qual-
low-viscosity blend constituents of the heavy fuel ity, it is the responsibility of the bunkering company
oil in order to achieve the specified reference vis- to supply a heavy fuel oil grade of quality matched
cosity may have poor ignition qualities. The cetane to the Diesel engine. Please refer to Figure 2.
number of these constituents should be > 35. An in-
creased aromatics content (above 35 %) also leads
to a decrease in ignition quality.
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
General
16/24 1
20/27
21/31 32/44CR
V D CCAI 23/30 32/36 40/54
1 800 800 25/30 32/40 48/60
27/38 40/45 52/55B
28/32 52/55A 58/64
820
810
840
820
2
860
830
3 880 A
840
4 900
5 850
920
940 860
10 2
960 870 B
20
980 880
30
50 1000 890
100 1020
900
200 C
1040
400 910
1000
920
5000
930
20000
50000
Figure 2 Nomogram for the determination of CCAI assignment of CCAI ranges to engine types
CCAI can also be calculated with the aid of the following formula:
CCAI = D - 141 log log (V+0.85) - 81
08.19 - ES1
MAN Diesel
Description
Quality of Heavy Fuel Oil (HFO) 504.20
Page 9 (10) edtion 08
General
Sulphuric acid corrosion The use of fuel additives during the guarantee pe-
riod is rejected as a matter of principle.
The engine should be operated at the cooling water
temperatures specified in the operating manual for Additives currently in use for Diesel engines are
the respective load. If the temperature of the com- listed in Table 4, together with their supposed ef-
ponent surface exposed to the acidic combustion fect on engine operation.
gases is below the acid dew point, acid corrosion
can no longer be sufficiently prevented even by an
alcaline lubricating oil. Precombustion • Dispersants/stabilisers
• Emulsion breakers
If the lube oil quality and engine cooling meet the • Biocides
respective requirements, the BN values (see “Qual-
ity of lube oil (SAE40) for heavy fuel oil operation Combustion • Combustion catalysts (fuel
(HFO)”) will be adequate, depending on the sulphur economy, emissions)
concentration in the heavy fuel oil. Postcombustion • Ash modifier (hot corrosion)
• Carbon remover (exhaust
Compatibility
system)
The supplier has to guarantee that the heavy fuel Table 4 Additives to heavy fuels Classification/
oil remains homogenous and stable even after effects
the usual period of storage. If different bunker oils
are mixed, separation may occur which results in
sludge formation in the fuel system, large quantities Low sulphur HFO
of sludge in the separator, clogging of filters, insuf-
ficient atomisation and high–residue combustion. From an engine manufacturer‘s point of view there
is no lower limit for the sulphur content of HFO. We
In such cases, one refers to incompatibility or insta- have not experienced any trouble with the currently
bility. The heavy fuel oil storage tanks should there- available low sulphur HFO, that are related to the
fore be emptied as far as possible prior to rebunker- sulphur content or specific to low sulphur HFO.
ing in order to preclude incompatibility. This may change in the future if new methods are
applied for the production of low sulphur HFO (de-
Blending heavy fuel oil sulphurization, uncommon blending components).
MAN Diesel will monitor developments and inform
If, for instance, heavy fuel for the main engine and our customers if necessary.
gas oil (MGO) are blended to achieve the heavy
fuel oil quality or viscosity specified for the auxil- If the engine is not operated permanently on low
iary engines, it is essential that the constituents are sulphur HFO, then the lubricating oil should be se-
compatible (refer to “Compatibility above). lected according to the highest sulphur content of
the fuels in operation.
Additives to heavy fuel oils
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
General
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description
Quality of Marine Diesel Fuel (MDO) 504.20
Page 1 (2) Edition 09
General
Diesel Fuel Oil, Diesel Oil, Bunker Diesel Oil, Ma- The usability of a fuel depends upon the engine
rine Diesel Fuel. design and available cleaning facilities as well as
on the conformity of the key properties with those
Marine Diesel Oil (MDO) is offered as heavy distil- listed in the table below which refer to the condition
late (designation ISO-F-DMB) or as a blend of distil- on delivery.
late and small amounts of residual oil (designation
ISO-F-DMC) exclusively for marine applications. The key properties have been established to a
The commonly used term for the blend, which is of great extent on the basis of ISO 8217-2005 and
dark brown to black colour, is Blended MDO. MDO CIMAC-2003. The key properties are based on the
is produced from crude oil and must be free from test methods specified.
organic acids and any non-mineral oil products.
Other specifications:
08028-0D/H5250/94.08.12
1)
With good illumination and at room temperature, appearance
of the fuel should be clear and transparent.
08.19 - ES1
MAN Diesel
General
08.19 - ES1
MAN Diesel
Description
Quality of Gas Oil / Diesel Fuel (MGO) 504.20
Page 1 (2) Edition 10
General
Gas oil, Marine Gas Oil (MGO), High Speed Diesel Suitability of the fuel depends on the conformity
Oil. with the key properties as specified hereunder, per-
taining to the condition on delivery.
Diesel fuel is a medium class distillate of crude oil
which therefore must not contain any residual com- On establishing the key properties, the standards
ponents. of DIN EN 590 and ISO 8217-2005 (Class DMA),
as well as CIMAC-2003 were taken into considera-
tion to a large extent. The key property ratings refer
to the testing methods specified.
≥ 1.5
Cinematic viscosity / 40° C mm2/s (cSt) ISO 3104
≤ 6.0
Filter ability1)
in summer ≤0
DIN EN 116
in winter °C ≤ 12
Other specifications:
1)
Determination of filter ability to DIN EN 116 is comparable to
Cloud Point as per ISO 3015.
2)
L/V 20/27 engines require a cetane number of at least 45
08.19 - ES1
MAN Diesel
General
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description 504.27
Page 1 (4) Analysis Data Edition 02
General
Comments on Analysis Data for Fuel Oils Asphaltenes also influences the lubricating properties
of the fuel oil and, in extreme cases, high asphalteness
Carbon Residue content may lead to fuel injection pump sticking.
The carbon residue of a fuel oil indicates its coke- Fuel oils with a high asphalteness content will have
forming tendency and can be used to determine the a tendency to form sludge, especially if the water
tendency to form deposits in the combustion chamber content is also high. The asphaltenes content of a
and gasways. The higher the carbon residue value, fuel oil is influenced by pre-treatment. The heaviest
the higher the fouling tendency. semi-solid asphaltenes, and asphaltenes bound to
water as sludge, can be separated by centrifuging.
Some changes in the combustion process, requir-
ing adjustment of the maximum pressure, may also
be attributed to a high carbon residue content. The Diesel Index
value is measured by standardized tests, such as
the Conradson or Ramsbottom tests which give Diesel index is a calculated value to determine the
similar results. ignition quality of a fuel oil. The ignition quality is re-
lated to the hydrocarbon composition, paraffin being
The non-vaporized residue from the carbonizing test of high quality, n-heptanes of moderate quality and
consists of carbonaceous material and inorganic im- aromatics of low quality.
purities and is expressed as percentage weight of the
fuel sample tested. Carbon residue and asphaltenes With certain exceptions the properties of the aniline
content generally move in parallel, both in relation to point and the specific gravity reflect the hydrocarbon
the carbon-to-hydrogen ratio, with increasing values composition of a fuel oil, and are therefore used in
for a higher ratio. the following simple formula as an expression of
ignition quality:
The carbon-to-hydrogen ratio and thus also the
carbon residue depends on the source of the crude Diesel index = (aniline point °F x API gravity) x
oil and the type of refinery processing used. 0.01.
The effect of carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment of the fuel oil, as centrifuging equal volumes of the fuel and aniline become just
only influences solid inorganic contaminants and miscible. The test relies on the fact that aromatic
hard asphalts, which are only small amounts of the hydrocarbons mix completely with aniline at compara-
percentage weight called carbon residue. tively low temperatures, whereas paraffins require
considerably higher temperatures before they are
completely miscible.
Asphaltenes
A high aniline point thus indicates a highly paraffinic
Asphaltenes is defined as the part of a fuel oil sam- fuel, and consequently a fuel oil of good ignition qual-
ple which is insoluble in heptane. The content of ity. Similarly, a high API gravity number denotes a
08028-0D/H5250/94.08.12
asphalteness is expressed as percentage weight of low specific gravity and high paraffinicity, and again
the fuel oil sample tested. a good ignition quality.
Asphaltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea of the
solid hydrocarbon compounds dispersed in the fuel ignition quality, but generally gives figures slightly
oil, has a similar effect on the combustion process above the cetane number.
to the carbon residue, the main impact being fouling
of gasways. The stability of the fuel oil is related to Fuel oils with poor ignition quality and a low diesel
the asphaltenes content. index might in particular cause problems in starting
diesel engines and running at low load.
02.16 - ES0 - G
MAN Diesel
504.27 Description
Edition 02 Analysis Data Page 2 (4)
General
In addition to starting difficulties, a prolonged ignition Especially if the weight ratio of sodium to vanadium
delay may give rise to alternations in the maximum exceeds 1:3, ash with a very low melting point and
pressure, leading to increased mechanical or ther- stiction temperature is formed, giving rise to high
mal load. temperature corrosion of exhaust valves and deposit
formation in turbochargers.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling It is possible to reduce the tendency for formation
of gasways. of detrimental vanadium-sodium ash by effective
centrifuging, which will remove sodium salts to-
gether with water. If a very low content of sodium is
Sulphur ensured, a relatively high vanadium content might
be acceptable.
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free Water
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low The water content of fuel oil is measured by a
temperature corrosion. During combustion, sulphur standardized distillation test and is expressed as
oxides are produced in the form of gases. Since percentage volume of the sample tested. Water in
humidity is also present sulphur and sulphuric acid the fuel oil may lead to several detrimental effects
may be formed on components in the combustion on the fuel oil system, and corrosion and cavitation
chamber and in the gasways, where the temperature of fuel injection pumps and fuel valves, and cause
is below that of the dew point for sulphuric acid. fouling of exhaust systems and turbochargers.
The detrimental effect of sulphur in fuel oil is coun- Due to its content of sodium, salt water in combina-
teracted by maintaining an adequate temperature of tion with vanadium contributes to the formation of
the combustion chamber components and by using low-melting corrosive ash, which attacks exhaust
alkaline lubricating oil to neutralize the sulphuric acid valves and turbochargers. When it disturbs the fuel
produced during combustion. atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
It is possible to reduce the water content of a fuel oil
Vanadium and sodium are constituents of the ash primarily by centrifuging, and this should be done
content. The amounts of these are measured by to the widest possible extent in order to avoid the
analyzing the residue from the combustion test used detrimental effects of water in the fuel oil.
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil Ash
sample being tested for ash content. Vanadium de-
08028-0D/H5250/94.08.12
rives from the crude oil itself and, being oil soluble, Ash content is a measure of the non-combustible
cannot be removed from the fuel oil by conventional material present in the fuel oil. The ash content is
pre-treatment. Sodium derives from the crude oil, and determined by a combustion test and it is expressed
also from contamination with salt water during storage as a percentage weight residue from complete com-
and transport of the fuel oil. Sodium is water- soluble bustion of the oil sample tested.
and, regardless of derivation, tends to combine with
the water present in the fuel oil. Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
Owing to its water solubility, it is possible to remove contamination of the fuel oil.
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.
02.16 - ES0 - G
MAN Diesel
Description 504.27
Page 3 (4) Analysis Data Edition 02
General
Ash-forming materials exist both as solid contami- Viscosity of Marine Gas Oil (MGO) and Marine
nants and in soluble compounds. The solid contami- Diesel Oil (MDO) are expressed in centistokes (cSt)
nants may lead to abrasive wear in the fuel injection at 40° C.
system. Ash formed during combustion may lead to
abrasive as well as corrosive wear of combustion Viscosity is an important parameter in connection with
chamber components and give rise to formation of pumping, pre-treatment and injection of fuel oil, since
detrimental deposits. It is therefore essential, to the the possibility and efficiency of these processes to a
greatest possible extent, to reduce the amount of large extent depend on adequate viscosity.
ash-forming materials by centrifuging.
Adjustment of viscosity to adequate values is possible
Solid contaminants such as sand, rust, certain by taking advantage of the interdependence between
metal oxides and catalyst fines can be removed by the temperature and viscosity index of the fuel oil.
centrifuging, and the same goes for water-soluble
salts such as sodium. The nominal viscosity of a fuel oil is the factor de-
termining the preheating temperatures necessary to
Some of the components included in the ash content obtain adequate viscosity for pumping, centrifuging
have been found to be particularly harmful and are and injection of the fuel oil, and thus also the factor
therefore stated individually in the analysis data. determining the capacity of the preheating equipment
in the fuel oil system.
sioning the centrifuge size are based on the fact As the formula indicates, the API gravity is in inverse
that approx. 1/3 of the catalyst particles in terms of proportion to density and specific gravity.
weight is removed.
Density is an important parameter in the centrifuging
process, where separating water and water-dissolved
Viscosity impurities from the fuel oil is based on the difference
in densities. If the density of the fuel oil approaches
Basically viscosity is a measure of the internal friction that of water, centrifuging thus becomes less effec-
or resistance of a liquid to flow. tive, necessitating a reduced flow rate and therefore
increased centrifuge capacity.
02.16 - ES0 - G
MAN Diesel
504.27 Description
Edition 02 Analysis Data Page 4 (4)
General
The water separation ability of fuel oil is increased Pour Point
by preheating the fuel oil prior to centrifuging since
the densities of fuel oil and water change with the The pour point is the lowest temperature at which an
temperature at different rates, thus making it possible oil will flow or can be poured. The pour point is meas-
to optimize density differences. ured under specific test conditions. Fuel oil must be
stored, handled and pumped at temperatures above
To some extent the quality of a fuel oil can be judged the pour point to avoid wax crystallization, which may
by the density, since this is directly proportional to the result in precipitation in storage tanks, blocking of
carbon-to-hydrogen ratio, which again is in direct pro- filters and pipe lines and prevention of pumpability.
portion to aromativity, carbon residue and asphaltene Normally, the pour point of residual fuel oil does not
content, but in reverse ratio to calorific value. create any problems, since the temperature needed
to reduce the viscosity to pumpable levels will be
adequately in excess of the pour point.
08028-0D/H5250/94.08.12
02.16- ES0 - G
MAN Diesel
Description 504.30
Page 1 (2) Fuel Oil Cleaning Edition 01
General
Purification Recommendations Especially for fuels above 180 cST/50°C (1500 sec.
RW/100°F) the highest possible temperature of 98°C
Fuel oils are always contaminated and should there- (208°F) should be maintained in the centrifuge oil
fore be cleaned thoroughly of 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 for as long as pos-
catalysts. Liquid contaminants are mainly water, i.e. sible by adjusting the flow rate through the centrifuge
either fresh water or sea water. so that it corresponds to the amount of fuel required
by the engine without excessive re-circulating. Con-
The impurities can cause damage to fuel injection sequently, the centrifuge should operate for 24 hours
pumps and fuel valves, result in increased cylinder a day except during necessary cleaning.
liner wear and cause the exhaust valve seats to
deteriorate. Increased fouling of gasways and tur- Taking today's fuel qualities into consideration the
bocharger blends may also result from the use of need to clean centrifuges ("shooting frequency")
inadequately 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 that the capacity removal. The centrifuge manual states the disc or
of the centrifuges installed be at least according to screw adjustment which should be chosen on the
the centrifuge 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 to allow the fuel oil to remain available for fuel cleaning. Results from experimen-
in the centrifuge bowl for as long 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 HFO by Centrifuging
series, in purifier/clarifier mode.
Single centrifuge as purifier.
Operating Therefore series operation of centrifuges to ensure
options Two centrifuges in parallel.
Two centrifuges in series. maximum safety is a fully accepted alternative to the
previously recommended parallel operation, provided
Optimum Operating Configurations the operating capacity of each individual centrifuge
can handle the total amount of fuel required by the
Water content Parallel operation engine, without exceeding the flow rate recommended
below 1 % Purifier / Purifier by the centrifuge maker for the operating mode in
Normal question.
or
conditions
Density at 15°C Series operation
below 0.991 Purifier + Clarifier If the centrifuge capacity installed is on the low side,
corresponding to the specific viscosity of the fuel
08028-0D/H5250/94.08.12
Water content oil used, and if more than one centrifuge is avail-
below 1 % Parallel operation able, parallel operation may be considered in order
to obtain an even lower flow rate. However, in view
Extreme Density at 15°C Purifier / Purifier of the above results and recommendations serious
conditions below 0.991 consideration should be given to installing new equip-
ment in accordance with today's fuel qualities and
High content Series operation flow recommendations.
of catalyst fines Purifier + Clarifier
97.40 - ES0
MAN Diesel
504.30 Description
Edition 01 Fuel Oil Cleaning Page 2 (2)
General
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
08028-0D/H5250/94.08.12
97.40 - ES0
MAN Diesel
Description
Page 1 (5) Freshwater System Treatment 504.40
Edition 02
General
Protection against Corrosion in Freshwater Cleaning agents emulsified in water as well as slightly
Cooling System alkaline cleaning agents can be used for the degrea-
sing process, whereas ready-mixed cleaning agents
The engine fresh water must be carefully treated, which involve the risk of fire must obviously not be
maintained and monitored so as to avoid corrosion used. For descaling with acid, especially products
or the formation of deposits which can result in insuf- based on amino-sulphonic acid, citric acid, and tar-
ficient heat transfer, it is necessary to treat the cooling taric acid are recommendable, as these acids are
water. MAN B&W recommend that this treatment is usually obtainable as solid substances, easily soluble
carried out according to the following procedure: in water, and do not emit poisonous vapours.
Before starting the inhibition process, any existing The filling-up with cooling water and the admixture
deposits of lime or rust, or any oil sludge, should be of the inhibitor is to be carried out directly after the
removed in order to improve the heat transfer and to cleaning in order to prevent formation of rust on the
ensure uniform protection of the surface by means cleaned surfaces.
of the inhibitor.
Raw Water
The cleaning should comprise degreasing to remove
oil sludge, and descaling with acid afterwards to The formation of lime stone on cylinder liners and in
remove rust and lime deposits. cylinder heads may reduce the heat transfer, which
will result in unacceptably high temperatures in the
Ready-mixed cleaning agents, specially made for material.
08028-0D/H5250/94.08.12
00.11- ES1
MAN Diesel
General
If deionized or distilled water cannot be obtained, Checking of the Cooling Water System and
normal drinking water can be used in exceptional the Cooling Water during Service
cases. If so, the total hardness of the water must
not exceed 9° dH (German hardness degrees). The If the cooling water is contaminated during service,
chloride, chlorine, sulphate, and silicate contents sludge or deposits may form. The condition of the
are also to be checked. These contents should not cooling water system should therefore be regularly
exceed the following values: checked, especially if deionized or distilled water is
not used. If deposits are found in the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces or, if necessary, the entire system
Chlorine 10 ppm (10 mg/litre) should be cleaned.
Sulphate 100 ppm (100 mg/litre)
Silicate 150 ppm (150 mg/litre) According to experience, a zinc galvanized coating
in the freshwater cooling system is often very suscep-
There should be no sulphide and ammonia content. tible to corrosion, which results in heavy formation of
Rain water must not be used, as it may be heavily sludge, even if the cooling water is correctly inhibited.
contaminated. The initial descaling with acid will, to a great extent,
remove the galvanized coating. Generally, therefore,
It should be noted that softening of water does not we advise against the use of galvanized piping in the
reduce its sulphate and chloride contents. freshwater cooling system.
Treatment of the cooling water with inhibting oils is not The concentration of inhibitor must under no
recommended, as such treatment involves the risk of circumstances be allowed to fall below that
oil adhering to the heat transmitting surfaces. recommended by the producer, as this would
increase the risk of corrosion.
Chromate inhibitors must not be used in plants
08028-0D/H5250/94.08.12
connected to a freshwater generator. A clear record of all measuring results should be kept,
so that the actual condition and trend of the system
Evaporated cooling water is to be replaced with may be currently ascertained and evaluated.
noninhibited water, whereas a loss of water through
leakage must be replaced with inhibited water. A sudden or gradual increase in the chloride content
of the cooling water may be indicative of salt water
When overhauling individual cylinders, a new dosage leakages. Such leakages are to be traced and repai-
of inhibitor must, if necessary, be added im-mediately red at the first opportunity.
after completing the job.
00.11- ES1
MAN Diesel
Description
Page 3 (5) Freshwater System Treatment 504.40
Edition 02
General
A chloride content in the cooling water higher than The cooling water system must not be kept under
the 50 ppm specified might, in exceptional cases pressure.
be tolerated. However, in that case the upper limit
specified by the individual inhibitor supplier must Check, and repair any leaks.
not be exceed.
Drain the system and fill up completely with clean
A clear record of all measuring results should be kept, tap water, in order to flush out any oil or grease from
so that the actual condition and trend of the system the tank.
may be currently ascertained and evaluated.
Circulate the water for 2 hours, and drain again.
A sudden or gradual decrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased Descaling with Acid Solution
by adding inhibtor; however, if major quantities are
necessary, the water should be replaced. Fill up with clean tap water and heat to 70-75° C.
Every third month a cooling water sample should be Dissolve the necessary dosage of acid compound
sent ashore for laboratory analysis, in particular to in a clean iron drum with hot water.
ascertain the contents of inhibtor, sulphate, and iron,
as well as the total salinity of the water. Fill the drum half up with water and slowly add the
acid compound, while stirring vigorously. Then fill the
drum up completely with hot water while continuing
Cleaning and Inhibiting Procedure to stir (e.g. using a steam hose).
The engine must not be running during the cleaning Be careful - use protective spectacles and
procedure, as this may involve the risk of overheating gloves.
when draining.
For engines which have been treated before the trial
trip, the lowest concentration recommended by the
Degreasing supplier will normally be sufficient.
Use clean tap water for filling-up. The cooling water For untreated engines, a higher concentration - de-
in the system can be used, if it does not contain pending on the condition of the cooling system - will
inhibitors. normally be necessary.
Heat the water to 60° C and circulate the water Drain some water from the system and add the acid
continuously. solution via the expansion tank.
Drain to lowest water level in expansion tank. The cooling water system must not be put under
pressure.
08028-0D/H5250/94.08.12
00.11- ES1
MAN Diesel
General
A number of descaling preparations contain colour Adding of Inhibitors
indicators which show the state of the acid solution.
If the acid content is exhausted, a new acid solution Fill up the cooling water system with water from the
can be added, in which case, the weakest recom- evaporator to the lowest water level in the expan-
mended concentration should be used. sion tank.
The solubility of acids in water is often limited. Weight out the quantity of inhibitors specified by the
Therefore if, in exceptional cases, a large amount is supplier and dissolve in a clean iron drum with hot
required, descaling can be carried out in two stages water from the evaporator.
with a new solution of compound and clean water.
Normally the supplier will specify the maximum Add the solution via the expansion tank to the system.
solubility. Then fill up to normal water level with water from the
evaporator.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized Allow the engine to run for not less than 24 hours to
with clean tap water containing 10 kg soda per ton ensure that a stable protection of the cooling surfa-
of water. Circulate the mixture for 30 minutes, then ces is formed.
drain and flush the system.
Subsequently, test the cooling water with a test
The cooling water system must not be put under kit (available from the inhibitor supplier) to ensure
pressure. that an adequate inhibitor concentration has been
obtained.
Continue to flush until water used is neutral (pH
approx. 7). This should be checked every week.
08028-0D/H5250/94.08.12
00.11- ES1
MAN Diesel
Description
Page 5 (5) Freshwater System Treatment 504.40
Edition 02
General
Nitrite-borate corrosion inhibitors
for cooling water treatment
Maker's minimum
Company Name of Inhibitor Delivery Form Recommended
Dosage*
The list is for guidance only and must not be consid- The suppliers are listed in alpabetical order.
08028-0D/H5250/94.08.12
00.11- ES1
Cylinder head
505/605
MAN Diesel
Description 505.01
Page 1 (1) Cylinder Head and Water Jacket Edition 02H
L16/24
Cylinder Head The water jacket is bolted to the cylinder head by five
bolts. The five connection bolts to the cylinder head
The cylinder head is of cast iron with an integrated are free accessible from the top side and permit also
charge air receiver, made in one piece. It has a bore- a dismantling of the cylinder head itself.
cooled thick walled bottom. It has a central bore for
the fuel injection valve and 4 valve cross flow design,
with high flow coefficient. Intensive water cooling of Air Inlet and Exhaust Valves
the nozzle tip area made it possible to omit direct
nozzle cooling. The valve pattern is turned about 20° The valve spindles are made of heat-resistant
to the axis and achieves a certain intake swirl. material and the spindle seats are armoured with
welded-on hard metal.
The cylinder head is tightened by means of 4 nuts
and 4 studs which are screwed into the engine All valve spindles are fitted with valve rotators which
frame. The nuts are tightened by means of hydraulic turn the spindles each time the valves are activated.
jacks. The turning of the spindles ensures even tem-pera-
ture levels on the valve discs and prevents deposits
The cylinder head has a screwed-on top cover. It has on the seating surfaces.
two basic functions: oil sealing of the rocker chamber
and covering of the complete head top face to protect The cylinder head is equipped with replaceable
bolts and reduce noise radiation. valve seat rings. The exhaust valve seat rings are
water cooled in order to assure low valve tempera-
The valve guides are identical and therefor inter- tures.
changeable.
The seat rings are made of heat-resistant steel. The
seating surfaces are hardened in order to minimize
Water Jacket wear and prevent dent marks.
98.38 - ES0
MAN Diesel
Working Card 505-01.00
Page 1 (3) Dismantling of Cylinder Unit from Engine Edition 10H
L16/24
Related procedure
Data
07.35 - ES0
MAN Diesel
505-01.00 Working Card
Edition 10H Dismantling of Cylinder Unit from Engine Page 2 (3)
L16/24
Preparation before Dismantling 9) Remove the 2 clamps securing the charge air
connections by unscrewing the locking bolts
1) Drain off the water from the engine. for the clamps.
2) Remove the top cover. 10) Push the charge air connections, inside the
cylinder head which are to be removed.
3) Remove the side covers on both sides of the
engine. 11) Turn the piston to top position.
Disassembly of Connections 12) Loosen the connecting rod nuts by means of the
hydraulic jacks, see working card 506-01.25.
5) Remove the clamp for connecting cylinder head
and exhaust gas receiver. 13) Remove the connecting rod nuts and bearing
cap by hand.
6) Remove the fuel oil high pressure pipe.
Cylinder unit
Fixing tool
08028-0D/H5250/94.08.12
07.35 - ES0
MAN Diesel
Working Card 505-01.00
Page 3 (3) Dismantling of Cylinder Unit from Engine Edition 10H
L16/24
Mounting of Support Tools
14) Mount the fixing part, see plate 52006 item 212
Cylinder unit
for locking the connecting rod to the cylinder
liner.
Work table
07.35 - ES0
MAN Diesel
Working Card 505-01.01
Page 1 (3) Disassembly of Cylinder Unit Edition 02H
L16/24
Starting position
Related procedure
Data
99.03 - ES0
MAN Diesel
505-01.01 Working Card
Edition 02H Disassembly of Cylinder Unit Page 2 (3)
L16/24
Before starting to dismantle the cylinder unit it must Removal of Cylinder Head
be placed on the grinding table.
4) Remove the five allen screws in the cylinder
head.
Removal of Piston and Connecting Rod
5) Remove the cylinder head by means of the
1) Remove the fixing part (please see plate 52006, lifting tool .
item 212) from the cylinder liner and connecting
rod.
Cylinder head
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Working Card 505-01.01
Page 3 (3) Disassembly of Cylinder Unit Edition 02H
L16/24
99.03 - ES0
MAN Diesel
Working Card 505-01.05
Page 1 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 07H
L16/24
Starting position
Related procedure
Data
03.42 - ES0
MAN Diesel
505-01.05 Working Card
Edition 07H Inspection of Inlet Valve, Exhaust Valve and Valve Guide Page 2 (3)
L16/24
Dismantling of Inlet and Exhaust Valve
Spindles
Or as an Alternative:
8) Loosen nut A and extractor plate B, see fig 10) Repeat point 4 - 9 to remove other valve
1. spindles.
03.42 - ES0
MAN Diesel
Working Card 505-01.05
Page 3 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 07H
L16/24
Inspection of Valves/Valve Seats
If the inner diameter of the valve spindle guide Fig 4 Measurement of valve spindle guide for wear.
exceeds the tolerance, please see page 500.35,
the valve spindle guide must be replaced.
Please see working card 505-01.20.
Note:
Please be aware of the different valve disk diameter
at inlet and exhaust valves.
Inlet valve : Ø57 mm
08028-0D/H5250/94.08.12
03.42 - ES0
MAN Diesel
Working Card Reconditioning of Valve Spindle Seat 505-01.10
Page 1 (3) Edition 02H
and Valve Seat Ring
L16/24
Valve spindle has been removed 505-01.05 All the hand tools and new stones are included
in the tools box for grinding machine.
Related procedure
Capacity : 1 man
Data
98.40 - ES0
MAN Diesel
505-01.10 Reconditioning of Valve Spindle Seat Working Card
Page 2 (3)
Edition 02H and Valve Seat Ring
L16/24
Reconditioning of Valve Seat Ring However, when seat "S" is ground to such an extent
that recess "R" disappears, see fig 1, the valve seat
Reconditioning of valve seat rings by machining is ring must be scrapped and a new one must be instal-
carried out by means of a grinding machine, the led, please see working card 505-01.35
pilot spindle of which must be mounted in the valve
spindle guide. For operation of the grinding machine, This is only valid for the exhaust valve seat, the inlet
see separate instructions. valve seat has no recess due to less wear of the
inlet valve seat.
0.05°
2) Continue grinding until a clean and uniform
"A" 30 ± 0
surface is obtained.
"R"
"S"
3) Check height "H"1 upon completion the grin-
ding, see fig 2.
98.40 - ES0
MAN Diesel
Working Card Reconditioning of Valve Spindle Seat 505-01.10
Page 3 (3) Edition 02H
and Valve Seat Ring
L16/24
4) After assembling the valves, check by mothing
the valve that distance "H"2 between the up-
per edge of the cylinder head and the upper
edge of the valve spindle, see fig 3, does not
exceed the maximum value, please see page
500.35.
98.40 - ES0
MAN Diesel
Working Card 505-01.15
Page 1 (2) Valve Rotator Edition 02H
L16/24
Starting position
Related procedure
Capacity : 1 man
Data
98.46 - ES0
MAN Diesel
505-01.15 Working Card
Edition 02H Valve Rotator Page 2 (2)
L16/24
Maintenance and Inspection of Rotocap Note: Having assembled the valve rotator in dry
condition it should be placed in clean lubricating oil
Dirt, especially in the ball pockets due to residues in for a short period of time.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and interrupt
the movement of the balls.
Dismantling of Rotocap
Fig 1 Valve rotator
Please see Working Card 505-01.05, steps 3 to 9.
1) Clean the valve rotator. Please see working card 505-01.05, steps 3 to 9,
opposite direction.
2) Remove the retaining ring and disassemble
the individual parts.
98.46 - ESO
MAN Diesel
Working Card 505-01.20
Page 1 (3) Replacement of Valve Guide Edition 05H
L16/24
Dismantling and mounting of valve guide for inlet Hammer / Lead hammer
and exhaust valve. Nitrogen (N2), or similar.
H7 reamer, 12 mm
Starting position
Related procedure
Data
01.14 - ES0
MAN Diesel
505-01.20 Working Card
Edition 05H Replacement of Valve Guide Page 2 (3)
L16/24
When to Replace the Valve Guide
01.14 - ESO
MAN Diesel
Working Card 505-01.20
Page 3 (3) Replacement of Valve Guide Edition 05H
L16/24
8) Insert a new O-ring in the valve guide, before
mounting of the valve spindle.
01.14 - ES0
MAN Diesel
Working Card 505-01.20
Page 1 (3) Replacement of Valve Guide Edition 12H
L16/24
Dismantling and mounting of valve guide for inlet Hammer / Lead hammer
and exhaust valve. Nitrogen (N2), or similar.
Starting position
Related procedure
Data
08.03 - ES0-ver08
MAN Diesel
505-01.20 Replacement of Valve Guide Working Card
Edition 12H Page 2 (3)
L16/24
When to Replace the Valve Guide
08.03 - ESO-ver08
MAN Diesel
Working Card 505-01.20
Page 3 (3) Replacement of Valve Guide Edition 12H
L16/24
8) Insert a new O-ring in the valve guide, before
mounting of the valve spindle.
08.03 - ES0-ver08
MAN Diesel
Working Card 505-01.35
Page 1 (2) Replacement of Valve Seat Ring Edition 05H
L16/24
Starting position
Related procedure
01.32 - ES0
MAN Diesel
505-01.35 Working Card
Edition 05H Replacement of Valve Seat Ring Page 2 (2)
L16/24
Dismounting of Valve Seat Rings Mounting of Valve Seat Rings
When reconditioning of a valve seat ring no longer is 5) Prior to mounting of a new valve seat ring,
possible due to dimensions exceeding the scrapping the bore must be cleaned thoroughly and
criteria, the seat ring has to be replaced. inspected for marks. Marks that can hinder
mounting of the valve seat ring must be remo-
Dismounting of a valve seat ring is carried out by ved.
means of a special extractor tool set comprising the
components, see fig 1. 6) To facilitate the valve mounting of the seat ring
it must be cooled down, however, a max. of
-25° C otherwise, the O-ring can be dama-
ged.
Coat with
loctite 648
O-ring
Coat with oil
Fig 1 Extraction of valve seat ring.
1) Weld approx. 5 seconds at 3 places around 7) Place the O-ring on the valve seat ring and
the old valve seat with electrode. coat with oil/loctite as shown in fig 2, just before
positioning it in the bore.
2) Wait 60 seconds while the seat is cooling down
and the shrink fit compression is relieved. 8) Prior to mounting of the valve spindle the valve
seat ring must be ground, to ensure correct
3) Mount the extraction tool and pull out the used centering af the valve guide and the valve seat
08028-0D/H5250/94.08.12
valve seat. (If the waiting time is not observed ring. This can be done according to working
the tool might be damaged). card 505-01.10.
01.32 - ESO
MAN Diesel
Working Card 505-01.45
Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 02H
L16/24
Starting position
Related procedure
Manpower
Plate No Item No Qty/
Working time : ¼ hour
Capacity : 1 man
Data
98.38 - ES0
MAN Diesel
505-01.45 Working Card
Edition 02H Inspection of Cylinder Head Cooling Water Space Page 2 (2)
L16/24
Inspection of Cylinder Head Cooling Water
Space
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
Workinag Card 505-01.50
Page 1 (3) Assembly of Cylinder Unit Edition 02H
L16/24
Related procedure
98.47 - ES0
MAN Diesel
505-01.50 Working Card
Edition 02H Assembly of Cylinder Unit Page 2 (3)
L16/24
Preparing before Mounting
4) Fit a new sealing ring on the cylinder liner. Note: After an overhaul the cylinder liner must always
be honed and the piston must be fitted with new
08028-0D/H5250/94.08.12
5) Mount two roller guides in the water jacket, see piston rings, see Working Card 506-01.35.
Working Card 508-01.00.
9) Mount the piston guide bush around the cylinder
unit.
Mounting of Cylinder Head
10) Lift the piston and connecting rod by means
6) Place two new o-rings at the top of the water of a suspension.
jacket and slightly lubricate with oil.
98.47 - ES0
MAN Diesel
Working Card 505-01.50
Page 3 (3) Assembly of Cylinder Unit Edition 02H
L16/24
11) Lubricate the piston rings and the cylinder liner
with oil.
98.47 - ES0
MAN Diesel
Working Card
Mounting of Cylinder Unit in Engine 505-01.55
Page 1 (4) Edition 02H
L16/24
Related procedure
99.03 - ES0
MAN Diesel
L16/24
Before the cylinder unit is mounted in the engine, be 3) Make sure the crank throw is in the top posi-
sure to clean the joint faces carefully. tion.
2) Lower the cylinder unit slowly into the engine 5) Land the connecting rod on the crankshaft.
by means of a lifting tool, (plate 52005 item
038). During this the connecting rod must be guided
by hand to ensure correct approach and landing
in the journal.
Fixing tool
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
L16/24
8) Lubricate threads and the contact face of the 13) Place the spacer ring around the nuts with a
connecting rod screws with molycote paste or slot in such a position that the tommy bar can
the like. be used.
9) Mount bolts and nuts and tighten them firmly 14) Tighten the hydraulic jacks and make sure
with a tommy bar. that the cylinder of the jacks bears firmly on
the spacer ring. Tighten up all the nuts, see
For tighting connecting rod bolts, please see description 500.40. For usage of the hydraulic
working card 506-01.25. tools, please see working card 520-01.05.
11) Fit the cylinder head nuts and make sure that
they run easily and that they bear on their entire Assembling of Connections
contact surfaces.
15) Mount the exhaust clamp between the cylinder
12) Tighten the nuts lightly with a tommy bar. head and the exhaust pipe.
99.03 - ES0
MAN Diesel
L16/24
18) Place new O-rings on the charge air connection 22) Bleed air from the venting screws on the charge
and push the connections into the next cylinder air cooler.
head.
23) Bleed air from the venting screws on the engine
19) Secure the charge air connection with a clamp top, or by the flange, connection F3, venting to
and tighten the bolt on the clamp. expansion tank.
20) Mount the high pressure fuel oil pipe, please 24) Open connection G2, L.T. fresh water - out-
see working card 514-01.05. let.
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Head 50501-11H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
50501-11H Cylinder Head Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Head 50501-16H
L16/24
040
255
015 052
064 076
088
027
039
206
267
111 279
123 172
184
135
147 196
159
160
08028-0D/H5250/94.08.12
218
231
243
See plate 50610
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
50502-08H Valve Spindles and Valve Gear Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
010 1/C Rocker arm, exhaust Vippearm, udstøds, 274 2/C Valve spindle, inlet Ventilspindel, indsugn.
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 046, 058, 071, 083
083
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-11H
L16/24
058
010
105 071
022 083
034 095
046 142
117 071
129 154
130
166
178
178 191
191 201
213
201
237
249
250
Cylinder Head,
see plate 50501
08028-0D/H5250/94.08.12
262
274
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
010 1/C Rocker arm, exhaust Vippearm, udstøds, 274 2/C Valve spindle, inlet Ventilspindel, indsugn.
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 046, 058, 071, 083
083
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
L16/24
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Plate
50510-02H Cylinder Head, Top Cover Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/E = Qty/Engine Qty/E = Qty/Motor
98.41 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Unit 50515-04H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
50515-04H Cylinder Unit Page 2 (2)
L16/24
Item
no Qty Designation Where to find in the engine instruction book
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Unit 50515-07H
L16/24
011
08028-0D/H5250/94.08.12
06.43 - ES0
MAN Diesel
Plate
50515-07H Cylinder Unit Page 2 (2)
L16/24
Item
no Qty Designation Where to find in the engine instruction book
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
06.43 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Unit 50515-11H
L16/24
011
08028-0D/H5250/94.08.12
L16/24
Item
no Qty Designation Where to find in the engine instruction book
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
L16/24
011
08028-0D/H5250/94.08.12
L16/24
Item
no Qty Designation Where to find in the engine instruction book
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
506/606
MAN Diesel
Description 506.01
Page 1 (2) Piston, Connecting Rod and Cylinder Liner Edition 02H
L16/24
Piston Connecting Rod
The piston, which is oil-cooled and of the composite The connecting rod is die-forged. The big-end has a
type, has a skirt made of nodular cast iron and a horizontal split. The connecting rod and piston are
crown made of forged deformation resistant steel. It disassembled together with the cylinder liner, thus
is fitted with 2 compression rings and 1 oil scraper ensuring a large bearing diameter and a low bear-
ring in hardened ring grooves. ing pressure.
By the use of compression rings with different bar- The connecting rod has bored channels for supply-
rel-shaped profiles and chrome-plated running sur- ing of oil from the big-end to the small-end.
faces, the piston ring pack is optimized for maximum
sealing effect and minimum wear rate. The big-end bearing is of the bi-metal type coated
with a running layer.
The piston has a cooling oil space close to the piston
crown and the piston ring zone. The heat transfer, The bearing shells are of the precision type and are
and thus the cooling effect, is based on the shaker therefore to be fitted without scraping or any other
effect arising during the piston movement. The kind of adaption.
cooling medium is oil from the engine's lubricating
oil system. The small-end bearing is of the bi-metal type and
is pressed into the connecting rod. The bush is
Oil is supplied to the cooling oil space in the piston equipped with an inner circumferential groove, and
through spray hole in the middle of the connecting a pocket for distribution of oil in the bush itself and
rod to the middle of the piston. Oil is drained from for the supply of oil to the pin bosses.
the cooling oil space through ducts situated dia-
metrically to the inlet channels.
98.46 - ES0
MAN Diesel
506.01 Description
Edition 02H
Piston, Connecting Rod and Cylinder Liner Page 2 (2)
L16/24
Cylinder Liner
08028-0D/H5250/94.08.12
98.46 - ES0
MAN Diesel
Working Card Separation/Assembly of Piston and Connecting Rod 506-01.05
Page 1 (3)
and fitting of Piston Rings Edition 07H
L16/24
Separation of piston and connecting rod for in- Wooden wedge, 2 pieces
spection or/and overhaul. Wooden support
Assembly of the piston and connecting rod after Wire
inspection or/and overhaul.
Starting position
Related procedure
07.05 - ES0
MAN Diesel
506-01.05 Separation/Assembly of Piston and Connecting Rod Working Card
Page 2 (3)
Edition 07H and fitting of Piston Rings
L16/24
1) Take out the securing ring (seeger circlips) with The piston rings should only be fitted to the piston
the plier (Plate 52006, Item 177). Push out the by the use of a special tool; the socalled piston ring
piston pin and lift the connecting rod away. opener.
3) For assembly of piston and connecting rod, The piston rings should be installed with the identi-
see point 1, but in the opposite direction. fication mark, which is stamped into the ring close
to the ring joints, facing upwords, see fig 2.
07.05 - ES0
MAN Diesel
Working Card Separation/Assembly of Piston and Connecting Rod 506-01.05
Page 3 (3)
and fitting of Piston Rings Edition 07H
L16/24
Piston Ring No 1:
marked with ident.
No "top 1445".
Piston Ring No 2:
marked with ident.
No "top 1461".
Scraper Ring:
marked with ident.
No "top 0254".
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.
07.05 - ES0
MAN Diesel
L16/24
Cleaning and inspection of piston. Replacement Tools for cleaning of piston, steel brush,
of piston ring, scraper ring and control of ring scraper etc.
grooves.
Starting position
Related procedure
Data
99.33 - ES0
MAN Diesel
L16/24
Inspection of Piston Mounting of Piston Crown
1) Remove the piston and scraper rings. 8) Lubricate the threads and bearing surface with
"molycote-paste G-n Plus".
2) Clean the piston on the outside and on the
inside. Note: always use new bolts when assembling the
piston
3) Inspect the piston ring and scraper ring grooves
for wear, see page 3. 9) Tighten the bolts crosswise with 20 Nm (cor-
responding to 35° to 90°).
4) Apply a torque spanner to the piston bolts, 11) Tighten the bolts again with a pretighten torque
adjusted to 20 Nm. of 10 Nm.
5) Turn the torque spanner. 12) Turn the bolts 60° further.
Note: It may turn out that the bolts do not turn during 13) Check the piston bolt tension, see "check of
the test: piston bolt tension".
If Then
99.33 - ES0
MAN Diesel
L16/24
The piston crow must be scrapped if: Piston and oil New ring
Ring grooves.
scraper ring. grooves.
Max. wear limit.
Nominal size. Tolerances.
A) The wear limit on the testing mandrel is ex- (mm)
(mm) (mm)
ceeded, see fig 1A
Piston ring -0.035 +0.145
5 5 5.38
1 -0.01 +0.130
or
Piston ring -0.035 +0.105
B) The clearance between the new piston/scraper 5 5 5.38
2 -0.01 +0.090
ring and the ring groove is exceeded, see fig
1B. Scraper ring -0.035 +0.035
5 5 5.38
-0.01 +0.020
Note: At each piston overhaul: Table 1. Nominal size, new ring groove tolerance and wear
limit for ring grooves.
- The piston and the scraper ring must be
replaced.
0.40 mm
Wear limit line.
99.33 - ES0
MAN Diesel
Working Card
Connecting Rod 506-01.15
Page 1 (4) Edition 06H
L16/24
Related procedure
Manpower
Replacement and wearing parts
08028-0D/H5250/94.08.12
Data
07.17 - ES0
MAN Diesel
506-01.15 Connecting Rod
Working Card
Edition 06H Page 2 (4)
L16/24
Cleaning of Connecting Rod Measurement of Big-end Bore
1) Clean all machined surfaces on the connecting For check of ovalness the bearing cap has to be
rod. mounted onto the big-end bore without bearing
shells.
2) Degrease the joint faces, holes and connecting
rod screws with a volatile solvent and blow dry Note: The ident. No on the connecting rod and the
with working air. bearing cap must always be the same, see fig 3.
have seizures in Renew the bolts/screws 12) Calculate the maximum ovalness as the diffe-
threads or pittings on rence between biggest and smallest diameter
contact surface measured.
cannot be turned onto Renew the bolts/screws 13) Check if maximum ovalness is exceeded,
bottom position by hand please see page 500.35.
07.17 - ES0
MAN Diesel
Working Card
Page 3 (4) Connecting Rod 506-01.15
Edition 06H
L16/24
If Then For connecting rod No 2 in the example the maximum
ovalness is 0.125 mm and therefore the connecting
maximum ovalness is Renew the complete rod is rejected.
exceeded connecting rod, screws
and bearing shells.
Inspection of Connecting Rod Bush
maximum ovalness is Reuse the connecting
not exceeded rod 14) Inspect the surface of the piston pin and the
connecting rod bush.
Corrosion/
Pitting
Corrosion/
Pitting
Corrosion/
Pitting
Criteria for replacement of connecting rod big-end
bearing, see working card 506-01.16.
A Impact mark Impact mark Impact mark
B
C
Remarks: Remarks: Remarks:
D
E
Connecting rod
Ident. No
07.17 - ES0
08028-0D/H5250/94.08.12
07.17 - ES0
Working Card
Page 4 (4)
L16/24
Edition 06H
necting rod and on the bearing
cap must always be the same.
MAN Diesel
Description:
Magnifier (x30).
Starting position:
Related procedure:
Data:
02.26 - ES0
MAN Diesel
In these cases, the bearing shells must be exchan- Criteria for bimetal bearing replacement
ged, of course, and in order to avoid further bearing
failures, the cause of the failure must be found and Actual wear can be determined by measuring wall
eliminated. thickness or via clearance measurements in com-
parison to the specification for a bearing in new
condition.
New Condition
A bearing should be replaced if the wear limit, as
The running surface has a silvery, bright color, see specified by the engine manufacturer, is reached
fig 1. or can be expected to be reached during the next
period of operation.
02.26 - ES0
MAN Diesel
Following pictures shows the typical running pattern Shallow scoring and / or imprints that are few in
where bearing shells are reusable. number. See fig 4.
1. Normal wear
Fig 4 Reusable
Fig 2 Reusable Minor and shallow material removal outside the most
loaded zone. See fig 5.
Fig 5 Reusable
Fig 3 Reusable
02.26 - ES0
MAN Diesel
Following pictures shows abnormal wear or dama- Many scores or multiple deep grooves and / or im-
ges that require replacement of bearing shells i.e. prints. See fig 8 and fig 9.
investigation of reasons.
Fig 8 Replace
– deep scoring, imprints. Lining material locally smeared
Fig 6 Replace
Fig 9 Replace
– many deep imprints
08028-0D/H5250/94.08.12
Fig 7 Replace
02.26 - ES0
MAN Diesel
Fig 10 Replace
Fig 12 Fatigue rupture
9. Deep cavitation
Fig 11 Replace
– deep cavitation
02.26 - ES0
MAN Diesel
Working Card 506-01.25
Page 1 (2) Hydraulic Tightening of Connecting Rod Screws Edition 02H
L16/24
Hand tools
Starting position
Related procedure
Data
99.33 - ES0
MAN Diesel
506-01.25 Working Card
Edition 02H Hydraulic Tightening od Connecting Rod Screws Page 2 (2)
L16/24
1) Mount the connecting rod bolts and tighten the 5) Relieve the hydraulic pressure on the tool.
nuts by hand.
6) Add the hydraulic pressure to the tool once
2) Mount the hydraulic tools, pos. 1, on both con- more.
necting rod bolts.
7) Tighten the nuts again.
Be aware of the max. lifting height of the tool
and adjust the distance between the piston and Note: The point 5 to 7 can be followed in order to
the cylinder before adding pressure to the tool. remove tensions in the bolts, if any.
please see working card 520-01.05.
8) If there still is a distance and the nuts still can
3) Connect the hoses and pressure pump to the be tightened then repeat the point 5 to 7.
hydraulic tool.
9) Release the hydraulic pressure on the tool and
4) Add the prescribed hydraulic pressure, (to both remove the hydraulic nuts.
bolts simultaneously), see description 500.40,
and tighten the nuts by using a handle. Note: General instruction about hydraulic tightening,
please see working card 520-01.05.
1. Hydraulic tools
08028-0D/H5250/94.08.12
99.33 - ES0
MAN Diesel
Working Card 506-01.30
Page 1 (3) In-situ Inspectioan of Connecting Rod Big-end Bearing Edition 02H
L16/24
Related procedure
Data
98.38 - ES0
MAN Diesel
506-01.30 Working Card
Edition 02H In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
L16/24
1) Turn the crankshaft into the top position. 7) Slowly turn the crankshaft clockwise until the
connecting rod is resting on the inspection
tool.
Removal of the Connecting Rod Bearing
Cap
Removal of the upper Connecting Rod Bea-
2) Loosen the hydraulic bolts by means of the ring Shell
hydraulic tools, please see working card 520-
01.05. 8) Mount the connecting rod on the inspection
tool by means of the connecting rod bolt and
3) Remove the hydraulic tools. a nut.
4) Remove the hydraulic nuts and the bearing Note: Make sure that only one connecting rod bolt is
cap with the lower bearing shell by hand. fit in the connecting rod before the crankshaft turns
any further.
Mounting of the Inspection Tool 9) Turn slowly the crankshaft clockwise until it is
possible to remove the upper connecting rod
5) Turn the crankshaft app. 45° clockwise allowing bearing shell.
the connecting rod bolts be removed.
10) Remove the upper connecting rod bearing
6) Mount the inspection tool acc to fig 1. shell.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
Working Card 506-01.30
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 02H
L16/24
Inspection of Bearing Shells 16) Turn slowly the crankshaft anti-clockwise until
it rests in the connecting rod.
11) Inspect the bearing shells, please see working
card 506-01.16. 17) Remove the inspection tool.
12) Clean carefully the joint faces, the bore and 18) Lubricate threads and contact face of the con-
the bearing shells. necting rod bolts with Copaslip or the like.
14) Coat the journal with clean lubricating oil. 22) Mount the screws and tighten them by hand.
15) Remove the bolt and nut from the connecting 23) Mount the hydraulic tool and tighten the bolts
rod and inspection tool. according to working card 506-01.25.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
Working Card 506-01.35
Page 1 (4) Inspection and Honing of Cylinder Liner Edition 06H
L16/24
Inspection and honing of cylinder liner with ho- Drilling machine 60-180 rpm.
ning brush. Honing oil.
Gas oil.
Starting position
Related procedure
Data
04.50 - ES0
MAN Diesel
506-01.35 Working Card
Edition 06H Inspection and Honing of Cylinder Liner Page 2 (4)
L16/24
Measurement of Cylinder Diameter Honing the Cylinder Liner
While the piston is removed from the cylinder, the Please note:
latter is measured to record the wear. The measure- In order to obtain a round cylindrical cylinder liner
ments are taken by means of an inside micrometer, a factory honing is required. A honing as described
with measuring points at TDC-position for the upper- below can only be regarded as a second best solu-
most piston ring, halfway down, and at the BDC in tion and might have an impact on the time between
the cylinder liner, see fig 1 and page 4. overhaul as well as on the lub. oil consumption.
80-160 rpm.
04.50 -ES0
MAN Diesel
Working Card 506-01.35
page 3 (4) Inspection and Honing of Cylinder Liner Edition 06H
L16/24
Note: Upon completion of the honing process
the used flame ring is discarded. A new flame ring
is always mounted in the cylinder when replacing
the piston rings.
04.50 - ES0
08028-0D/H5250/94.08.12
MAN Diesel
04.50 - ES0
Working Card
Page 4 (4)
L A
e
n B
g
t C
h
w
45
i
A s
e
135
C A
r B
B o
s C
s
312
w
i
s
e
C Liner
temp.
°C
Remarks...
506-01.35
L16/24
Edition 06H
MAN Diesel
Working Card Grinding of Seal Face on 506-01.45
Page 1 (2) Edition 02H
Cylinder Liner and Cylinder Head
L16/24
Starting position
Related procedure
Data
98.38 - ES0
MAN Diesel
506-01.45 Grinding of Seal Face on Working Card
Page 2 (2)
Edition 02H
Cylinder Liner and Cylinder Head
L16/24
Note: The grinding tool is used for both grinding
the groove in the cylinder liner flange (1), the surface
of the cylinder crankcase (2) and the sealing surface
on the cylinder head (3), see fig. 1.
3) Move back and forth the tool and lift it out from
time to time.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2)
at Low Overhaul Height Edition 02H
L16/24
Dismounting of cylinder unit for inspection and/or Inside micrometer (195 mm)
overhaul. Feeler gauge 0.15 - 0.20 mm
Starting position
Related procedure
Data
99.33 - ES0
MAN Diesel
506-01.50 Dismantling of Piston and Cylinder Liner Working Card
Edition 02H Page 2 (2)
at Low Overhaul Heights
L16/24
Note: The push rods will fall out if they are not sup-
ported by hand.
08028-0D/H5250/94.08.12
99.33 - ES0
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod 50601-03H
L16/24
093
103
127
081
019
032
176
152
056
140
08028-0D/H5250/94.08.12
139
068
164
07.07 - ES0
MAN Diesel
Plate
50601-03H Piston and Connecting Rod Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
07.07 - ES0
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod 50601-08H
L16/24
08028-0D/H5250/94.08.12
01.32 - ES0
MAN Diesel
Plate
50601-08H Piston and Connecting Rod Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
01.32 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Liner 50610-03H
L16/24
08028-0D/H5250/94.08.12
97.07 - ES0
MAN Diesel
Plate
50610-03H Cylinder Liner Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
97.07 - ES0
Camshaft
507/607
MAN Diesel
Description 507.01
Page 1 (1) Camshafts and Camshaft Drive Edition 02H
L16/24
Camshafts and Camshaft Drive The camshafts are located in bearing bushes which
are fitted in bores in the engine frame; each bearing
The inlet and exhaust valves as well as the fuel is replaceable and locked in position in the engine
pumps of the engine are actuated by two cam- frame by means of a locking screw.
shafts.
The gear wheel for driving the camshaft as well as
Due to the two-camshaft design an optimal adjust- a gear wheel connection for the governor drive are
ment of the gas exchange is possible without inter- screwed on to the aftmost section.
rupting the fuel injection timing. It is also possible
to adjust the fuel injection without interrupting the
gas exchange.
98.45 - ES0
MAN Diesel
Working Card 507-01.00
Page 1 (2) Check of Camshaft and Camshaft Drive Edition 02H
L16/24
Description
Related procedure
Data
98.38 - ES0
MAN Diesel
507-01.00 Working Card
Edition 02H Check of Camshaft- and Camshaft Drive Page 2 (2)
L16/24
1) Dismount the covers which give access to the 3) Check all screws, nuts and bolted connections,
gear wheels, camshaft and crankcase. including locking devices everywhere in the
gear wheel housing, camshaft housing and
2) Examine all gear wheels for cracks, wear and crankcase to check that they have not worked
deformations. While turning the engine to ena- loose. Tightening torques, please see page
ble inspection allover the circumference of the 500.40.
gear wheels.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
01.08 - ES0
MAN Diesel
L16/24
To Replace Camshaft Bearing for Injection Pull the disconnected sections of the camshaft
or valve camshaft so far aft that the bearing which is to be replaced
is free.
If one or several of the camshaft bearings should
be replaced, the camshaft must be wholly or partly 6) Remove the spur wheel and the bearing plate,
dismantled. see fig 1 so the camshaft can be moved toward
the generator.
Note: Before dismantling last bearing and spur gear
wheel the engine has to be turned so marks at gear 7) Push the bearing out of the bore in the engine
wheels are corresponding, please see Working frame.
Card 507-01.20. Engine must be locked in this
position. 8) Check the lubricating oil ducts to the bearing
08028-0D/H5250/94.08.12
01.08 - ES0
MAN Diesel
Working Card 507-01.05
Page 3 (3) Inspection and Replacement of Camshaft Bearing Edition 05H
L16/24
11) Coat all the journals of the camshaft section
with clean lubricating oil and push the camshaft
into position, making sure that the marks on
the flanges coincide.
01.08 - ES0
MAN Diesel
L16/24
Hand tools
Description
Starting position
Related procedure
Data
07.48 - ES0
MAN Diesel
L16/24
Assembly of gear wheels for valve cam-
shaft and Injection valve camshaft, without
mounted flywheel
Small
Mounting of intermediate gearwheels holes
Note: The punch mark on the crankshaft gearwheel Fig 2 Position of small holes in the circumference of the two
intermediated gearwheels
is placed on the 13 teeth counting counter clockwise
from the joint of the gearwheel, see fig 3.
08028-0D/H5250/94.08.12
Small
holes
13 teeth
07.48 - ES0
MAN Diesel
L16/24
4) Tighten up the intermediate gearwheels.Tight- 3) Position the support of the measuring tool
ening torque, please see page 500.40. on the two bolts of the camshaft covering.
Slip on the distance sleeves and fasten to
the cylinder crankcase by means of hexagon
Mounting of gearwheel for valve camshaft nuts.
5) Before mounting the gearwheel, must marks for Note: During attaching, pay attention to the cor-
crankshaft and lower intermediate gearwheel rect fitting position of the contact point.
correspond, see fig 1(E2). Secondly must the
small holes for both intermediate gearwheels 4) Insert the dial gauge into the support.
be corresponding.
5) Turn the engine until the cam base circle is
6) Turn the valve camshaft, until the mark on the reached (approx 40° BTDC).
gearwheel for valve camshaft corresponds with
the 2 marks on upper intermediate gearwheel, 6) Set the dial gauge to "Zero".
see fig 1 (E1).
7) Turn the engine until the TDC mark (ignition
7) Tighten up the gearwheel. Tightening torque, DC) for the actual cylinder is reached.
please see page 500.40. Read the dial gauge and note down the
gauge value in sheet on page 4.
Mounting the gearwheel for injection cam- 8) Determine the values for the other cylinders
shaft in the same way.
8) Before mounting the gearwheel, must marks for Calculate the average value of all measure-
crankshaft and lower intermediate gearwheel ments.
correspond, see fig 1(E2). Secondly must the
small holes for both intermediate gearwheels 9) Compare the calculated value determined
be corresponding. with the value mentioned below.
9) Turn the injection valve camshaft, until the 10) If the values exceeds the limits, an adjust-
mark on the gearwheel for valve camshaft cor- ment must be done in order to correct the
respond with the 2 marks on upper intermediate errors.
gearwheel, see fig 1 (E1).
11) Remove the complete measuring tool.
Note: Adjustment of injection valve camshaft is now
needed, please see separately chapter “Adjustment 12) Mount all camshaft covers.
of Fuel Injection Camshaft / Injection Timing”.
07.48 - ES0
MAN Diesel
L16/24
Fig 4
08028-0D/H5250/94.08.12
07.48 - ES0
MAN Diesel
Plate
Page 1 (2) Intermediate Wheel 50701-02H
L16/24
097
085
121 061
120
036
085
107
073 097
085
119
061
048
024
08028-0D/H5250/94.08.12
012
085
107
073
119
07.48 - ES0
MAN Diesel
Plate
50701-02H Intermediate Wheel Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.48 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft (Valve Camshaft) 50705-15H
L16/24
349
291 291
266 230
278
278 350 254
266 266
301
313*
350
014
014
266 719
278
291 291
5 cyl.
278
026 038
266 038 026
6 cyl.
063 087
Item No for 051 075 099
08028-0D/H5250/94.08.12
7 cyl.
109 122 110
242 110 122 109
8 cyl.
bearing disks 146 075 183
134 158 171 195
9 cyl.
205 087 229 217
217 229 087 205
06.18 - ES0
MAN Diesel
Plate
50705-15H Camshaft (Valve Camshaft) Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
217
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
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
06.18 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft (Injection Camshaft) 50705-16H
L16/24
291 266
266 589
278
636
278 648
600
266
648 266
624
362
362
5 cyl.
374 386
590 386 374
6 cyl.
408 433
Item No for 398 421 445
7 cyl.
08028-0D/H5250/94.08.12
9 cyl.
553 433 577 565
565 577 433 553
06.18 - ES0
MAN Diesel
Plate
50705-16H Camshaft (Injection Camshaft) Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
362 1/C Camshaft part Styreakselsektion 565 2/E Bearing disk, Lejesøle,
piece 9 cyl. engine 9 cyl. motor
374 2/E Bearing disk, Lejesøle, 577 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor
386 2/E Bearing disk, Lejesøle, 589 1/E Axial bearing disk Aksial lejesøle
5 cyl. engine 5 cyl. motor
590 1/E Bearing segment Lejesøle, ende
398 1/E Bearing disk, Lejesøle, end
6 cyl. engine 6 cyl. motor
600 1/E Spur wheel, Cylindrisk tandhjul,
408 1/E Bearing disk, Lejesøle,
6 cyl. engine 6 cyl. motor 624 1/E Bearing plate, com- Lejeplade, komplet
plete
421 Bearing disk Lejesøle
1/E 6 cyl. engine 6 cyl. motor 636 1/E Ring Ring
1/E 8 cyl. engine 8 cyl. motor
648 Camshaft bearing Styreakselleje
433 Bearing disk Lejesøle 6/E 5 cyl. engine 5 cyl. motor
1/E 6 cyl. engine 6 cyl. motor 7/E 6 cyl. engine 6 cyl. motor
2/E 9 cyl. engine 9 cyl. motor 8/E 7 cyl. engine 7 cyl. motor
9/E 8 cyl. engine 8 cyl. motor
445 1/E Bearing disk, Lejesøle, 10/E 9 cyl. engine 9 cyl. motor
6 cyl. engine 6 cyl. motor
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
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
06.18 - ES0
Operating gear
508/608
MAN Diesel
Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition 02H
L16/24
Roller Guides for valve clearance.
The valve actuating gear is pressure-feed lubricated
The fuel injection pumps and rocker arms for inlet from the centralized lubricating system, through the
and exhaust valves are operated by the cams on the water chamber part and from there into the rocker
camshafts through roller guides. The roller guides for arm shaft to the rocker bearing.
inlet and exhaust valves are located in bores in the
water jacket for each cylinder.
98.38 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
Data
98.47 - ES0
MAN Diesel
L16/24
1) Turn the water jacket upside down so the roller
guides can slip out at the water jacket.
Replacement of Roller and Shaft Pin Fig 1 Inspection of roller guide and roller.
98.47 - ES0
MAN Diesel
Working Card 508-01.10
Page 1 (2) Control of Valve Clearance Edition 09H
L16/24
Starting position
Related procedure
03.43 - ES0
MAN Diesel
508-01.10 Working Card
Edition 09H Control of Valve Clearance Page 2 (2)
L16/24
1) Turn the engine so that the roller, rests on the 2) Lift rocker arm in order to open the valves.
circular part of the cam, i.e. the inlet valves and Control that the valves start to open at the
the exhaust valves are closed. same time.
08028-0D/H5250/94.08.12
03.31 - ES0
MAN Diesel
Working Card 50801.10
Page 1 (3) Safe Valve Adjustment Edition 10H
L16/24
Starting position:
Related procedure:
03.43 ESO
MAN Diesel
50801.10 Working Card
Edition 10H Safe Valve Adjustment Page 2 (3)
L16/24
1) Before adjustment the rocker arms must be
removed.
03.43 ESO
MAN Diesel
Working Card 50801.10
Page 3 (3) Safe Valve Adjustment Edition 10H
L16/24
6) If the valve bridge is correctly adjusted there 9) Install the rocker arms and adjust the clearance
will be ink on both contact surfaces and the to specified value.
ink will be clearly touched on both valve spin-
dles.
Fig.5. Control of adjustment of valve bridge. 10) Tighten the nut with torque wrench to correct
torque. Check the valve clearance once more
7) Mark the valve bridge adjusting screw and after the nut is tightend with correct torque.
locking nut clearly to indicate it has been The rocker arm adjusting screw and nut to
correctly adjusted and tightened. Mark inlet be marked clearly to indicate it is correct
and exhaust differently to insure they are not adjusted.
interchanged.
Remark
03.43 ESO
MAN Diesel
Plate
Page 1 (2) Roller Guide and Push Rods 50801-02H
L16/24
08028-0D/H5250/94.08.12
97.43 - ES0
MAN Diesel
Plate
50801-02H Roller Guide and Push Rods Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
97.43 - ES0
Control/safety
509/609
MAN Diesel
Description 509.01
Page 1 (7) Safety, Control and Monitoring System Edition 13
General
05.18 - NG - ES1
MAN Diesel
509.01 Description
Edition 13 Safety, Control and Monitoring System Page 2 (7)
General
05.18 - NG - ES1
MAN Diesel
Description 509.01
Page 3 (7) Safety, Control and Monitoring System Edition 13
General
In situations where the vessel’s system cannot oper- ● Indication of:
ate a MODBUS communication unit, MBD-H offers – Engine rpm
an output module (OM) to be installed in the vessel’s – TC rpm
control room. – Starting air pressure
– Display for digital read out
By means of the OM it is possible to connect all dig- – Indication of software version
ital and analogue signals to the vessel’s monitoring
system in a conventional manner. ● Shutdowns indication:
– overspeed
Communication between the base module (BM) and – low lub. oil pressure
the output module (OM) takes place via a 3-wire – high fresh water temp.
interlink bus (RS485). – emergency stop / oil mist
In the base module all the alarms are generated and Please note that the local stop push button must be
delay and cut-off at standstill is done. Set points and activated at least 3 sec. before the engine will stop.
special conditions can be found in "Operation Data
& Set Points, B 19 00 0".
1) Overspeed
2) Low lube oil pressure
3) High cooling water temperature
– remote mode The manual start button must be activated until ig-
– local mode nition, takes place. If the engine have been without
– blocking/reset mode prelubrication in more than 20 minutes the engine
– lamp test can not be electrical started.
– arrow up - shift upwards through measure-
ments for display The push buttons REMOTE - LOCAL - BLOCKING is
– arrow down - shift downwards through only related to the start function. In case of BLOCK-
measurements for display ING the engine can not be started from local or from
remote (switchboard).
05.18 - NG - ES1
MAN Diesel
509.01 Description
Edition 13 Safety, Control and Monitoring System Page 4 (7)
General
Fig 3 Monitoring of temperature/pressure module (MTP). The temperature shown on the MEG module is indi-
cated with segments illuminated from the left to the
right. The number of segments illuminated depends
on the actual temperature of the exhaust gas.
08028-0D/H5250/94.08.12
05.18 - NG - ES1
MAN Diesel
Description 509.01
Page 5 (7) Safety, Control and Monitoring System Edition 13
General
For emergency operation in case of totally black-out By performing an offset adjustment equalisation of the
on the 24 V DC supply the engine is equipped with temperature when the engine is adjusted correctly the
manometers for: operator will get the impression that the temperatures
then are identical when the pumps etc are adjusted
– Lub. oil pressure correctly. If a deviation of the temperatures occurs,
– Cooling water pressure it is because of problems with the combustion or the
– Fuel oil pressure fuel pumps just as the operator is used to.
Fig 6 Monitor exh. gas temperature (MEG). Monitoring of Bearing Temperature, MBT
(option)
Equaliser Function for Exhaust Gas Tem- The temperature shown on the MBT module is
perature indicated with segments illuminated from the left
to the right. The number of segments illuminated
08028-0D/H5250/94.08.12
An equaliser function has been introduced to take depends on the actual temperature of the bearing
into consideration the old learning that the exhaust temperature.
temperature values must be identical on a four-stroke
diesel engine.
05.18 - NG - ES1
MAN Diesel
509.01 Description
Edition 13 Safety, Control and Monitoring System Page 6 (7)
General
08028-0D/H5250/94.08.12
05.18 - NG - ES1
MAN Diesel
Description 509.01
Page 7 (7) Safety, Control and Monitoring System Edition 13
General
Instrumentation The temperature sensors are placed at the measur-
ing point.
Pressure measurements are generated from the
pressure transmitters.
Data
The exhaust gas temperatures are generated by
NiCr/Ni thermo sensors. Power supply : 24 VDC -20 to +30%,
max ripple 10%
Temperatures are generated by PT100 sensors. Power consumption : < 2 amp
Ambient temp. : -20oC to 70oC
The above transmitters and sensors are specially External
designed for installation on diesel engines. communication links : MODBUS ASCII / RTU or
interlink (RS422 / RS485)
The pressure sensors are placed centrally at the
front of the engine, facilitating easy access for
maintenance and overhauls, and minimizing wire
connections.
08028-0D/H5250/94.08.12
05.18 - NG - ES1
MAN Diesel
Description
Lambda Controller 509.10
Page 1 (1)
Edition 07H
L16/24
V28/32S
Purpose At a 50% load change the system will be activated
for about 3-8 seconds.
The purpose with the lambda controller is to prevent If the system is activated more than 10 seconds,
injection of more fuel in the combustion chamber than the solenoid valve will be shut off and there will be
can be burned during a momentary load increase. a remote signal for "jet system failure".
This is carried out by controlling the relation between
the fuel index and the charge air pressure. The jet system is blocked when engine speed is
below 50 rpm.
The Lambda controller is also used as stop cylin-
der. During the start procedure the jet system is used as
a charge air booster.
02.41 - ES0
MAN Diesel
Description
Communication from the GenSet 509.55
Page 1 (10) Edition 09
General
2) An output module (OM) can be placed in The BM has a standard MODBUS ASCII and RTU
the control room switchboard or alarm disk. interface which may be selected, by means of a DIP
Communication from the BM-module to the switch on the BM, to be either:
OM-module is made via the 3 wire module
interlink bus. – RS422 5 wire (Rx+, Rx-, Tx+, Tx-, GND) or
– RS485 3 wire (Rx+/Tx+, Rx-/Tx-, GND)
In the OM-module all the signals are converted
into 4-20 mA signals and digital outputs.
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
General
The communication setup is: 9600 baud, 8 databits, The general „message frame format“ has the fol-
1 stopbit, no parity. lowing outlook:
The BM MODBUS protocol accept one command [:] [SLAVE] [FCT] [DATA] [CHECKSUM] [CR] [LF]
(Function Code 03) for reading analog and digital
input values one at a time, or as a block of up to – [:] 1 char. Begin of frame
32 inputs. – [SLAVE] 2 char. Modbus slave address
Selected on DIP-switch at BM
MODBUS is defined by the company AEG Modicon print
and the implementated protocol in the BM is de- – [FCT] 2 char. Function code
signed to observe the relevant demands in the latest – [DATA] n X 2 chars data.
protocol description from AEG Modicon: – [CHECKSUM] 2 char checksum (LRC)
– [CR] 1 char CR
MODBUS was originally defined by EAG Modicon, – [LF] 1 char LF (end of frame)
but is now adminstered by the MODBUS-IDA group.
The MODBUS protocol implemented for the BM is Notice: The MODBUS address [SLAVE] should
defined in the document "MODBUS over serial line be adjusted on the DIP-switch (SW 1) on the BM.
specification and implementation V1.0", available at Allowed addresses are 1..63 (address 0 is not al-
http://www.modbus.org/ lowed). Broadcast packages will not be accepted
(to be ignored), see fig 2.
The following chapter describes the commands in
the MODBUS protocol, which are implementated, The following function codes (FCT) is accepted:
and how they work.
– 03H: Read n words at specific address.
– 10H: Write n words at specific address.
Protocol Description
In response to the message frame, the slave (BM)
The ASCII and RTU version of the MODBUS proto- must answer with appropriate data. If this is not pos-
col is used, where the BM works as MODBUS slave. sible, a package with the most important bit in FCT
All data bytes will be converted to 2-ASCII charac- set to 1 will be returned, followed by an exception
ters (hex-values). Thus, when below is referred to code, where the following is supported:
„bytes“ or „words“, these will fill out 2 or 4 characters,
respectively in the protocol. – 01: Illegal function
– 02: Illegal data address
– 03: Illegal data value
– 06: BUSY. Message rejected
SW 1: MODBUS address
08028-0D/H5250/94.08.12
Switch no 1 2 3 4 5 6
Address:
0 OFF OFF OFF OFF OFF OFF Not allowed
1 ON OFF OFF OFF OFF OFF
2 OFF ON OFF OFF OFF OFF
63 ON ON ON ON ON ON Not allowed
06.44 - ES1
MAN Diesel
Description
Communication from the GenSet 509.55
Page 3 (10) Edition 09
General
FCT = 03H: Read n words MODBUS addressing
The master transmits an inquiry to the slave (BM) In order to be able to read from the different I/O
to read a number (n) of datawords from a given and data areas, they have to be supplied with an
address. The slave (BM) replies with the required „address“.
number (n) of datawords. To read a single register
(n) must be set to 1. To read block type register (n) In the MODBUS protocol each address refers to a
must be in the range 1...32. word or „register“. For the GenSet there are follow-
ing I/O registers:
Request (master):
[DATA] = [ADR][n] – Block (multiple) I/O registers occupying up to
[ADR]=Word stating the address in 32 word of registers (see table 3, 4, 5 and 6).
HEX.
[n]=Word stating the number of words to Block I/O registers hold up to 32 discrete I/O's placed
be read. at adjacent addresses, so it is possible to request
any number of I/O's up to 32 in a single MODBUS
Answer (slave-BM): command. Please refer to table 3, 4, 5 and 6 which
[DATA] = [bb][1. word][2. word]....[n. word] specifies the block I/Os registers addresses and how
[bb]=Byte, stating number of subsequent the individual I/O's are situated within the „block".
bytes.
[1. word]=1. dataword
[2. word]=2. dataword Data Format
[n. word]=No n. dataword
The following types of data format have been cho-
FCT = 10H: Write n words sen:
The master sends data to the slave (BM) starting Digital: Consists of 1 word (register):
from a particular address. The slave (BM) returns the 1 word: [0000H]=OFF
written number of bytes, plus echoes the address. [FFFFH]=ON
06.44 - ES1
MAN Diesel
General
MODBUS Timeout However the implementation of the protocol in the
GenSet Base Module is able to handle much smaller
To prevent lock up of the protocol, ie. a breakdown timeouts (response times), which may be required
on the connection, a number of timeouts are to in order to obtain an acceptable worst-case I/O
be built in, as specified in the MODBUS protocol scan time:
specification:
Base Module, max. time between characters in a
MODBUS specification max. time between charac- frame:5 ms
ters in a frame: 10 ms
Base Module, max. time between receipt of frame
MODBUS specification max. time between receipt and answer: 100 ms
of frame and answer: 1 second
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
Description
Communication from the GenSet 509.55
Page 5 (10) Edition 09
General
In the tables below each signal has a importance h) "Safety system failure" consists of following
statement with following meaning: signals: Power supply failure and internal watch
dog alarm.
Required by the classification society or MAN i) "Safety sensor cable failure" means cable fail-
B&W. ure on one or more of following sensors: lub. oil
Recommended by MAN B&W. pressostate PSL22, cool. water ther-mostate
"Nice to have". TSH12, speed pick-up SE90-2 or emergency
stop switch ZS82 (as option TSH29/27 for
In the tables below some signals have a remark with L27/38 or LSH92 for L27/38 and L32/40)
following meaning: j) "Local shutdown" only consists of the shut-
a) Required by American Bureau of Shipping, downs (PSL22, TSH, SSH81, and ZS82) in the
ABS. safety system.
b) Required by Bureau Veritas, BV. k) For L27/38, L21/31 and L32/40 the signal
c) Required by Jugoslavenski Register & DnV. ZS82, also includes high oil mist shutdown,
d) Required by Registro Italiano Navale, RINA. LSH92 if it is installed (option).
e) Required by Nippon Kaiji Kyokai, NKK & DnV. l) Oil mist (LSH/LAH92) is standard for 7, 8, 9 cyl.
f) Bureau Veritas, Lloyds Register of Shipping L27/38 (for marine application) and L32/40. For
and ABS demand alarm point for low/high 5, 6 cyl. L27/38 and L21/31 it is an option.
heavy fuel oil temp. Normally this is placed m) Required by Det Norske Veritas, DnV.
at yard side as an common alarm for all aux. n) For L16/24 engine type TC rpm range is 0-
engines. The signal can also be generated from 80000.
iTI40. o) Not accepted by all classification societies.
g) "Common shutdown" consists of following p) For GenSets with high voltage alternators.
signals: PSL22, TSH12, SSH81 and ZS82
(as option TSH29/27 for L27/38 or LSH92 for General) All alarm signals are already performed
L27/38 and L32/40). Furthermore it consist with necessary time delay. F.ex. lub. oil level
also of the redundant shutdowns performed in alarms (LAL/LAH28) includes 30 sec. alarm
the Base Module. delay. Start air alarm (PAL70) includes 15 sec.
alarm delay. No further delay are needed.
Table 3 (Block scanning)
Signal Name/description Address Data format Importance Remark Meas. range
oPDAH21-22 Diff. press. high, lub. oil filter 400A Digital Required
oPAL 22 Lub. oil press. inlet low 400B Digital Required
oPAL40 Fuel press. low 400C Digital Required
oTAH12 HT water temp. high 400D Digital Required
oTAH21 Lub. oil temp. inlet high 400E Digital Required
oLAL28 Low oil level base frame 400F Digital Recommended b)
oLAH28 High oil level base frame 4010 Digital Recommended
iZS75 Microswitch, turning gear engaged 4011 Digital Recommended b)
oSAH81 Overspeed alarm 4012 Digital Recommended
oTAD60 Exh. gas temp. high or low 4013 Digital Recommended m)
oTAH61 TC temp. outlet, high 4014 Digital Recommended
oTAH62 TC temp. inlet, high 4015 Digital Recommended m)
Cont.
06.44 - ES1
MAN Diesel
General
Cont. of table 3
Signal Name/description Address Data format Importance Remark Meas. range
iPSL22 Lub. oil inlet low pressure, stop 4042 Digital Nice to have
iTSH12 HT water outlet high temp., stop 4043 Digital Nice to have
iZS82 (LSH92) Emergency shutdown (oil mist) 4044 Digital Nice to have k)+l)
iSSH81 Overspeed stop 4045 Digital Nice to have
oZS96 Local indication 4046 Digital Nice to have
oZS97 Remote indication 4047 Digital Nice to have
oSA99 (Spare) 4048 Digital
oSS90A Engine running 4049 Digital Nice to have
iTE60-1 Exh. gas temp., cylinder 1 404A Integer 12 Bit Nice to have c) 0-800° C
iTE60-2 Exh. gas temp., cylinder 2 404B Integer 12 Bit Nice to have c) 0-800° C
iTE60-3 Exh. gas temp., cylinder 3 404C Integer 12 Bit Nice to have c) 0-800° C
iTE60-4 Exh. gas temp., cylinder 4 404D Integer 12 Bit Nice to have c) 0-800° C
iTE60-5 Exh. gas temp., cylinder 5 404E Integer 12 Bit Nice to have c) 0-800° C
iTE60-6 Exh. gas temp., cylinder 6 404F Integer 12 Bit Nice to have c) 0-800° C
iTE60-7 Exh. gas temp., cylinder 7 4050 Integer 12 Bit Nice to have c) 0-800° C
iTE60-8 Exh. gas temp., cylinder 8 4051 Integer 12 Bit Nice to have c) 0-800° C
iTE60-9 Exh. gas temp., cylinder 9 4052 Integer 12 Bit Nice to have c) 0-800° C
iTE61 Exh. gas temp. outlet TC 4053 Integer 12 Bit Nice to have d) 0-800° C
iTE62 Exhaust gas temp. inlet TC 4054 Integer 12 Bit Nice to have e) 0-800° C
iTI01 LT water temp. inlet 4055 Integer 12 Bit Nice to have 0-200° C
iTI31 Charge air temp. 4056 Integer 12 Bit Nice to have 0-200° C
08028-0D/H5250/94.08.12
iPI01 LT water press. inlet 4057 Integer 12 Bit Nice to have 0-6 bar
iPI21 Lub. oil press. inlet filter 4058 Integer 12 Bit Nice to have 0-10 bar
iPI23 Lub. oil TC press. 4059 Integer 12 Bit Nice to have 0-4 bar
iPI31 Charge air press. 405A Integer 12 Bit Nice to have 0-4 bar
oSE90 Engine RPM pickup 405B Integer 12 Bit Nice to have 0-1600 rpm
oSE89 TC RPM pickup 405C Integer 12 Bit Nice to have n) 0-60000 rpm
oUX95-2_Dly (Spare) 405D Digital
oSX84 Stop failure 405E Digital Nice to have
iSS86-3 Shutdown from safety system 405F Digital Nice to have j)
oPAL01 LT water press. inlet 4060 Digital Nice to have
oPAL23 Lub. oil press. TC, low 4061 Digital Nice to have
06.44 - ES1
MAN Diesel
Description
Communication from the GenSet 509.55
Page 7 (10) Edition 09
General
Table 5 (Block scanning)
Signal Name/description Address Data format Importance Remark Meas. range
Individual scanning
Signal Name/description Address Data format Importance Remark Meas. range
oZS57 Earth connector & diff. protection 4090 Digital Nice to have p)
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
509.55 Description
Edition 09 Communication from the GenSet Page 8 (10)
General
Table 6 (Block scanning)
Signal Name/description Address Data format Importance Remark Meas. range
Following signals are only available as option for engine type L27/38.
iTI29-1 Main bearing temp. 4005H Integer 12 Bit Nice to have 0-800° C
iTI29-2 Main bearing temp. 4004H Integer 12 Bit Nice to have 0-800° C
iTI29-3 Main bearing temp. 4003H Integer 12 Bit Nice to have 0-800° C
iTI29-4 Main bearing temp. 4002H Integer 12 Bit Nice to have 0-800° C
iTI29-5 Main bearing temp. 4006H Integer 12 Bit Nice to have 0-800° C
iTI29-6 Main bearing temp. 4007H Integer 12 Bit Nice to have 0-800° C
iTI29-7 Main bearing temp. 4008H Integer 12 Bit Nice to have 0-800° C
iTI29-8 Main bearing temp. 4009H Integer 12 Bit Nice to have 0-800° C
iTI29-9 Main bearing temp. 400AH Integer 12 Bit Nice to have 0-800° C
iTI29-10 Main bearing temp. 400BC Integer 12 Bit Nice to have 0-800° C
iTI29-11 Guide bearing temp. 400CH Integer 12 Bit Nice to have 0-800° C
oTI29-1 Cable break 400DH Digital Nice to have
oTI29-2 Cable break 400EH Digital Nice to have
oTI29-3 Cable break 400FH Digital Nice to have
oTI29-4 Cable break 4010H Digital Nice to have
oTI29-5 Cable break 4011H Digital Nice to have
oTI29-6 Cable break 4012H Digital Nice to have
oTI29-7 Cable break 4013H Digital Nice to have
oTI29-8 Cable break 4014H Digital Nice to have
oTI29-9 Cable break 4015H Digital Nice to have
oTI29-10 Cable break 4016H Digital Nice to have
oTI29-11 Cable break 4017H Digital Nice to have
iTI27-1 Alternator bearing temp. 4018H Integer 12 Bit Nice to have 0-200° C
iTI27-2 Alternator bearing temp. 4019H Integer 12 Bit Nice to have 0-200° C
iTI INTERNT. Compensation resistor 401AH Integer 12 Bit Nice to have 0-200° C
oTSH29/27 High bearing temp. shutdown 401BH Digital Nice to have
oTSH29/27 High bearing temp. shutdown 401CH Digital Nice to have
oTSH29/27A Common alarm main bearing temp. 401DH Digital Nice to have
oTSH29/27B Common alarm main bearing temp. 401EH Digital Nice to have
oUX29/27 Common cable failure 401FH Digital Nice to have
06.44 - ES1
MAN Diesel
Description 509.55
Page 9 (10) Communication from the GenSet Edition 09
General
Engine type L16/24, L21/31, L27/38 or L32/40
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
General
Engine type L27/38 incl. bearing surveillance module
06.44 - ES1
MAN Diesel
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2)
Alarm and Monitoring Equipment Edition 02H
L16/24
Function test and adjustment of safety, alarm and See "Related procedure"
monitoring equipment.
Starting position
Related procedure
Capacity : man
Data
98.38 - ES0
MAN Diesel
509-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 02H Page 2 (2)
Alarm and Monitoring Equipment
L16/24
Maintenance of Monitoring and Safety It is recommended that all functions are tested every
Systems three months according to the mentioned working
cards.
One of the most important parameters of preventive
work is that the alarm system, as well as the shutdown To check these functions use the working cards
and overspeed devices, are functioning 100%. mentioned under related procedure on page 1.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
General
Starting position
Related procedure
Capacity : 1 man
Data
04.29 - ES0
MAN Diesel
General
It is of the utmost importance that the shutdown
function is working properly.Therefore, the shutdown
function must be tested at regular intervals according
to the planned maintenance programme 500.25.
3) Reset the overspeed shutdown on the operation 4) Start the engine and keep it at no load.
box.
5) Mount the manometer/test pump on the test
valve outlet, situated right under the pressostate
Adjustment PSL 22, fig 1.
Correct detection of RPM (counting of teeths) de- 6) Close oil pressure valve, fig 1.
pends on the size of the gap between the movable
flywheel and the front of the pick-up sensor. If no or 7) Relieve the pressure slowly and check that the
08028-0D/H5250/94.08.12
wrong signal is detected by the sensor, the measuring switch changes back to the pressure stated as
gap must be adjusted or cleaned. the shutdown point, see 500.30.
The gap is expected to be 2.0 mm ± 0.3 mm (the The engine must stop.
pitch of the thread on the pick-up is 1.0 mm). The
number of teeth relative speed values/limits can be Note: If adjustment is needed, turn the screw clock-
found in the Engine Automatic diagram, section 509 wise or anticlockwise, see fig 2.
and description 500.30 in section 500.
8) Disconnect the manometer/test pump.
The overspeed shutdown limits can not be adjusted
by the user.
04.29 - ES0
MAN Diesel
General
9) Open the oil pressure valve on the pressure
block.
Protection
cap
10) Reset the low lubricating oil pressure shutdown
on the operation box.
Fig 3 Thermostate
Alarm System
Fig 2 Adjustment of pressostate and thermostate
It is important that all alarms lead to prompt investi-
gation and remedy of the error.
No alarm is insignificant. It is therefore important that
11) Take the sensor out of the pocket. all engine crew members are
familiar with and well trained in the use and impor-
12) Test the sensor in a water bath, which is con- tance of the alarm system.
trolled by the temperature or a special testing The most serious alarms are equipped with slowdown
device. and/or shutdown functions.
04.29
MAN Diesel
Working Card
Adjustment and Test of Analog Pressure Transmitter 509-05.03
Page 1 (2) Edition 03
General
Starting position
Related procedure
Data
02.20 - ES0
MAN Diesel
General
The pressure transmitter registers the actual pressure
and converts the pressure to an electrical signal.
Adjustment
span screw
2) Adjust the „span“ screw, see fig 1, to change
the value of the electrical signal acc. to the
pressure measurement area.
Fig 1 Adjustment of pressure transmitter
Test
02.20 - ESO
MAN Diesel
Working Card Adjustment and Test of 509-05.04
Page 1 (2) Analogous Temperature Transmitter Edition 04H
L16/24
Starting position
Related procedure
Data
98.43 - ES0
MAN Diesel
509-05.04 Adjustment and Test of Working Card
Edition 04H Analogous Temperature Transmitter Page 2 (2)
L16/24
The nickel-chrome-nickel sensor, which is used only
for measurement of the exhaust gas temperature, Test
generates a mV signal depending on the tempera-
ture. 2) Functional test of the PT 100 sensor can be
carried out according to the following proce-
The PT 100 sensor consists of a resistance wire dure.
which changes resistance depending on the tem-
perature. 3) Take the sensor out of the pocket.
Look and design vary depending on the place of 4) Test the thermostate by submerging the sen-
measurement and manufacture. sor in the water bath, which is controlled by a
special testing apparatus producing a constant
Adjustment temperature.
1) Since the nickel-chrome-nickel sensor and the If the alarm plant has an instrument unit, the tem-
PT 100 sensor cannot be adjusted the alarm perature can be read on this.
limit must be set on the alarm plant.
Otherwise the test can be carried out by seeing
Set point, see page 500.30. whether the alarm plant gives an alarm when the
alarm limit stated on page 500.30 is exceeded (if
the alarm plant is adjusted).
08028-0D/H5250/94.08.12
98.43 - ES0
MAN Diesel
Working Card 509-05.06
Page 1 (2) Adjustment and test of tacho and proximity sensors Edition 01
L21/31
Starting position
Related procedure
Data
04.04 - ES0
MAN Diesel
509-05.06 Working Card
Edition 01
Adjustment and test of tacho and proximity sensors Page 2 (2)
L21/31
Adjustment
Test
It is possible to test the functioning of the tacho Fig 1 Tacho and proximity sensors
and proximity sensors. This is done in the following
manner:
04.04 - ES0
MAN Diesel
Working card 509-08.00
Page 1 (2) Mounting and Adjustment of Pick-ups on Engine Edition 01H
L16/24
Description
Hand tools
Starting position
Related procedure
Man power
00.12 - ES0
MAN Diesel
509-08.00 Working card
Edition 01H Mounting and Adjustment of Pick-ups on Engine Page 2 (2)
L16/24
Mounting Guidance
Check of Plug
Mounting of Pick-up
Incorrect plug, see fig 4, square, black head and
The pick-up is screwed clockwise until it touches the black wire.
top of a tooth on the gear rim, please see fig 2.
00.12 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
Data
98.48 - ES0
MAN Diesel
509-10.00 Working Card
Edition 05H
Adjustment of Lambda Controller Page 2 (2)
L16/24
6) Adjustment completed.
9) Adjustment completed.
98.48 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 50901-19H
L16/24
393
For governor,
see special
instruction book
464
403 415
439
440
452
141
153
165
189
190 177
200 033
045
356 224
212+
344
057
069 236
070 248
082 261
08028-0D/H5250/94.08.12
094 273
285
297
307
332
320
06.32 - ES0
MAN Diesel
Plate
50901-19H Governor and Governor Drive Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
033 1/E Plug screw Propskrue 403 1/E Governor, Europa Regulator, Europa
(1200 rpm) (1200 rpm)
045 1/E Gasket Pakning
415 4/E Screw Skrue
057 4/E Nut Møtrik
439 1/E Governor, Europa Regulator, Europa
069 2/E Stud Tap (1000 rpm) (1000 rpm)
070 1/E O-ring O-ring 440 1/E Governor, Europa Regulator, Europa
(1000 rpm) (1000 rpm)
082 1/E Castle nut Kronemøtrik
452 1/E Governor, Europa Regulator, Europa
094 1/E Split pin Split (1200 rpm) (1200 rpm)
141 1/E Shim (set 0.1 - Mellemlæg (sæt 0,1 - 464 1/E Shutdown solenoid Shutdown spole
0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)
153 1/E Disc Skive + item 212 require + Item nr. 212 kræver
an individual match- en individuel tilpas-
165 1/E Ball bearing Kugleleje ing (by shims) before ning (med mellemlæg)
moun ting, contact, før montering, kontakt
177 1/E Bevel gear wheel Konisk tandhjul MAN B&W, Holeby. MAN B&W, Holeby
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
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 50901-20H
L16/24
For governor,
see special
instruction book
381
128
141
153
165
189
190 177
200 033
368 045
356 224
212+
344
057
069 236
070 248
082 261
094 273
08028-0D/H5250/94.08.12
285
297
307
332
320
06.32 - ES0
MAN Diesel
Plate
50901-20H Governor and Governor Drive Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
033 1/E Plug screw Propskrue 368 1/E O-ring only valid for O-ring anv. kun til
electronic actuator elektronisk aktuator
045 1/E Gasket Pakning
381 1/E Actuator, electronic Elektronisk aktuator
057 4/E Nut Møtrik
069 2/E Stud Tap + item 212 require + Item nr. 212 kræver
an individual match- en individuel tilpas-
070 1/E O-ring O-ring ing (by shims) before ning (med mellemlæg)
moun ting, contact, før montering, kontakt
082 1/E Castle nut Kronemøtrik MAN B&W, Holeby. MAN B&W, Holeby
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
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Regulating Device 50902-10H
L16/24
302
231
184
292
160 159
135
338 375
Pick-up, see
Plate 50907/276 351 231
111
363
196 218
015 255
052 314
326 218 123
172 064
231
135
231
06.24 - ES0
MAN Diesel
Plate
50902-10H Regulating Device Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
015 1/C Bearing bracket, com- Konsol, komplet inkl. 351 1/E Shaft, 8 cyl. engine Aksel, 8 cyl. motor
plete incl. bush bøsning
363 1/E Shaft, 9 cyl. engine Aksel, 9 cyl. motor
039 2/C Screw Skrue
375 1/E Nut Møtrik
040 1/C Lever Arm
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
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
06.24 - ES0
MAN Diesel
Plate
Page 1 (5) Instruments 50907-18
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
Thermostat
-1 - 4 bar PS 31 037
L
08028-0D/H5250/94.08.12
L1
Pressure control
08.08 - ES0
MAN Diesel
Plate
50907-18 Instruments Page 2 (5)
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
0 - 4 bar 90 30 PT 23 048
PT 31
0 - 6 bar 90 30 PT 10 085
PT 01
L
0 - 10 bar 90 30 PT 21 132
PT 22
0 - 16 bar 90 30 PT 40 156
L1
0 - 40 bar PT 70 168
Pressure transmitter
Female plug - see item 288
Pick-up
Pick-up
08.08 - ES0
MAN Diesel
Plate
Page 3 (5) Instruments 50907-18
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
0 - 1 kHz 22 ZT 88 227
L
Pick-up
Thermometer
(Female plug - see item 288)
Thermometer
08.08 - ES0
MAN Diesel
Plate
50907-18 Instruments Page 4 (5)
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
Temperature sensor
(Female plug - see item 288)
Temperature sensor
08028-0D/H5250/94.08.12
08.08- ES0
MAN Diesel
Plate
Page 5 (5) Instruments 50907-18
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
26.5 50 288
L1
Thermometer
08028-0D/H5250/94.08.12
08.08 - ES0
MAN Diesel
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-12H
L16/24
216 241
228 253
265 169
277 157
049 Base frame,
see plate 51111
062
170
050
121
098
182
108 194
182
133
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
50920-12H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.22 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-06H
L16/24
A-A 058
022 010
034
416
046
404
C C
333 178
345 333
286 357
C-C
382 369
08028-0D/H5250/94.08.12
394 370
06.22 - ES0
MAN Diesel
Plate
50925-06H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L16/24
Item Item
No. Qty Designation Benævnelse No. Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.22 - ES0
MAN Diesel
Plate
Page 1 (2) Monitoring Box 50935-18H
L16/24
Front view
OB MTP
015 027
To check software
version push “lamp
test” for 3-5 sec.
The display will
indicate the software
version no for BM MEG
module.
483
292
302
135
314 A1
338
351 Diagnose led
495
471
Fuses
F1 - sensors CPU
363 F2 - output relays
Led sensor
power
07.41 - ES0
MAN Diesel
Plate
50935-18H Monitoring Box Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
07.41 - ES0
MAN Diesel
Plate
Page 1 (2) Terminal Box 50936-16H
L16/24
Front view
453
465
477 536
489
490
500
095
Inside view
105
345
24VDC 400mA 0V 24V C 0 1 2 3 4 5 6 7 0 CO 1 C1 2 C2 2 3 C3 3 0 1 2 3 4 5 6 7
SENSOR SUPPLY DC INPUT DC INPUT 0V 24V DC INPUT
225
R
Advant Controller 31
Basic Unit EXTENSION
4 RELAY OUTPUT 2A EXTENSION
394
S 8 24VDC INPUTS 4 RELAY OUTPUT NO/NC 3A 16 24VDC INPUTS
6 RELAY OUTPUTS
404
416
428 250
08028-0D/H5250/94.08.12
142 GRD
GRD
441
-F4.0
-F4.1
-F4.7
-F4.8
GRD
548
274
154
561
07.43 - ES0
MAN Diesel
Plate
50936-16H Terminal Box Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
07.43 - ES0
MAN Diesel
Plate
Page 1 (2) Digital Load Sharing & Speed Control 50945-03
General
08028-0D/H5250/94.08.12
04.03 - EO0-ny
MAN Diesel
Plate
50945-03 Digital Load Sharing & Speed Control Page 2 (2)
General
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
Qty/Q = Qty/Plant Qty/Q = Qty/Anlæg
04.03 - EO0-ny
MAN Diesel
Plate
Page 1 (2) Alarm Panel 50946-01
General
015
High diff. press. lub. oil Low lub. oil level base
filter PDAH 21-22 frame LAL 28
027
08028-0D/H5250/94.08.12
00.39 - EO0-ny
MAN Diesel
Plate
50946-01 Alarm Panel Page 2 (2)
General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
00.39 - EO0-ny
MAN Diesel
Plate
Page 1 (2) Output Module 50947-05
L16/24
L21/31
L27/38
083
201 225
213 237
262
274
095
105
OUTPUT MODULE 117
130
142
250
08028-0D/H5250/94.08.12
J12 J4 J5 J8 J9 J10
07.33 - EO0
MAN Diesel
Plate
50947-05 Output Module Page 2 (2)
L16/24
L21/31
L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.33 - EO0
MAN Diesel
Plate
Page 1 (2) APM Motor Control 50948-01
General
08028-0D/H5250/94.08.12
98.13 - EO0
MAN Diesel
Plate
50948-01 APM Motor Control Page 2 (2)
General
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
98.13 - EO0
MAN Diesel
Plate
Page 1 (2) Valve Control Box 50949-01
General
059
060 084
072 096 106
118
08028-0D/H5250/94.08.12
131
143
98.16 - EO0-ny
MAN Diesel
Plate
50949-01 Valve Control Box Page 2 (2)
General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
98.16 - EO0-ny
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Pump Starter 50951-01
L16/24
OFF
PUMP ON
MAN. AUTO.
OFF
PUMP ON
MAN. AUTO.
OFF
PUMP ON
MAN. AUTO.
OFF 144
119 156
120 2S4 2S7 2S10 2S13 168
132 181
193 073
085
097
372
276 252 384
288 396 264 455
311 360
323
3T2 3Q5 4Q2 5Q2 6Q2 3K8 4K5 5K5 6K5
08028-0D/H5250/94.08.12
467
335 3F5 4F2 5F2 6F2 479
347
455
EARTH
EARTH
EARTH
EARTH
EARTH
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
L1
L2
L3
1
2
3
4
5
6
7
8
9
406 431
418 443
455 359 406 455
455
06.39 - ES0
MAN Diesel
Plate
50951-01 Prelubricating Oil Pump Starter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
024 1/E Name plate Navneplade 372 4/E Circuit breaker, Sikkerhedsafbryder,
10 amp 10 amp
036 1/E Name plate Navneplade
384 4/E Auxilliary switch Hjælpekontakt
048 1/E Name plate Navneplade
396 2/E Circuit breaker, Sikkerhedsafbryder,
061 1/E Name plate Navneplade 2 amp 2 amp
107 4/E Pilot lamp, green Lampeglas, grøn 443 1/E Earth terminal Jordklemme
119 4/E Lamp holder Lampefatning 455 17/E End angle Endevinkel
120 4/E Glow lamp Glødelampe 467 4/E Auxilliary relay Hjælperelæ
132 4/E Label, PUMP ON Label, PUMP ON 479 4/E Socket Sokkel
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
06.39 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Pump Starter 50951-02
L16/24
024 036
012
227
239
1AE1 1AE2 1AE3
085 PRELUB. OIL PUMP PRELUB. OIL PUMP PRELUB. OIL PUMP
240
ENGINE 1 ENGINE 2 ENGINE 3
097
3H10 3S5 4H7 4S2 5H7 5S2
PUMP ON
MAN. AUTO.
PUMP ON
MAN. AUTO.
PUMP ON
MAN. AUTO. 048
OFF OFF OFF
107
119 144
2S4 2S7 2S10
120 156
132 168
1AE5 181
193
203 073
215 085
276 252
097
288 264 372
467 384
335 479 396 455
347
455 360
311
EARTH
EARTH
EARTH
EARTH
323 3T2
13
14
15
16
17
18
21
22
23
25
26
27
28
29
30
31
L1
L2
L3
1
2
3
4
5
6
7
8
9
06.39 - ES0
MAN Diesel
Plate
50951-02 Prelubricating Oil Pump Starter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
012 1/E Prelubricating oil Forsmøreolie- 347 3/E Thermal relay Terminalrelæ
pump starter pumpestarter
panel complete komplet 359 /I Channel track Kanalspor
036 1/E Name plate Navneplade 372 3/E Circuit breaker, Sikkerhedsafbryder,
10 amp 10 amp
048 1/E Name plate Navneplade
384 3/E Auxilliary switch Hjælpekontakt
073 1/E Name plate Navneplade
396 2/E Circuit breaker, Sikkerhedsafbryder,
085 8/E Screw M3 Skrue M3 2 amp 2 amp
107 3/E Pilot lamp, green Lampeglas, grøn 418 3/E Earth terminal Jordklemme
119 3/E Lamp holder Lampefatning 443 1/E Earth terminal Jordklemme
120 3/E Glow lamp Glødelampe 455 13/E End angle Endevinkel
132 3/E Label, PUMP ON Label, PUMP ON 467 3/E Auxilliary relay Hjælperelæ
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
06.39 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Pump Starter 50951-03
L16/24
024 036
012
227
239
1AE1 1AE2
085 PRELUB. OIL PUMP PRELUB. OIL PUMP
240
ENGINE 1 ENGINE 2
097
3H10 3S5 4H7 4S2
MAN. AUTO. MAN. AUTO.
PUMP ON PUMP ON
OFF OFF
107
119 144
2S4 2S7
120 156
132 168
1AE5 181
193
203 073
215 085
276 252
097
288 264 372
467 384
335 479 396 455
347
455 360
3F5 4F2
08028-0D/H5250/94.08.12
311
EARTH
EARTH
EARTH
323
13
14
15
16
21
22
25
26
27
28
29
L1
L2
L3
3T2
1
2
3
4
5
6
06.39 - ES0
MAN Diesel
Plate
50951-03 Prelubricating Oil Pump Starter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
024 1/E Name plate Navneplade 372 2/E Circuit breaker, Sikkerhedsafbryder,
10 amp 10 amp
036 1/E Name plate Navneplade
384 2/E Auxilliary switch Hjælpekontakt
073 1/E Name plate Navneplade
396 2/E Circuit breaker, Sikkerhedsafbryder,
085 6/E Screw M3 Skrue M3 2 amp 2 amp
107 2/E Pilot lamp, green Lampeglas, grøn 418 3/E Earth terminal Jordklemme
119 2/E Lamp holder Lampefatning 443 1/E Earth terminal Jordklemme
120 2/E Glow lamp Glødelampe 455 13/E End angle Endevinkel
132 2/E Label, PUMP ON Label, PUMP ON 467 2/E Auxilliary relay Hjælperelæ
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
06.39 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Pump Starter 50951-04
L16/24
024 012
227
1AE1
239
240
PRELUB. OIL PUMP
ENGINE
085
3H10 3S5
097
PUMP MAN. AUTO
ON OFF
107 144
119 156
120 168
132 2S4
181
193 073
1AE2
085
097
276 276
288 252 288
467 359 264 396
335 479
347 372
384
455
360
08028-0D/H5250/94.08.12
311
EARTH
EARTH
3T2
13
14
15
16
17
18
L1
L2
L3
1
2
3
323
06.39 - ES0
MAN Diesel
Plate
50951-04 Prelubricating Oil Pump Starter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
107 1/E Pilot lamp, green Lampeglas, grøn 467 1/E Auxilliary relay Hjælperelæ
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
06.39 - ES0
MAN Diesel
Plate
Page 1 (2) Converter 50956-01
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
50956-01 Converter Page 2 (2)
General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.37 - ES0
MAN Diesel
Plate
Page 1 (2) Oil Mist Detector 50960-03H
L16/24
05.25 - ES0
MAN Diesel
Plate
50960-03H Oil Mist Detector Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
05.25 - ES0
Crankshaft
510/610
MAN Diesel
Description 510.01
Page 1 (1) Crankshaft and Main Bearings Edition 02H
L16/24
Crankshaft and Main Bearings Vibration Damper
The crankshaft, which is a one-piece forging, is A vibration damper is mounted on the crankshaft
suspended in underslung bearings. The main bea- to limit torsional vibrations. The damper consists of
rings are of the trimetal type, which are coated with a primary and a secondary part. Between these,
a running layer. To attain a suitable bearing pressure groups of leaf spring packs are arranged, which are
and vibration level the crankshaft is provided with clamped at their outer ends.
counterweights, which are attached to th/e crank-
shaft by means of one hydraulic screws. These spring packs form, together with the primary
and secondary members, chambers which are filled
At the flywheel end the crankshaft is fitted with a with oil. If the exterior member vibrates in relation
gear wheel which, through two intermediate wheels, to the inner member, the leaf springs are bent and
drives the camshafts. force oil from one chamber into another, retarding
the relative movement of the two parts and thus
Also fitted here is a coupling flange for the connec- damping the torsional vibration. In order to protect
tion of an alternator. At the opposite end (front end) the leaf springs against overloading, their deflection
there is a gear wheel connection for lube oil and is limited by buffers.
water pumps.
The elasticity is determined by careful choise of the
Lubricating oil for the main bearings is supplied leaf springs, the damping factor by the gap between
through holes drilled in the engine frame. From primary and secondary members.
the main bearings the oil passes through bores in
the crankshaft to the big-end bearings and thence
through channels in the connecting rods to lubricate
the piston pins and cool the pistons.
08028-0D/H5250/94.08.12
98.43 - ES0
MAN Diesel
Working Card 510-01.00
Page 1 (6) Checking of Alternator / Crankshaft Alignment (Autolog) Edition 15H
L16/24
Starting position:
Related procedure:
Data:
08.09 - ES0
MAN Diesel
510-01.00 Checking of Alternator / Crankshaft Alignment (Autolog) Working Card
Edition 15H Page 2 (6)
L16/24
Procedure
08028-0D/H5250/94.08.12
08.09 - ES0
MAN Diesel
Working Card
Page 3 (6) Checking of Alternator / Crankshaft Alignment (Autolog) 510-01.00
Edition 15H
L16/24
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
Fig 2 Fig 5
Fig 6
C and D should be nearly the same, reading for crank throw 4 to be repeated.
S P
Y X
08028-0D/H5250/94.08.12
Fig 7 Fig 8
08.09 - ES0
MAN Diesel
510-01.00 Working Card
Edition 15H Checking of Alternator / Crankshaft Alignment (Autolog) Page 4 (6)
L16/24
08028-0D/H5250/94.08.12
08.09 - ES0
MAN Diesel
Working Card 510-01.00
Page 5 (6) Checking of Alternator / Crankshaft Alignment (Autolog) Edition 15H
L16/24
Instruction/Instruktion
Top
Right side
Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
08028-0D/H5250/94.08.12
08.09 - ES0
MAN Diesel
510-01.00 Checking of Main Bearings Alignment (Autolog)
Working Card
Edition 15H Page 6 (6)
L16/24
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.
Left side - Right
08028-0D/H5250/94.08.12
side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
08.09 - ES0
MAN Diesel
L16/24
Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Sopaslip
Related procedure
Data
99.33 - ES0
MAN Diesel
L16/24
Preparing for Dismantling of the Main and Dismantling of the Main and Guide Bearing
Guide Bearing Cap
1) Dismount crankcase covers in front and op- 6) Fit the lifting handle, (Plate 52010, Item 035),
posite the bearing concerned. so as to support the bearing cap.
2) Turn the engine until the crank is in a convenient 7) Work the main bearing cap loose from the
possition for carrying out the work. engine frame with a lead hammer or similar.
3) Mount the hydraulic tool and loosen the brac- 8) Lift the main bearing cap a little and unscrew
ing stud nuts, see fig 1. For operating of the the bearing stud nut.
hydraulic tool, please see working card 520-
01.05, 9) Lift out the bearing cap from the engine.
11) Fit the tool for the upper main bearing tool,
for dismantling of upper main bearing shell,
in the lubricating hole in the crankshaft and
turn out the upper bearing shell by turning the
crankshaft, see fig 2.
Fig 1 Mount the hydraulic tool and loosen the bracing stud
08028-0D/H5250/94.08.12
nuts.
99.33 - ES0
MAN Diesel
L16/24
15) Fit the tool for upper main and guide bearing 20) Tighten the nuts for the bearing cap as pre-
in the lubricating hole in the crankshaft and scribed on page 500.40.
turn in the upper bearing shell by turning the
crankshaft. 21) Tighten up the bracing screw to second step,
please see page 500.40.
Make sure the shell enters its correct position then
remove the tool for upper main and guide bearing. 22) Tighten the bearings one at a time.
99.33 - ES0
MAN Diesel
L16/24
Inspection
Starting position
Related procedure
Capacity : 1 man
See plate 51004
Data
98.44 - ES0
MAN Diesel
510-04.00 Working Card
Edition 03H Vibration Damper Page 2 (3)
L16/24
Together with every main revision of the engine Inner Spring Ends and Groove Flanks
the damper is to be inspected as well. Generally
an inspection of this kind is to be carried out every Wear takes place due to lack of oil supply.
28-30.000 hours of service together with service
and the replacement of certain parts, which are Spring packs consisting of two conical spring blades
exposed to wear. only are clamped in the innerstar groove at their
inner spring ends, thus producing a slight preload
Note: Regular inspection and supervision of the of the springs. The allowable wear will be attained
damper allows for preliminary planning and to order as soon as the preload of the springs is not existing
spare parts in time. any more and an additional clearance of "z" mm per
side between spring ends and groove flanks occures
(totalling 2 x z mm if one side of spring end rests on
Allowable Wear groove flank), see fig 2.
Type z
D 56/49/1 0.23
D 56/50 0.18
D 50/4 0.12
98.44 - ES0
MAN Diesel
L16/24
Circularity of Outer Member (correction)
Appendix
98.44 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 51001-03H
L16/24
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Plate
51001-03H Crankshaft Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/E = Qty/Engine Qty/E = Qty/Motor
98.41 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 51001-12H
L16/24
116
153
141 165
177
189
190
200
190
082
094
104
212
070
116
021
08028-0D/H5250/94.08.12
033
045
057
128 069
06.20 - ES0
MAN Diesel
Plate
51001-12H Crankshaft Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.20 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 51003-16H
L16/24
010
022 058
034 105
071
046
083
08028-0D/H5250/94.08.12
095
06.17 - ES0
MAN Diesel
Plate
51003-16H Flywheel with Gear Rim Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.17 - ES0
MAN Diesel
Plate
Page 1 (2) Vibration Damper / Tuning Wheel 51004-04H
L16/24
173
041
Crankshaft
053 see plate 51001
124
041
Crankshaft
see plate 51001
053
124
6L16/24, 1000 rpm
148
08028-0D/H5250/94.08.12
028
041
053
124
08.39 - ES0
MAN Diesel
Plate
51004-04H Vibration Damper / Tuning Wheel Page 2 (2)
L16/24
Item Item
No. Qty Designation Benævnelse No. Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
08.39 - ES0
Engine frame/Oil pan
511/611
MAN Diesel
Description
Engine Frame and Base Frame 511.01
Page 1 (1)
Edition 02H
L16/24
Engine Frame On the sides of the frame there are covers for ac-
cess to the camshafts and crankcase. Some covers
The monobloc cast iron engine frame is designed are fitted with relief valves which will operate if oil
to be very rigid. All the components of the engine vapours in the crankcase are ignited (for instance
frame are held under compression stress. The frame in the case of a hot bearing).
is designed for an ideal flow of forces from the cylin-
der head down to the crankshaft and gives the outer
shell low surface vibrations. Base Frame
Two camshafts are located in the engine frame. The engine and alternator are mounted on a rigid
The valve camshaft is located on the exhaust side base frame. The base frame acts as a lubricating
in a very high position and the injection camshaft is oil reservoir for the engine. The alternator is consid-
located on the service side of the engine. ered as an integral part during engine design. This
GenSet is flexible mounted on the foundation with
The main bearings for the underslung crankshaft rubber elements under the base frame.
are carried in heavy supports by tierods from the
intermediate frame floor, and are secured with the
bearing caps. These are provided with side guides
and held in place by means of studs with hydrauli-
cally tightened nuts. The main bearing is equipped
with replaceable shells which have the final toler-
ances.
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Working Card 511-01.00
Page 1 (2) Functional Test of Crankcase Safety Relief Valves Edition 11H
L16/24
Starting position
Related procedure
Capacity : 1 man
51106 237 1/cover
51106 490 4/relief valve
Data 51106 740 1/relief valve
06.46 - ES0
MAN Diesel
L16/24
Functional Testing
Relief
valve
When Painting
06.46 - ES0
MAN Diesel
Plate
Page 1 (2) Frame with Main Bearings 51101-23
L16/24
194 037
086
013 098
074 133
265 145
277
049
241
08028-0D/H5250/94.08.12
241
253 204
204 204
157 216
086 170
228
050 169 086
086
08.41 - ES0
MAN Diesel
Plate
51101-23 Frame with Main Bearings Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
098 1/E Frame, 5 cyl. engine Stativ, 5 cyl. motor 241 Main bearing shell Hovedlejeskal 2/2
2/2
108 1/E Frame , 6 cyl. engine Stativ, 6 cyl. motor 7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
121 1/E Frame, 7 cyl. engine Stativ, 7 cyl. motor 9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
133 1/E Frame, 8 cyl. engine Stativ, 8 cyl. motor 11/E 9 cyl. engine 9 cyl. motor
145 1/E Frame, 9 cyl. engine Stativ, 9 cyl. motor 253 2/E Thrust bearing ring Tryklejering
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
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
08.41 - ES0
MAN Diesel
Plate
Page 1 (3) Front End Box 51103-06H
L16/24
08028-0D/H5250/94.08.12
03.06 - ES0
MAN Diesel
Plate
51103-06H Front End Box Page 2 (3)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
014 1/E Front end box Front end box 349 4/E Screw Skrue
099 3/E Washer Skive 421 1/E Housing for Hus for
lub. oil separator smøreolieseparator
109 1/E Plate Plade
433 12/E Screw Skrue
110 4/E Screw Skrue
445 1/E O-ring O-ring
122 2/E Plug screw Propskrue
457 1/E Bracket for by-pass Konsol for centrifugal
134 2/E Packing ring Pakningsring centrifugal filter by-pass filter
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
03.06 - ES0
MAN Diesel
Plate
Page 3 (3) Front End Box 51103-06H
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
03.06 - ES0
MAN Diesel
Plate
Page 1 (3) Front-end Box 51103-17H
L16/24
171 109
158
291 110
08028-0D/H5250/94.08.12
08.16 - ES0
MAN Diesel
Plate
51103-17H Front-end Box Page 2 (3)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
014 1/E Front end box Front end box 362 2/E Flange (1-string) Flange (1-streng)
026 5/E Plate Plade 374 2/E Gasket (1-string) Pakning (1-streng)
109 1/E Plate Plade 457 1/E Bracket for by-pass Konsol for centrifugal
centrifugal filter by-pass filter
110 4/E Screw Skrue
469 4/E Screw Skrue
122 2/E Plug screw Propskrue
470 1/E Plug screw Propskrue
134 2/E Packing ring Pakningsring
482 1/E Packing ring Pakningsring
146 2/E Thermostatic Termostatelement
element for lub. oil for smøreolie 494 1/E Cover Dæksel
266 1/E Housing (1-string) Hus (1-streng) 624 1/E Screw Skrue
267 1/E Housing (2-string) Hus (2-streng) 636 1/E Thrust piece Trykstykke
278 2/E Thermostatic ele- Termostatelement 648 1/E Covering plate Dækselplade
ment for HT cooling for HT kølevand
water 661 1/E Setting screw Skrue
350 8/E Screw (1-string) Skrue (1-streng) 688 2/E Plug screw Propskrue
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
08.16 - ES0
MAN Diesel
Plate
Page 3 (3) Front-end Box 51103-17H
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
08.16 - ES0
MAN Diesel
Plate
Page 1 (2) Covers on Frame 51106-21H
L16/24
740 453
490
500
286 357
154 298 369
249 370
250 382
394
166 262 811
441
428
416
345
404
536
250
178 249
237
321
08028-0D/H5250/94.08.12
191
Frame, 201
see plate 51101 250 308
249
06.19 - ES0
MAN Diesel
Plate
51106-21H Covers on Frame Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
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
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/D = Qty/Cover Qty/D = Qty/Dæksel
06.19 - ES0
MAN Diesel
Plate
Page 1 (2) Cover on Frame 51106-22H
L16/24
08028-0D/H5250/94.08.12
06.17 - ES0
MAN Diesel
Plate
51106-22H Cover on Frame Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.17 - ES0
MAN Diesel
Plate
Page 1 (2) Base Frame 51111-09H
L16/24
080
126
138
092
151
163
043
055
067
06.22 - ES0
MAN Diesel
Plate
51111-09H Base Frame Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.22 - ES0
Turbocharger
512/612
MAN Diesel
Description 512.01
Page 1 (2) Turbocharger System Edition 05H
L16/24
the engine room through the air filters. the charge air is controlled by the scavenging pres-
sure to ensure sufficient scavenging temperature
The turbocharger forces the air through the char- for burning HFO.
ging air cooler to the charging air receiver. From the
charging air receiver the air flows to each cylinder From the exhaust valves, the exhaust gas is led
through the inlet valves. through to the exhaust gas receiver where the
pulsatory pressure from the individual cylinders is
equalized and passed on to the turbocharger as a
constant pressure, and further to the exhaust outlet
and silencer arrangement.
99.37 - ES0S
MAN Diesel
512.01 Description
Edition 05H
Turbocharger System Page 2 (2)
L16/24
The exhaust gas receiver is made of pipe sections,
one for each cylinder, connected to each other by
means of compensators to prevent excessive stress
in the pipes due to heat expansion.
08028-0D/H5250/94.08.12
99.37 - ES0S
MAN Diesel
Working Card 512-01.00
Page 1 (4) Overhaul of Charging Air Cooler Edition 02H
L16/24
Starting position
Related procedure
01.30 - ES0
MAN Diesel
512-01.00 Working Card
Edition 02H Overhaul of Charging Air Cooler Page 2 (4)
L16/24
The charging air cooler is normally cleaned and
overhauled at the intervals indicated in the "Planned
Maintenance Program", or if observations prove that Charge air pipe
the cooler does not work adequately, see section
502.
Lifting hole
A-A
A
Screw (1)
A
08028-0D/H5250/94.08.12
Chamber (4)
Gasket (7)
Gasket (6)
01.30 - ES0
MAN Diesel
Working Card 512-01.00
Page 3 (4) Overhaul of Charging Air Cooler Edition 02H
L16/24
Cleaning and Inspecting
01.30 - ES0
MAN Diesel
512-01.00 Working Card
Edition 02H Overhaul of Charging Air Cooler Page 4 (4)
L16/24
Mounting of Charge Air Cooler
1
10) Renew gaskets (6) and (7) before assembling
endcover (3) reversal chamber (4) and top
plate (5). See fig 1.
11) Lift the air cooler by the lifting tool and push it
carefully half-way into its housing.
12) Remove the lifting tool and push the air cooler
into place.
13) Mount the screws see fig 2, pos. 1 and the Fig 4 Mounting of charging air cooler
charge air pipe, see fig 1.
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Working Card 512-01.10
Page 1 (2) Exhaust Pipe Compensator Edition 01H
L16/24
Starting position
Related procedure
Data
97.40 - ES0
MAN Diesel
512-01.10 Working Card
Edition 01H Exhaust Pipe Compensator Page 2 (2)
L16/24
Description
08028-0D/H5250/94.08.12
97.40 - ES0
MAN Diesel
Working Card 512-10.00
Page 1 (2) Cleaning the Turbine, dry cleaning Edition 03H
L16/24
Starting position
Related procedure
Data
97.50 - ES0
MAN Diesel
Working Card 512-10.00
Page 2 (2) Cleaning the Turbine, dry cleaning Edition 03H
L16/24
5-7 bar
1 Stop valve
2 Container
3 Valve
4 Working air
1 2 3 4
Dry cleaning Fill the container (2) with granulate. The amount
depending on the type of turbocharger;
Depending on the type of engine and turbocharger,
the arrangement of items may also differ somewhat NR12, NR14, NR15,
from that shown in the schematic. NR17, NR20 ...................................0.3 liter
Appropriate cleaning materials are granulates from NR24, NR26 ...................................0.4 liter
nut shells or activated charcoal of a grain size of 1
mm (max. 1.5 mm). NR29, NR34 ...................................0.5 liter
97.50 - ES0
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler 51201-06H
L16/24
08028-0D/H5250/94.08.12
97.43 - ES0
MAN Diesel
Plate
51201-06H Charging Air Cooler Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/K = Qty/Cooler Qty/K = Qty/Køler
Qty./E = Qty./Engine Qty./E = Qty./Motor
97.43 - ES0
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler with Preheating 51201-16H
L16/24
101
174
091
125
113
186
029
198
030
017
186
137 042
198
066
150
054
149
08028-0D/H5250/94.08.12
066
054
078
08.39 - ES0
MAN Diesel
Plate
51201-16H Charging Air Cooler with Preheating Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/K = Qty/Cooler Qty/K = Qty/Køler
Qty./E = Qty./Engine Qty./E = Qty./Motor
08.39 - ES0
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler without Preheating 51201-17H
L16/24
101
174
091
125 113
186
029
198
030
017
186
042
137 198
066
150 054
149
066
08028-0D/H5250/94.08.12
054
078
07.47 - ES0
MAN Diesel
Plate
51201-17H Charging Air Cooler without Preheating Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/K = Qty/Cooler Qty/K = Qty/Køler
Qty./E = Qty./Engine Qty./E = Qty./Motor
07.47 - ES0
MAN Diesel
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-17H
L16/24
08028-0D/H5250/94.08.12
06.24 - ES0
MAN Diesel
Plate
51202-17H Exhaust Pipe Arrangement Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
06.24 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Turbocharger 51203-07H
L16/24
08028-0D/H5250/94.08.12
99.06 - ES0
MAN Diesel
Plate
51203-07H Mounting of Turbocharger Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
99.06 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Turbocharger 51203-27H
712 L16/24
724
665
677
653
S2 S2
S3 S3
665
S2 : S2
690
S3 : S3
700
700
712
724 653
785
748
797
773 736
665
761
08028-0D/H5250/94.08.12
690
807
819
665
689
07.18 - ES0
MAN Diesel
Plate
51203-27H Mounting of Turbocharger Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.18 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Turbocharger 51203-28H
712 L16/24
724 665
677
653
S2 S2
S3 S3
665
S2 : S2
690
S3 : S3
700
700
712
724 653
785
748
797
773 736
665
761
08028-0D/H5250/94.08.12
690
807
819
665
689
07.18 - ES0
MAN Diesel
Plate
51203-28H Mounting of Turbocharger Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.18 - ES0
MAN Diesel
Plate
Page 1 (2) Connection Pipe 51206-02H
L16/24
08028-0D/H5250/94.08.12
99.17 - ES0
MAN Diesel
Plate
51206-02H Connection Pipe Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
99.17 - ES0
MAN Diesel
Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 51210-02
L16/24
197
161 256 173 185 268 207 219
281
220 315
0.2 L
232
0.3 L
303
244
0.4 L
293
08028-0D/H5250/94.08.12
08.26 - ES0
MAN Diesel
Plate
51210-02 Blowgun for Dry Cleaning of Turbocharger Page 2 (2)
L16/24
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
08.26 - ES0
MAN Diesel
Plate
Page 1 (2) Heat Insulation of Exhaust Pipes 51211-01H
L16/24
S1
S1
011 047 059
060
S1
08028-0D/H5250/94.08.12
06.50 - ES0
MAN Diesel
Plate
51211-01H Heat Insulation of Exhaust Pipes Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.50 - ES0
MAN Diesel
Plate
Page 1 (2) Cover of Exhaust Pipes 51211-02H
L16/24
A3 A2
A3 A2
08028-0D/H5250/94.08.12
143
A2 A3
167
155
06.50 - ES0
MAN Diesel
Plate
51211-02H Cover of Exhaust Pipes Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.50 - ES0
MAN Diesel
Plate
Page 1 (2) Heat Insulation and Cover before Turbocharger 51211-03H
L16/24
180
179
192
202
08028-0D/H5250/94.08.12
214
226
06.50 - ES0
MAN Diesel
Plate
51211-03H Heat Insulation and Cover before Turbocharger Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
06.50 - ES0
MAN Diesel
Plate
Page 1 (2) Charge Air Pipes 51230-03H
L16/24
08028-0D/H5250/94.08.12
02.36 - ES0
MAN Diesel
Plate
51230-03H Charge Air Pipes Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
015 1/E Flange Flange 302 4/E Screw, 5-6 cyl. Skrue, 5-6 cyl.
7 cyl. 1000 rpm 7 cyl. 1000 rpm
027 Seal ring Tætningsring
11/E 5 cyl. engine 5 cyl. motor 326 1/E Covering sheet Dækplade
13/E 6 cyl. engine 6 cyl. motor
15/E 7 cyl. engine 7 cyl. motor 338 17/E Screw Skrue
17/E 8 cyl. engine 8 cyl. motor
19/E 9 cyl. engine 9 cyl. motor 483 1/C Screw Skrue
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
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
02.36 - ES0
MAN Diesel
Plate
Page 1 (2) Oil Drain from Turbocharger 51231-07H
L16/24
View with turbocharger NR14/S
345
500
512
345
453 357
465
369 404
428 394
489 416
477
370
490
382
441
477
585 548
573
597 561
08.27 - ES0
MAN Diesel
Plate
51231-07H Oil Drain from Turbocharger Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
08.27 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Charge Air Cooler 51235-04H
L16/24
S1 : S1
S1 S2 S3 S4 S5
S2
S1
360 S3 S5
S4 : S4
443
467
575
07.46 - ES0
MAN Diesel
Plate
51235-04H Mounting of Charge Air Cooler Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
07.46 - ES0
MAN Diesel
Plate
Page 1 (2) Control Air for Preheating Valve 51236-02H
L16/24
317
329
295
305
401
425
234
246
258
271
222
210
234
283
330
342
08028-0D/H5250/94.08.12
07.48 - ES0
MAN Diesel
Plate
51236-02H Control Air for Preheating Valve Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
07.48 - ES0
Compressed air system
513/613
MAN Diesel
Description
Compressed Air System (low pressure) 513.01
Page 1 (2)
Edition 16H
L16/24
SA SSH
On-off valve for shutdown 99 81-1
(with push button for Air starter
SS SX SX SSH
84 84 83 81-2
emergency stop)
UX
95
Cyl. 1 Monito- Safety
ring system SS
system 86
SX
ZS ZS SX ZS 86
SS 75 96 32 97
Compressed air to TC, 82
(see combustion air diagram) Cylinder for Stop solenoid
lambda controller on governor
and overspeed stop Charging air inlet,
(see combustion air diagram)
The compressed air system on the engine consists The engine is started by means of a built-on air
of a starting system, starting control system and starter, which is a turbine motor with safety clutch
safety system. Further, the system supplies air to and drive shaft with pinion. Further, there is a main
the jet assist system. starting valve.
05.05 - ES1
MAN Diesel
L16/24
For remote activation the starting coil is connected Pneumatic Start Sequence
so that every starting signal to the starting coil goes
through the safe start function which is connected to When the starting valve is opened, air will be supplied
the basemodule mounted on the engine. to the drive shaft housing of the air starter.
Further, the starting valve also acts as an emergency The air supply will - by activating a piston - bring the
starting valve which makes it possible to activate the drive pinion into engagement with the gear rim on
air starter manually in case of power failure. the engine flywheel.
As shown in fig. 2.
When the pinion is fully engaged, the pilot air will
flow to, and open the main starting valve, whereby
Safety System air will be led to the air starter, which will start to
turn the engine.
As standard the engine is equipped with a pneuma-
tic/mechanic stop cylinder, which starts to operate if When engine rpm exceeds approx. 158 and firing
the safety system is activated.The system is activated has taken place, the starting valve is closed whereby
electrically or mechanically by 3/2-way valve on top the air starter is disengaged.
of engine, behind regulator.
08028-0D/H5250/94.08.12
05.05 - ES1
MAN Diesel
Description
Compressed Air System 513.01
Page 1 (2)
Edition 17H
L16/24
The compressed air system on the engine consists The engine is started by means of a built-on air
of a starting system, starting control system and starter, which is a turbine motor with safety clutch
safety system. Further, the system supplies air to and drive shaft with pinion. Further, there is a main
the jet assist system. starting valve.
is mounted in the inlet line to the engine. manually from the starting box on the engine, and
it can be arranged for remote control, manual or
automatic.
05.05 - ES1
MAN Diesel
513.01 Compressed Air System Description
Page 2 (2)
Edition 17H
L16/24
For remote activation the starting coil is connected Pneumatic Start Sequence
so that every starting signal to the starting coil goes
through the safe start function which is connected to When the starting valve is opened, air will be supplied
the basemodule mounted on the engine. to the drive shaft housing of the air starter.
Further, the starting valve also acts as an emergency The air supply will - by activating a piston - bring the
starting valve which makes it possible to activate the drive pinion into engagement with the gear rim on
air starter manually in case of power failure. the engine flywheel.
As shown in fig. 2.
When the pinion is fully engaged, the pilot air will
flow to, and open the main starting valve, whereby
Safety System air will be led to the air starter, which will start to
turn the engine.
As standard the engine is equipped with a pneuma-
tic/mechanic stop cylinder, which starts to operate if When engine rpm exceeds approx. 158 and firing
the safety system is activated.The system is activated has taken place, the starting valve is closed whereby
electrically or mechanically by 3/2-way valve on top the air starter is disengaged.
of engine, behind regulator.
08028-0D/H5250/94.08.12
05.05 - ES1
MAN Diesel
General
Starting position
Related procedure
08028-0D/H5250/94.08.12
Data
08.21 - ES0
MAN Diesel
General
Cleaning Air Filter To replace filter element
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
08.21 - ES0
MAN Diesel
Working Card 513-01.30
Page 1 (4) Overhaul, Test and Inspection of Air Starter Edition 03H
L16/24
Starting position
Related procedure
Data
98.48 - ES0
MAN Diesel
513-01.30 Working Card
Edition 03H Overhaul, Test and Inspection of Air Starter Page 2 (4)
L16/24
It is not nessesary to disassemble the air starter
for inspection, only if overhaul is necessary due to
worn parts.
Inspection
08028-0D/H5250/94.08.12
98.48 - ES0
MAN Diesel
Working Card 513-01.30
Page 3 (4) Overhaul, Test and Inspection of Air Starter Edition 03H
L16/24
Disassembly 11) Remove the drive housing seal (16) from the
flange cover.
Always wear eye protection when performing any
maintenance on this air starter. 12) Turn the air starter over and secure it vertically
in a fixture.
Always turn off the air supply and disconnect the air
supply before installing, removing or adjusting any Note: Use care when removing the housing cover
accessory on this air starter or before performing bolts (12) holding the housing cover (11) to the air
any maintenance on this air starter. starter. The liner (9) is spring loaded and will pro-
trude approximately one inch beyong the housing
1) Do not disassemble the air starter any further when released.
than necessary to replace worn parts.
13) To remove the housing cover, slowly loosen
2) When grasping a part in a vise, always use the four housing cover bolts while holding the
leather-covered or copper-covered vise jaws to housing cover in place.
protect the surface of the part and help prevent
distortion. This is paritcularly true of threaded 14) Slide the liner assembly out of the housing.
members.
15) Remove the return spring (8).
3) Do not remove any part which is a press fit in
or on a subassembly unless the removal of that
part is necessary for replacement or repairs. Assembly
4) Always have a complete set of seals and o-rings 16) Always press on the inner ring of a ball-type
on hand before starting any overhaul of the air bearing when installing the bearing on a
starter. Never reuse old seals or gaskets. shaft.
5) When disassembling, always mark adjacent 17) Always press on the outer ring of a ball-type
parts so the members can be located in the bearing when pressing the bearing into a bear-
same relative position when the air starter is ing recess.
reassembled.
18) Whenever grasping an air starter or part in a
6) Never wash the liner assembly (9) in a sol- vise, always use leather-covered or copper-
vent. covered vise jaws. Take extra care with treaded
parts or housings.
98.48 - ES0
MAN Diesel
513-01.30 Working Card
Edition 03H Overhaul, Test and Inspection of Air Starter Page 4 (4)
L16/24
21) Attach the housing cover (11) to the housing 29) Attach the drive pinion (2) to the drive shaft
with just one housing cover bolt (12). Engage using the drive pinion screw (1) and Locktite,
only a few threads so that the housing cover tighten to 40-45 ft-lb (54-61 Nm) torque, fig
can be easily rotated. 1.
08028-0D/H5250/94.08.12
98.48 - ES0
MAN Diesel
Working Card 513-01.30
Page 1 (2) Overhaul, Test and Inspection of Air Starter Edition 06H
L16/24
Starting position
Related procedure
51309 614 1
(set of seals, air starter)
Data
51309 615 1
Data for pressure and tolerance (Page 500.35) (repair kit, air starter)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
03.14 - ES0
MAN Diesel
L16/24
Before putting into operation In case of manual start, operate the push-button
valve for very short periods only.
– Check if the installation has been accomplished
in accordance with our instructions.
Complete Overhaul
– Check the adjustment of the auto-start device
(if installed), to ensure: – Strip the starter and clean all lines and pipe-
work.
– the speed of the starter shaft never exceeds
the value of 3.500 rpm. – Check rotors and advance mechanism; clean
same and replace worn or rusted parts.
– the starter stops working, once the engine
hasattained a speed 1 to 1.5 times is igni- – Check the driving pinion for wear and replace
tion speed. it if necessary.
– Check that the air receiver is charged and that – Revice all valves and replace joints.
the flow valve is opened.
– Test for leaks and check that the control circuit Storage
is not chocked.
When leaving our works, the starters contain antirust
– Check for correct meshing of the driving pinion oil to protect their inner parts. In spite o this, we must
with the flywheel gear ring by means of several recommended storage in a dry place.
short starter impulses.
08028-0D/H5250/94.08.12
03.14 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
Data
98.45 - ES0
MAN Diesel
513-01.40 Working Card
Edition 02H Emergency Starting Valve Page 2 (2)
L16/24
Emergency Starting Valve
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel
General
Starting position
Related procedure
Capacity : 1 man
Data
02.20 - ES0
MAN Diesel
General
With Air Connected With Air Disconnected and Stopped En-
gine
1) Examine the piping system for leaks.
6) Move all valves and cocks in the piping sys-
2) Retighten all bolts and nuts in the piping sy- tem. Lubricate valve spindles with graphite or
stem. similar.
3) Drain the system for condensed water. This 7) Connect the air supply and make a function
should be based on observations. test of the emergency valve. See Description
513.01.
4) Check flexible connections for leaks and da-
mages.
5) Check manometers.
08028-0D/H5250/94.08.12
02.20 - ES0
MAN Diesel
Plate
Page 1 (2) Air Starter 51309-18H
L16/24
08028-0D/H5250/94.08.12
08.04 - ES0
MAN Diesel
Plate
51309-18H Air Starter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
014 1/S Drive pinion screw Tandhjulsskrue 624 1/S Spare parts kit for Reservedelskit for
air starter, incl. item startemotor, inkl. item
026 1/S Drive pinion, Tandhjul, 014, 038, 051, 063, 014, 038, 051, 063,
incl item 291 inkl. item 291 087, 291 087, 291
038 1/S Gasket for housing Pakning for 648 1/S Spare parts kit for Reservedelskit for
cover motorhusdæksel item 325, consisting item 325, indeholder
of element, gasket element, pakning
051 1/S Front drive shaft Forreste
bearing drivakselleje 673 1/S Straight male stud Ligeforskruning
coupling
063 1/S Drive housing seal Tætning for drivgear
685 1/S Reducing stand Reduktionsrør
087 6/S Flange cap screw Dækselskrue for pipe
flange
697 1/S Adjustable Justerbar
099 1/S Flange cover Flangedæksel T-coupling T-forskruning
elbow vinkelforskruning
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
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
08.04 - ES0
MAN Diesel
Plate
Page 1 (2) Air Starter 51309-14H
L16/24
215 222
232 229 209
220 214 216 210
201 230 221
234
208
209
210
211
231
202 226
233 227
Pinion see, 1½
232
213
207
206
All valves and fittings
has to be approved by
classification society.
223
08028-0D/H5250/94.08.12
212 209
210
For details for serial no. q 04-0118, see plate 51309-15H
For details for serial no. d 04-0118, see plate 51309-20H
09.41 - ES0
MAN Diesel
Plate
51309-14H Air Starter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
08.41 - ES0
MAN Diesel
Plate
Page 1 (2) Air Starter 51309-15H
08.41 - ES0
MAN Diesel
Plate
51309-15H Air Starter Page 2 (2)
500 1/E Air starter, Startemotor, 568 1/S Inlet nozzle Indstrømningsdyse
complete komplet
574 1/S Silencer Lyddæmper
501 1/S Front cover Fordæksel
576 4/S Washer Skive
502 1/S Outer bearing ring Udvendig lejering
578 1/S Non-return valve Kontraventil
504 1/S Needle bearing Nåleleje
582 1/S Silencer Lyddæmper
506 1/S Circlip Sikringsring
583 4/S Nut Møtrik
507 1/S Hauling crown Rotordæksel
584 1/S Air tube Luftrør
508 25/S Cylinder roller Cylinderrulle
586 1/S Membrane plug Membranprop
510 1/S Bearing disc Lejeskive
591 4/S Plug Prop
511 1/S Splined shaft Fjedrende aksel
592 4/S Nut Møtrik
512 1/S Plug Prop
596 1/S Flange Flange
513 1/S Spring Fjeder
600 1/S Washer Skive
514 8/S Allen screw Stiftskrue
601 1/S Air tube Lufttrør
516 1/S Lock nut Låsemøtrik
603 1/S Set ring Låsering
517 1/S Protection Beskyttelses-
cover dæksel 604 1/S Valve body Ventilhus
539 1/S Secondary Sekondær 615 1/S Repair kit complete Reparationssæt
rotor rotor for air starter, con- komplet for luftstar-
sisting of item 539, ter, bestående af
544 1/S Primary rotor Primær rotor 544, 614 item 539, 544, 614
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
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
08.41 - ES0
MAN Diesel
Plate
Page 1 (3) Air Starter 51309-20H
10 12 13 14 15
80
26 27 28 30
32
72
103 106 105
102
101 104
A
34
A
Clean air filter
34 periodically
39
40
71 75
23 86 87 89 25
24
81 82 84 85
76
46
18 19 74
83 92 44 88
47 48 71
21 73 20
90 91 93
45
94 41 42 43 95 96 97 98
08028-0D/H5250/94.08.12
77
63
78
61
66
50 51 52 53 54 55 56 57 58 59 60
67
64
69 70
68
08.38 - ES0
MAN Diesel
Plate
51309-20H Air Starter Page 2 (3)
8 1/S Outer ring bearing Yderleje 44 1/S Secondary rotor Sekundær rotor
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
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
08.38 - ES0
MAN Diesel
Plate
Page 3 (3) Air Starter 51309-20H
78 1/S Sleeve Bøsning 107 1/S Set of seals com- Tætningssæt inde-
prising item 7, 14, holdende item 7, 14,
79 1/S Locker ring Låsering 19, 47, 50, 52, 55, 56, 19, 47, 50, 52, 55,
66, 68, 74, 75, 76, 79, 56, 66, 68, 74, 75,
80 1/S Locker ring Låsering 80, 82, 84, 87, 89, 76, 79, 80, 82, 84,
90, 92, 96, 98, 101, 87, 89, 90, 92, 96,
81 1/S Front locker Tætning 104, 106 98, 101, 104, 106
82 1/S O-ring O-ring 108 1/S Repair kit compris- Reparationskit inde-
ing item 24, 44 and holdende item 24, 44
83 1/S Needle bearing Nåleleje a set of seals og et tætningssæt
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
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
08.38 - ES0
MAN Diesel
Plate
Page 1 (2) Main Stop Valve 51315-02H
L16/24
99.03 - EO0
MAN Diesel
Plate
51315-02H Main Stop Valve Page 2 (2)
L16/24
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./C = Qty./Valve. Antal/V = Antal/Ventil.
99.03 - EO0
MAN Diesel
Plate
Page 1 (2) Air Filter 51321-03
General
190
08.21 - ES0
MAN Diesel
Plate
51321-03 Air Filter Page 2 (2)
General
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
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.
08.21 - ES0
MAN Diesel
Plate
Page 1 (2) Pressure Reduction Valve 51322-08
L16/24
L21/31
483 483
495 458 495
505 517 409 387 471 505
434
08028-0D/H5250/94.08.12
07.04 - EO0
MAN Diesel
Plate
51322-08 Pressure Reduction Valve Page 2 (2)
L16/24
L21/31
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.04 - EO0
MAN Diesel
Plate
Page 1 (2) Pressure Reduction Valve 51322-09
L16/24
L21/31
483
495 458
517 505 409 387 471
434
08028-0D/H5250/94.08.12
07.04 - EO0
MAN Diesel
Plate
51322-09 Pressure Reduction Valve Page 2 (2)
L16/24
L21/31
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.04 - EO0
MAN Diesel
Plate
Page 1 (2) Turning Gear with Attachment 51325-02H
L16/24
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Plate
51325-02H Turning Gear with Attachment Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
99.03 - ES0
MAN Diesel
Plate
Page 1 (2) Overspeed Stop Valve 51327-02
General
08028-0D/H5250/94.08.12
04.50 - ES0
MAN Diesel
Plate
51327-02 Overspeed Stop Valve Page 2 (2)
General
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
04.50 - ES0
MAN Diesel
Plate
Page 1 (2) Arrangement of Jet System 51330-02H
L16/24
99.03 - ES0
MAN Diesel
Plate
51330-02H Arrangement of Jet System Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
99.03 - ES0
MAN Diesel
Plate
Page 1 (2) Starting Air Receiver 51335-01H
General
99.15 - EO0
MAN Diesel
Plate
51335-01H Starting Air Receiver Page 2 (2)
General
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
99.15 - EO0
Fuel oil system
514/614
MAN Diesel
Description 514.01
Page 1 (2) Internal Fuel Oil System Edition 02H
L16/24
Fuel Oil System The fuel injection valve is located in a valve sleeve
in the centre of the cylinder head. The opening of
The built-on fuel oil system consists of inlet pipes for the valve is controlled by the fuel oil pressure, and
fuel oil, mechanical fuel pump units, high-pressure the valve is closed by a spring.
pipes as well as return pipes for fuel oil.
The high pressure pipe which is led through a bore
Waste oil and fuel oil leakages are led to a leakage in the cylinder head is surrounded by a shielding
alarm which is heated by means of the inlet fuel tube.
oil.
The shielding tube also acts as a drain channel in
order to ensure any leakage from the fuel valve and
Fuel Injection System the high pressure pipe will be drained off.
The engine is provided with one fuel injection pump The complete injection equipment including injec-
08028-0D/H5250/94.08.12
unit, an injection valve, and a high pressure pipe for tion pumps and high pressure pipes is well enclosed
each cylinder. behind removable covers.
98.41 - ES0
MAN Diesel
514.01 Description
Edition 02H
Internal Fuel Oil System Page 2 (2)
L16/24
Running-in Filter
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Working Card Dismounting/Mounting of 514-01.05
Page 1 (3) Edition 06H
Fuel Injection Pump (L'Orange)
L16/24
Related procedure
Data
01.08 - ES0
MAN Diesel
514-01.05 Dismounting/Mounting of Working Card
Edition 06H Page 2 (3)
Fuel Injection Pump (L'Orange)
L16/24
7) Remove the screws in the bottom flange and 9) Reconnect the regulating rod to the spring
take the fuel injection pump away. loaded lever.
08028-0D/H5250/94.08.12
New pumps: Remove preserving agents. 10) Renew O-ring (pos 2, fig. 4), and coat the high-
pressure connecting threds at the pump and
The injection pumps are adjusted by the manufacturer at the pressure piece including the O-rings.
to a uniform delivery quantity of 75% by means of a
01.08 - ES0
MAN Diesel
Working Card Dismounting/Mounting of 514-01.05
Page 3 (3) Edition 06H
Fuel Injection Pump (L'Orange)
L16/24
11) Screw the pressure pipe manually to the pres- Mounting of Fuel and Drain Pipes
sure piece.
15) Check the fuel and leakage pipes, they must
12) The correct positioning of the sealing cone not have any sharp bores on the outer circum-
from the pressure pipe has to be checked. The ference, the inner circumference must be free
sealing cone must be completely ummersed of any residuals.
into the pressure nozzle of the injection pump
(approx. 3.6 mm). The sleeve nut has to be 16) Rub the O-rings in the injection pump with
screwed manually to the pressure socket of paste for lip-type packing.
the injection pump.
17) Mount the pipes opposite order of dismantling
13) Tighten the sleeve nut at the pressure piece point 4-5.
with 65 + 5 Nm.
01.08 - ES0
MAN Diesel
Working Card Dismounting/Mounting of 514-01.05
Page 1 (3)
Fuel Injection Pump (Woodward) Edition 07H
L16/24
Related procedure
Data
01.05 - ES0
MAN Diesel
514-01.05 Dismounting/Mounting of Working Card
Edition 07H Page 2 (3)
Fuel Injection Pump (Woodward)
L16/24
6) Separate the spring loaded lever from the 9) Reconnect the regulating rod to the spring
regulating rod on the fuel injection pump. loaded lever.
10) Renew O-ring (pos 2, fig. 4), and coat the high-
Mounting of Fuel Injection Pump pressure connecting threds at the pump and
at the pressure piece including the O-rings.
New pumps: Remove preserving agents.
11) Screw the pressure pipe manually to the pres-
The injection pumps are adjusted by the manufacturer sure piece.
to a uniform delivery quantity of 75% by means of a
pointer.The pointer position for the adjustment value,
the "adjustment point", is a 18 mm and can be read
from the scale on the control rack.
01.05 - ES0
MAN Diesel
Working Card Dismounting/Mounting of 514-01.05
Page 3 (3) Edition 07H
Fuel Injection Pump (Woodward)
L16/24
12) The correct positioning of the sealing cone Mounting of Fuel and Drain Pipes
from the pressure pipe has to be checked. The
sealing cone must be completely ummersed 15) Check the fuel and leakage pipes, they must
into the pressure nozzle of the injection pump not have any sharp bores on the outer circum-
(approx. 3.6 mm). The sleeve nut has to be ference, the inner circumference must be free
screwed manually to the pressure socket of of any residuals.
the injection pump.
16) Rub the O-rings in the injection pump with
13) Tighten the sleeve nut at the pressure piece paste for lip-type packing.
with 65 + 5 Nm.
17) Mount the pipes opposite order of dismantling
14) Tighten the sleeve nut at the connecting socket point 4-5.
of the pump with 65 + 5 Nm.
08028-0D/H5250/94.08.12
01.05 - ES0
MAN Diesel
Working Card Disassembly/assembly and Repair of 514-01.06
Page 1 (5) Edition 05H
Fuel Injection Pump (Woodward)
L16/24
Related procedure
Mounting of fuel injection pump 514-01.05
01.05 - ES0
MAN Diesel
514-01.06 Disassembly/assembly and Repair of Working Card
Edition 05H Page 2 (5)
Fuel Injection Pump (Woodward)
L16/24
If damages occur at the injection pump during the
warranty period the service of the manufacturer or
of a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.
torque), too.
Caution! The holding screw (24), see fig 1 and the Exchange of Pressure Valve
cylindrical screw (12) are provided with a TufLok
bolt protection. The bolts can be re-used. If there is 1) Loosen the cylindrical screws (25), see fig 1.
no TufLok (blue medium in the thread) in the thread
any more a new screw must be used. 2) Remove the delivery socket (1), the stroke lim-
iter (17) and the pressure valve spring (15).
01.05 - ES0
MAN Diesel
Working Card Disassembly/assembly and Repair of 514-01.06
Page 3 (5) Edition 05H
Fuel Injection Pump (Woodward)
L16/24
3) Exchange the pressure valve (The pressure 7) Screw off the sliding block (10).
valve can be exchanged as a component group
only). 8) Loosen the springforce and demount the instal-
lation device.
4) Assembly in reciprocal order.
Tightening torque 45 Nm. 9) Take off the roller (22) and the roller pin (23).
Caution! Installation of the pressure-valve housing 10) Loosen the 2 nbs. cylindrical screws (12)
(16) with an aluminum arbor and a non-fuzzing cloth M5x14, and take off the roller tappet (13).
to protect the high-pressure surface.
11) Pull out the thrust piece (11) with the plunger
(18), afterwards the pump spring (9), the spring
Disassembly of the Pump Element plate (8), and control sleeve (19).
5) Loosen the 4 nbs. holding screws (24) M6x35, 12) Turn the injection pump vertically by 180 de-
see fig 1. grees.
6) Press in the roller tappet (14) by means of the 13) Further disassembly as under "Exchange of
installation device, see fig 2. pressure valve".
Installation
17) Insert the barrel (7), see fig 1 carefully into the
injection-pump casing (4) with an aluminum
arbor and a non-fuzzing cloth to protect the
high-pressure surface, and screw in the block-
ing screw (2).Tightening torque 5 Nm.
20) Install the control sleeve (19) - care for the mark-
ing! - control sleeve (19) milled tooth, control
rack (3) groove around circumference.
01.05 - ES0
MAN Diesel
514-01.06 Disassembly/assembly and Repair of Working Card
Edition 05H Page 4 (5)
Fuel Injection Pump (Woodward)
L16/24
22) Marking on the driving pin, installed towards Caution! Secure the countersunk screws (20) by
the boring of the control rack. Loctite 601 - tightening torque 4 Nm
The injection pump is assembled without pump spring In case a pump-element sticking has occurred, utilize
(9) and cavitation screws (6). the service of the manufacturer or of a contracted
workshop. If this is not possible the following proce-
The plunger (18) is fixed in the control boring by the dure is recommended:
measuring pin, see fig 3.
23) Loosen the holding screws (24) M6x35, see
The span between the measuring sleeve and the fig 1.
roller is measured by a depth micrometer.
24) Remove the roller (22) with the roller pin
The difference to the required dimension of 10 ± 0.05 (23).
mm has to be newly adjusted by the thrust piece
(21), if necessary. 25) Attach the installation device, see fig 2 and
locate it in such a way that it acts as a secur-
If the pre-stroke is not correct, the max firing pressure ing element of the roller tappet which is under
of the mentioned cylinder will be wrong. pre-tension by the spring.
If the pre-stroke is correct then reassembly the pump 26) Remove the sliding block (10)
with spring (9) and cavitation screws (6) and tighten
with correct torque acc. to description 500.40. 27) Turn the injection pump vertically by 180 de-
grees.
Preservation
01.05 - ES0
MAN Diesel
Working Card Disassembly/assembly and Repair of 514-01.06
Page 5 (5) Edition 05H
Fuel Injection Pump (Woodward)
L16/24
P3 gero cut S 102 having a viscosity of 3.5 mm2/sec The suction chamber of the injection pump is filled
at 20°C according to DIN 53015 is used as preser- with preserving agent through the fuel discharge
ving agent. boring, and closed.
All external surfaces are primed. By moving the plunger, the hollows are filled with
preserving agent.
The processed external surfaces are coated with
anti-rust grease or preserved with preserving oil All external surfaces coated with anti-rust agent must
Castrol Rustilo DWX31 having a specific gravity of be preserved once more.
820 kg/m3 at 15°C according to DIN 51757.
The control rack has to be moved in regular inter-
This preservation is effective for 2 years. vals of approx. 3 months to avoid a sticking of the
plunger.
Re-preservation
01.05 - ES0
MAN Diesel
Working Card Disassembly/assembly and Repair of 514-01.06
Page 1 (4) Edition 06H
Fuel Injection Pump (L'Orange)
L16/24
Related procedure
Mounting of fuel injection pump 514-01.05
01.05 - ES0
MAN Diesel
514-01.06 Disassembly/assembly and Repair of Working Card
Edition 06H Page 2 (4)
Fuel Injection Pump (L'Orange)
L16/24
If damages occur at the injection pump during the
warranty period the service of the manufacturer or
of a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.
10
The Following Guidelines shall be
11
Considered
12 22
⇒ Do not mix up parts of the pump element and 13
of the constant-pressure release valve. 14
torque), too.
01.05 - ES0
MAN Diesel
Working Card Disassembly/assembly and Repair of 514-01.06
Page 3 (4) Edition 06H
Fuel Injection Pump (L'Orange)
L16/24
4) Take out the tappet insert (13), roller tappet Installation
(14), roller (22), thrust piece (11), pump spring
(9) and plunger (17/18). 8) Pump elements can be exchanged as compo-
nent groups only. (plunger and barrel).
Caution! Be sure not to damage the plunger.
9) Insert the barrel (7), see fig. 1 carefully into the
5) If necessary remove the lockring (20), guide injection-pump casing (4) with an aluminum
pin (21) and take out the regulating rod (3) as arbor and a non-fuzzing cloth to protect the
well as the plug screw (23) in the opposite end high-pressure surface.
of the regulating rod (3).
10) Mount the connection socket tighten the 4
6) Loosen the 4 cylindrical screws (2) and remove cylindrical screws. Tighten torque 40 Nm.
the connection socket (1) and barrel (7). Pres-
sure valve is included in connection socket (1) 11) Turn the injection pump vertically by 180 de-
and can be exchanged as a component group grees.
only.
12) Install the control sleeve (19) - care for the
7) Carefully press out the barrel (7) with an alu- marking!
minum arbor.
13) The further assembly is carried in reciprocal
order of disassembly (driving pin of the plunger
in the direction of the slot of the control sleeve).
Guiding screw has to be mounted with loctite
0577.
01.05 - ES0
MAN Diesel
514-01.06 Disassembly/assembly and Repair of Working Card
Edition 06H Page 4 (4)
Fuel Injection Pump (L'Orange)
L16/24
If a pump element is exchanged it is recommended Preservation
to check the pre-stroke. Proceed as follows:
The main functional components of each injection
The injection pump is assembled without pump spring pump supplied by the manufacturer has been pre-
(9) and cavitation screws (6). served during its check-up in the test stand.
The plunger (18) is fixed in the control boring by the P3 gero cut S 102 having a viscosity of 3.5 mm2/sec
measuring pin, see fig. 3. at 20°C according to DIN 53015 is used as preser-
ving agent.
The span between the measuring sleeve and the
roller is measured by a depth micrometer. All external surfaces are primed.
The difference to the required dimension of 10 ± 0.05 The processed external surfaces are coated with
mm has to be newly adjusted by the thrust piece anti-rust grease or preserved with preserving oil
(21), if necessary. Castrol Rustilo DWX31 having a specific gravity of
820 kg/m3 at 15°C according to DIN 51757.
If the prestroke is not correct, the max firing pressure
of the mentioned cylinder will be wrong. This preservation is effective for 2 years.
01.05 - ES0
MAN Diesel
Working Card 514-01.10
Page 1 (5) Fuel Injection Valve (L'Orange) Edition 08H
L16/24
Description
Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump has been dismounted. Ring and open end spanner 24 mm
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).
Related procedure
Manpower
Replacement and wearing parts
Working time : 2 hours
Capacity : 1 man Plate no Item no Qty/
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
514-01.10 Working Card
Edition 08H Fuel Injection Valve (L'Orange) Page 2 (5)
L16/24
The fuel injection valve is the single component that 6) Loosen the nozzle nut (5). If it is jammed, then
has the greatest influence on the diesel engine condi- heat the nozzle nut up in hot oil.
tion. Various forms of operation and quality of fuel oil
affect the overhaul intervals. In some cases it may be 7) Remove the injector nozzle (6). Be careful that
necessary to shorten the prescribed intervals. the the injector needle does not fall out.
1) Dismount the fuel injection valve from the Do not damage the lapped surface.
cylinder head by means of the special tool as
shown in fig 1. 8) Dismount all other components.
2) Mount the fuel injection valve on the pressure 9) All parts must be cleaned with kerosene or gas
testing pump. oil and a hard brush (not a steel brush).
Note: Utmost cleanliness and care are required dur- 10) Clean the nozzle holes of charred coke by
ing the disassembly of fuel injection valve. means of the supplied special drill please see
plate 52014 with holder.
3) Loosen the nut, see fig 2, pos 2.
11) Clean carefully the injector body by placing
4) Then release the pressure spring (3). these in a cleaning liquid and then blow through
the parts with dry air.
5) Clean the lower part of the nozzle from carbon-
ized oil disposits.
08028-0D/H5250/94.08.12
Fig 1 Tool for dismounting of fuel injection valve. Fig 2 Fuel injection valve.
01.44 - ES0
MAN Diesel
Working Card 514-01.10
Page 3 (5) Fuel Injection Valve (L'Orange) Edition 08H
L16/24
12) Nozzles are matched by lapping and are there- d. Tighten torque for lock nut (2): 100 Nm.
fore only interchangeable as units.
13) The injector needle, which has been previ- Pressure Testing of Fuel Injection Valve
ously cleaned, wetted by test oil P3 gero cut
S 102 or diesel fuel and inserted into nozzle 19) The most effective checking of the fuel injection
body, is pulled out to approx. one third of its valves is obtained through pressure testing,
sliding surface. At an almost vertical position, preferably carried out after each overhaul and
the injector needle must quickly slide onto the also in case of irregularities in operation. The
tight seat by its deadweight. This check-up has pressure testing is carried out in the following
to be carried out for three almost uniformly way by means of the pressure testing apparatus
distributed turning position of the needle. supplied.
14) If the holes are oval worn, which is checked by 20) Mount the fuel injection valve in the test tool
means of a magnifying glass, the nozzle must again. The bracket to be in such a position
be scrapped. that the nozzle of the injector is pointing down-
wards.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the 21) To flush off possibly existing dirt particles in the
nozzle which, in general, only can be made fuel system of the injection valve, it is recom-
at the manufacturer's works on a special test mended to pump through fuel several times,
stand. while the released pressure spring (3) of the
nozzle holder is increase pressure by means
16) Every effort to refurbish will result in alterations of the lever on the test pump, and adjust the
of these values and malfunction of the noz- opening pressure to 450 bar, by the adjusting
zle. If heavy abrasion symptoms, respectively screw (1), see fig. 2, then tighten lock nut (2)
damages are observed at the visual inspec- and check opening pressure again.
tion of the parts, the parts in question must be
replaced. 22) The fuel injection valve shall properly spray
at a pumping frequency of approx. 1 to 2
strokes/second, do not expect chattering. The
Reassembling fuel (MDO) must be atomized by uniform jets.
After the jets are cut off, no fuel (MDO) drop
17) When all parts have been overhauled, found shall fall down from the bottom of the spraying
in good order and carefully cleaned, assemble ball during 10 seconds when the injector nozzle
the fuel injection valve again. is vertically placed. Do not expect a nozzle tip
with more than 1000 running hours to perform
18) When assembling the fuel injection valve, like a new nozzle in the test pump.
proceed in the opposite order compared to the
disassembly. Pay attention to the following: 23) All connecting and attached points of the fuel
injection valve must not leak during this check-
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
L16/24
If the injector nozzle is deformed by the tightening of 25) Coat the O-rings at the injection valve with
the nozzle nut (5), the injector needle will be jammed graphite paste.
in the nozzle body. Then fuel will be leaving the spray
holes as not or only partially atomized straight jet only. 26) The injection valve has to be inserted into the
Tightening torque for nozzle nut (5) 120 Nm. cylinder head. Care for the alignment of the
high-pressure cone connection.The alignment
of the injection valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
01.44 - ES0
MAN Diesel
L16/24
30) When the pressure piece has been tightened, 32) Screw the pressure pipe manually to the pres-
the fixing flange for the injection valve must be sure piece.
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve 33) The correct positioning of the sealing cone
is pressed to the sealed seat by an alternate from the pressure pipe has to be checked at
tightening of the nuts. The nuts shall be tight- the pump.The sealing cone must be completely
ened with 9 Nm and with use of antiseizure ummersed into the pressure nozzle of the in-
products. jection pump (approx. 3.6 mm). The sleeve nut
has to be screwed manually to the pressure
socket of the injection pump.
Assembly of the Pressure Pipe
34) Tighten the sleeve nut at the pressure piece
31) Renew O-ring (pos 2, fig. 4), and coat the high- with 65 + 5 Nm.
pressure connecting threds at the pump and
at the pressure piece including the O-rings. 35) Tighten the sleeve nut at the connecting socket
of the pump with 65 + 5 Nm.
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
Working Card 514-01.10
Page 1 (5) Fuel Injection Valve (Woodward) Edition 09H
L16/24
Description
Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump has been dismounted. Ring and open end spanner 24 mm
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).
Related procedure
Manpower
Replacement and wearing parts
Working time : 2 hours
Capacity : 1 man Plate no Item no Qty/
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
514-01.10 Working Card
Edition 09H Fuel Injection Valve (Woodward) Page 2 (5)
L16/24
The fuel injection valve is the single component that 6) Loosen the nozzle nut (5). If it is jammed, then
has the greatest influence on the diesel engine condi- heat the nozzle nut up in hot oil.
tion. Various forms of operation and quality of fuel oil
affect the overhaul intervals. In some cases it may be 7) Remove the injector nozzle (6). Be careful that
necessary to shorten the prescribed intervals. the the injector needle does not fall out.
1) Dismount the fuel injection valve from the Do not damage the lapped surface.
cylinder head by means of the special tool as
shown in fig 1. 8) Dismount all other components.
2) Mount the fuel injection valve on the pressure 9) All parts must be cleaned with kerosene or gas
testing pump. oil and a hard brush (not a steel brush).
Note: Utmost cleanliness and care are required dur- 10) Clean the nozzle holes of charred coke by
ing the disassembly of fuel injection valve. means of the supplied special drill please see
plate 52014 with holder.
3) Loosen the nut, see fig 2, pos 2.
11) Clean carefully the injector body by placing
4) Then release the pressure spring (3). these in a cleaning liquid and then blow through
the parts with dry air.
5) Clean the lower part of the nozzle from carbon-
ized oil disposits.
08028-0D/H5250/94.08.12
Fig 1 Tool for dismounting of fuel injection valve. Fig 2 Fuel injection valve.
01.44 - ES0
MAN Diesel
Working Card 514-01.10
Page 3 (5) Fuel Injection Valve (Woodward) Edition 09H
L16/24
Inspection of the Parts c. Renew the O-rings (pos 4, fig 2).
12) Nozzles are matched by lapping and are there- d. Tighten torque for lock nut (2): 50 Nm.
fore only interchangeable as units.
13) The injector needle, which has been previ- Pressure Testing of Fuel Injection Valve
ously cleaned, wetted by test oil P3 gero cut
S 102 or diesel fuel and inserted into nozzle 19) The most effective checking of the fuel injection
body, is pulled out to approx. one third of its valves is obtained through pressure testing,
sliding surface. At an almost vertical position, preferably carried out after each overhaul and
the injector needle must quickly slide onto the also in case of irregularities in operation. The
tight seat by its deadweight. This check-up has pressure testing is carried out in the following
to be carried out for three almost uniformly way by means of the pressure testing apparatus
distributed turning position of the needle. supplied.
14) If the holes are oval worn, which is checked by 20) Mount the fuel injection valve in the test tool
means of a magnifying glass, the nozzle must again. The bracket to be in such a position
be scrapped. that the nozzle of the injector is pointing down-
wards.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the 21) To flush off possibly existing dirt particles in the
nozzle which, in general, only can be made fuel system of the injection valve, it is recom-
at the manufacturer's works on a special test mended to pump through fuel several times,
stand. while the released pressure spring (3) of the
nozzle holder is increase pressure by means
16) Every effort to refurbish will result in alterations of the lever on the test pump, and adjust the
of these values and malfunction of the noz- opening pressure to 450 bar, by the adjusting
zle. If heavy abrasion symptoms, respectively screw (1), see fig. 2, then tighten lock nut (2)
damages are observed at the visual inspec- and check opening pressure again.
tion of the parts, the parts in question must be
replaced. 22) The fuel injection valve shall properly spray
at a pumping frequency of approx. 1 to 2
strokes/second, do not expect chattering. The
Reassembling fuel (MDO) must be atomized by uniform jets.
After the jets are cut off, no fuel (MDO) drop
17) When all parts have been overhauled, found shall fall down from the bottom of the spraying
in good order and carefully cleaned, assemble ball during 10 seconds when the injector nozzle
the fuel injection valve again. is vertically placed. Do not expect a nozzle tip
with more than 1000 running hours to perform
18) When assembling the fuel injection valve, like a new nozzle in the test pump.
proceed in the opposite order compared to the
disassembly. Pay attention to the following: 23) All connecting and attached points of the fuel
injection valve must not leak during this check-
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
L16/24
No Jamming Assembly of the Injection Valve
If the injector nozzle is deformed by the tightening of 25) Coat the O-rings at the injection valve with
the nozzle nut (5), the injector needle will be jammed graphite paste.
in the nozzle body. Then fuel will be leaving the spray
holes as not or only partially atomized straight jet only. 26) The injection valve has to be inserted into the
Tightening torque for nozzle nut (5) 200 Nm. cylinder head. Care for the alignment of the
high-pressure cone connection.The alignment
of the injection valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
01.44 - ES0
MAN Diesel
L16/24
30) When the pressure piece has been tightened, 32) Screw the pressure pipe manually to the pres-
the fixing flange for the injection valve must be sure piece.
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve 33) The correct positioning of the sealing cone
is pressed to the sealed seat by an alternate from the pressure pipe has to be checked at
tightening of the nuts. The nuts shall be tight- the pump.The sealing cone must be completely
ened with 9 Nm and with use of antiseizure ummersed into the pressure nozzle of the in-
products. jection pump (approx. 3.6 mm). The sleeve nut
has to be screwed manually to the pressure
socket of the injection pump.
Assembly of the Pressure Pipe
34) Tighten the sleeve nut at the pressure piece
31) Renew O-ring (pos 2, fig. 4), and coat the high- with 65 + 5 Nm.
pressure connecting threds at the pump and
at the pressure piece including the O-rings. 35) Tighten the sleeve nut at the connecting socket
of the pump with 65 + 5 Nm.
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
Working Card 514-01.90
Page 1 (2) Check of Fuel Oil Piping System Edition 04H
L16/24
Description
Hand tools
Check of fuel oil piping system.
Starting position
Engine is running.
Related procedure
Data
01.08 - ES0
MAN Diesel
514-01.90 Working Card
Edition 04H Check of Fuel Oil Piping System Page 2 (2)
L16/24
Fuel Oil System 4) Move all valves in the piping system.
Lubricate valve spindles with graphite or simi-
Important for starting up new engines or newly lar.
overhauled engines!
5) Check flexible connections for leaks and dam-
The system includes all parts in the internal fuel oil ages.
system, ie main components as pumps, high pressure
pipes, pressure piece, injection valve and all types It is important that the flexible connections are free
of connections, all types of pipes as well as leakage from paint and grease and in healthy condition.
alarm and safety filter.
6) Check for any leak of the O-ring for the fuel
These components have to be checked at intervals ac- injection pipe.
cording to the "Planned maintenance programme".
When the engine has reached normal working
1) Dismount the covers to the injection pumps. temperature and no later than 24 operating hours
Blow through drain pipes. after starting up, the complete fuel oil system has
to be checked according to the above-mentioned
2) Examine the piping system for leaks. No outer instruction book working card "Check of the fuel oil
leaks can be permitted. piping system".
3) Retighten all bolts, nuts and plugs in the pip- If the above instructions are not followed carefully,
ing system. Especially does all high pressure there is a risk of oil leakage that can result in danger-
parts have to be tightened correctly. Please, ous vaporised fuel emission into the engine room.
see working cards in section 514 "Fuel Oil
system". Concerning fuel oil condition, see section 504.
08028-0D/H5250/94.08.12
01.08 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump (Woodward) 51401-16H
L16/24
08028-0D/H5250/94.08.12
06.27 - ES0
MAN Diesel
Plate
51401-16H Fuel Injection Pump (Woodward) Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
014 1/P Roller guide, com- Rullestyr, komplet inkl. 278 1/P Spring plate Fjederplade
plete incl. item 026, item 026, 038, 051,
038, 051, 063, 075, 063, 075, 408 291 1/P Pump spring Pumpefjeder
408
301* 1/P pressure valve Fjeder for
026* 1/P Roller Rulle spring trykventil
038* 1/P Roller pin Rulletap 313* 1/P Stroke limiter Begrænser
051* 1/P Roller guide Rullestyr 325 1/P Blocking screw Skrue
063 4/P Holding screw Skrue 337 1/P Guiding screw Styreskrue
075 1/P Cylindrical pin Cylindrisk stift 349 1/P Locking screw Låseskrue
087 1/P Pump element, com- Pumpeelement, kom- 350 2/P Throttle screw Skrue
plete incl. item 099, plet inkl. item 099,
109, 110 109, 110 362 1/P Pointer Viser
110* 2/P O-ring O-ring 398 2/P Cylindrical screw Cylindrisk skrue
122 1/P Pressure valve, com- Trykventil, komplet inkl. 408 1/P Cylindrical screw Cylindrisk skrue
plete incl. item 134, item 134, 146, 158,
146, 158, 301, 313 301, 313 421 6/P Cylindrical screw Cylindrisk skrue
134* 1/P Pressure valve Hus for trykventil 433 1/P Pan head screw Skrue
housing
445 4/P O-ring O-ring
146* 1/P Constant pressure Konstant trykventil
valve 457 1/P O-ring O-ring
171 1/P Pressure piece, com- Trykstykke, komplet 470 2/P Seal ring Tætningsring
plete incl. item 183, inkl. item 183, 195,
195, 205, 217 205, 217 482 2/P Seal ring Tætningsring
183 1/P Slotted disk Skive 494 1/P Seal ring Tætningsring
195 1/P Spacer plate Afstandsplade 504 1/P Seal ring Tætningsring
205 1/P Thrust piece Trykstykke 516 1/P Fitting disk Skive
217 3/P Countersunk screw Skrue 528 1/P Fitting disk Skive
229 1/P Pump casing Pumpehus 541 1/P Fitting disk Skive
08028-0D/H5250/94.08.12
230 1/P Connecting piece Forbindelsesstykke 553 1/P Fitting disk Skive
242 2/P Buffer bolt Bolt 565 1/C Fuel Injection Pump, Brændselspumpe,
complete as shown komplet som vist på
254 1/P Control rack Reguleringsstang on front page forsiden
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
06.27 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump (L'Orange) 51401-07H
L16/24
08028-0D/H5250/94.08.12
01.09 - ES0
MAN Diesel
Plate
51401-07H Fuel Injection Pump (L'Orange) Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
014 1/P Roller guide, com- Rullestyr, komplet inkl. 482* 1/P Seal ring Tætningsring
plete incl. item 026, item 026, 038, 051,
038, 051, 063 063 516 1/P Shim, Mellemlæg,
set of 4 pcs sæt af 4 stk
026* 1/P Roller Rulle 565 1/C
Fuel Injection Pump, Brændselspumpe,
038* 1/P Roller pin Rulletap complete as shown komplet som vist på
on front page forsiden
051* 1/P Roller guide Rullestyr
577 1/P Cylindrical pin Cylindrisk stift
063* 1/P Bolt Bolt
600 4/P Screw Skrue
087 1/P Pump element, com- Pumpeelement, kom-
plete incl. plunger plet inkl. stempel og 697* 2/P Support ring Støttering
and barrel cylinder
707* 1/P O-ring O-ring
110* 1/P O-ring O-ring
756* 1/P Circlip Snapring
158* 1/P O-ring O-ring
768* 6/P Seal ring Tætningsring
183 1/P Shim Skive
781* 1/P Lock ring Låsering
205 1/P Piston spring plate Stempelfjederplade
793 1/P Screw plug Propskrue
229 1/P Pump casing Pumpehus
803* 1/P Seal ring Tætningsring
230 1/P Connecting socket Forbindelsesstykke
complete incl. valve komplet, inkl. ventil- 827 /I Loctite 0577 Loctite 0577
cones, springs and spindler, fjedre og item
item 577 577 839 1/P Seal kit for fuel in- Pakningssæt for
jection pump, incl. brændselspumpe,
242 1/P Buffer bolt Bolt item110, 158, 457, inkl. item 110, 158,
469, 482, 697, 707, 457, 469, 482, 697,
254 1/P Control rack Reguleringsstang 756, 768, 781, 803, 707, 756, 768, 781,
984 803, 984
266 1/P Regulating sleeve Reguleringsbøsning
incl. clamping sle- inkl. xxxxx 984 1/P O-ring O-ring
eve
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
01.09 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve (Woodward) 51402-11H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
51402-11H Fuel Injection Valve (Woodward) Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/V = Qty/Valve Qty/V = Qty/Ventil
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve (L'Orange) 51402-12H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
51402-12H Fuel Injection Valve (L'Orange) Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/V = Qty/Valve Qty/V = Qty/Ventil
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pipe (Woodward) 51404-06H
L16/24
08028-0D/H5250/94.08.12
00.48 - ES0
MAN Diesel
Plate
51404-06H Fuel Injection Pipe (Woodward) Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty./Engine Qty/E = Qty./Motor
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
00.48 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pipe (L'Orange) 51404-07H
L16/24
08028-0D/H5250/94.08.12
00.48 - ES0
MAN Diesel
Plate
51404-07H Fuel Injection Pipe (L'Orange) Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty./Engine Qty/E = Qty./Motor
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
00.48 - ES0
MAN Diesel
Plate
Page 1 (2) Safety Filter 51415-03
General
08028-0D/H5250/94.08.12
03.18 - EO0
MAN Diesel
Plate
51415-03 Safety Filter Page 2 (2)
General
Qty. Designation Benævnelse Qty. Designation Benævnelse
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./Engine
Qty./F = Qty./Filter Qty./F = Qty./Filter
03.18 - EO0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Arrangement 51430-02H
L16/24
08028-0D/H5250/94.08.12
97.40 - ES0
MAN Diesel
Plate
51430-02H Fuel Oil Arrangement Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
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
97.40 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Arrangement 51430-19H
L16/24
061 193
073
360 107
264 119
156
085 168
097
181 203
443
036 120
264 132
288 144
311 252 215
012 239
024 240
276
227
323
384 239
335
240
347
431
359
372
406
467
Loop expansion joint, see plate 51902
418
Fuel oil leakage alarm, see plate 50925
08028-0D/H5250/94.08.12
07.21 - ES0
MAN Diesel
Plate
51430-19H Fuel Oil Arrangement Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
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
07.21 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump Connections (L'Orange) 51435-03H
L16/24
08028-0D/H5250/94.08.12
07.17
MAN Diesel
Plate
51435-03H Fuel Injection Pump Connections (L'Orange) Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
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
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
07.17
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump Connections (Woodward) 51435-04H
L16/24
08028-0D/H5250/94.08.12
00.50 - ES0
MAN Diesel
Plate
51435-04H Fuel Injection Pump Connections Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
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
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
00.50 - ES0
Lubricating oil system
515/615
MAN Diesel
Description 515.01
Page 1 (2) Internal Lubricating Oil System Edition 04H
L16/24
98.50 - ES0
MAN Diesel
515.01 Description
Edition 04H
Internal Lubricating Oil System Page 2 (2)
L16/24
Channels have been bored into the connecting Lubricating Oil Cooler
rods for supply of oil from the big-end bearings
to the small-end bearings, which has an inner The lubricating oil cooler is of the plate type. The
circumferential groove, and a pocket for distri- cooler is mounted on the front-end box.
bution of oil in the bush itself. For supply of oil
to the pin bosses and the piston cooling.
Thermostatic Valve
From the front main bearings channels have
been bored in the crankshaft for lubricating of The thermostatic valve is a fully automatic 3-way
the pump drive. valve with thermostatic elements set at fixed tem-
perature.
ad 3) The camshaft drive gear wheels are being
lubricated via the oil-mist principle. Oil-mist is
being generated by oil, which is led out from Lubricating Oil Filter
the bearing in the intermediate wheels.
The lubricating oil filter is a full-flow depth filter of
ad 4) From bores in the engine frame the governor the duplex paper car tridge type, with a fineness of
drive is being pressure lubricated. 10-15 microns, and a safety filter with a fineness of
60 microns.
ad 5) The lubricating oil to the rocker arms is led
through bores in the engine frame to each cy-
linder head. The oil continues through bores in Pre-lubricating
the cylinder head to lubricate the rocker arms
and valve bridges. Further, lub oil is led to the The engine is equipped with an electric-driven prelub.
movable parts in need of lubrication. pump mounted parallel to the main pump. The pump
is arranged for automatic operation, ensuring stand-
ad 6) Lubrication to the fuel pump is supplied via still of the prelubricating pump when the engine is
the fuel camshaft bearing. running, and running during engine stand-still in
stand-by position by the engine control system.
98.50 - ES0
MAN Diesel
Working Card 515-01.00
Page 1 (3) Lubricating Oil Pump Edition 03H
L16/24
Disassembly, overhaul and assembly of lubrica- Feeler gauge 0.1 mm, min length 40-50 cm
ting oil pump Feeler gauge 0.3 mm, min length 40-50 cm
Feeler gauge 0.35 mm, min length 40-50 cm
Starting position
Related procedure
06.51 - ES0
MAN Diesel
515-01.00 Lubricating Oil Pump
Working Card
Edition 03H Page 2 (3)
L16/24
Preparing before Dismounting Mounting
For access to the lubricating oil pump it is neces- 8) Change the O-rings on the pump.
sary to remove the lubricating oil cooler. Please see
worcking card 515-06.00. 9) Mount the pump by the bolts and tighten these
according to description 500.40.
Dismounting 10) Re-new the O-rings for oil and water connec-
tions to the lub. oil cooler.
1) Remove the bolts which are holding the lub.
oil pump. 11) Mount the lub. oil cooler to the frame plate.
Overhaul 3 1
5
3) Remove the bolt (1) and the spur gear (2), see
fig 1.
2 Spur gear
4) Remove the bolt (3) and the cover (4), see fig
1. 4
Take out the pinion spindles (5) and clean all parts
in gas oil and with a hard bush, (never use a steel 5 Axle for spur gear
bush). The parts are blown clean with working air. Must be placed correctly
in relation to guide pin
Guide pin
5) Check the wear of the bearing bush.
Fig 1 Lubricating oil pump
6) If the bearing bush is to be removed the existing
bearing bush is plugged out by means of a
mandrel, the bores are cleaned, see fig 2, and
new bearing bush is mounted.
The bush is cooled down to -130°C, the housing
or cover has room temperature.
Note: check that the oil pump can run easily when
the pump is assembled.
06.51 - ES0
MAN Diesel
Working Card 515-01.00
Page 3 (3) Lubricating Oil Pump Edition 03H
A min. 0.1 mm
max. 0.3 mm
If Then
06.51 - ES0
MAN Diesel
L16/24
L23/30H
Dismantling, replacement of the mechanical seals Ring and open end spanner, 13 mm.
and assembly of prelubricating pump. Ring and open end spanner, 15 mm.
Socket spanner, 15 mm.
Adjustable spanner.
Screw driver.
Lubricating light oil and grease.
Starting position Vessels for cleaning.
Related procedure
Data
98.47 - ES0
MAN Diesel
515-01.05 Working Card
Edition 03H
Prelubricating Pump Page 2 (4)
L16/24
L23/30H
Periodic Overhauls 2) Shut off the suction to the pump and block the
electric motor starting button.
Periodic overhauls for the purpose of avoiding func-
tional trouble are not normally necessary for the 3) Loosen the screws which hold the motor and
prelubricating pumps. When properly used, there is pump together and lift away the motor.
very little wear on the pump screws.
4) Remove the front end cover of the pump (1).
If oils and other liquids with abrasive properties are Do not damage the joint (2) between front end
pumped periodic overhauls may nevertheless be cover and pump body.
carried out so that worn parts can be replaced in
good time. The intervals between such overhauls are 5) Press the stationary seal with o-ring (27 and
determined by experience in each individual case. 23) see fig. 2, out of the front cover.
Dismantling
21 9
rotor (17). Due to the rubber bellows (25) fig.
20 2, the necessary press-off power may be
comparatively big.
10
11
12
19 18 17 16 15 14 13
98.47 - ES0
MAN Diesel
L16/24
L23/30H
Reassembly
12) Insert the power rotor in the pump casing Note: Do not let the pump run for more than one
(3). minute without working.
Starting
16) Mount the electric motor on the pump so that the
set screw (20) enters the motor-shaft keyway. Starting should always take place with fully open
Tighten the screws joining pump and motor valves in the suction and delivery lines.
flanges.
98.47 - ES0
MAN Diesel
L16/24
L23/30H
As the prelubricating pump is self-priming it carries off If the pump refuses to work properly after having
the air in the suction line and the noise reveals when been started, it must not be allowed to run for more
the pump begins to work. It is essential for the air to than about half a minute. Fresh attempts to make
be led off without any appreciable counter-pressure the pump go may be made at intervals of about a
in the delivery line. minute and in conjunction with these attempts the
bypass valve tension should be increased slightly. If
As soon as the pump has started to work normally, thes does not help, something must be wrong and
the by-pass valve must be set by means of a pres- the fault must be located and remedied before the
sure gauge at the required pressure. pump is put into operation.
08028-0D/H5250/94.08.12
98.47 - ES0
MAN Diesel
Working Card 515-01.10
Page 1 (3) Lubricating Oil Filter Edition 02H
L16/24
Description
Hand tools
Replacement of paper filter element(s).
Cleaning of safety filter and filter housing. Open-end ring spanner, 19"
Allen key, 6 mm
Allen key, 10 mm
Starting position
Related procedure
98.45 - ES0
MAN Diesel
515-01.10 Working Card
Edition 02H Lubricating Oil Filter Page 2 (3)
L16/24
Please note: Never open the filter while it is in use. 9) Remove the outer elements.
The filter to be cleaned must be out of operation.
Note: Our filter elements are of the disposable type.
Always change to new original filter.
Normal Running
10) Clean the filter housing and the cap.
1) The valve is in position 2 or 4, see fig 2, and
the element not in use is vented and ready to 11) Check the seal in the cap. Change if needed.
use (standby).
12) Assemble the filter in reverse order.
Changing the Filter 13) Switch to position 2 or 4 and vent the exchanged
element by means of the vent screw.
2) Switch to position 3, fig 2, and wait 5 minutes.
Then continue to position 1 or 5, fig 2.
Vent screws
3) Wait 2 minutes.
5) Wait 20 minutes
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel
Working Card 515-01.10
Page 3 (3) Lubricating Oil Filter Edition 02H
L16/24
Pos.
98.45 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
Data
98.47 - ES0
MAN Diesel
L16/24
Adjustment and Maintenance Check the Element
The thermostatic valve cannot be adjusted and un- 10) Place the element in a bucket of water -12°
der normal working conditions maintenance is not C below the nominal rating and stir the water
required. However, in some cases it is necessary to vigorously with the element for 5 minutes (the
replace the element. sliding valve should not be off its seat).
L16/24
Starting position
Engine is running.
Related procedure
Data
98.41 - ES0
MAN Diesel
515-01.90 Working Card
Edition 02H Check of Lubricating Oil Piping System Page 2 (2)
L16/24
Checks to be Carried Out
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
Capacity : 1 man
Data
98.43 - ES0
MAN Diesel
515-06.00 Working Card
Edition 03H Lubricating Oil Cooler Page 2 (5)
L16/24
Introduction Upon completion of the procedure “Cooling and
Pressure Relief”, separate the frame by retaining
Cleaning of the cooler must take place, when the two or four diagonally placed bolts.
pressure drop on the oil and water side exceeds an
allowable value and/or if oil cannot be sufficiently Note: Take care that the pressure plate does not
cooled. tilt!
Before opening the plate heat exchanger, it must Note: When using plate heat exchangers on board
be cooled down to below 40o C and be without ships, the pressure plate must be secured in order to
pressure! avoid danger during the movements of the ship.
Detergents
and gaskets.
98.43 - ES0
MAN Diesel
Working Card 515-06.00
Page 3 (5) Lubricating Oil Cooler Edition 03H
L16/24
Oil and fats are removed by using a water emulsify- Replacement of Plates and Gaskets
ing oil solvent, e.g. BP-system cleaner.
Marking
Organic and greasy coatings are removed by using
sodium hydroxide (NaOH): The plates are marked with material codes and refer-
ence numbers at each end, plus codes for non-glued
- max. concentration 1.5% gaskets, if any, and stamped with letters V and H
(1.5% concentration corresponds to 3.75 at either end (fig 1).
l 30% NaOH per 100 l water).
- max. temperature 85o C. When facing the gasket, the plate is designated as
a left plate, when letter V turns upwards - and as a
Stone and lime/calcareous deposits are removed by right plate when letter H turns upwards. Inlets and
using nitric acid (HNO3): outlets of the V-plates are taking place through the
corner holes Nos 1 and 4. Inlets and outlets of the
- max. concentration 1.5% H-plates take place through corner holes Nos 2
(1.5% concentration corresponds to 1.75 l and 3.
62% HNO3 per 100 l water).
- max. temperature 65o C.
Replacement of Plates
Note: The nitric acid has an important constructive
effect on the protective film of stainless steel. Before mounting a spare plate in the plate stack,
please make sure that the spare plate is identical
with the faulty one.
Control of Cleaning Fluid Concentrations
Note: The same corner holes must be opened and
Sodium hydroxide (NaOH) solution is titrated with letters V and H must be placed properly.
0.1 n hydro-chloric acid (HCI) with methyl orange
or methyl red as an indicator.
Replacement of Glued Gaskets
Nitric acid (HNO3) solution is titrated with 0.1 n
sodium hydroxide (NaOH) with phenolphtalin as an On Plate 51506 stated are gasket and glue quan-
indicator. tity.
The concentration of the cleaning fluid in % can be Please use a degreasing agent on the new gas-
calculated from the titration result with of the follow- kets.
ing formula:
The first plate after the end cover and the connector
Concentration = bxnxm % grid must have gaskets in all grooves. The gaskets
a x 10 must be cut according to the existing gaskets.
98.43 - ES0
MAN Diesel
515-06.00 Working Card
Edition 03H Lubricating Oil Cooler Page 4 (5)
L16/24
Loosen the glued gaskets by heating the plate in The plates with the gaskets are mounted in the frame
water at 100o C. Clean the plates and remove the which is lightly clamped. In the case of using rubber
coatings, if any. grooves, they are assembled to the minimum measure
stated on the engine sign plus 0.2 mm per plate.
Cleaning of New Gaskets and Plates Heat up the plate heat exchanger to 90-100° C by
means of water or steam.
New gaskets and gasket grooves of the plates are
cleaned with a cloth moistened with degreasing Please note:
agent. The glued surfaces must be absolutely clean
- without finger prints etc. - The temperature must be kept for 1 1/2-2
hours.
Please use our cleaning fluid, which conforms to - The liquid pressure must be kept as low as
suppliers recommendations. possible.
Gluing
Serial number
(please state when
Pliobond 25, which is a solvent-based nitrile rubber Material Code ordering single plates)
glue (25% solids).The glue is applied with a brush in a
thin layer on the backs of the gaskets and the gaskets
must be dried in a clean place free of dust.
1 2
Apply a thin layer of glue on the gasket grooves
of the plates and press the gaskets down into the
gasket grooves.
08028-0D/H5250/94.08.12
98.43 - ES0
MAN Diesel
L16/24
Serial numbers are stamped in the right top corner Fastening
of the plates. Further, please note that the gasket
side must face the fixed cover. Fasten the nuts crosswise until the movable cover
to the measure x at each nut.
Cyl x
5 82.5 mm
6 86.3 mm
7 100.0 mm
8 117.3 mm
9 131.1 mm
Fig 3 Measuring x
08028-0D/H5250/94.08.12
98.43 - ES0
MAN Diesel
L16/24
Starting position
Related procedure
98.47 - ES0
MAN Diesel
L16/24
Cleaning Procedure 5) Remove stand tube (075) and clean.
038 Note: Ensure that rotor cover and rotor body are
always matched by balance number and pin location.
Do not interchange rotor cover.
Fig 1 Centrifugal bypass filter All rotors are correctly balanced before leaving the
factory. An out-of-balance condition can occur as a
result of an uneven build up of sludge in the rotor or
as a result of excessive bearing or spindle wear.
98.47 - ES0
MAN Diesel
L16/24
To Check Bearing Clearances Spindle top journal diameter 14.98 mm Min.
Spindle bottom journal diameter21.63 mm Min.
This is most easily done by applying a dial gauge Top bearing bore diameter 15.06 mm Max.
to the outside of the rotor opposite each bearing in Bottom bearing bore diameter 21.69 mm Max.
turn and measuring the total play thus:
The spindle and body assembly and the rotor bear-
14) Apply dial gauge and measure play. ing tube assembly are factory assembled items and
should only be replaced with complete assemblies.
15) Turn rotor 90° and repeat measurement.
98.47 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pump 51501-06H
L16/24
08028-0D/H5250/94.08.12
06.32 - ES0
MAN Diesel
Plate
51501-06H Lubricating Oil Pump Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
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
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Filter 51502-12H
L16/24
050
037 025
216
049
Front-end box,
see Plate 51103
049
216
025
204
170
182
133
145
169
194
300
157 312
062 182
013 204 324
074 013
062 074 289
013 013 265
074 277 086
013 290 253
08028-0D/H5250/94.08.12
074 108
013 049 241
289 253
265
277 228
086 098
098 241
108 228 121
06.25 - ES0
MAN Diesel
Plate
51502-12H Lubricating Oil Filter Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
013 6/E Filter cartridge Filterindsats 312 1/E Latch pin Låsestift
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
06.25 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Pump 51504-04H
L16/24
99.07 - ES0
MAN Diesel
Plate
51504-04H Prelubricating Pump Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
014 1/P Front cover Fordæksel 516 1/E Ball bearing, rear Kugleleje, bagside
026 1/P Joint Pakning 528 1/E Ball bearing, front Kugleleje, forside
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
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
99.07 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Cooler 51506-10H
L16/24
064 015
076 027
172 039
184 040
196 052
206
218
040
088
111
Mandrel, 159
see plate 52015
231 135
123 147 160
243 483 529
495 530
505 542
517 554
08028-0D/H5250/94.08.12
06.48 - ES0
MAN Diesel
Plate
51506-10H Lubricating Oil Cooler Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
040 4/K O-ring, oval O-ring, oval 517 10/K Screw Skrue
9 cyl. engine 9 cyl. motor
052 8/K Screw Skrue
529 /I Plate Plade
064 1/K Plug screw Propskrue 6 cyl. engine 6 cyl. motor
123 10/K Self locking nut Selvlåsende møtrik 554 /I Plate Plade
9 cyl. engine 9 cyl. motor
135 10/K Washer Skive
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
Qty/K = Qty/Cooler Qty/K = Qty/Køler
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
06.48 - ES0
MAN Diesel
Plate
Page 1 (2) Centrifugal By-pass Filter 51515-02H
L16/24
171
291 195
278 122
158
337
146
229
183
242
109
230
075
205
217
08028-0D/H5250/94.08.12
014
051 087
038 063
07.27 - ES0
MAN Diesel
Plate
51515-02H Centrifugal By-pass Filter Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
014 1/F Body , complete incl. Sokkel, komplet inkl. 291 1/F Stiffner plate Plade
item 026, 038, 051, 063, item 026, 038, 051, 063,
075, 087, 099, 109 075, 087, 099, 109 301 1/F Cover nut fixing kit, Dækselmøtrikskit, inde-
consisting of item 134, holdende item 134, 146,
026 1/F Valve body Ventilsokkel 146, 158, 171 158, 171
038 1/F Valve handle Ventilhåndtag 313 1/F Valve kit, consisting Ventilkit, indeholdende
of item 026, 038, 051, item 026, 038, 051, 063,
051 1/F Nyloc nut Møtrik 063, 075, 087 075, 087
063 1/F Valve adaptor Ventiladapter 325 1/F Seals kit, consisting Tætningskit, indehold-
of item 087, 099, 109, ende item 087, 099,
075 1/F Valve stop Ventilstop 158, 242 109, 158, 242
087 1/F Valve seal Ventiltætning 337 1/E Centrifugal by-pass Centrifugal by-pass fil-
filter, complete as ter, komplet som vist på
099 1/F Flange gasket Flangepakning shown on front page forsiden
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
Qty/F = Qty/Filter Qty/F = Qty/Filter
07.27 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Separator 51530-02H
L16/24
08028-0D/H5250/94.08.12
99.06 - ES0
MAN Diesel
Plate
51530-02H Lubricating Oil Separator Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor
99.06 - ES0
MAN Diesel
Plate
Page 1 (2) Crankcase Venting 51531-05H
L16/24
011
08028-0D/H5250/94.08.12
07.44 - ES0
MAN Diesel
Plate
51531-05H Crankcase Venting Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.44 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-02H
L16/24
08028-0D/H5250/94.08.12
00.14 - ES0
MAN Diesel
Plate
51535-02H Prelubricating Oil Arrangement Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
00.14 - ES0
Cooling water system
516/616
MAN Diesel
Description 516.01
Page 1 (1) Internal Cooling Water System Edition 04H
L16/24
Cooling Water System
Thermostatic Valves
99.03 - ES0
MAN Diesel
Working Card 516-01.90
Page 1 (2) Check of Cooling Water System Edition 02H
L16/24
Starting position
Engine is running.
Related procedure
Data
98.41 - ES0
MAN Diesel
516-01.90 Working Card
Edition 02H Check of Cooling Water System Page 2 (2)
L16/24
Checks to be Carried Out 4) Check the condition of the outermost of the
two O-rings (which make up the tightening
1) Examine the cooling water connections for between the water jacket and the combustion
leaks. space) by means of the inspection holes in the
cylinder cover.
2) Check flexible connections for leaks.
Concerning check of the fresh water condition, see
It is important that the flexible connections are free section 504.
from paint and grease and in healthy condition.
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Working Card 516-04.00
Page 1 (2) Cooling Water, Thermostatic Valve Edition 02H
L16/24
Starting position
Related procedure
Data
98.41 - ES0
MAN Diesel
516-04.00 Working Card
Edition 02H Cooling Water, Thermostatic Valve Page 2 (2)
L16/24
The thermostatic valves cannot be adjusted and 5) Remount a new element (4) by wriggling it
under normal conditions maintenance is not required. somewhat over side.
However, in some cases it is necessary to clean or
replace elements. 6) Mount lock ring (2) in the recees.
98.41 - ES0
MAN Diesel
Working Card 516-10.00
Page 1 (2) HT and LT Water Pumps Edition 01H
L16/24
Starting position
Related procedure
Capacity : 1 man
51610 010 4/E
51610 022 2/E
Data 51610 095 2/E
51610 250 1/E
Data for pressure and tolerance (Page 500.35)
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
98.41 - ES0
MAN Diesel
516-10.00 Working Card
Edition 01H HT and LT Water Pumps Page 2 (2)
L16/24
After the cooling water thermostat casing is removed Inspection of the Pump
the cooling water pumps can be dismounted.
6) Inspect the shaft for seizures after removing
1) Remove the screws (1), see fig. 1 and pull out the shaft seal and bearings, also inspect the
the pump by means of the spring bolts. impeller for pittings and caviations. Clean all
parts carefully.
10) Fit carefully the slide ring joint (10), then fit the
washer (8) and the impeller (9) and tight the
nut (7) according to page 500.40.
11) Mount the cover (6) with the screw (5) and tight
them according to page 500.40.
5) Take out the lock ring (11), then pull out the
shaft (12) with bearings (13) and (14) and the
shaft seal (15).
98.41 - ES0
MAN Diesel
Plate
Page 1 (2) High- and Low Temperature Freshwater Pumps 51610-11H
L16/24
129
022 010
095
130
250
105
201 117
191 237
142
166
154
225
213
071
08028-0D/H5250/94.08.12
058
046
178
034
083
07.06 - ES0
MAN Diesel
Plate
51610-11H High- and Low Temperature Freshwater Pumps Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
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
Qty./P = Qty./Pump Qty./P = Qty./Pumpe
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
07.06 - ES0
MAN Diesel
Plate
Page 1 (2) Cooling Water Connections 51630-02H
L16/24
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel
Plate
51630-02H Cooling Water Connections Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
98.45 - ES0
Special equipment
517/617
MAN Diesel
Kit
Page 1 (2) Kit for Complete Cylinder Unit Exchange 51703-02
L16/24
045
104
033a
014
033b
027
08028-0D/H5250/94.08.12
033b
243
231
04.43 - ES0
MAN Diesel
Kit
51703-02 Kit for Complete Cylinder Unit Exchange Page 2 (2)
L16/24
Item
No Qty Designation Where to find in the engine instruction book
045 1/C Kit for cylinder unit, complete Plate 50500 Item 045
consisting of:
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
04.43 - ES0
MAN Diesel
Kit
Page 1 (2) Kit for Cylinder Unit 51704-02
L16/24
021
08028-0D/H5250/94.08.12
04.17 - ES0
MAN Diesel
Kit
51704-02 Kit for Cylinder Unit Page 2 (2)
L16/24
Item
No Qty Designation Where to find in the engine instruction book
Qty/C = Qty/Cylinder
Qty/V = Qty/Valve
Qty/I = Qty/individual
04.17 - ES0
Specific plant
information
519/619
MAN Diesel
Description
Page 1 (2) Resilient Mounting of Generating Sets 519.03
Edition 03H
L16/24
Resilient Mounting of Generating Sets 1) The support between the bottom flange of the
conical mounting and the foundation is made
On resiliently mounted generating sets, the diesel with a loose steel shim. This steel shim is ad-
engine and the alternator are placed on a common justed to an exact measurement (min. 75 mm)
rigid base frame mounted on the ship's/machine for each conical mounting.
house's foundation by means of resilient supports,
Conical type. 2) The support can also be made by means of
two steel shims, at the top a loose steel shim
All connections from the generating set to the external of at least 75 mm and below a steel shim of at
systems should be equipped with flexible connections least 10 mm which are adjusted for each conical
and pipes. Gangway etc. must not be welded to the mounting and then welded to the foundation.
external part of the installation.
Resilient Support
99.44 - ES1
MAN Diesel
L16/24
3) Finally, the support can be made by means Adjustment of Engine and Alternator on
of chockfast. It is necessary to use two steel Base Frame
shims, the top steel shim should be loose and
have a minimum thickness of 75 mm and the The resiliently mounted generating set is normally
bottom steel shim should be cast in chockfast delivered from the factory with engine and alternator
with a thickness of at least 10 mm. mounted on the common base frame. Eventhough
the engine and alternator have been adjusted by the
Irrespective of the method of support, the 75 mm factory with the alternator rotor placed correctly in
steel shim is necessary to facilitate a possible future the stator and the crankshaft bend of the engine is
replacement of the conical mountings, which are within the prescribed tolerances.
always replaced in pairs.
08028-0D/H5250/94.08.12
99.44 - ES1
MAN Diesel
Working card 519-03.00
Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 24
L16/24
L21/31
Mounting and adjustment instruction for new Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Starting position
Related procedure
Data
03.50 - ES1
MAN Diesel
L16/24
L21/31
Mounting and Adjustment Instructions for 5) Position the jacking bolt with a through-going
New Generating Sets (Method 1) of minimum 75 mm.
Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests completely
ments on the foundation.
If the conical elements have not been mounted by 7) Check that all the jacking bolts have full contact
the factory, they must be mounted on the prepared with the foundation.
brackets on the base frame. In case they have been
mounted by the factory, please start with item 4. 8) Loosen the nut (7).
1) Remove nut (7) and ring (6) from the conical 9) Turn all the internal buffers by applying a span-
element. ner to the hexagon (S = 19) to check that they
can move freely.
2) Fit the conical element to the bracket on the
suspended equipment by means of fixing the
central buffer (2), the ring (6) and nut (7). If all internal buffers Then
3) Tighten the nut (7) by hand and simultane- Can move freely Let conical elements
ously block the central buffer (2) by applying settle for 48 hours.
a spanner to the hexagon (S = 19) on the top
of the central buffer (2). Cannot be moved Turn the jacking bolts
freely clockwise to release the
4) Position the four jacking bolts in the tapped internal buffer.
holes (8) in the bottom flange.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
Working card
Page 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 24
L16/24
L21/31
Adjustment of Conical Elements after 48 Drill the mounting holes in the steel shim according
Hours Settling to the conical base casting dimensions.
preparation. foundation.
03.50 - ES1
MAN Diesel
L16/24
L21/31
Mounting of Conical Elements on the Foun- or
dation
b) Drill the mounting holes in the foundation by
23) Drill four mounting holes in the foundation for means of the drilling pattern from the installa-
each conical element, either tion drawing.
a) Mark the positions of the mounting holes on The drilling has to be done on beforehand and
the foundation through the conical element. the set must be aligned with the foundation
holes before the work starts to avoid further
(Re)move the set completely so that the mark- removal of the set.
ings can be reached by drilling with conventional
tools. 24) Fix the conical element and the steel shim to
the foundation with four bolts.
Place the set on its former position by aligning
it with the drilled holes. Note! After completion of all works the buffer clear-
ance must be checked, see points 19, 20, 21 and
22.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
Working card 519-03.00
Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 25
L16/24
L21/31
Mounting and adjustment instruction for new Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Starting position
Related procedure
Data
03.50 - ES1
MAN Diesel
L16/24
L21/31
Mounting and Adjustment Instructions for for four jacking bolts and mounting holes drilled
New Generating Sets (Method 2) according to conical base casting dimensions, is
required.
Make Ready for Adjustment of Conical Ele-
ments 4) Position the supporting steel shim as per fig
1 and locate the conical element by means of
If the conical elements have not been mounted by dowel pins.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been 5) Position the jacking bolts in the tapped holes
mounted by the factory, please start with item 4. in the supporting steel shim as per fig 1.
1) Remove nut (7) and ring (6) from the conical 6) Position the jacking bolts with a through-going
element. of minimum 10 mm, see fig 1.
2) Fit the conical element to the bracket on the 7) Lowed generating set until it rests completely
suspended equipment by means of fixing the on the foundation.
central buffer (2), the ring (6) and nut (7).
8) Check that all jacking bolts have full contact
3) Tighten the nut (7) by hand and simultane- with the foundation.
ously block the central buffer (2) by applying
a spanner to the hexagon (S = 19) on the top 9) Loosen the nut (7).
of the central buffer (2).
10) Turn all the internal buffers by applying a span-
A 75 mm supporting steel shim, complete with holes ner to the hexagon (S = 19) to check that they
can move freely.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
Working card
Page 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 25
L16/24
L21/31
If all internal buffers Then Measuring of Steel Shim
Can move freely Let conical elements 12) Measure the steel shim on several points to
settle for 48 hours. obtain the highest possible accuracy during
preparation.
Cannot be moved Turn the three jacking
freely bolts in the supporting
steel shim clockwise, or Fabricating Steel Shim
anticlockwise to release
the internal buffer. 13) Make sure that the minimum height of the steel
shim is 10 mm to secure the future replacement
of the supporting steel shim.
Adjustment of Conical Elements after 48
Hours Settling Drill the mounting holes in the steel shim according
to the conical base casting dimensions.
After the conical elements have been deflected un-
der static load for 48 hours, the loaded height (H1)
see fig 1, should be measured and compared to the Mounting of the Completed Steel Shim
recommended loaded height.
14) Lift the generating set 1 mm totally be means
11) Care must be taken, during levelling of the of the three jacking bolts.
installation, to ensure that individual mountings
are not overloaded.The variation in laden height 15) Position each completed steel shim.
should not exceed 2 mm and should ideally
be less. The laden height can be measured 16) Re-lower the generating set by means of the
between top and base casting at H, on two three jacking bolts until it rests completely in
sides (see fig 1). itself.
H1 + H2 + H3 ----- HN
Ex:Average = Adjustment of Internal Buffer
Number of conical elements
17) Turn the internal buffer clockwise (downwards)
If Then until it makes contact with the steel shim or
foundation.
Difference exceeds Level the conical element
2 mm. by adjusting the jacking 18) Turn the internal buffer anticlockwise (upwards)
bolts - commencing with until it obtains contact with the base casting.
the conical element with
the largest deviation. This must be four full turns.
08028-0D/H5250/94.08.12
Difference does not ex- The height of the steel 19) Turn the internal buffer two full turns clockwise
ceed 2 mm shim can be measured. (downwards) and check with a feeler gauge
between the base casting of the conical ele-
ment and the steel shim that the internal buffer
The difference between the two sides of the conical (2), see fig 1, does not touch the steel shim or
mounting should not be more than 0.5 mm. foundation.
03.50 - ES1
MAN Diesel
L16/24
L21/31
Mounting of Conical Elements on the Foun- b) Drill the mounting holes in the foundation by
dation means of the drilling pattern from the installa-
tion drawing.
21) Remove the dowel pins.
The drilling has to be done on beforehand and
22) Drill four mounting holes in the foundation for the set must be aligned with the foundation
each conical element, either holes before the work starts to avoid further
removal of the set.
a) Mark the positions of the mounting holes on
the foundation through the conical element. 23) Fix the conical element and the supporting
steel shim/steel shim to the foundation with
(Re)move the set completely so that the mark- four bolts.
ings can be reached by drilling with conventional
tools. 24) Weld the lowest steel shim to the foundation.
Place the set on its former position by aligning Note! After completion of all works, the buffer clear-
it with the drilled holes. ance must be checked, see points 17, 18, 19
and 20.
or
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
Working card 519-03.00
Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 26
L16/24
L21/31
Mounting and adjustment instruction for new Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Starting position
Related procedure
Data
03.50 - ES0
MAN Diesel
L16/24
L21/31
Mounting and Adjustment Instructions for A 75 mm supporting steel shim, complete with tapped
New Generating Sets (Method 3) holes for three jacking bolts, four mounting holes and
four tapped holes, drilled according to the conical
Make Ready for Adjustment of Conical Ele- base casting dimension, is required see fig 1.
ments
4) Position the supporting steel shim as per fig
If the conical elements have not been mounted by 1 and locate the conical element by means of
the factory, they must be mounted on the prepared four hold-down bolts.
brackets on the base frame. In case they have been
mounted by the factory, please start with item 4. 5) Position the jacking bolts in the tapped holes
in the supporting steel shim as per fig 1.
1) Remove nut (7) and ring (6) from the conical
element. 6) Position the jacking bolts with a through-going
of minimum 10 mm plus permitted thickness,
2) Fit the conical element to the bracket on the as specified from the chockfast supplier, see
suspended equipment by means of fixing the fig 1.
central buffer (2), the ring (6) and nut (7).
7) Lowed the generating set until it rests com-
3) Tighten the nut (7) by hand and simultane- pletely on the foundation.
ously block the central buffer (2) by applying
a spanner to the hexagon (S = 19) on the top 8) Check that all jacking bolts have full contact
of the central buffer (2). with the foundation.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
Working card 519-03.00
Page 3 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 26
L16/24
L21/31
If all internal buffers Then Measuring of Steel Shim and Chockfast
Can move freely Let conical elements 10) The steel shim should be at least 10 mm
settle for 48 hours. heigh.
Cannot be moved Turn the three jacking Check the minimum permitted thickness of chock-
freely bolts in the supporting fast for the load and surface of this application
steel shim clockwise, or with chockfast supplier.
anticlockwise and
slacken the four hold-
down bolts to release Fabricating Steel Shim
the internal buffer.
Make sure that the minimum height of the steel shim
is 10 mm to secure a future replacement of the sup-
Adjustment of Conical Element after 48 porting steel shim.
Hours Settling
11) Drill the mounting holes in the steel shim ac-
After the conical elements have been deflected un- cording to the mounting holes in the supporting
der static load for 48 hours, the loaded height (H1) steel shim.
see fig 1, should be measured and compared to the
recommended loaded height.
Adjustment of Internal Buffer
9) Care must be taken, during levelling of the
installation, to ensure that individual mountings 12) Turn the internal buffer clockwise (downwards)
are not overloaded.The variation in laden height until it makes contact with the steel shim or
should not exceed 2 mm and should ideally foundation.
be less. The laden height can be measured
between top and base casting at H, on two 13) Turn the internal buffer anticlockwise (upwards)
sides (see fig 1). until it obtains contact with the base casting.
the largest deviation. blocking the internal buffer (2) with a spanner
at the same time, see fig 1.
Difference does not ex- The height of the steel
ceed 2 mm shim and the chockfast
can be measured. Mounting of Conical Elements on the Foun-
dation
The difference between the two sides of the conical 16) Drill mounting holes in the foundation accord-
mounting should not be more than 0.5 mm. ing to the supporting steel shim/steel shim and
chockfast, either
03.50 - ES1
MAN Diesel
L16/24
L21/31
a) Mark the positions of the mounting holes on b) Drill the mounting holes in the foundation by
the foundation through the supporting steel means of the drilling pattern.
shim.
The drilling has to be done on beforehand and
(Re)move the set completely so that the mark- the set must be aligned with the foundation
ings can be reached by drilling with conventional holes before the work starts to avoid further
tools. removal of the set.
Place the set on its former position by aligning Make sure that the mounting bolts are isolated from
it with the drilled holes. the chockfast.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
L16/24
L21/31
Starting position
Safety precautions.
Related procedure
Data
98.41 - ES0
MAN Diesel
L16/24
L21/31
Replacement of Conicals
1) Loosen all the holding down-bolts for the co- 3) Lift the GenSet until the steel shim can be remo-
nicals in one side. ved. This will give enough space for removing
damaged conical.
2) Mount a jack under the base frame, see fig
1. 4) Mount the GenSet conical.
Deck
Jack
08028-0D/H5250/94.08.12
One pair
98.41 - ES0
MAN Diesel
Working Card 519-03.10
Page 1 (2) Maintenance of Conicals Edition 02
L16/24
L21/31
Starting position
Related procedure
Data
98.41 - ES0
MAN Diesel
519-03.10 Working Card
Edition 02 Maintenance of Conicals Page 2 (2)
L16/24
L21/31
Visual Check Result of Clearance Check
What to Check 8) Turn internal buffer (2) two full rotations clock-
wise. This will ensure full vertical movement for
4) Check clearance on all conicals between steel the buffer.
shim and internal buffer through the slot in the
base casting of the conical (see fig 1) with a 9) Check all conicals again.
feeler gauge of approx. 2 mm.
10) Tighten the nut (1), see page 500.40 and at
the same time block the internal buffer (2) with
a spanner.
1. Nut
2. Internal buffer
08028-0D/H5250/94.08.12
2
3. Conical base casting
4. Steel shim
3
Fig 1 Conical
98.41 - ES0S
MAN Diesel
Plate
Page 1 (2) Flexible External Connections 51902-04H
L16/24
Item
Fig. Designation Connection
No
99.09 - ES0
MAN Diesel
Plate
51902-04H Flexible External Connections Page 2 (2)
L16/24
Item
Fig. Designation Connection
No
08028-0D/H5250/94.08.12
99.09 - ES0
MAN Diesel
Plate
Page 1 (2) Conical Element 51903-02
L16/24
L21/31
08028-0D/H5250/94.08.12
97.49 - ES0
MAN Diesel
Plate
51903-02 Conical Element Page 2 (2)
L16/24
L21/31
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/M = Qty/Conical mounting. Qty/M = Qty/Conical montering.
97.49 - ES0
Tools
520/620
MAN Diesel
General
Starting position
Related procedure
Data
99.43 - ES0
MAN Diesel
520-01.05 Working Card
Edition 02 Function of the Hydraulic Tools Page 2 (7)
General
Function of the Bolt Tensioning Device 8. The operation and handling of the device are
to be carried out by expert staff only.
In order to achieve an optimal result with one or
several devices, some rules have to be considered. 9. The given max. operation pressure is not to
We expressly point out that a conscientious handling be exceeded in any case and is to be watched
of the device as well as the accessories is of high- at the manometer of the pressure generator
est importance. To ignore these rules or separate during the complete tensioning or loosening
hints means danger to life or danger of injuries! See procedure. When having achieved the given
Safety Hints. pressure, stop the pressurization immedi-
ately.
6. During the pressurization the people involved (for example by using a master manometer).
have to remain in an appropriate distance. Tensioning forces can be checked for example
Staying in direction towards the bolt axis is by measuring the linear deformation. Damaged
forbidden. manometers have to be exchanged immedi-
ately.
7. Tensioning pressures or tensioning forces are
to be given or changed by authorized personnel
only while considering the admissible compo-
nent loads, see item 4.
99.43 - ES0
MAN Diesel
Working Card 520-01.05
Page 3 (7) Function of the Hydraulic Tools Edition 02
General
Working Hints
99.43 - ES0
MAN Diesel
520-01.05 Working Card
Edition 02 Function of the Hydraulic Tools Page 4 (7)
General
- By drawing the hose with a manual force of that the max. admissible stroke of the device is not
about 100 N make sure that the connection is exceeded. Beside that, it has to be ensured that the
correctly barred. cylinder and the support sleeve remain centrically
towards each other (consider centering shoulder).
- For decoupling the high-pressure hose in
a pressureless condition, first pull back the Having made all hydraulic connections correctly,
coupling socket and then take off the hose. see fig. 2, start the pressurization for the tensioning
procedure. If the necessary pressure is achieved
stop pressurization. The inducted force causes the
bolt to extend or an edging of the components to
be tensioned so that the main nut is lifted from the
flange. Screw it back to the flange, see fig. 3. Check
by help of a feeler gauge leaf whether the main nut
really fits tight to the flange. After that, bleed hydraulic
pressure. Now the connection is tensioned.
Fig. 2. Coupling of the high-pressure hoses. Having brought the piston to its zero position, see fig.
4, the hydraulic hoses can be decoupled. In order to
prevent impurities, it is advisable to close coupling
Hoses with fast-lock coupling sockets avoid, also sockets and coupling nipples at once by protecting
when uncoupled, that oil runs out. When the hoses caps. The device can be unscrewed from the bolt.
get heated, there can be an inside pressure in the
uncoupled condition making a coupling impossible. ● Always consider the safety and working
By loosening one screw connection (see fig. 2) the hints!
pressure can be bleeded
Screw the device until the support sleeve or the sup- Hint: The adjusted slit measure may never exceed
port cylinder fits exactly to the flange. The piston of the admissible stroke of the device! Furthermore,
the device must be at its zero position. Furthermore, take care that the window for the adjusting rod are
take care that the hydraulic connector and the window well accessible.
for the adjusting rod is well accessible. Having made all hydraulic connections correctly, see
If necessary, turn back the device, but make sure fig. 2, start the pressurization.
99.43 - ES0
MAN Diesel
General
During the pressurization, a slight turn-back momen- Hint:
tum is applied to the main nut with the adjusting rod.
At the moment, when the main nut can be loosened, a) Should it be impossible to unscrew the device
interrupt the pressurization. Should it not be possible after the depressurization, it has been turned
to loosen the main nut when achieving the original back by a too low measure prior to the pres-
tensioning pressure, interrupt the pressurization im- surization. Pressurize again until the original
mediately. Find the cause with expert staff. tensioning pressure is reached, turn the main
nut and bleed the pressure again (tensioning
Having achieved the loosening pressure, turn back procedure). Now you can turn back the device
the main nut by the value that the bolt and the com- further. (Attention: consider the admissible
ponents spring back during the loosening procedure. stroke of the device!) Now repeat the loosening
The slit measure, however, must be lower than the procedure explained above.
slit measure adjusted at the device before, see also
hint b. b) Should it be impossible to loosen the main nut
after the depressurization, it has been turned
The main nut may never be turned back until it fits back by a too low measure prior to the pres-
to the piston or the cylinder since then the device surization. Pressurize again and turn the main
can be tensioned in itself. nut further back. Bleed the pressure again.
Having turned back the main nut, the pressure can Hint: Never screw the main nut back until it fits to
be bled. The bolt connection is loosened. Before the piston since the device can be tensioned
unscrewing the device, bring the piston back to its in itself.
zero position, see fig. 4. After that, the hydraulic hoses
can be decoupled. In order to prevent impurities, it
is advisable to close coupling sockets and coupling Adjustment and Turn Back of the Main Nut
nipples at once by protecting caps. The device can
be unscrewed from the bolt. During the pressurization of the device, the bolt
is being extended by the tensioning force and the
● Make sure that no operational forces (e.g. components are being edged. The result is that the
inner pressure) affect the components to be main nut does no longer fit to the flange.
loosened since only part of the bolts take over
these forces and thus the bolts, which are not Having achieved the necessary pressure, adjust the
yet loosened, might be overburdened. main nut - when tensioning - until it fits to the flange
again before bleeding the pressure, see Tensioning
● The pressure when the main nut can be loos- Procedure. When loosening the bolts, turn back the
ened may never exceed the tensioning pressure main nut after the pressurization according to the
by help of which the connection was tensioned! bolt and component deformations, (see Loosening
Should it not be possible to loosen the main nut Procedure.
when reaching the original tensioning pressure
08028-0D/H5250/94.08.12
interrupt the pressurization immediately. Find Hint: During the loosening procedure, never turn
the cause with expert staff. back the main nut until it fits to the piston or the
cylinder since the main nut sticks after the depres-
● Always consider the safety and working surization.
hints!
The main nut is equipped with several radial bores
where the adjusting rod can be put in. The main nut
is accessible through the window in the support
sleeve.
99.43 - ES0
MAN Diesel
General
During the piston return stroke, considerable back-
pressures can occur in the piston area of the device
since quite large quantities of oil have to flow back
through the small cross sections of the high-pres-
sure connections.
99.43 - ES0
MAN Diesel
General
As shown in the picture, first assemble the backup
ring, then put the seal onto the backup ring. Piston
and cylinder can now be assembled again by putting
the components together. By slightly hammering on
the piston (with plastic spacer), it can be driven in
until it fits tightly to the cylinder (piston in its zero
position). It is essential that the piston does not tilt
during being driven in since this might damage the
seals as well as the components. When assembling
the piston it has to be taken care that the air can
come out of the piston area.
a) Storage
99.43 - ES0
MAN Diesel
Working Card 520-01.06
Page 1 (4) Application of Hydraulic Tools Edition 06H
L16/24
Starting position
Related procedure
Data
01.35 - ES0
MAN Diesel
520-01.06 Working Card
Edition 06H Application of Hydraulic Tools Page 2 (4)
L16/24
08028-0D/H5250/94.08.12
01.35 - ES0
MAN Diesel
Working Card 520-01.06
Page 3 (4) Application of Hydraulic Tools Edition 06H
L16/24
01.35 - ES0
MAN Diesel
520-01.06 Working Card
Edition 06H Application of Hydraulic Tools Page 4 (4)
L16/24
01.35 - ES0
MAN Diesel
Working Card 520-01.07
Page 1 (4) Hand Lever Pump Edition 01
General
Starting position
Related procedure
Data
00.45 - ES0
MAN Diesel
General
Warning: The hand lever pump is not equipped with Initial Start-up and Venting
a pressure relief valve.
Never use the pump without a mounted manometer. In general and venting
Always pay attention to the given pressure of the
connected pressure consumers. Do never exceed Please make sure that all parts of the pump, espe-
this pressure or the max. pressure of the hand lever cially the manometer and the pressure port, are in a
pump. perfect condition. Defect parts are to be exchanged
against new ones immediately.
Important: Except for hydraulic oil, never use different
liquids such as petrol, water, diesel oil, alcohol or brake Turn the carrying handle with counter-clockwise
liquid, since these can lead to damages or even to rotation out of his fixing. Then turn it into the hand
destruction of the pump and/or the parts connected lever of the pump against the stopping face.
with it. Choose a place of assembling and operation
where the pump can always stand safe and firm on Attention: If the carrying handle is not srewed-in
a horizontal plain. There should always be sufficient into the hand lever, it can cause injuries while using
space for operating the pump. the pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the oil filler cap and check the oil level. If nec-
pump to great heat, fire or extreme coldness, since cessary, fill up the tank with hydraulic oil according
this leads to damages or even destruction. Protect to IS0 VG 32. Never overfill the tank. Close the oil
the pump from falling objects and avoid hard blows filler cap.
or pushes. Open the tank breather with the square wrench
(included in the scope of supply) by about one turn.
Attention - Danger to life Now loosen the breather screw at the pump on the
Check the manometer of the pump for the needed left side on the pump housing with an allen key SW
hydraulic pressure, given by an authorized person, 2,5 by about one turn. Close the depressurization
not to be exceeded. Make sure that the pressure valve tightly. Seal the nipple on the pump with a hose
you want to generate is also admissible for all con- and pump at the hand lever until oil flows out of the
nection parts. breather screw bladder-free. Only then are you al-
lowed to close the breather screw. The pump is now
All pressure connections and connecting elements vented and ready for operation.
have to be clean and undamaged. High-pressure
connections from the pump to the tools have to be After each operation and for the transport, close
established correctly prior to any pressurization. the tank breather in order to avoid the hydraulic oil’s
Disregard leads to danger to life. Please see working running out.
card 520-01.06.
00.45 - ES0
MAN Diesel
Working Card 520-01.07
Page 3 (4) Hand Lever Pump Edition 01
General
Remark: The depressurization valve is designed Below of the pressure relief valve is an adjusting screw
for manual operation. The use of any tools at the with inner hexagon (wrench size 10 mm). Turning out
depressurization valve could cause damages of the counter-clockwisely the adjusting screw minimizes
valve or the valve seat. the change-over pressure, turning in clockwise ma-
ximizes the change-over pressure.
- Pump at the hand lever until the wanted pres-
sure is achieved. Check the pressurization Attention: Inside of the adjusting screw is another
at the manometer and take care of possible grub screw with inner hexagon (wrench size 4 mm) to
leakages. limit the stroke of the change-over piston inside of
the pump block. It is absolutely necessary, to screw
Remark: The pump works with two stages. The out the grub screw approx. 2 times before turning
change from the first stage to the second stage the adjusting screw!
happens automatical at a system pressure of about
30 bar. The regulation of the adjusting screw follows gra-
dually in approx. 10° - steps. After everv adjusting
Attention: The pump is not equipped with an internal step the grub screw is to screw in until it fits closely
pressure relief valve.The use of a manometer and the and approx. a l/4 turn to loosen.
control of the system pressure during pressurization
is indispensable. Check by carefully pumping if the change-over pres-
sure wanted has been reached. If necessary, repeat
Attention: Do not stand directly over the moving the procedure as described above.
line of the pump lever. Under arising circumstances
the lever can “hit back”. To avoid accidents stand
sideways the pump.
Depressurization
00.45 - ES0
MAN Diesel
General
00.45 - ES0
MAN Diesel
Plate
Page 1 (4) Tools for Cylinder Head 52005-06H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Mandrel E 122
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52005-06H Tools for Cylinder Head Page 2 (4)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 3 (4) Tools for Cylinder Head 52005-06H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Guide E 195
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52005-06H Tools for Cylinder Head Page 4 (4)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
08028-0D/H5250/94.08.12
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 1 (4) Tools for Piston, Connecting Rod and Cylinder Liner 52006-08H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52006-08H Tools for Piston, Connecting Rod and Cylinder Liner Page 2 (4)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
08028-0D/H5250/94.08.12
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 3 (4) Tools for Piston, Connecting Rod and Cylinder Liner 52006-08H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52006-08H Tools for Piston, Connecting Rod and Cylinder Liner Page 4 (4)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Honing brush,
incl. wooden box S 224
08028-0D/H5250/94.08.12
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Camshaft and Camshaft Drive 52007-03H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
07.50 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Operating Gear for Inlet and Exhaust Valves 52008-07H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Crankshaft and Main Bearings 52010-05H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
210
08028-0D/H5250/94.08.12
S = Standard E = Extra
08.03 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Charge Air Cooler 52012-03H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 1 (3) Tools for Fuel oil and injection equipment 52014-06H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52014-06H Tools for Fuel oil and injection equipment Page 2 (3)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Bow E 098
08028-0D/H5250/94.08.12
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 3 (3) Tools for Fuel oil and injection equipment 52014-06H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Lubricating Oil Cooler 52015-04H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 1 (4) Hydraulic Tools 52021-09H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Manometer 023
Distributor 417
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52021-09H Hydraulic Tools Page 2 (4)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Gasket 155
Gasket 155
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
Page 3 (4) Hydraulic Tools 52021-09H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Spanner S 310
08028-0D/H5250/94.08.12
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52021-09H Hydraulic Tools Page 4 (4)
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Adapter 836
S = Standard E = Extra
02.22 - ES0