L27/38

Instruction Manual - Marine

Four-stroke GenSet
compliant with IMO Tier II
Complete manual
date 2014.04.28
MAN Diesel & Turbo

Index
Page 1 (8) Instruction manual Index

L27/38

Text Index Drawing No

Engine data 500/600

Preface Description
Warning Description
Questionnaire Description
Safety precautions Description 5003 (01)
Main particulars Description 500.00 (32)
Introduction Description 500.01 (03)
Safety Description 500.02 (02)
Cross section Description 500.05 (13)
Key for engine designation Description 500.10 (04)
Designation of cylinders Description 500.11 (03)
Engine rotation clockwise Description 500.12 (02)
Code identification for instruments Description 500.20 (04)
Planned maintenance programme Description 500.23 (01)
Introduction to plant maintenance program Description 500.24 (03)
Planned maintenance programme, major overhaul/inspection Description 500.25 (40)
Planned maintenance programme, duties during operation Description 500.26 (20H)
Operation data & set points Description 500.30 (96)
Green Passport Description 500.33 (02)
Data for pressure and tolerance Description 500.35 (59)
Data for tightening torque Description 500.40 (36)
Declaration of weight Description 500.45 (11)
Ordering of spare parts Description 500.50 (03)
How to return spare parts Description 500.51 (05)
Service letters Description 500.55 (01)
Conversion table Description 500.60 (01)
Basic symbols for piping Description 500.65 (01)

Operation of engine 501/601

Operation Description 501.01 (20)

Out of service Description 501.05 (07)
Starting-up after repair Description 501.10 (03)
Guidelines for longterm low-load operation on HFO Description 501.15 (03)
Guidelines regarding MAN Diesel GenSets operating on low
sulphur fuel oil Description 501.16 (02)

Performance and condition 502/602

Engine performance and condition Description 502.01 (08)

Evaluation of readings regarding combustion condition Description 502.02 (04)
Condensate amount Description 502.05 (03)
Engine performance data Working card 502-01.00 (11)
Check of leakages from inspection holes Working card 502-05.00 (02)

Trouble shooting 503/603

Starting failures Description 503.01 (02)

Faults in fuel oil system Description 503.02 (05)
Disturbances during running Description 503.03 (06)

2014.04.28
 MAN Diesel & Turbo

Index
Index Instruction Manual Page 2 (8)

L27/38

Text Index Drawing No

Ignition in crankcase Description 503.04 (03)

Trouble shooting guide for centrifugal by-pass filter Description 503.05 (03)
Trouble shooting guide for air starter Description 503.06 (04)
Trouble shooting guide for air starter Description 503.06 (05)
Tourblw shooting guide for air starter Description 503.06 (06H)
Trouble shooting for cooling water system Description 503.09 (03)
Trouble shooting for lubricating cooler Description 503.10 (01)

Media specification 504/604

Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO) Description 010.000.023-11
Specification of lube oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuel Description 010.000.023-07
Treatment and maintenance of lubricating oil Description 504.03 (08)
Criteria for cleaning/exchange of lubricating oil Description 504.04 (07)
Lubricating points Description 504.05 (03)
Lubricating oil in base frame Description 504.06 (03H)
Specific lubricating oil consumption - SLOC Description 504.07 (03)
Specification for heavy fuel oil (HFO) Description 6680 3.3.3-01
Diesel oil (MDO) specification Description 010.000.023-04
Gas oil / diesel oil (MGO) specification Description 010.000.023-01
Bio fuel specification Description 6680 3.3.1-02
Crude oil specification Description 504.24 (01)
Viscosity-temperature diagram (VT diagram) Description 010.000.023-06
Firing pressure comparison Description 504.28 (05)
Fuel oil cleaning Description 504.30 (01)
Engine cooling water specifications Description 010.000.023-13
Cooling water inspecting Description 010.000.002-03
Cooling water system cleaning Description 010.000.002-04
Water specification for fuel-water emulsions Description 010.000.023-16
Specifications for intake air (combustion air) Description 010.000.023-17
Specification for compressed air Description 010.000.023-21

Cylinder head 505/605

Cylinder head and water jacket Description 505.01 (03)

Dismantling of cylinder unit from engine Working card 505-01.00 (12)
Disassembly of cylinder unit Working card 505-01.01 (03)
Inspection of inlet valve, exhaust valve and valve guide Working card 505-01.05 (04)
Reconditioning of valve spindle seat and valve seat ring Working card 505-01.10 (04)
Valve rotator Working card 505-01.15 (05)
Replacement of valve guide Working card 505-01.20 (10)
Check / adjustment of safety valve opening pressure Working card 505-01.25 (01)
Indicator valve Working card 505-01.26 (05)
Replacement of valve seat ring Working card 505-01.35 (04)
Inspection of cylinder head cooling water space Working card 505-01.45 (03)
Assembly of cylinder unit Working card 505-01.50 (04)
Mounting of cylinder unit in engine Working card 505-01.55 (10)
Cylinder head Plate 50501-24
Valve spindles and valve gear Plate 50502-15
Water guide jacket Plate 50507-04

2014.04.28
MAN Diesel & Turbo

Index
Page 3 (8) Instruction manual Index

L27/38

Text Index Drawing No

Safety valve and indicator valve Plate 50508-03

Cylinder head, top cover Plate P50510-09
Cylinder unit Plate 50515-18

Piston/connecting rod 506/606

Piston, connecting rod and cylinder liner Description 506.01 (03H)

Separation/assembly of piston and connecting rod and fitting of piston
rings Working card 506-01.05 (09)
Piston Working card 506-01.10 (21)
Connecting rod Working card 506-01.15 (09)
Criteria for replacement of connecting rod big-end and main
bearing shells Working card 506-01.16 (02)
Criteria for replacement of connecting rod big-end and main
bearing shells Working card 506-01.16 (04)
Criteria for replacement of connecting rod big-end and main
bearing shells Working card 506-01.16 (05)
Removal/mounting of marine head from engine Working card 506-01.24 (01)
Hydraulic tightening of piston and marine head screws Working card 506-01.25 (06)
In-situ inspection of connecting rod big-end bearing Working card 506-01.30 (03)
Inspection and honing of cylinder liner Working card 506-01.35 (09)
Grinding of seal face on cylinder liner and cylinder head Working card 506-01.45 (03)
Dismantling of piston and cylinder liner at low overhaul height Working card 506-01.50 (06)
Piston and connecting rod Plate 50601-33
Cylinder liner Plate 50610-11H

Camshaft 507/607

Camshaft and camshaft drive Description 507.01 (03)

Check of camshaft and camshaft drive Working card 507-01.00 (05)
Inspection and replacement of camshaft bearing Working card 507-01.05 (04)
Adjustment of camshaft for valve and injection timing Working card 507-01.20 (18)
Intermediate wheel Plate 50701-06
Camshaft bearing Plate 50704-01
Camshaft bearing Plate 50704-02
Camshaft (injection camshaft) Plate 50705-21H
Camshaft (valve camshaft) Plate P50705-28

Operating gear 508/608

Operating gear for inlet valves, exhaust valves and fuel injection pumps Description 508.01 (03H)
Inspection of valve camshaft lower and upper rocker arms Working card 508-01.00 (17)
Control and adjusting of valve clearance Working card 508-01.10 (14)
Roller guide and push rods Plate P50801-05

Control/safety 509/609

Safety, control and monitoring system Description 509.01 (16)

Communication from the GenSet Description 509.55 (14)
Function test of shutdown Working card 509-01.05 (11)
Actuator and actuator drive Plate 50901-28

2014.04.28
 MAN Diesel & Turbo

Index
Index Instruction Manual Page 4 (8)

L27/38

Text Index Drawing No

Actuator and actuator drive Plate 50901-29

Regulating device Plate 50902-05H
Instruments Plate 50907-21
Level switch in oil sump (LAL/LAH 28) Plate 50920-03H
Fuel oil leakage alarm (LAH 42) Plate 50925-07
Prelubricating oil pump starter Plate P50951-07
Main bearing monitoring Plate 50961-06
Crankcase oil temperature monitoring/oil splash Plate 50962-03
Operating Instruction - SaCoSone - GenSet Description V1.9
Instruction manual for Actuator - RE2800 Description 285.14301-0006
Service bulletin for Actuator - RE2800 Description SB 001

Crankshaft 510/610

Crankshaft and main bearings Description 510.01 (05H)

Checking of main bearings alignment (autolog) Working card 510-01.00 (14)
Inspection of main and guide bearing shells Working card 510-01.05 (10)
Crankshaft Plate 51001-10H
Crankshaft Plate 51001-11H
Crankshaft Plate 51001-16
Crankshaft Plate 51001-17
Flywheel with gear rim Plate 51003-14H
Vibration damper with attachment Plate 51004-23
Vibration damper with attachment Plate 51004-24
Vibration damper with attachment Plate 51004-25
Assembly and inspection instructions for flexible coupling Description DCB-GS

Engine frame/Oil pan 511/611

Engine frame and base frame Description 511.01 (04H)

Functional test of crankcase safety relief valves Working card 511-01.00 (08)
Frame Plate P51101-27
Frame Plate P51101-28
Frame Plate P51101-29
Frame Plate P51101-30
Frame Plate P51101-31
Front-end box (seen from right) Plate 51103-19H
Front-end box (seen from left) Plate 51103-08H
Front-end box Plate 51103-29
Main bearing Plate 51104-04
Main bearing Plate 51104-05
Main bearing Plate 51104-06
Covers on frame Plate 51106-38
Covers on frame Plate 51106-43
Covers on frame Plate 51106-40
Covers on frame Plate 51106-42
Coupling guard Plate 51109-01
Coupling guard Plate 51109-02
Coupling guard Plate 51109-03
Coupling guard Plate 51109-04

2014.04.28
 MAN Diesel & Turbo

Index
Index Instruction Manual Page 5 (8)

L27/38

Text Index Drawing No

Coupling guard Plate 51109-05

Coupling guard Plate 51109-06
Coupling guard Plate 51109-07
Coupling guard Plate 51109-08
Base frame Plate 51111-07H
Base frame Plate 51111-10
Covering Plate 51120-01H

Turbocharger 512/612

Turbocharger system Description 512.01 (14)

Turbocharger system Description 512.01 (15)
Cleaning the turbocharger in service, water washing of compressor Description 512.05 (01)
Cleaning the turbocharger in service, dry cleaning - turbine side Description 512.10 (02H)
Cleaning of turbocharger in service, water washing - turbine side Description 512.15 (03)
Control air for charge air blow off Description 512.38 (01H)
Overhaul of charging air cooler Working card 512-01.00 (03)
Exhaust pipe compensator Working card 512-01.10 (02)
Water washing of compressor side Working card 512-05.00 (01)
Cleaning the turbine, dry cleaning Working card 512-10.00 (05)
Cleaning the turbocharger in service, water washing - turbine side Working card 512.15-00 (03)
Water washing of turbine Working card 512-15.00 (04)
Charge air cooler Plate 51201-19
Exhaust pipe arrangement Plate 51202-20
Mounting of turbocharger Plate 51203-30
Mounting of turbocharger Plate 51203-32
Exhaust pipe before turbocharger Plate 51204-03
Exhaust pipe before turbocharger Plate 51204-05
Water washing of compressor side Plate 51205-02
Blowgun for dry cleaning of turbocharger Plate 51210-01
Heat insulation and cover before turbocharger Plate 51211-09
Water washing of turbine side Plate 51215-02
Water washing of turbine side Plate P51215-04
Charge air pipes Plate 51230-14
Charge air pipes Plate 51230-25

Compressed air system 513/613

Compressed air system Description 513.01 (28)

Compressed air system Description 513.01 (29)
Air filter Working card 513-01.21 (02)
Overhaul, test and inspection of air starter Working card 513-01.30 (04)
Overhaul, test and inspection of air starter Working card 513-01.30 (05)
Emergency starting valve Working card 513-01.40 (03)
Check of compressed air piping system Working card 513-01.90 (03)
Manual turning gear Working card 513-25.00 (03)
Air starter Plate P51309-09
Air starter Plate 51309-11H
Air starter (supplement for plate 51309-11H) Plate 51309-12H
Air starter (supplement for plate 51309-11H) Plate P51309-13
Main starting valve Plate P51310-06

2014.04.28
 MAN Diesel & Turbo

Index
Index Instruction Manual Page 6 (8)

L27/38

Text Index Drawing No

Main stop valve Plate 51315-03

Solenoid valve, 3/2 Plate 51318-01H
Solenoid valve, 3/2 Plate P51318-02
Solenoid valve, 3/2 Plate P51318-03
Air filter Plate 51321-03
Pressure reduction valve Plate 51322-06H
Pressure reduction valve Plate 51322-04H
Cover for turning gear Plate 51325-12
Manual turning gear Plate 51325-20
Pneumatic turning gear Plate 51325-21
Electric turning gear (3 x 400V) Plate 51325-22
Electric turning gear (3 x 440V) Plate 51325-23
Electric turning gear (3 x 480V) Plate 51325-24

Fuel oil system 514/614

Internal fuel oil system Description 514.01 (16)

Internal fuel oil system Description 514.01 (19)
Fuel injection pump Description 514.02 (01)
Fuel injection valve Description 514.06 (01)
HFO/MDO changing valves (V1 and V2) Description 514.25 (02H)
Removal and refitting of fuel injection valve Working card 514-01.01 (01)
Fuel injection valve to be checked Working card 514-01.02 (01)
Fuel injection valve to be separated Working card 514-01.03 (01)
Assembly of the fuel injection valve Working card 514-01.04 (01)
Dismounting/mounting of fuel injection pump Working card 514-01.05 (08)
Disassembly/assembly and repair of fuel injection pump Working card 514-01.06 (19)
Grinding of fuel injection valve seat face Working card 514-01.07 (01)
Check of fuel oil piping system Working card 514-01.90 (05)
Fuel injection pump Plate 51401-23H
Fuel injection pump Plate 51401-24H
Fuel injection valve Plate 51402-27H
Fuel injection pipe Plate 51404-14H
Fuel oil filter duplex Plate 51415-11
Fuel oil filter duplex Plate 51415-12
Fuel oil filter duplex Plate 51415-13
Fuel oil filter duplex Plate 51415-14
Ball valve with actuator Plate 51425-01
Butterfly Valve with actuator Plate 51425-03H
Butterfly valve with actuator Plate 51425-06H
Fuel oil arrangement Plate 51430-24
Pipes on cylinder section Plate 51434-02H
Fuel injection pump connections Plate 51435-07H
Installation & operation of safety filter Description 2.04.5

Lubricating oil system 515/615

Internal lubricating oil system Description 515.01 (12)

Internal lubricating oil system Description 515.01 (15)
Crankcase ventilation Description 515.31 (03)
Lubricating oil pump Working card 515-01.00 (04)

2014.04.28
 MAN Diesel & Turbo

Index
Index Instruction Manual Page 7 (8)

L27/38

Text Index Drawing No

Prelubricating pump Working card 515-01.05 (08)

Lubricating oil filter Working card 515-01.10 (03)
Lubricating oil, thermostatic valve Working card 515-01.20 (04)
Check of lubricating oil piping system Working card 515-01.90 (03)
Lubricating oil cooler Working card 515-06.00 (09)
Centrifugal bypass filter Working card 515-15.00 (09)
Lubricating oil pump Plate P51501-07
Lubricating oil filter Plate 51502-19H
Prelubricating pump with el-motor Plate 51504-05
Lubricating oil cooler Plate P51506-18
Centrifugal bypass filter Plate 51515-03
Cover / Automatic filter Plate P51517-03
Crankcase venting Plate 51531-08H
Crankcase venting Plate 51531-09H
Prelubricating pump arrangement Plate 51535-08H
Lub. oil thermostatic element Plate P51545-03

Cooling water system 516/616

Cooling water system Description 516.01 (12)

Cooling water system Description 516.01 (13)
Check of cooling water system Working card 516-01.90 (03)
Cooling water, thermostatic valve Working card 516-04.00 (03)
HT and LT water pumps Working card 516-10.00 (02)
Mounting of cooling water thermostatic elements Plate 51605-14
High and low temperature fresh water pumps Plate 51610-10H
Cooling water connections Plate 51630-07H
Preheater unit Plate 51635-02H
Preheater unit Plate 51635-07H

Special equipment 517/617

Kit for inspection of fuel valve Kit 51701-09

Kit for overhaul of fuel valve Kit 51702-11
Kit for complete cylinder unit exchange Kit 51703-09
Kit for cylinder unit Kit 51704-21
Kit for renewal of piston rings Kit 51706-10
Kit for high and low temperature freshwater pumps Kit 51710-06
Kit for lubricating oil filter Kit 51725-01
Kit for fuel injection pump connections Kit 51732-03
Kit for vibration damper Kit 51735-04

Specific plant information 519/619

Resilient mounting of generating sets Description 519.03 (08)

Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (27)
Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (28)
Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (29)
Replacement of conicals Working card 519-03.05 (03)
Maintenance of conicals Working card 519-03.10 (03)
Flexible external connections Plate 51902-13H

2014.04.28
 MAN Diesel & Turbo

Index
Index Instruction Manual Page 8 (8)

L27/38

Text Index Drawing No

Conical element Plate 51903-03H

Conical element Plate 51903-07H

Tools 520/620

Function of the hydraulic tools Working card 520-01.05 (02)

Application of hydraulic tools Working card 520-01.06 (05)
Hand lever pump Working card 520-01.07 (01)
Standard tools for normal maintenance Plate 52000-16
Additional tools Plate 52002-06
Hand tools Plate 52004-02
Operating manual for testing tool (Fuel injection valve) Description GXO-D001

2014.04.28
Engine data

500/600
MAN Diesel & Turbo

Instruction Manual for:

MAN Diesel & Turbo Identification No. for Instruction Manual.

Identification No. for Description: 000 . 00

Function

Section No.

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

Sub-function

Function

Section No.

Identification No. for Plates: 00000 - 00 H

H for Holeby

Edition

Section No. and Function

For ordering of spare parts, see page 500.50 / 600.50

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

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

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

Original instructions

2011.06.28
 MAN Diesel & Turbo

MAN Diesel & Turbo | PrimeServ

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

24-hour hotline number:

+49 1801 15 15 15
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Copyright 2011 © MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany, registered with the Danish
Commerce and Companies Agency under CVR Nr.: 31611792, (herein referred to as “MAN Diesel & Turbo”).

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

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

2011.06.28
MAN Diesel & Turbo
Description 5001. Edition
Page 1 (1) Warning 01

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

Warning
(Marine engines only)
It is important that all MAN Diesel & Turbo engines
are operated within the given specifications and
performance tolerances specified in the engines'
Technical Files and are maintained according to the
MAN Diesel & Turbo maintenance instructions in
order to comply with given emissions regulations.
In accordance with Chapter I of the Code of Federal
Regulations, Part 94, Subpart C, §94.211 NOTICE
is hereby given that Chapter I of the Code of Fed-
eral Regulations, Part 94, Subpart K, §94.1004
requires that the emissions related maintenance of
the diesel engine shall be performed as specified in
MAN Diesel & Turbo instructions including, but not
limited to, the instructions to that effect included in
the Technical File.

2012.02.06
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1 (1)
MAN Diesel & Turbo
Description 5003.
Page 1 (5) Safety precautions
Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, V28/32DF, L18/28,

L23/30DF
General Special dangers
Correct operation and maintenance, which is the Warning!
aim of this book, are crucial points for obtaining
optimum safety in the engine room. The general Keep clear of the space below a crane with load.
measures mentioned here should therefore be rou- Opening of cocks may cause discharge of hot liq-
tine practice for the entire engine crew. uids or gases.
Observe which way liquids, gases or flames will
Engine room staff move, and keep clear.
Operation & Maintenance of MAN Engines is to be Dismantling of parts may cause the release of
carried out by qualified professional personal. springs.
Do not stand near turbochargers in case of any
abnormal running.
Do not stand near crankcase doors or relief valves
- nor in corridors near doors to the engine room
casing - when alarms for oil mist, high lube oil tem-
perature.

Turning gear
Before engaging the turning gear, ensure that the
starting air supply is shut off, the main starting - and
that the indicator cocks are open.
When the turning gear is engaged, check that the
indicator lamp “Turning gear engaged” has
switched on.
The turning gear remote control is a critical devise
and should always be kept in optimal working con-
dition. Any fault in the devise or cable must be recti-
Minimum safety equipment requirements: fied before use.
1. Safety shoes When operation the turning gear it is important to
note the following:
2. Hearing protection
The turning gear to be operated by the remote con-
3. Boiler suit ore other protective wear
trol and only by the person working on engine.
Warnings must be given before each turning.
Signs / Nameplates
Signs and nameplates mounted on the engine are
Cleanliness
not to be removed, painted over, or in any other
way be made unreadable. This includes safety The engine and engine room should be kept clean
signs, signs with serial numbers, signs with instruc- and tidy.
tions, etc. Oily rags must never be left around the engine room
spaces as they are highly flamable and slippery.
Remove any oil spil at once.
If there is a risk of grit or sand blowing into the
engine room, stop the ventilation and close the ven-
tilating ducts, skylights and engine room doors.

2013.09.09
 MAN Diesel & Turbo
5003. Description
Safety precautions Page 2 (5)
Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, V28/32DF, L18/28,

L23/30DF
Welding, or other work which causes spreading of Harmful materials
grit and/or swarf, must not be carried out near the
engine unless it is closed or protected, and the tur- Always follow the manufactures specific instruc-
bocharger air intake filters covered. tions, i.e. the material safety data sheet.

The exterior of the engine should be kept clean, and Use protective gloves, goggles, breathing mask and
the paintwork maintained, so that leakages can be any other recommended protective gear, as stated
easily detected. in the material safety data sheet.
While handling harmful materials is it important to
Fire secure proper ventilation and shielding if needed.
In the event of leaks or spillage, spread binding
Warning! agents immediately and disposal according to the
Keep the areas around the relief valves free of oil, material safety data sheet.
grease, etc. to prevent the risk of fire caused by
the emitted hot air/gas in the event that the relief Lifting precautions
valves open. Lift of engine components needs to be planned
Do not weld or use naked lights in the engine room, through all steps of the lifting procedure.
until it has been ascertained that no explosive When lifting loads below 500 kg the use of a tackle
gases, vapour or liquids are present. is required.
If the crankcase is opened before the engine has Lifting attachments are to be tightened into full con-
cooled down, welding and the use of naked flames tact with the component to be lifted.
will involve the risk of explosions and fire. The same
Only use designated lifting points, see Instruction
applies to inspection of oil tanks and of the spaces
Manual for guidance.
below the floor.
Make sure the lowest Safe Working Load (SWL) of
Attention is furthermore drawn to the danger of fire
the lifting equipment in the lifting chain is never
when using paint and solvents having a low flash
exceeded.
point. Porous insulating material, soaked with oil
from leakages, is easily inflammable and should be Keep lifting equipment clear of sharp edges.
renewed. Make sure to attach the load correctly on the crane
hook.
Order / Tidiness Always keep clear of the space below a crane with
Hand tools should be securely fastened and placed load.
on easily accessible tool panels. Special tools
should be fastened in the engine room, close to the Working air
area to be used.
Use of working air requires safety goggles and
No major objects must be left unfastened, and the gloves.
floor and passages should be kept clear.
Avoid blowing pressurised air directly at skin.

Spares
Sealing materials
All spares should be protected against corrosion
Use gloves made of neopren or PVC when remov-
and mechanical damage. The stock should be
ing O-rings and other rubber/plastic-based sealing
checked at intervals and replenished in good time.
materials which have been subjected to abnormally
high temperatures.
Lighting
First aid measures: In the event of skin contact -
Ample working light should be permanently installed rinse with plenty of water - remove all contaminated
at appropriate places in the engine room spaces, clothing - consult a doctor - dispose of all material
and portable working light should be obtainable and gloves in accordance with laws and regula-
everywhere. 24v safety lamps must be available for tions.
use inside the engine.

2013.09.09
MAN Diesel & Turbo
Description 5003.
Page 3 (5) Safety precautions
Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, V28/32DF, L18/28,

L23/30DF
Special notes
Hot surfaces
Beware of hot surfaces and use gloves. Health Risk!
Warning!
Alarms
Health Risk!
It is important that all alarms lead to prompt investi-
gation and remedy of the error. No alarm is insignifi- Due to vibrations during engine operation, espe-
cant. The most serious alarms are equipped with cially in awkward positions!
slow-down and/or shut-down functions. It is there-
fore important that all engine operation personel are The area around the engine
familiar with and well trained in the use and impor-
tance of the alarm system. Warning!
The area around the engine must be clean and
Safety notes tidy!
Danger!
This warning is used when an operation, proce- Tool
dure, or use may cause personal injury or loss of
Warning!
life.
Use original tool!
Warning!
This warning is used when an operation, proce- Tool and wire
dure, or use may cause a latently dangerous state
of personal injury or loss of life. Warning!
Use original tool!
Caution!
Use original wire for lifting!
This warning is used when an operation, proce-
dure, or use may cause damage to or destruction
of equipment and a slight or serious injury.
Safety precautions at maintenance
Before maintenance work is carried out, the engine
Note! must be stopped and blocked according to the
safety precautions given on the specific data page,
This warning is used when an operation, proce-
page 1 of each Working Card.
dure, or use may cause damage to or destruction
of equipment. The necessary items to be stopped and / or
blocked are marked as shown in below examples.

Subsuppliers and external equipment

Please check the special instructions concerning
subsupplier delivery and external equipment for
specific warnings!

Figure 1: .

2013.09.09
 MAN Diesel & Turbo
5003. Description
Safety precautions Page 4 (5)
Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, V28/32DF, L18/28,

L23/30DF

Figure 2: .

Data sheet signs

Data sheets may include warning signs for special
dangers that could arrise in connection with the
maintenance procedures.

Warning signs Mandatory action signs

General warning sign General mandatory action
sign

Explosive material Wear ear protection

Drop (fall) Wear eye protection

Slippery surface Wear safety footwear

Electricity Wear protective gloves

Overhead load Wear face shield

Hot surface Wear head protection

Crushing Wear mask

Overhead obstacle Wear respitory protection

2013.09.09
MAN Diesel & Turbo
Description 5003.
Page 5 (5) Safety precautions
Edition 01

L16/24, L23/30H, V28/32S, L21/31, L27/38, L28/32DF, V28/32DF, L18/28,

L23/30DF
Warning signs Mandatory action signs
Flammable Wear safety harness

Crushing of hands Disconnect before carrying

out maintenance

Pressurized cylinder

Pressurized device

2013.09.09
MAN Diesel & Turbo

Description
Main Particulars 500.00
Page 1 (1) Edition 32

L27/38
Cycle : 4-stroke

Configuration : In-line

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

Power range : 1500-2970 kW (HFO/MDO)

2100-3150 kW (MGO)

Speed : 720/750 rpm

Bore : 270 mm

Stroke : 380 mm

Stroke/bore ratio : 1.4:1

Piston area per cyl. : 572.6 cm2

Swept volume per cyl. : 21.8 ltr.

Compression ratio : 15.9:1

Max. combustion pressure : 200 bar (in combustion chamber)

210 bar (indicator cock)

Turbocharging principle : Constant pressure system and inter­cool­ing

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

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

Power lay-out MCR version

Speed rpm 720 750

Mean piston speed m/sec. 9.1 9.5

Mean effective pressure:

5 cylinder engine (HFO/MDO) bar 23.0 23.5
6, 7, 8, 9 cylinder engine (HFO/MDO) bar 25.3 24.3
6, 7, 8, 9 cyl engine (MGO) bar 26.8 25.7

Power per cylinder:

5 cylinder engine (HFO/MDO) kW/cyl. 300 320
6, 7, 8, 9 cylinder engine (HFO/MDO) kW/cyl. 330 330
6, 7, 8, 9 cyl engine (MGO) kW/cyl. 350 350

12.02 - ES1 - Tier I + II - GenSet

MAN Diesel & Turbo
Description 500.01
Page 1 (1) Introduction Edition 03

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

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

Figure 1: Structure of instruction book

2010.11.22 - ES0
MAN Diesel & Turbo
Description 500.02
Page 1 (2) Safety Edition 02

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

General should be wellpreserved against corrosion and pro-

tected against mechanical damage. Stock should
Proper maintenance, which is the aim of this book, be checked at intervals and replenished in time.
is a crucial aspect of achieving optimum safety in
the engine room. The general measures mentioned
here should, therefore, be a natural routine for the
Light
entire engine room staff. Ample working light should be permanently installed
at appropriate places in the engine room, and port-
Cleanliness able working light in explosion-proof fittings should
be available everywhere.
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the
engine room while the ship is in port, the ventilation
Freezing
should be stopped and ventilating ducts, skylights, If there is a risk of damage due to freezing when the
and doors in the engine room should be closed. plant is out of service, engines, pumps, coolers and
In particular, welding or work which causes the pipe systems should be emptied of cooling water.
spreading of grit and chips must be avoided near
the engine, unless this is closed or covered, and the Warning
turbocharger air intake filters are covered.
The exterior of the engine should be kept clean and Opening of cocks may cause discharge of hot liq-
the paintwork maintained, so that leakages can uids or gases. Dismantling of parts may cause
easily be detected. springs to be released.
The removal of fuel valves (or other valves in the cyl-
inder head) may cause oil to run down to the piston
Fire
crown, and if the piston is hot an explosion may
If the crankcase is opened before the engine is then blow out the valve.
cold, welding and the use of naked light will involve When testing fuel valves with the hand pump do not
the risk of explosions and fire. The same applies to touch the spray holes, as the jet may pierce the
inspection of oil tanks and the space below the skin. Consider beforehand which way the liquids,
cooler. Attention should furthermore be paid to the gases or flames will move, and keep clear.
danger of fire when using paint and solvents with a
low flash point. Porous insulating material drenched
with oil from leakages is easily inflammable and Crankcase Work
should be renewed. See also: "Ignition in Crank- Check beforehand that the starting air supply to the
case" in section 503. engine is shut off.

Order Feeling Over

Hand tools should be placed to be easily accessible Whenever repairs or alterations have been made to
on tool boards. Special tools should be fastened to the running gear, apply the "feel-over sequence"
tool panels (if supplied) in the engine room close to until it is ensured that there is no undue heating, oil-
the area of use. No major objects may be left unfas- mist formation, blow-by, or failure of cooling water
tened, and the floor and passages should be kept or lubricating oil systems.
clear.

Feel-over Sequence
Spares
Feel over after 5-15 and 30 minutes' idle running
Large spare parts should, as far as possible, be and finally when the engine is running at full load.
placed well strapped near the area of use and See also "Operation" in the section 501.
should be accessible by crane. The spare parts

2001.08.05 - ES0
 MAN Diesel & Turbo
500.02 Description
Edition 02
Safety Page 2 (2)

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

Turning
After prolonged out-of-service periods or overhaul
work which may involve a risk of accumulation of
liquid in the combustion spaces, turning should
always be effected through at least two complete
revolutions.

Check and Maintain

Lubricating oil condition, filter elements and meas-
uring equipment, see "Planned Maintenance Pro-
gramme".

2001.08.05 - ES0
MAN Diesel & Turbo

Description
Cross Section 500.05
Page 1 (1) Edition 13

L27/38

09.26 - ES1
MAN Diesel & Turbo
Description 500.10
Page 1 (1) Key for engine designation
Edition 04

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

Key for engine designation

2014.02.20
MAN Diesel & Turbo
Description 500.11
Page 1 (1) Designation of Cylinders
Edition 03

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

General

2013.04.18 - ES1
MAN Diesel & Turbo
Description 500.12
Page 1 (1) Engine Rotation Clockwise
Edition 02

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

Engine rotation clockwise

2010.09.27
MAN Diesel & Turbo
Description 500.20
Page 1 (3) Code Identification for Instruments
Edition 04

L32/40, L16/24, L23/30H, L28/32H, V28/32H, V28/32S, L21/31, L27/38

Explanation of symbols

Specification of letter code for measuring devices

1st letter Following letters
F Flow A Alarm

L Level D Differential

P Pressure E Element

S Speed, System H High

T Temperature I Indicating

U Voltage L Low

V Viscosity S Switching, Stop

X Sound T Transmitting

Z Position X Failure

V Valve, Actuator

2012.12.06.
 MAN Diesel & Turbo
500.20 Description
Code Identification for Instruments Page 2 (3)
Edition 04

L32/40, L16/24, L23/30H, L28/32H, V28/32H, V28/32S, L21/31, L27/38

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
03 outlet from lub. oil cooler 06 outlet from fresh water cooler 09
(SW)

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

Lubricating oil system

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

Charging air system

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

Fuel oil system

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

Nozzle cooling system

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

Exhaust gas system

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

2012.12.06.
MAN Diesel & Turbo
Description 500.20
Page 3 (3) Code Identification for Instruments
Edition 04

L32/40, L16/24, L23/30H, L28/32H, V28/32H, V28/32S, L21/31, L27/38

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

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

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

2012.12.06.
MAN Diesel & Turbo
Description 500.23
Page 1 (6) Planned maintenance programme
Edition 01

L27/38

Description 4. Related procedures – indicates other works,

depending on the present work – or works
The overhaul intervals are based on operation on a which it would be expedient to carry out.
specified fuel oil quality at normal service output,
which means 70-100% of MCR. 5. Indicates x number of men in x number of hours
to accomplish the work.
In the long run it is not possible to achieve safe and
optimum economical running without an effective The stated consumption of hours is only inten-
maintenance system. ded as a guide.
The structure and amount of information in the Experience with the specific station/personnel
maintenance programme mean that it can be inte- may lead to updating.
grated in the entire ship's/power station's mainte- 6. Refers to data required to carry out the work.
nance system or it can be used separately.
7. Special tools which must be used. Please note
The core of the maintenance system is the key dia- that not all tools are standard equipment.
gram, see pages 500.25 and 500.26, indicating the
8. Various requisite hand tools.
inspection intervals for the components/ systems,
so that the crew can make the necessary overhauls 9. Indicates the components/parts which it is advi-
based on the engines' condition and/or the time cri- sible to replace during the maintenance work.
teria. Please note that this is a condition for the inter-
vals stated.
The maintenance system is divided into 2 main
groups:
1) Major overhaul / inspection (page 500.25):
These works are to be carried out during major
overhauls and inspections of the engine.
2) Duty during operation (page 500.26): indicated
the works to be carried out by the personnel
during the daily operation of the engine.
The stated recommended intervals are only for
guidance as different service conditions, the quality
of the fuel oil and the lubricating oil, treatment of the
cooling water, etc., will decisively influence the
actual service results and thus the intervals between
necessary overhauls.
Experience with the specific plant/personnel should
be used to adjust the time between overhauls. It
should also be used to adjust the timetable stated
for guidance in the working cards.

Working cards
Each of the working cards can be divided into two:
Figure 1: Instruction guide for working cards
a front page and one or several pages describing
and illustrating the maintenance work.
The front page indicates the following:
1. Safety regulations, which MUST be carried out
before the maintenance work can start.
2. A brief description of the work.
3. Reference to any work which must be carried
out before the maintenance work can start.

2013.04.16 - MDO/MGO
 MAN Diesel & Turbo
500.23 Description
Planned maintenance programme Page 2 (6)
Edition 01

L27/38

Major overhaul/inspection

2013.04.16 - MDO/MGO
MAN Diesel & Turbo
Description 500.23
Page 3 (6) Planned maintenance programme
Edition 01

L27/38

2013.04.16 - MDO/MGO
 MAN Diesel & Turbo
500.23 Description
Planned maintenance programme Page 4 (6)
Edition 01

L27/38

2013.04.16 - MDO/MGO
MAN Diesel & Turbo
Description 500.23
Page 5 (6) Planned maintenance programme
Edition 01

L27/38

Duties during operation

2013.04.16 - MDO/MGO
 MAN Diesel & Turbo
500.23 Description
Planned maintenance programme Page 6 (6)
Edition 01

L27/38

2013.04.16 - MDO/MGO
 MAN Diesel

Description
Introduction to Planned Maintenance Programme 500.24
Page 1 (2)
Edition 03

General

General The front page indicates the following:

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.

The maintenance system is divided into 2 main

groups:

a. Major overhaul / inspection (page 500.25):

These works are to be carried out during major
overhauls and inspections of the engine.
1
7
b. Duty during operation (page 500.26): indicated
the works to be carried out by the personnel
2
during the daily operation of the engine.

The stated recommended intervals are only for 3

guidance as different service conditions, the quality 8
of the fuel oil and the lubricating oil, treatment of
4
the cooling water, etc., will decisively influence the
actual service results and thus the intervals between
necessary overhauls.
5
9
08028-0D/H5250/94.08.12

Experience with the specific plant/personnel should

6
be used to adjust the time between overhauls. It
should also be used to adjust the timetable stated
for guidance in the working cards.

Working Cards Fig. 1 Instruction guide for working cards.

Each of the working cards can be divided into two: a

front page and one or several pages describing and
illustrating the maintenance work.

98.19 - ES0
 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 & Turbo

Description
Planned Maintenance Programme 500.25
Page 1 (3) Edition 40

L27/38

Major overhaul/inspection
Time Between Overhauls

overhauled parts
Working

Observations
Description

3rd month
l = Overhaul to be carried out Card

after - hours
Check new/

Monthly
Weekly
200

16000
32000
50

2000
8000

Daily
n = Check the condition No

Cylinder Unit:

Dismantling of cylinder unit.............................................. l 505-01.55

Dismantling of cylinder head, water jacket and cyl. liner.

Cylinder Head and Water Jacket

Inspection of inlet, exhaust valves and valve guide.......... l 505-01.05
Valve rotator..................................................................... n 505-01.15
Safety valve - overhaul and adjustment of
opening pressure.............................................................. n 505-01.25
Indicator valve.................................................................. n 505-01.26
Cylinder head cooling water space - Inspection............... n 505-01.45
Cylinder head nut, Retightening....................................... 200 505-01.55

Piston, Connecting Rod and Cylinder Liner

Inspection of piston.......................................................... n 506-01.10
Piston ring, scraper ring and flame ring............................ l 506-01.10
Piston pin and bush for connecting rod - Check of
clearance.......................................................................... n 506-01.15

Connecting rod, Measuring of big-end bore..................... n 506-01.15

Inspection of big-end bearing shells................................. n 506-01.16

Cylinder liner, Cleaning, honing and measuring............... l 506-01.35

Camshaft and Camshaft Drive

Camshaft, Inspection of gear wheels, bolt, connections

etc..................................................................................... 200 n 507-01.00
Camshaft bearing, Inspection of clearance...................... n 507-01.05
Camshaft adjustment, check the condition....................... n 507-01.20

Lubrication of camshaft bearing, Check........................... n 507-01.00

12.24 - ES0
 MAN Diesel & Turbo

500.25 Description
Edition 40 Planned Maintenance Programme Page 2 (3)

L27/38

Major overhaul/inspection
Time Between Overhauls

overhauled parts
Working

Observations
= Overhaul to be carried out
Description l

3rd month
Card

after - hours
Check new/

Monthly
Weekly
= Check the condition

200

8000
16000
32000
50

2000
n

Daily
No

Operating Gear for Inlet Valves and

Exhaust Valves

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

Valve gear, Valve bridge, spring, push rod, etc................. n 508-01.10

Lubricating of operating gear, Check................................ n 508-01.00

Crankshaft and Main Bearing

Inspection of main bearing............................................... n 510-01.05
Inspection of guide bearing.............................................. n 510-01.05

Vibration damper, see special instruction manual............

Turbocharger System

Charging air cooler, Cleaning and inspection................... n 512-01.00
Retightening of all bolts and connections, see special
instruction manual............................................................
For turbocharger, see special instruction manual.............

Compressed Air System

Air starter motor, Dismantling and inspection................... n 513-01.30

Fuel Oil System and Injection Equipment

Fuel oil injection pump, Check of condition...................... l 514-01.06

Fuel injection valve, Adjustment of opening pressure...... 200* n 514-01.10

* After major overhaul

12.24 - ES0
MAN Diesel & Turbo

Description 500.25
Page 3 (3) Planned Maintenance Programme Edition 40

L27/38

Major overhaul/inspection
Time Between Overhauls

overhauled parts
Working

Observations
= Overhaul to be carried out
Description l

3rd month
Card

after - hours
Check new/

Monthly
Weekly
= Check the condition

200

8000
16000
32000
n

50

2000

Daily
No

Lubricating Oil System

Lubricating oil pump, Engine driven................................. n 515-01.00

Lubricating oil cooler........................................................ l 515-06.00

Prelubricating pump, El. driven......................................... n 515-01.05

Thermostatic valve........................................................... n 515-01.20

Cooling Water System

Cooling water pump, Engine driven (HT / LT water)......... n

Thermostatic valve........................................................... n 516-04.00

Alternator, see special instruction manual in section 518

Planned maintenance programme during operation,

see 500.26.

12.24 - ES0
 MAN Diesel
Description
Planned Maintenance Programme 500.26
Page 1 (2) Edition 20H

L27/38
Duties during Operation
Time Between Overhauls

overhauled parts
Working

Observations
Description

3rd month
after - hours
Card

Check new/
= Overhaul to be carried out

Monthly


200

8000
16000
32000

Weekly
50

2000

Daily
 = Check the condition No

Operating of Engine

Readings of data for Engine and Generator, with refer-

ence to "Engine Performance Data", section 502-1.........  502-01.00
Check for leakages...........................................................  502-05.00

Specification - Cooling water

Cooling water system - Water samples, see section 504 .  516-01.90

Cylinder Head

Inlet and exhaust valve - check and adjustment of valve

clearance..........................................................................  508-01.10
Lubricating of operating gear - Check.............................. 
Check of valve rotators' rotation during engine rotation ..  505-01.15


Control and Safety System, Automatics and
Instruments

Safety, alarm and monitoring equipment .........................  509-01.00

Lambda controller - Adjustment.......................................  509-10.00
Governor - Check oil level, see governor instruction
book, section 509 ............................................................  section 509

Turbocharger System

Dry cleaning of turbine side . ...........................................  512-10.00

08028-0D/H5250/94.08.12

Water washing of compressor side .................................  512-05.00

Exhaust pipe compensator...............................................  512-01.10
Retightening of all bolts and connections, se special
Instruction book................................................................
Cleaning of air filter - Compressor side, see special
instruction book................................................................

10.19
 MAN Diesel
500.26 Planned Maintenance Programme Description
Edition 20H Page 2 (2)

L27/38
Duties during Operation
Time Between Overhaul

Overhauled parts
Working

Observations
Description

3th month
 = Overhaul to be carried out Card

Check new/

after -hours
50

2000
8000
200

32000

Weekly
16000

Montly
Daily
 = Check the condition No

Compressed Air System

Function test - Main and emergency starting valve..........  513-01.40

Air filter, draining of bowl (filter element to be replaced
when pressure drop exceeds 0,7 bar)..............................  513-01.21

Compressed air system - Check of the system................  513-01.90

Fuel Oil System and Injection Equipment

Fuel oil system - Check the system..................................  514-01.90

Fuel oil - Oil samples after every bunkering, see sec.504 section 504
Fuel injection valve...........................................................  514-01.10

Lubricating Oil System

Lubricating oil filter - Cleaning and replacement .............  515-01.10

Centrifugal filter - Cleaning and replacement paper filter .  515-15.00

Lubricating oil - Oil samples ............................................ 

Lubricating oil system - Check the system.......................  515-01.90

Cooling Water System

Cooling water system - Water samples ........................... 

Cooling water system - Check the system.......................  516-01.90

Alternator - see special instruction book

08028-0D/H5250/94.08.12

Major overhaul/inspection, see 500.25

10.19
MAN Diesel & Turbo

Description
Operation Data & Set Points 500.30
Page 1 (4) Edition 96

L27/38

Acceptable Alarm Set point

Normal Value at Full value at shop
load at ISO conditions test or after Autostop of engine
Delay
repair sec.

Lubricating Oil System

Temp. after cooler

(inlet filter) SAE 40 TI 21 68-73° C <73° C TAH 21 80° C 3
Pressure after filter(inlet engine) PI 22 4.2-5.0 bar >4.5 bar PAL 22 3.5 bar 3 PSL 22 3.0 bar
PSL 22 3.0 bar (D)
Pressure drop across filter PDAH 0.1-1 bar <0.5 bar PDAH 1.5 bar 3
21-22 21-22
Prelubricating pressure (PI 22) 0.14-1.4 bar <1.0 bar PAL 25 0.12 bar (H) 60
Pressure inlet turbocharger PI 23 1.3 - 2.2 bar >1.3 bar PAL 23 1.1 bar 3
(C)
Lub. oil level in base frame LAL 28 Low level 30
LAH 28 High level 30
Pressure before filter PI 21 4.5-5.5 bar
Crankcase protection (M) LAH 92 High level 3 LSH 92 High level
TAH 58 95° C 3 TSH 58 100° C
TDAH 58 4K 3 TDSH 58 6K
Temp. main bearing TI 29 80-95° C TAH 29 100° C 3 TSH 29 105° C
Fuel Oil System

Pressure after filter MDO PI 40 3-6 bar PAL 40 2 bar 5

HFO PI 40 5-16 bar (A) PAL 40 4-6 bar (E) 5
Leaking oil LAH 42 High level 5
Temperature inlet engine MDO TI 40 30-40°C
HFO TI 40 110-150°C
Cooling Water System

Press. LT system, inlet engine PI 01 2.5-4.5 bar >1.8 bar PAL 01 0.4 + (B) bar 3
Press. HT system, inlet engine PI 10 2.0-5.0 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
TSH 12 95° C (D)
Temp. LT system, inlet engine TI 01 30-40°C
Exhaust Gas and Charge Air

Exh. gas temp. before TC

330 kW/cyl TI 62 480-530° C TAH 62 570° C 30
350 kW/cyl TI 62 480-530° C TAH 62 620° C 30
Exh. gas temp. outlet cyl.
330 kW/cyl TI 60 350-450° C TAH 60 465° C 30
350 kW/cyl TI 60 350-450° C TAH 60 600° C 30
Diff. between individual cyl. average average TAD 60 average (K) 120
± 30° C ±25° C ± 50° C
± 100° C
Exh. gas temp. after TC
330 kW/cyl TI 61 275-400° C TAH 61 450° C 30
350 kW/cyl TI 61 275-400° C TAH 61 500° C 30
Ch. air press. after cooler PI 31 2.9-3.2 bar
Ch. air temp. after cooler TI 31 40-55° C <55° C

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

13.33 - ES1 - Tier II

 MAN Diesel & Turbo

500.30 Operating Data and Set Points Description

Edition 96 Page 2 (4)

L27/38

Acceptable Alarm Set point

Normal Value at Full value at shop
load at ISO conditions test or after Autostop of engine
Delay
repair sec.

Compressed Air System

Press. inlet engine PI 70 8- 10 bar >7.5-<10 bar PAL 70 7.5 bar 15

Speed Control System

Engine speed elec. SI 90 750 rpm SAH 81 850 rpm 3 SSH 81 862 rpm (D)

SI 90 720 rpm SAH 81 815 rpm 3 SSH 81 828 rpm (D)

Turbocharger speed SI 89 (L) SAH 89 (J) 3
Alternator

Cooling water leakage LAH98 LAH98 switch 3

Winding temperature TI 98 100° C TAH 98 130° C 3
Bearing temperature TI 27 40-60° C TAH 27 85° C 3
Miscellaneous

Start failure SX 83 switch (G) 10

Stop signal SS 84 switch (F) 0
Stop failure SX 84 switch 30
Engine run SI 90 720/750 rpm SS 90A (I)
Ready to start SS 87 switch 0

For these alarms (with underscore) there are alarm cut-out at engine standstill.

13.33 - ES1 - Tier II

MAN Diesel & Turbo

Description
Operation Data & Set Points 500.30
Page 3 (4) Edition 96

L27/38
Remarks to Individual Parameters F. Start Interlock

The following signals are used for start interlock/

A. Fuel Oil Pressure, HFO-operation blocking:

When operating on HFO, the system pressure must 1) Turning must not be engaged
be sufficient to depress any tendency to gasification 2) Engine must not be running
of the hot fuel. 3) "Remote" must be activated
4) No shutdowns must be activated.
The system pressure has to be adjusted according 5) The prelub. oil pressure must be OK, 20 min.
to the fuel oil preheating temperature. after stop.
6) "Stop" signal must not be activated
B. Cooling Water Pressure, Alarm Set Points
G. Start Failure
As the system pressure in case of pump failure will
depend on the height of the expansion tank above Start failure is generated if engine speed has not
the engine, the alarm set point has to be adjusted to exceeded the ignition speed limit within a defined
0.4 bar plus the static pressure. The static pressure span of time or engine speed has not exceeded the
set point can be adjusted in the display module. minimum speed limit within a defined span time.

C. Lub. Oil Pressure, Offset Adjustment Start failure alarm is automatically reset after engine
is standstill.
The read outs of lub. oil pressure has an offset
adjustment because of the transmitter placement. H. Alarm Hysterese and Set Point
This has to be taken into account in case of test and
calibration of the transmitter. On all alarm points (except prelub. oil pressure) a
hysterese of 0.1 bar are present. On prelub. oil pres-
D. Software Created Signal sure alarm the hysterese is 0.02 bar.

Software created signal from PI 22, TI 12, SI 90. The alarm set point for prelub. oil pressure is only
valid if lubricating oil temperature is below 62° C.
E. Set Points depending on Fuel Temperature
I. Engine Run Signal

The signal SS90A indicates engine running for exter-

nal systems like Power Management System.

The engine run signal SS90A is set if engine exceeds

"95% of engine nominal speed".
The engine run signal SS90A is used to release the
generator synchronizing.

J. Limits for Turbocharger Overspeed Alarm

(SAH 89)

Engine type 720 rpm 750 rpm

5L27/38 / TCR18 39,285 39,285
6L27/38 / TCR18 39,285 39,285
Fig 1 Set point curve.
7L27/38 / TCR20 32,786 32,786
8L27/38 / TCR20 32,786 32,786
9L27/38 / TCR20 32,786 32,786

13.33 - ES1 - Tier II

 MAN Diesel & Turbo

500.30 Operating Data and Set Points Description

Edition 96 Page 4 (4)

L27/38

K. Exhaust Gas Temperatures M. Crankcase Protection

The exhaust gas temperature deviation alarm is For engines above 2250 kW or bore > 300 mm,
normally: crankcase protection is standard for marine appli-
cation. The system is optional for smaller engines.
Engine load < 25% TAD = ± 100° C
This will be done by an oil mist detector (LAH/LSH
Engine load > 25% TAD = ± 50° C 92) as standard or with a splash oil/crankcase pro-
tection system (TAH/TSH/TDAH/TDSH 58 + TAH/
L. Turbocharger Speed TSH 29) as option.

Normal value at full load of the turbocharger is de-

pendent on engine type (cyl. no) and engine rpm.
The value given is just a guide line. Actual values
can be found in the acceptance test protocol.

13.33 - ES1 - Tier II

MAN Diesel & Turbo
Description 500.33
Page 1 (1) "Green Passport"
Edition 02

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

Green Passport
In 2009 IMO adopted the „Hong Kong International
Convention for the Safe and Environmentally Sound
Recycling of Ships, 2009“.
Until this convention enters into force the recom-
mendatory guidelines “Resolution A.962(23)” (adop-
ted 2003) apply. This resolution has been imple-
mented by some classification societies as “Green
Passport”.
MAN Diesel & Turbo is able to provide a list of haz-
ardous materials complying with the requirements
of the IMO Convention. This list is accepted by clas-
sification societies as a material declaration for
“Green Passport”.
This material declaration can be provided on
request.

2013.04.18
MAN Diesel & Turbo

Description
Data for Pressure and Tolerance 500.35
Page 1 (2) Edition 59

L27/38

Section Description mm / bar

505 Safety valve to be adjusted to 230+7 bar at 20°C

Maximum inner diameter, valve guide 20.2 mm
For grinding of valve spindle and valve seat ring
(see also working card 505-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H"1 9.0 mm
Maximum height of spindle above cylinder head, "H" 2

506 Piston and piston ring grooves (see working card 506-01.10)
Maximum clearance between connecting rod bush and piston pin 0.29 mm
Maximum ovalness in big-end bore (without bearing) 0.08 mm
Maximum inside diameter cylinder liner, maximum ovalness 0.1 mm Ø 270.2 mm
Sealing minimum height above the cylinder liner 0.2 mm

507 Maximum tolerance at the valve cam bearing 0.3 mm

Maximum tolerance at the fuel cam bearing 0.35 mm
Clearance between teeth on intermediate wheel
Plunger lift at TDC, injection timing:
IMO Tier II - E2 11.30+0.05 mm*
IMO Tier II - E3 11.00+0.05 mm*
IMO Tier II - D2 10.75+0.05 mm*
*) for information on max settings check the engine's IMO Technical file.
Plunger Lift, World Bank II**
**) Standard injection timing value is based on ISO condition.
Special injection timing of engines can be necessary due to
Power plant size and/or Ambient conditions.

508 Valve clearance, Inlet valve (cold engine 15 - 50°C) 0.7 mm

Valve clearance, Exhaust valve (cold engine 15 - 50°C) 0.7 mm
Maximum clearance between rocker arm bush and rocker arm shaft 0.3 mm
Maximum total tolerance between shaft bushing and roller 0.35 mm

509 Free spand between pick-up and band steel (Lambda controller), only
for single engine plant with hydraulic speed governor.

510 Deflection of crankshaft (autolog) (see working card 510-01.00)

Minimum axial guide bearing clearance 0.400 mm
Maximum axial guide bearing clearance 0.663 mm
Minimum radial main bearing clearance 0.225 mm
Maximum radial main bearing clearance 0.336 mm
Main bearing journal, min. diameter 249.9 mm
Main bearing journal, max. ovality 0.03 mm
Crankpin journal, min. diameter 249.9 mm
Crankpin journal, max. ovality 0.03 mm

12.08 - ES0, Tier II, WB II

 MAN Diesel & Turbo

500.35 Description
Edition 59
Data for Pressure and Tolerance Page 2 (2)

L27/38

Section Description mm / bar

514 Combustion pressure range at full load (Measured at indicator cock) 189 - 210 bar
(Depending on rating/ambient condition)
Combustion pressure range at full load (Inside combustion chamber) 185 - 200 bar
Individual cylinders; admissible deviation from average ± 5 bar
Fuel valve, adjusment of opening pressure 400 - 410 bar
(when new spring) (420 bar)
Clearance (A) of plunger between thrust plate 0.07-0.11 mm
and plunger base plate / fuel injection pump
Clearance (B) from roller to mounting surface 160±0.18
Clearance (C) axial and radial clearance of roller on fuelinjection pump 0.4 - 0.7 mm

12.08 - ES0, Tier II, WB II

MAN Diesel & Turbo

Description 500.40
Page 1 (6) Data for Tightening Torque Edition 36

L27/38
Lubricant

Pressure limitation of the hydraulic high pressure

M Lubricating paste up to 200°C Coefficient of
friction 0.08 - 0.12 pump to be set to 50 bar above hydraulic oil pres-
sure for tightening.
MH High temperature lubricating Coefficient of For correct use of hydraulic tools, please see work-
paste above 200°C friction 0.08 - 0.12
ing card 520-01.05.
O Oil
Note: For tightening bolts to a specified torqe,
∆l Elongation of screw
only use the specified lubricants. For component
Tab. 1. temperatures up to 200°C, e.g. Molykote Pasta d or
Optimoly Paste White-T. For component tempera-
tures above 200°C, e.g. Molykote Paste HSC or Copa
Slip.

Oil Tightening
Screw Connection
pressure Screw-in torques (Nm) Working Plate Item
(bar) moment torsions angle (°) Card
- lubricant
012 Cylinder Crankcase

012-1 (long)
Cap main bearing / 1.step Hand O 510-01.05 51101 182, 086, 194
Cylinder crankcase crown nut Item 194
with Loctite 243
2.step 100
3. step 1200
∆l = 3.2-3.9 mm

012-1 (short)
Cap main bearing / 1.step 300-M O 510-01.05 51101 456, 086
Cylinder crankcase 2.step 100
3. step 1200
∆l = 0.7-1.0 mm

012-2
Cap main bearing / 1.step Hand-M MH 510-01.05 51101 216, 228
Cylinder crankcase 2.step 100 MH
3. step 1200

012-3
Crankcase / 1. step Hand-M MH 505-01-55 51101 062, 086
Cylinder head 2. step 400
3. step 1200

012-4
Crankcase/ 22-M 190-MH 514-01.05 51101 277, 289
Fuel injection pump Loctite 243

11.40 - ES0
 MAN Diesel & Turbo

500.40 Description
Edition 36 Data for Tightening Torque Page 2 (6)

L27/38
Oil Tightening
Screw Connection
pressure Screw-in torques (Nm) Working Plate Item
(bar) moment torsions angle (°) Card
- lubricant

020 Crankshaft

020-1
Crankshaft / Counter 1. step 130-M M 51001 082, 094
weight 2. step 100
3. step 1200 
∆l = 0.55-0.70 mm

020-2
Crankshaft/ 200-M or 51001 141
Spur wheel 250-O

020-3
Lock of crankshaft lub. oil bores 1. step 50-M
2. step 250-M
020-4
1st gear wheel part / 270-M or 51001 189
2nd gear wheel part 340-O

026 Turning Gear

026-1
Spur gear/Shaft 260-M or 51325 179
325-O

027 Vibration Damper

027-1
Gear wheel / Damper 1. step Hand-M M 51004 053,161
2. step 100
3. step 1200

Damper assembly bolts 580 Nm 510-04.00 750

030 Connecting Rod

030-1
Connecting rod cover / Con- 1. step Hand-M M 506-01.25 50601 152, 164
necting rod cover 2. step 600
3. step 1200
∆l = 0.35-0.55 mm

030-2
Connection shaft / connecting 1. step Hand-M M 506-01.25 50601 188, 211
rod bearing body 2. step 100
3. step 1200
∆l = 0.3-0.4 mm

034 Piston

034-1
Stud screw / nut 506-01.10 50601 176

034-2
Stud screw / nut 506-01.10 50601 176

11.40 - ES0
MAN Diesel & Turbo

Description 500.40
Page 3 (6) Data for Tightening Torque Edition 36

L27/38
Oil Tightening
Screw Connection
pressure Screw-in torques (Nm) Working Plate Item
(bar) moment torsions angle (°) Card
- lubricant

056 Mounting of Fuel

Injection Valve

056-1
Clamp / Cylinder head XX 115-MH 514-01.10 51402 153, 177

072 Covering on free end

072-1
Stud screw / nut XX 140-M or 51502 755
175-O

100 Control Drive

100-1
Cylinder crankcase / 1.step Hand-M M 507-01.20 50701 073, 119
Stepped spur gear 2. step 100
3. step 1200
∆l = 0.65-0.80 mm

101 Camshaft
(Valve camshaft)

101-1
Camshaft part piece / 200-M or 507-01.00 50705 266
Bearing disk 250-O

101 Camshaft
(Injection camshaft)

101-4
Camshaft part piece / 210-M or 507-01.00 50705 266
Bearing disk 250-O 507-01.05

111 Valve Bridge

111-1
Valve bridge / Setting screws 200-M or 508-01.00 50502 071, 154
250-O

111 Rocker arm

111-1
Rocker arm / Setting screws 200-M or 508-01.00 50502 071, 142
250-O

200 Fuel Injection Pump

with drive

200-1
Valve support/Pump element 1. step 25-M or
30-O 514-01.05/06 51401 421
2. step 50-M or
60-O
3. step 75-M or
90-O

11.40 - ES0
 MAN Diesel & Turbo

500.40 Description
Edition 36 Data for Tightening Torque Page 4 (6)

L27/38
Oil Tightening
Screw Connection
pressure Screw-in torques (Nm) Working Plate Item
(bar) moment torsions angle (°) Card
- lubricant
200-1
Thrust ring/Pump casing 90-M or 110-O 514-01.05/06 51401 600

200-2
Screw plug, disc 250-M or 310-O 514-01.05/06 51401 242

221 Fuel Injection Valve

221-1
Support body / Nozzle body 270-MH 514-01.10 51402 045

221-2
Lock nut for setting screw 150-200 MH 514-01.10 51402 082

289 Exhaust Pipe

289-2
Clamping strap / Cyl. cover 80-MH 505-01.55 51202 107, 119

289-5
Pipe piece / Compensator 50-MH 512-01.10 51202 024, 036, 048

289-6
Pipe piece / Compensator 15-MH 512-01.10 51202 024, 036, 048

289 Exhaust Pipe before

Turbocharger

289-2
Clamping strap / cover 80-MH 505-01.55 41202 107, 119

289-3
Intermedial / Compensator /
Turbocharger 80-MH 512-01.10 51203 258, 271

289-5
Intermedial / Compensator /
Turbocharger 50-MH 512-01.10 51202 024, 036, 048

289-6
Compensator / Intermediat 25-MH 512-01.10 51202 024, 036, 048

300 Lub Oil Pump with

Attachment

300-1
Pinion spindle/Spur gear 550-M or 515-01.00 51501 199
680-O

350 Fresh Water Pump

350-3
Water pump shaft / Spur gear 110-O 516-10.00 51610 237

350-4
Water pump shaft / Impeller 1 step 100-O 516-10.00 51610 191
2 step 50-O

11.40 - ES0
MAN Diesel & Turbo

Description 500.40
Page 5 (6) Data for Tightening Torque Edition 36

Oil Tightening
Screw Connection
pressure Screw-in torques (Nm) Working Plate Item
(bar) moment torsions angle (°) Card
- lubricant
434 Fuel Injection Pipe

434-1
Threaded piece /
Fuel injection valve 75-M or 95-O 51404 010

434-2
Fuel Injection pipe/
Threaded piece 50-M or 65-O 51404 033
Fuel injection pipe/
Fuel injection pump

434 Fuel Oil Pipe

434-3
Screw plug / Sealing ring 250-M or 310-O

447 Water Cooling Pipe

447-1
V-profile clamp /
Intermediate pieces 12 51630 200

701 Flywheel with Gear

Ring

701-1
Crankshaft / Flywheel 1200 Hand-M M 51003 095, 105

11.40 - ES0
 MAN Diesel & Turbo

Description 500.40
Page 6 (6) Data for Tightening Torque Edition 36

L27/38
Tightening of Screwed Connections by the Thread mm Tightening torque in Nm
Torque quality class 8.8 10.9
M/MH O M/MH O
If screwed connections other than those listed are
to be tightened using a torque wrench, see tab. 2,
M 6 7 10 10 14
should be looked up for approximate tightening
M 8 17 25 25 35
torques. The following should be observed:
M 10 35 50 50 70
M 12 60 85 85 120
The load acting on a screwed connection depends on
M 14 90 130 130 190
the tightening torque applied, on the lubricant used,
M 16 140 200 200 280
the finished condition of the surfaces and threads,
M 18 200 280 280 390
and on the materials paired. It is, therefore, of great
M 20 270 400 380 560
importance that all these conditions are met.
M 24 470 690 660 970

Tab. 2 lists the tightening torques for various threads Tab. 2. Tightening torques for schoulder screws.
as a function of the coefficient of friction µ, i.e. of the Valve from AN 268 (if no data given in tabel).
lubricant used.The torques are based on bolt material
of the strength class 8.8 with the bolts stressed up
to approximately 7% below the elastic limit. Strength class 5.6 6.8 10.9 12.9

For other strength classes, the tightening torques Conversion factor x 0.47 0.75 1.40 1.7
listed in the table have to be multiplied by the corre-
sponding conversion factors, see tab. 3. the strength Tab. 3. Conversion factors for tightening torques as a function of
class is stamped on the bolt head. the bolt strength class.

11.40 - ES0
MAN Diesel & Turbo

Description
Declaration of Weight 500.45
Page 1 (1) Edition 11

L27/38

Weight in Kg
Section Component Plate No Item No
approx.

505 Cylinder head, incl. rocker arms 50501 027 400

50502 010/022
Cylinder unit 50500 021 700

506 Piston, complete 50601 081 66

Connecting rod, complete 50601 272 120
Connecting rod 50601 272 52
Cylinder liner, complete 50610 018 140

511 Cover for crankcase 51106 010 31.5

512 Turbocharger, TCR 18, complete 512 460

Turbocharger, TCR 20, complete 512 780
Charge Air cooler 51201 162 490

514 Fuel injection pump 51401 565 75

515 Lubricating oil pump 51501 031/043 40

516 HT- and LT-cooling water pump 51610 105 30

11.41 - ES0, Tier II, VBII

MAN Diesel & Turbo

Description 500.50
Page 1 (2) Ordering of Spare Parts Edition 03

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

Information found on the name­plate of the engine(s)

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

Information found on each plate at the instruction manual:

Plate No Edition No Item No Qty. Description

51435 13 440 1 Leak oil pipe

12.11 - ES0
MAN Diesel & Turbo

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

General

Name of customer Name of Plant/Vessel IMO No

Engine type Engine No Engine Builder

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

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

12.11 - ES0
MAN Diesel & Turbo

Description 500.51
Page 1 (1) How to Return Spare Parts and/or Tools Edition 05

General
How to return spare parts and/or tools

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

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

Send an email to our office via - Spare Parts:

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

Note: Please be aware that it is only spare parts

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

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

out a written agreement you will be charged a
fee for unauthorised returns.

11.09 - ES0
MAN Diesel & Turbo
Description 500.55
Page 1 (1) Service letters
Edition 01

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

L16/24S, L21/31S, L23/30S, L27/38S, L28/32S-DF
Description
In order to ensure the most efficient, economical
and up-to-date operation of our engines, we regu-
larly send out "Service Letters" containing first-hand
information regarding accumulated service experi-
ence.
The service letters can either deal with specific
engine types, or contain general instructions and
recommendations for all engine types, and are used
as a reference when we prepare up-dated editions
of instruction books.
Since new service letters might be of great impor-
tance to the operation of the plant, we recommend
that engine staff file them as supplements to the rel-
evant chapters of this instruction book.

2014.03.28
 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

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

Quantity Name Symbol Definition 1 kp/mm2 = 100 kp/cm2 9.807 N/mm2

1 lbf/sq. in (psi) = 0.07031 at 6.895 x 10-3 N/mm2
time minute min 1 min = 60 s
time hour h 1h = 60 min
plane angle degree ° 1° = (p/180) rad Dynamic viscosity (N s/m2)
volume litre l 1l = 1 dm3
pressure bar bar 1 bar = 105 Pa 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)
1 poundal s/sq.ft 1.488 N s/m2
1 lbf/sq.ft 47.88 N s/m2
Length (m)
poise is a special name taken from the CGS system. 1 P = 0.1 Pa s
1 in (inch) 25.40 mm = 0.0254 m 1 cP = 1 mPa s = 10-3 Pa s
1 ft (foot) = 12 inches 0.3048 m
1 yd (yard) = 3 ft = 36 inches 0.9144 m Kinematic viscosity (m2/s)
1 statute mile = 1760 yds 1609 m
1 n mile (international nautical mile) 1852 m 1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *

* 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name

SI Prefixes taken from the CGS system. 1 St = 10-4 m2/s

Factor Prefix Symbol Factor Prefix Symbol Energy, Work (1 Nm = 1 J, Wh)

1018 exa E 10-1 deci d 1 cal I.T* 4.187 J*

1015 peta P 10-2 centi c 1 kpm 9.807 J
1012 10-3 2.648 x 106 J = 0.7355
08028-0D/H5250/94.08.12

tera T milli m 1 hph (metric) kWh

109 giga G 10-6 micro μ 1 ft. lbf 1.356 J
106 mega M 10-9 nano n 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
103 kilo k 10-12 pico p 1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
102 hecto h 10-15 femto f
10 deca da 10-18 atto a * Exact value: 4.1868 J
I.T. = International Steam Table

Area (m2)

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

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

04.37 - ES0
 MAN Diesel

500.60 Conversion Table Description

Edition 01 Page 2 (3)

General

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

1 kpm/s 9.807 W 1 kcalI.T./(kg x °C) 4.187 x 103 J/(kg K)

1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW 1 BTU*/(lb x °F) = 1 kcalI.T. /(kg °C) 4.187 x 103 J/(kg K)
1 kcalI.T./h 1.163 W
1 ft lbf/s 1.356 W * British Thermal Unit (see table for energy conversions)
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 BTU/h 0.2931 W
Heat conductance (W/(m K))

Moment of Force, Torque (kg m2/s2 = Nm) 1 calI.T./(cm x s x °C) 418.7 W/(m K)
1 kcalI.T./(m x h x °C) 1.163 W/(m K)
Can easily be derived from the above tables. 1 BTU*/(ft x h x °F) 1.731 W/(m K)

* British Thermal Unit (see table for energy conversions)

Moment of Inertia (kg m2)

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

1 WR2 (old notation)* = 1 x I* kg m2
1 calI.T./(cm x s x °C) 41.87 x 103 W/(m2 K)
*I = ∫ dmr x r 2
mr = mass at the radius r 1 kcalI.T./(m" x h x °C) 1.163 W/(m2 K)
G = W = mass in kg D = Diameter of gyration 1 BTU*/(ft2 x h x °F 5.678 W/(m2 K)
R = Radius of gyration

Specific fuel oil consumption (SFOC)

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

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

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

Temperature levels (K)

(see "Derived SI Units with special Names)

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

Derived Si Units with Special Names

08028-0D/H5250/94.08.12

Quantity Name Symbol Expressed in basic,

supplementary or
derived SI units

frequency hertz Hz 1 Hz = 1 s-1

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

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

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

04.37 - ES0
 MAN Diesel

Description
Conversion Table 500.60
Page 3 (3) Edition 01

General

Volume (1 m3 = 1000 l)

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

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

* 1 gallon = 4 quarts = 8 pints

Mass (kg)

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

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

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

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

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

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

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

Some physical data in SI units

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

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

Water 18 999 4.18 x 103

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

04.37 - ES0
 MAN Diesel

Description
Page 1 (3) Basic Symbols for Piping 500.65
Edition 01

General

No Symbol Symbol designation No Symbol Symbol designation

2.14 Spectacle flange
1. GENERAL CONVENTIONAL SYMBOLS

1.1 Pipe 2.15 Orifice

1.2 Pipe with indication of direction of flow 2.16 Orifice

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

1.4 Appliances 2.18. Snap coupling

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

1.6 High-pressure pipe

3. VALVES, GATE VALVES, COCKS AND FLAPS
1.7 Tracing 3.1 Valve, straight through

1.8 Enclosure for several components as-sem- 3.2 Valve, angle

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

2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight

2.2 Crossing pipes, connected 3.5 Non-return valve (flap), angle

2.3 Tee pipe 3.6 Non-return valve (flap), straight screw

down
2.4 Flexible pipe 3.7 Non-return valve (flap), angle, screw down

2.5 Expansion pipe (corrugated) general 3.8 Safety valve

2.6 Joint, screwed 3.9 Angle safety valve

2.7 Joint, flanged 3.10 Self-closing valve

08028-0D/H5250/94.08.12

2.8 Joint, sleeve 3.11 Quick-opening valve

2.9 Joint, quick-releasing 3.12 Quick-closing valve

2.10 Expansion joint with gland 3.13 Regulating valve

2.11 Expansion pipe 3.14 Ball valve (cock)

2.12 Cap nut 3.15 Butterfly valve

2.13 Blank flange 3.16 Gate valve

05.02 - ES0
 MAN Diesel

500.65 Basic Symbols for Piping

Description
Page 2 (3)
Edition 01

General

No Symbol Symbol designation No Symbol Symbol designation

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

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

3.20 Double-seated changeover valve, straight 4.3 Spring

3.21 Double-seated changeover valve, angle 4.4 Mass

3.22 Cock, straight through 4.5 Float

3.23 Cock, angle 4.6 Piston

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

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

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

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

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

3.29 Cock, angle, with bottom connection 4.12 Spring

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

3.31 Thermostatic valve 4.14 Solenoid and pilot directional valve

3.32 Valve with test flange 4.15 By plunger or tracer

3.33 3-way valve with remote control (actuator)

5. APPLIANCES
08028-0D/H5250/94.08.12

3.34 Non-return valve (air) 5.1 Mudbox

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

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

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

3.38 Reducing valve (adjustable) 5.5 Steam trap

3.39 5.6 Centrifugal pump

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

05.02 - ES0
 MAN Diesel

Description
Basic Symbols for Piping 500.65
Page 3 (3) Edition 01

General

No. Symbol Symbol designation No. Symbol Symbol designation

5.7 Gear or screw pump
6. FITTINGS

5.8 Hand pump (bucket) 6.1 Funnel / waste tray

5.9 Ejector 6.2 Drain

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

5.11 Piston pump 6.4 Waste tray with plug

5.12 Heat exchanger 6.5 Turbocharger

5.13 Electric preheater 6.6 Fuel oil pump

5.14 Air filter 6.7 Bearing

5.15 Air filter with manual control 6.8 Water jacket

5.16 Air filter with automatic drain 6.9 Overspeed device

5.17 Water trap with manual control

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

5.19 Silencer 7.2 Observation glass

5.20 7.3 Level indicator

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

5.22 Double acting cylinder with spring returned 7.5 Recorder

5.23 Steam trap

08028-0D/H5250/94.08.12

05.02 - ES0
Operation of engine

501/601
MAN Diesel & Turbo
Description 501.01
Page 1 (4) Operation
Edition 20

L16/24, L21/31, L27/38

Operation Note: To avoid shock effects owing to large tem-

perature fluctuations just after start, it is recommen-
ded:
Preparations for Starting
▪ to preheat the engine. Cooling water at least
The following describes what to do before starting 60°C should be circulated through the cylinder
when the engine has been out of service for a head for at least 2 hours before start:
period of time.
– by means of cooling water from engines
which are running or by means of a pre-
Lubricating Oil System heater (if installed).
1) Check the oil level in the base frame with the ▪ When starting without preheated cooling water,
dipstick. the engine may only be started on MDO (Marine
2) Check the oil level in the actuator. Diesel Oil).
3) Start up the prelubricating pump. Note: When starting on HFO (Heavy Fuel Oil), only
item a) applies.

HFO System
7) Open the fuel oil supply.
Starting on HFO: circulate preheated fuel
through the pumps until correct working tem-
peratures have been achieved. This normally
takes 30-60 minutes.
8) Regulating gear - please check:
▪ that all fuel injection pumps are set at index "0"
when the regulating shaft is in STOP position.
▪ that each fuel injection pump can be pressed by
hand to full index when the regulating shaft are
in STOP position, and that the pumps return
automatically to the "0" index when the hand is
removed.

Starting Air System

Figure 1: RE2800 actuator 9) Check the pressure in the starting air receiver(s).
10) Drain the starting air system.
Note: It is recommended that the engine is prelubri-
11) Open the starting air supply.
cated for at least 30 minutes prior to start-up (at the
first starting-up, or if the engine is cold, the engine 12) Check the air pressure on the operating box
must be prelubricated for at least 60 minutes) or according to the data and setpoints sheet.
check that there is oil coming out at bearings, pis-
tons and rocker arms. Turning of Engine (not valid for L16/24
4) Check prelubricating oil pressure at inlet to filter, engine)
inlet of the engine and inlet turbocharger at the
display module according to the data and set- 13) Open the indicator valves and turn the engine
points sheet. some few revolutions, check that no liquid is
flowing out from any indicator valves during the
turning.
Cooling Water System
5) Open the cooling water supply.
6) Check the cooling water pressure.

2012.09.06 - ES0
 MAN Diesel & Turbo
501.01 Description
Operation Page 2 (4)
Edition 20

L16/24, L21/31, L27/38

14) Slow turning must always be carried out, before Note: If the engine have been without prelubrication
the engine is started after prolonged out of- for more than 20 min. it will not be possible to start
service-periods and after overhauls, which may the engine (either remote or local). The only possibil-
involve a risk of liquid having collected in the ity in this case is to activate the emergency start,
cylinders. located directly on the starter.
15) Close the indicator valves.
Cold Start procedure
Starting 18) Speed setpoint is set to 50% of nominal speed
16) The engine may be started according to the fol- with use of SaCoSone Expert. If SaCoSone Expert
lowing procedure: is not available, a spanner at the actuator arm is
used to keep the speed at 50% of nominal
▪ Normal start without preheated cooling water. speed while decrease speed is activated during
Only on MDO. starting.
▪ Normal start with preheated cooling water. Minimum speed is approx. 50% of nominal
MDO or HFO. speed.
▪ Stand-by engine. Emergency start, with prehea- 19) Start the engine either by local start or emer-
ted cooling water, intermediate prelubricating or gency start button on air starter. Run for 5
continuos prelubricating. MDO or HFO. minutes.
Hold a adjustablespanner at linkage between
Starting and Stopping on HFO fuel rack and actuator in order to have total
control over the speed.
Starting and stopping of the engine should take When the engine ignites on all cylinders reduce
place on HFO in order to prevent any incompatibility the fuel admission with the spanner until the
problems on changeover to MDO. engine can just keep running.
MDO should only be used in connection with main- At first start up the engine speed must not
tenance work on the engine or before a longer exceed 50 % of nominal speed.
period of engine standstill. 20) Check pressure difference on lubricating oil
Before starting on HFO the engine must be properly pressures before and after filter. The differencial
preheated as described in "Preparations for Start- pressure must be shortly above 1.5 bar with
ing" and as described below. cold engine and it is acceptable if it is below
after 10 minutes.
Stopping the engine on HFO is no problem, but it
should be ensured that the temperature of fuel 21) Check that all cylinder ignites.
pipes is not reduced to a level below the pour point 22) Check the lubrication at the rocker arms and
of the fuel. Otherwise reestablishing the circulation check all fuel oil pipes for leakages.
might cause problems.
23) During the 15 minutes the speed will slowly be
increased to nominal speed, if no abnormal
Starting on MDO noise or leakages.
For starting on MDO there are no restrictions 24) Check that pressure difference on lubrication oil
except that lubricating oil viscosity may not be before and after filer is ok. Ascertain the running
higher than 1500 cSt (10°C SAE 40). is normal.
Initial ignition may be difficult if the engine and ambi-
ent temperatures are lower than 5°C and 15°C Testing during Running
cooling water temperature.
Check the following on the display module accord-
ing to the data and setpoints sheet.
Normal Starting procedure
25) Check the lubricating oil pressure.
17) Start the engine by activating the start button
26) Check the cooling water pressure.
on the display module.
27) Check the fuel oil feed pressure.

2012.09.06 - ES0
MAN Diesel & Turbo
Description 501.01
Page 3 (4) Operation
Edition 20

L16/24, L21/31, L27/38

28) Check that the turbocharger is running. 37) The exhaust gases should be free of visible
29) Check that the prelubricating oil pump stops smoke at all loads. For normal exhaust temper-
automatically. atures, see the test report from shop and sea
trials.
30) Check that all cylinders are firing, see exhaust
gas temperatures. 38) Keep the charging air pressure and temperature
under control. For normal values, see the test
Note: Check the stop cylinder (Lambda controller) report from shop and sea trials.
for regulating the shaft works properly, both when
stopping normally and at overspeed and shut 39) Recharge the starting air receivers to the descri-
down. bed value.
Check that all shutdowns are connected and func- 40) To ensure full operational reliability, the condi-
tion satisfactory. tion of the engine should be continuously
31) Test the overspeed, see Working Card observed so that order for preventive mainte-
509-01.05. nance work can be carried out before serious
breakdowns occur, see also section 502.
32) Check that all alarms are connected.
Stopping
Operation
41) Before stopping, it is recommended to run the
The engine may be loaded according to the follow- engine at reduced load, or to idle for about 5
ing procedure: minutes for cooling-down purposes.
▪ Normal start without preheated cooling water. 42) The engine is stopped by activating the stop
Only on MDO. button on the display module.
▪ Normal start with preheated cooling water.
MDO or HFO.
▪ Stand-by engine. Emergency start, with prehea-
ted cooling water, intermediate prelubricating or
continuos prelubricating. MDO or HFO.
See loading chart fig 2.
Note: When the engine is running the planned
maintenance programme and the following should
be checked:
33) The lubricating oil pressure must be within the
stated limits and may not fall below the stated
minimum pressure. The paper filter cartridges
must be replaced before the pressure drop
across the filter reaches the stated maximum
value, or the pressure after the filter has fallen
below the stated minimum value. Dirty filter car-
tridges cannot be cleaned for re-use.
34) The lubricating oil temperature must be kept
within the stated limits indicated on the data
and setpoints sheet.
35) The fuel oil pressure must be kept at the stated
value.
36) The cylinder cooling water temperature must be
kept within the limits indicated on the data and
setpoints sheet.

2012.09.06 - ES0
 MAN Diesel & Turbo
501.01 Description
Operation Page 4 (4)
Edition 20

L16/24, L21/31, L27/38

Figure 2: Loading chart

2012.09.06 - ES0
MAN Diesel & Turbo
Description 501.05
Page 1 (2) Out of Service Edition 07

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

Out of Service Work during Repairs
The following should be carried out during major
Stand-by mode repairs.
During engine standstill in stand-by position the 5) Retighten all bolts and nuts in the crankcase.
media cooling water and fuel oil should be continu- 6) Check the various gearwheel drives for the
ously circulated at temperatures similar to the oper- camshafts.
ating conditions.
7) Remedy leakages of water and oil in the
The prelubricating pump must always run in engine, and blow through blocked-up drain
standby mode. pipes.
8) Drain starting air pipes of water.
Maintenance during Standstill
9) Empty the oil sump of lubricating oil and check
In periods during standstill of the engine (not in the bottom of the oil sump for fragments of
stand-by position) it is recommended to start the babbitt from bearings. Remove the sludge, if
prelubricating oil pump for minimum 20 minutes not done within a period of one year. Clean the
once every week and to turn the engine during the sump very thoroughly and subsequently coat
prelubricating period by 2-3 revolutions. with clean lubricating oil.

Laid-up Vessels Work after Repairs

During the lay-up period we recommend that our
special instructions for preservation of the engines Cleaning of Lubricating Oil System
are followed.
10) If opening-up the engine or lubricating oil sys-
tem has caused the ingress of impurities,
Work before Major Repairs cleaning should be carried out very carefully
Follow all Working Cards carefully. Carry out all the before starting the engine.
measuring and inspection stated on these Working The differential pressure across the lubricating
Cards. oil filter must be watched very carefully after
cleaning and starting- up the engine. Be sure
1) After stopping the engine, while the oil is still
to replace filter cartridges in due time.
warm, start the el-driven prelub. pump, open
up the crankcase and camshaft housings and 11) After restoring normal prelubricating oil circula-
check that the oil is flowing freely from all bear- tion, turn the engine at least two revolutions by
ings. means of the turning device to check the mov-
After overhaul of pistons, bearings, etc. this ability of the relevant parts of the engine.
check should be repeated before starting the 12) Close drain cocks in the exhaust gas system if
engine. mounted.
2) Open up all filters to check that filter elements
are intact. Filter cartridges in the lub. oil filter Lubrication of Manoeuvering Gear
are to be replaced before start, after repair, or
after excessive differential pressure. After 13) Lubricate the bearings and rod connections in
removal, dirty elements can be examined for the manoeuvering gear. Move the rod connec-
particles of bearing metal at the bottom of the tions by hand to check that the friction in bear-
paper lamella (the elements cannot be used ings and fuel injection pumps is sufficiently low.
again). 14) Checks to be made just before starting the
3) A lubricating oil sample should be sent to a lab- engine are described under 501.01.
oratory for immediate analysis.
4) The installed drain fasilities in the exhaust gas
system must be open.

2011.08.08
 MAN Diesel & Turbo
501.05 Description
Edition 07
Out of Service Page 2 (2)

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

Check of Speed Control System Note!

Note! It is a condition for this test that the engine and

turbocharger are in perfect operating condition,
At starting-up after an overhaul the overspeed so that possible sources of error can be elimina-
shutdown must be testet at correct setpoint ted immediately.
after the following has been done:
a) Start the engine and keep it at no load. ▪ Hunting: run the engine at synchronous rpm,
b) Overspeed is tested by setting the overspeed and without load. Provided that the actuator oil
test active at the display module. Overspeed will is warm, the regulating lever must not perform
occur at 85% of nominal speed. Alternatively any major periodical movements, and neither
overspeed can be tested by use of a spanner at must there be any variation in the engine speed.
the linkage between the actuator and the fuel If that is the case, readjustment of the actuator
rack. according to the actuator instruction manual.
▪ Speed drop: in case of unsatisfactory load shar-
Note! ing between two or more engines this can be
If both overspeed shutdown (SSH 81) are acti- rectified by increasing the speed drop of the
vated, nuts and bolts have to be retightened engine that is subject to the greatest load (or by
before the engine is started, (Nuts and bolts reducing the setting of the other engines).
according to the colomn "Check new/over- The setting should normally not be increased
hauled parts after - hours" in the planned main- beyond the "max" value (stated below) on the scale,
tenance program). and satisfactory parallel operation can generally be
obtained at settings "normal range" (stated below).
15) Check the actuator as follows: start up the Setting "Default" stated below can be used in most
engine and run it at the synchronous number of cases.
revolutions.
▪ Speed-setting: before switching-in the alterna-
tor on the switchboard please check that the
servomotor adjusts the rpm with a suitable
quickness after actuation of the synchronizer
knob on the switchboard. The range from - 5%
to + 5% from the synchronous rpm should be
tested.
▪ Adjustment speed: switch in the alternator on
the switchboard and set the load to about 40%.
On reaching normal oil temperatures in actuator
and engine increase the load instantly to about
80% (by starting a major pump or compressor).
This must not cause the frequency to fall by
more than some 8%, and the engine must
return to a constant no. rpm after about 3 sec-
onds (although this rpm will be a little lower than
before owing to the speed drop of the actuator).
If the engine is operated in parallel with other
engines, an even sharing of the load must be
established within about 3 seconds. If the
actuator reacts too slowly, compensating
adjustment is effected as indicated in the actua-
tor's instruction manual (Compensating Adjust-
ment).

2011.08.08
MAN Diesel & Turbo
Description 501.10
Page 1 (1) Starting-up after Repair
Edition 03

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

L27/38S
Starting-up after Repair Feel: main bearings, big-end bearings, alternator
bearings, and camshaft bearings, cylinder liners,
The following enumerated checks are to be made roller guides and gear wheels.
immediately after starting and during load increase.
After the last feel-over, repeat check 1) on page
501.05, see also "Ignition in Crankcase" on page
Note! 503.04 in section 503.
After repair or renewal of cylinder liners, piston rings
In the following it is assumed that the engine
or bearings, allowance must be made for a runni-
has been out of service for some time due to
ngin period, i.e. the engine load should be
repairs and that checks during out of service
increased gradually as indicated in the tables below.
periods have been carried out as described in
The engine output is determined on the basis of the
the previous chapter.
fuel index and the load on the electric switchboard.
The turbocharger speed gives some indication of
the engine output, but is not directly proportional to
When starting up after repair, the following checks
the output throughout the service period.
must be made, in the order stated in addition to
normal surveillance and recording. Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for cer-
tain that there are no hot spots in the engine. Then
To be Checked Immediately after Starting increase the speed to the normal rpm and connect
1) Check that the turbocharger is running. to the switchboard and put on load.
2) Check that the lubricating oil pressure is in
order. The load increase during the starting-up sequence
3) Check that all cylinders are fi ring (see exhaust may, for instance, be:
temperatures). ▪ 25 % load for 2 hours
4) Check that everyting is normal for the engine ▪ 50 % load for 2 hours
speed, fuel oil, cooling water and system oil.
▪ 75 % load for 2 hours
5) Check by simulation of the overspeed shut
down device that the engine stops, see work- ▪ 100 % load may be put on
ing card 509-01.05.
For loads: see the fuel pump index on the testbed
figures in section 502.
Note!
After completing the starting-up sequence, make
The overspeed setting should be according to sure that all fuel injection pumps are set at the same
"Operation data & set points", 500.30. index and that the governor can cause all fuel
pumps to move to "0" index.

To be Checked during Starting-up, but

only if Required after Repairs or
Alterations
6) If the condition of the machinery is not well-
known, especially after repairs or alterations,
the "feel-over sequence" should always be fol-
lowed, i.e.:
After 5-15 and 30 minutes' idle running, open the
crankcase and the camshaft housing and perform
feel-over on the surfaces of all moving parts where
friction may arise and cause undue heating.

2014.03.18
MAN Diesel & Turbo
Description 501.15
Page 1 (2) Guidelines for Longterm Low-Load Operation on HFO
Edition 03

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

Part load/low load operation

Figure 1: Low-load operation

and combustion air channels, combustion cham-
In certain ship and power station operation modes bers and turbocharger. HFO-operation at loads
the diesel generating sets are exposed to part lower than 20% MCR should therefore only take
load/low load operation. place within certain time limitations according to the
curves.
During manoeuvring of the ship all diesel generating
sets are often started up for safety reasons, result- After a certain period of HFO-operation at loads
ing in low load operation of all the engines. During lower than 20% MCR, a change to MDO should
harbour stay one diesel generator could be low-loa- take place in order to prevent further retardation of
ded when only hotel purposes are consuming elec- the engine performance condition. Alternatively, the
tricity. engine load should be raised to 70% MCR over a
period of 15 minutes and maintained here for some
Island mode operation of diesel generating sets in time in order to burn off the carbon deposits, thus
power stations is frequently exposed to low load re-establishing adequate performance condition.
operation like on a ship. After such a "clean burning period" low load opera-
At part load/low load it is important to maintain con- tion on HFO can be continued.
stant media temperatures, i.e. for cooling water, However, the operator must be aware of the fact
lubricating oil and fuel oil in order to ensure ade- that fouling in the combustion air inlet channels, if
quate combustion chamber temperature and thus any, will not be cleaned at high load operation.
complete combustion.
At loads lower than 20% MCR there is a risk of time
dependant retardation of the engine performance
condition due to fouling of the exhaust gas channels

2008.05.12 - ES1
 MAN Diesel & Turbo
501.15 Description
Guidelines for Longterm Low-Load Operation on HFO Page 2 (2)
Edition 03

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

Extensive low load running can therefore result in
the need for manual cleaning of the combustion air
inlet channels.
If special application conditions require continuous
HFO-operation at loads lower than 20% MCR and
occasionally performed "clean-burning" periods are
inconvenient or impossible, special equipment and
arrangements must be established.

2008.05.12 - ES1
MAN Diesel & Turbo
Description Guidelines regarding MAN Diesel & Turbo GenSets 501.16
Page 1 (1)
operating on low sulphur fuel oil Edition 02

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

General When operating on MDO/MGO a larger leak oil
amount from fuel oil injection pumps and fuel oil
Exhaust emissions from marine diesel engines have injection valves can be expected compared to oper-
been the focus of recent legislation. Apart from ation on HFO.
nitrous oxides (NOx), sulphur oxides (SOx) are con-
sidered to be the most important pollution factor. A In order to carry out a quick change between HFO
range of new regulations have been implemented and MDO/MGO the change over should be carried
and others will follow (IMO, EU Directive, and out by means of the valve V1-V2 installed in front of
CARB). These regulations demand reduction of the engine.
SOx emissions by restricting the sulphur content of For the selection of the lubricating oil the same
the fuel. That is to say sulphur limits for HFO as well applies as for HFO. For temporary operation on dis-
as mandatory use of low sulphur distillate fuels for tillate fuels including low sulphur distillates nothing
particular applications. This guideline covers the has to be considered. A lubricating oil suitable for
engine related aspects of the use of such fuels. operation on diesel fuel should only be selected if a
distillate fuel is used continuously.
Low sulphur HFO
From an engine manufacturer’s point of view there
is no lower limit for the sulphur content of HFO. We
have not experienced any trouble with the currently
available low sulphur HFO, that are related to the
sulphur content or specific to low sulphur HFO. This
may change in the future if new methods are
applied for the production of low sulphur HFO
(desulphurization, uncommon blending compo-
nents). MAN Diesel & Turbo will monitor develop-
ments and inform our customers if necessary.
If the engine is not operated permanently on low
sulphur HFO, then the lubricating oil should be
selected according to the highest sulphur content
of the fuels in operation.

Low sulphur distillates

In general our GenSet is developed for continuous
operation on HFO as well as on MDO/MGO. Occa-
sionally changes in operation mode between HFO
and MDO/MGO are considered to be within normal
operation procedures for our engine types and do
thus not require special precautions.
Running on low sulphur fuel (< 0.1% S) will not
cause problems, but please notice the following
restrictions:
In order to avoid seizure of the fuel oil injection
pump components the viscosity at engine fuel oil
inlet must be > 2 cSt. In order achieve this it may be
necessary to install a fuel oil cooler, when the
engine is running on MGO. This is both to ensure
correct viscosity and avoid heating up the service
tank, which is important as the fuel oil injection
pumps are cooled by the fuel.

2010.04.19
Performance and
condition

502/602
MAN Diesel & Turbo
Description 502.01
Page 1 (3) Engine Performance and Condition
Edition 08

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

Performance data and engine condition Reduction of the charge air pressure results in a
corresponding reduction of the compression pres-
During operation small changes in the engine condi- sure and max. combustion pressure.
tion take place continuously as a result of combus-
tion, including fouling of airways and gasways, for- When checking the max. pressure adjustment of
mation of deposits, wear, corrosion, etc. If continu- the engine, it is therefore to be ensured that the
ously recorded, these changes in the condition can existing charge air pressure is correct. Is not avaia-
give valuable information about the operational and ble for L16/24.
maintenance condition of the engine. Continuous
observation can contribute to forming a precise and Fuel injection pump
valuable basis for evaluation of the optimum opera-
The amount of fuel injected is equivalent to the sup-
tion and maintenance programmes for the individual
plied energy and is thus an expression of the load
plant.
and mean effective pressure of the engine. The fuel
pump index can therefore be assumed to be pro-
Engine performance data portional to the mean pressure. Consequently, it
If abnormal or incomprehensible deviations in oper- can be assumed that the connected values of the
ation are recorded, expert assistance in the evalua- pump index are proportional to the load.
tion thereof should be obtained. The specific fuel consumption, SFOC (measured by
We recommend taking weekly records of the most weight) will, on the whole, remain unchanged
important performance data of the engine plant. whether the engine is operating on HFO or on
During recording (working card 502-01.00 can be MDO, when considering the difference in calorimet-
used) the observations are to be compared continu- ric heat value. However, when operating on HFO,
ously in order to ascertain alterations at an early the combination of density and calorific value may
stage and before these exert any appreciable influ- result in a change of up to 6% in the volumetric
ence on the operation of the plant. consumption at a given load. This will result in a
corresponding change in the fuel pump index, and
As a reference condition for the performance data, attention should be paid to this when adjusting the
the testbed measurements of the engine or possibly overload preventive device of the engine.
the measurements taken during the sea trial on the
delivery of the ship can be used. If considerable To avoid overloading of the engine the charge air
deviations from the normal conditions are observed, pressure and turbine speed recorded at the shop
it will be possible, in a majority of cases, to diag- test should not be exceeded.
nose the cause of such deviations by means of a At the Power Control Synchronizing (PCS) panel in
total evaluation and a set of measurements, after the engine control room it is possible to reduce the
which possible adjustment/overhauls can be deci- load by adjusting the setting for maximum MCR
ded on and planned. load limit.
Abrasive particles in the fuel oil result in wear of fuel
Evaluation of performance data injection pumps and fuel valve nozzles. Effective
treatment of the fuel oil in the purifier can keep the
Air cooler content of abrasive particles to a minimum. Worn
fuel injection pumps will result in an increase of the
Fouling of the air side of the air cooler will manifest index on account of an increased loss in the pumps
itself as an increasing pressure drop, lower charge due to leakage.
air pressure and an increased exhaust/charge air
When evaluating operational results, a distinction is
temperature level (with consequential influence on
to be made between changes which affect the
the overhaul intervals for the exhaust valves).
whole engine (all cylinder units) and changes which
An increase in charge air temperature involves a occur in only one or a few cylinders.
corresponding increase in the exhaust gas temper-
Deviations occuring for a few cylinders are, as a
ature level by a ratio of about 1:1.5, i.e. 1°C higher
rule, caused by malfunctioning of individual compo-
charge air temperature causes about 1.5°C higher
nents, for example a fuel valve with a too low open-
exhaust gas temperature.

2012.01.23
 MAN Diesel & Turbo
502.01 Description
Engine Performance and Condition Page 2 (3)
Edition 08

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

ing pressure, blocked nozzle holes, wear or other Abrasive particles in the fuel oil involve heavier wear
defects, an inlet or exhaust valve with wrongly of the fuel valve needle, seat, and fuel nozzle holes.
adjusted clearance, burned valve seat, etc. Therefore, abrasive particles are to the greatest
possible extent to be removed at the purification.
Turbochargers
Fouling of the turbine side of the turbocharger will,
Exhaust valves
in its first phase, manifest itself in increasing turbo- The overhaul intervals for exhaust valves is one of
charger revolutions on account of increased gas the key parameters when the reliability of the entire
velocity through the narrowed nozzle ring area. In engine is to be judged. The performance of the
the long run, the charging air quantity will decrease exhaust valves is therefore extremely informative.
on account of the greater flow resistance through Especially under unfavourable conditions, fuel quali-
the nozzle ring, resulting in higher wall temperatures ties with a high vanadium and sodium content will
in the combustion chambers. promote burning of the valve seats. Combinations
Service experience has shown that the turbine side of vanadium and sodium oxides with a corrosive
is exposed to increased fouling when operating on effect will be formed during combustion. This adhe-
HFO. sive ash may, especially in the event of increased
The rate of fouling and thereby the influence on the valve tem-peratures, form deposits on the seats. An
operation of the engine is greatest for small turbo- increasing sodium content will reduce the melting
chargers where the flow openings between the point and thereby the adhesive temperature of the
guide vanes of the nozzle ring are relatively small. ash, which will involve a greater risk of deposits.
Deposits occur especially on the guide vanes of the This condition will be especially unfavourable when
nozzle ring and on the rotor blades. In the long run, the na/va weight ratio increases beyond 1:3.
fouling will reduce the efficiency of the turbocharger The exhaust valve temperature depends on the
and thereby also the quantity of air supplied for the actual maintenance condition and the load of the
combustion of the engine. A reduced quantity of air engine. With correct maintenance, the valve tem-
will result in higher wall temperatures in the com- perature is kept at a satisfactory low level at all
bustion spaces of the engine. loads. The air supply to the engine (turbocharger/air
Detailed information and instructions regarding cooler) and the maximum pressure adjustment are
water washing of the turbocharger are given in the key parameters in this connection.
instruction manual. It is important for the functioning of the valves that
the valve seats are overhauled correctly in accord-
Fuel valves ance with our instructions.
The use of rotocaps ensures a uniform distribution
Assuming that the fuel oil is purified effectively and
of temperature on the valves.
that the engine is well-maintained, the operational
conditions for the fuel valves and the overhaul inter-
vals will not normally be altered essentially when Air inlet valves
operating on HFO. The operational conditions of the air inlet valves are
If, for any reason, the surface temperature of the not altered substantially when using residual fuel.
fuel valve nozzle is lower than the condensation
temperature of sulphuric acid, sulphuric acid con- Fuel injection pumps
densate can form and corrosion take place (cold
corrosion). The formation of sulphuric acid also Assuming effective purification of the fuel oil, the
depends on the sulphur content in the fuel oil. operation of the fuel injection pumps will not be very
much affected.
Normally, the fuel nozzle temperature will be higher
than the approx. 180°C at which cold corrosion The occurrence of increasing abrasive wear of
starts to occur. plunger and barrel can be a consequence of insuffi-
cient purification of the fuel oil, especially if a fuel
which contains residues from catalytic cracking is
used. Water in the fuel oil increases the risk of cavi-

2012.01.23
MAN Diesel & Turbo
Description 502.01
Page 3 (3) Engine Performance and Condition
Edition 08

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

tation in connection with pressure impulses occur-
ring at the fuel injection pump cut-off. A fuel with a
high asphalt content has deteriorating lubricating
properties and can, in extreme cases, result in
sticking of the fuel injection pump plungers.

Engine room ventilation, exhaust system

Good ventilation of the engine room and suitable
location of the fresh air intake on the deck are
important. Sea water in the intake air might involve
corrosive attack and influence the overhaul intervals
for the exhaust valves.
The fresh air supply (ventilation) to the engine room
should correspond to approximately 1.5 times the
air consumption of the engines and possible boilers
in operation. Under-pressure in the engine room will
involve an increased exhaust temperature level.
The exhaust back-pressure measured after the tur-
bochargers at full load must not exceed 300 mm
water column. An increase in the exhaust back-
pressure will also cause an increased exhaust valve
temperature level, and increased fuel consumption.

2012.01.23
MAN Diesel & Turbo

Description Evaluation of Readings Regarding 502.02

Page 1 (1)
Combustion Condition Edition 04

General

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

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

TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.

ONE CYLINDER DECREASING CHARGE

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

Remarks: except for L16/24 Please also see Description 502.01,

Engine Performance and Condition

11.23 - ES0
MAN Diesel & Turbo
Description 502.05
Page 1 (2) Condensate amount
Edition 03

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

L16/24S, L21/31S, L23/30S, L27/38S, L28/32S-DF
General

Figure 1: Nomogram for calculation of condensate amount.

There is always a certain amount of water in air. Then, normally, the air cannot absorb the same
When the air is saturated with aqueous vapour, the amount of water as before.
humidity is said to be 100% and there is as much Condensation of water in the engine's charge air
water in the air as it can absorb without condens- receiver is consequently dependent on the humidity
ing. The amount of water in kg/kg air can be found and the temperature of the ambient air. To find out
from the diagram. The ability to absorb the water if condensation in the charge air receiver will occur
depends on the pressure and temperature of the the diagram can be used.
air.

Example:
Amount of condensation water in the
charge air receiver Diesel engine power 1260 kW
Ambient air condition:
Both higher pressure and lower temperature reduce air temperature 35°C
the ability to absorb water. A turbocharged diesel relative air humidity 90%
engine takes air from outside, compresses and Charge air temperature 50°C
cools the air. Charge air pressure 2.6 bar

2014.03.28
 MAN Diesel & Turbo
502.05 Description
Condensate amount Page 2 (2)
Edition 03

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

L16/24S, L21/31S, L23/30S, L27/38S, L28/32S-DF
As a guidance, an air consumption of 8.2 kg/kWh
(Le) at full load can be used for MAN Diesel & Turbo
engines.
Solution according to diagram: Water content of air (l) 0.033 kg/kg
Max. water cont. of air (lll) 0.0015 kg/kg
Water content of air (l) 0.033 kg/kg
Max. water cont. of air (ll) 0.021 kg/kg Amount of condensate in air tank
Amount of condensate in charge air receiver = (I - III) x m.
= (0.033 - 0.0015) x 138 = 4.35 kg.
= (I - II) x le x P.
= (0.033 - 0.021) x 8.2 x 1260 = 123 kg/h.

Draining of condensation water

This phenomenon will occur on all turbocharged
engines. For MAN Diesel & Turbo 4-stroke engines,
there is no risk with a small amount of water in the
charge air receiver.
But if the charge air receiver is filled with water,
there is a risk of getting water into the cylinder. This
water have to be drained away.
As standard a valve is mounted on the charge air
receiver/cooler on the engine. This valve is to be
used for draining of the water.
If there is a great amount, the valve can be left half-
open.
If the amount is small, the charge air receiver can
be drained periodically.

Amount of condensate water in air tanks

The volume of condensate in the air tank is deter-
mined by means of the curve at the bottom to the
right of the diagram, representing an operating
pressure of 30 bar.

Example:
Amount of condensate in air tank.
Volumetric capacity of tank(V) 4000 dm³
Temperature in tank (T) 40°C=313K
Internal press. of tank (p) 30 bar
= 31 x 105 N/m² (abs.)
Gas constant for air (R) 287 Nm/kg.K
Ambient air temperature 35°C
Relative air humidity 90%
Weight of air in tank

Solution acc. to above diagram:

2014.03.28
MAN Diesel & Turbo
Work Card 502-01.00
Page 1 (3) Engine Performance Data
Edition 11

L16/24, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52002 138 only for L21/31, L27/38
52002 498 only for L27/38
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Measurements of engine performance data.

Starting Position Hand Tools

Engine is running.

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2012.01.23. - ES0
 MAN Diesel & Turbo
502-01.00 Work Card
Engine Performance Data Page 2 (3)
Edition 11

L16/24, L21/31, L27/38

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

The area around the engine

Warning!
The area around the engine must be clean and
tidy!

2012.01.23. - ES0
MAN Diesel & Turbo
Work Card 502-01.00
Page 3 (3) Engine Performance Data
Edition 11

L16/24, L21/31, L27/38

Diagram

2012.01.23. - ES0
MAN Diesel & Turbo
Work Card 502-05.00
Page 1 (3) Check of Leakages from Inspection Holes
Edition 02

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of leakages from inspection holes.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2001.07.23 - ES0
 MAN Diesel & Turbo
502-05.00 Work Card
Check of Leakages from Inspection Holes Page 2 (3)
Edition 02

L27/38

Description

1) Leakages from cylinder head, see fig. 1.

If Then
Water leaks from the inspection hole The O-ring on the top of the liner has to be replaced
Gas leaks from the inspection hole The sealing ring cylinder head/liner has to be replaced

Figure 1: Inspection holes in the cylinder unit

2001.07.23 - ES0
MAN Diesel & Turbo
Work Card 502-05.00
Page 3 (3) Check of Leakages from Inspection Holes
Edition 02

L27/38

2) Leakages from HT cooling water pump,

see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing

3) Leakages from LT cooling water pump,

see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing

Figure 2: Inspection holes in the front-end box

2001.07.23 - ES0
Trouble shooting

503/603
MAN Diesel & Turbo

Description
Starting Failures 503.01
Page 1 (1)
Edition 02

General

Trouble Possible cause Troubleshooting

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

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

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

valve interposed in line between
receiver and engine.

Pinion does not engage with Check the air starter.

the flywheel.

Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing or clutch
jaws,
see Working Card 513-01.30.

Faults in electrical system. Check electrical parts.

Engine turns too slowly or 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.

Start valve is sticking in closed Check start valve.

position.

Low air pressure. Raise the air receiver pres-

sure.

Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.

04.31 - ES0
MAN Diesel & Turbo
Description 503.02
Page 1 (3) Faults in Fuel Oil System
Edition 05

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

L27/38S
Faults in fuel oil system
Trouble Possible cause Troubleshooting
Engine turns, but ignition fails. Fuel Sluggish movement of manoeuvering Lubricate and mobilize rod connections
pumps are not actuated. gear. in manoeuvering gear.
Incorrect adjustment of manoeuvering Check rod connection.
gear. Check that fuel pump index corre-
sponds to 'Adjustments after trials' in
testbed chart.
Safety system stop activated. Reset safety system stop.
Piston in Lambda controller is actu- Check that piston is not sticking.
ated. Check that pressure in cylinder is
relieved.
Check that the shutdown trip is not
actuated
Piston in Lambda controller cylinder is Check pressures and temperatures.
actuated due to stop function or fuel lli- Check for faults in shut-down devices.
mitation Check for faults in fuel limitation devi-
ces.
Check adjustment according to Work
Card 509-10.00
Incorrect adjustment of Lambda con- Adjust setting of adjustment screw, see
troller's adjustment screw. Work Card 509-10.00.
Governor setting incorrect. Adjust governor/actuator, see instruc-
tion manual for governor/actuator.
Failures in governor/actuator. Check that governor is working prop-
erly.
For further faults location, see instruc-
tion manual for governor/actuator.
Sticking fuel pumps. Dismantle and clean.

Trouble Possible cause Troubleshooting

Pump oil into the tank.
Engine turns, but no fuel is injected Fuel oil service tank empty. If Then
owing to failure in fuel system.
Air in the fuel Loosen hexagon
pumps. socket screw on
fuel pumps until air
disappears.
Engine runs, but does not ignite on all Air in fuel valves. Ignition fails on Vent the respec-
cylinders. one or more cylin- tive fuel valves.
ders due to air in
the fuel valves.

2014.04.24
 MAN Diesel & Turbo
503.02 Description
Faults in Fuel Oil System Page 2 (3)
Edition 05

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

L27/38S
Trouble Possible cause Troubleshooting
Engine runs, but does not ignite on all Air in fuel valves. Ignition fails on Change the fuel
cylinders. one or more cylin- valves and check
ders and no air them for sticking
bubbles appear spindle or broken
spring.
Check for collect-
ing oil on piston
top.
Air appears in the Check stuffing box
entire system and sealing in the
fuel system
Worn-out fuel pump Change fuel pumps
If Then
Pressure before Clean fuel filter.
pumps is too low Check that bypass
valve for feed
pump is not open.
Pressure is still too Increase the fuel
low oil feed pump
pressure

Trouble Possible cause Troubleshooting

Engine turns, fuel is injected, but igni- Water in the fuel Drain of water and repeat venting of
tion fails. fuel pumps by loosening the hexagonal
socket screw until air disappears.
Fuel valves or nozzles defective Change defective fuel valves, see Work
Card 514-01.10.
If Then
Compression dur- Check intake and
ing start too low. exhaust valve for
tight closing.
Check piston
rings.
Timing of fuel Check fuel cam-
camshaft is incor- shaft adjustment,
rect. see Work Card
507-01.20.
Major alteration of Adjust camshaft,
the fuel demand see Work Card
adjustment of the 507-01.20.
fuel pump timing.
Oil has collected Slow turning to
on piston crown. remove oil. Locate
and change
detective fuel
valve.

2014.04.24
MAN Diesel & Turbo
Description 503.02
Page 3 (3) Faults in Fuel Oil System
Edition 05

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

L27/38S
Trouble Possible cause Troubleshooting
First ignitions are too violent. Engine Sluggish movement of manoeuvering Lubricate and mobilize rod connections
runs erratically. gear. and bearings in manoeuvring gear.
Fuel pump index too high Check rod connection in manouevring
gear. Check that governor/actuator is
working properly.

2014.04.24
MAN Diesel & Turbo

Description
Disturbances During Running 503.03
Page 1 (3) Edition 06

L21/31
L27/38
V28/32S

Trouble Possible cause Troubleshooting

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.

Insufficient cleaning of fuel oil or Check separator and fuel filters.

changed combustion characteristics.

Wrong maximum combustion pressure Check camshaft adjustment, see working card
/fuel injection timing 507-01.20.

Poor fuel quality. Change fuel.

Exhaust gas temperature Fuel valve or valve nozzle defective. Overhaul fuel valve, see working card 514-01.10.
increased on one cylinder.
Leaky exhaust valves. Check the valve clearance, see working card 514-01.10
or
change the leaky valve and recondition the exhaust valve,
see working card 505-01.05.

Note: This manifests itself by a rise If Then

in the exhaust temperature and faill- Stopping of the The fuel pump of the cylinder con-
ing of the compression and maximum engine is not cerned should be put out of opera-
combustion pressure of the respective possible or tion by moving the index to stop
cylinder. convenient. and locking it in this position.

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.

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.

05.08 - ES0
MAN Diesel & Turbo

503.03 Disturbances During Running

Description
Edition 06 Page 2 (3)

L21/31
L27/38
V28/32S
Trouble Possible cause Troubleshooting

Engine speed decreases. Pressure before fuel pumps too low. Raise fuel oil feed pump pressure to normal.
or
check filter, see working card 514-01.15.

Fuel valve defective. Change defective valve, see working card 514-01.10.

Fuel injection pump defective. Change or overhaul.

Water in the fuel. Drain off water from service and setting tanks. Check fuel
oil centrifuge.

Governor defective. See governor manual.

Linkage adjustment wrong

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.

Shut-down for high HT cooling water Check HT system and pumps.

temperature.

Smoky exhaust. Turbine speed lagging behind engine Clean turbine(s), see turbocharger manual
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 turbocharger manual
Clean turbine, see turbocharger manual

Fuel valves or nozzles defective. Check fuel valves, see working card 514-01.10.

Exhaust valve knocking. Adjusting screw for valve setting Inspect and replace defective parts, see working card
clearance loose. Push rod thrust disc 508-01.00.
damaged.

Rising cooling water Thermostatic function Check thermostat.

temperature.
Pump defective Stop the engine and repair the pump.

Decreased flow Check valves.

If Then
The cooling water Open the test cocks (if
fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-100°C. Cont.

05.08- ES0
MAN Diesel & Turbo

Description
Disturbances During Running 503.03
Page 3 (3) Edition 06

L21/31
L27/38
V28/32S

Trouble Possible cause Troubleshooting

Check whether steam has

developed.

Steam has developed. Stop the engine.

Leave the engine to cool
while the discharge valve
is closed.

After 15 minutes open the

discharge valve a little to
allow the water to rise
slowly in the cooling
jackets.

Check filling at test cocks.

Lubricating oil pressure Lubricating oil pump defective. Check lubricating oil pump, see working card 515-01.00.
fails.
Filters fouled. Clean filter, see working card 515-01.10.

Cooler fouled. Clean cooler, see working card 515-06.00.

If Then
The lubricating oil Stop the engine: find the
pressure drops below cause of the pressure drop
the minimum stated and remedy the defect
before
in the Data sheet. restarting the engine.

Note: Feel over 5-15-30 minutes after starting, and again

when full load is achieved.

See section 502.

Alternator (GenSet only) Short circuit Flywheel must be dismounted and guide pin replaced

05.08 - ES0
MAN Diesel & Turbo

Description 503.04
Page 1 (1) Ignition in Crankcase Edition 03

General

Cause 1) Stop the Engine

During running the atmosphere in the crankcase 2) Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip­
proportions as in the ambient air, but an intense ment.
spray of oil drops is slung around everywhere. If
undue friction, and thus heating, arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is otherwise transmitted to after stopping the engine. When opening up, keep
the crankcase, the heated surface will cause eva­ clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed onto it. When do not smoke.
the oil vapours condense they form milky white oil
mist which can ignite. Such ignition may be caused 3) Cut off starting air.
by the same "hot spot" that produced the oil mist. 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.

Oil Mist in Crankcase 7) Stop and feel over. Look out for oil mist.

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 & Turbo

Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page 1 (1) Edition 03

L21/31
L27/38
Tabulated below are the remedial actions to be taken
if the following faults are observed:

Trouble Possible cause Trouble shooting

Oil leakage through cover nut. Missing or damaged O-ring Replace O ring.
(see Item 158, Plate 51515).

Seal face damaged. Replace cover assembly.

Excessive vibrations. Rotor out of balance owing to uneven

build-up of deposit on rotor walls
resulting from:

Missing or damaged O ring (see Item Replace O ring.

109, Plate 51515), allowing leakage.

O-ring seat on rotor joint faces Replace rotor assembly.

damaged.

Rotor assembly inadequately Tighten and bring to notice of main­tenance

tightened. staff.

Standtube incorrectly seated or da- Refit or replace if damaged.

maged.

Dirt deposit not completely removed. Clean and bring to notice of main­tenance
staff.

Rotor castings distorted through Replace rotor assembly.

maltreatment.

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

wrong sequence. in section 515.

Bushes loose or worn in tube as­ Fit new bearing tube assembly.
sembly.

99.25 - ES0
 MAN Diesel

Description 503.06
Page 1 (2) Trouble Shooting Guide for Air Starter Edition 04

L21/31
L27/38

Trouble Possible Cause, see Plate 51309 Trouble Shooting

On pressing push-button, starter - Empty air receiver(s) Charge receiver(s)

does not respond and no air flow - Flow valve(s) close Open flow valve(s)
seems to exist in control circuit. - Control circuit blocked Disconnect and clean out

On pressing push-button, starter - Leak in control duct Repair or replace

does not respond, although air - Insufficient air pressure Increase pressure in receiver
flows through control circuit. - Push button stuck Remove and clean same
- Excessive length of main air Approach push-button to starter
pipework or install a solenoid valve near the
latter

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
and ring gear one. Check for distortion of ring
gear

Pinion revolves but does not - Follower Item 130 inoperative Disassemble, check, smoothen
advance. guide diameter, clean or replace if
rusted
- Insufficient air pressure Increase pressure in receiver
- Splined shaft Item 11 sticking Disassemble, clean, check spring
Item 13 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 - Pneumatic motor inoperative Disassemble, inspect rotor for
revolve foreign matters between teeth and
for possible wear of gears.
- Check valve Item 131 Clean and reassemble. Replace
worn parts
Disassemble, clean and reassem-
ble

Pinion engages gear ring, but will - Main valve Item 133 blocked Disassemble, clean and reassem-
08028-0D/H5250/94.08.12

not turn the engine ble or replace

- Rotors worn or blocked Disassemble, clean and reassem-
ble or replace rotors
- Insufficient air pressure Increase pressure in receiver
- Main air pipework restricted or of Check all pipework and replace it if
insufficient bore it necessary

Starter starts working upon ope- - Incorrect connection of control Connect control pipes as per instal-
ning the flow valve of the feed line, pipes (with separate solenoid- lation instruction
although push-button (or solenoid valve)
valve) are not actuated. - Main valve Item 133 blocked and Disassemble, clean and replace
open joint if needed

00.13 - ES0
 MAN Diesel

503.06 Description
Edition 04
Trouble Shooting Guide for Air Starter Page 2 (2)

L21/31
L27/38

Trouble Possible Cause, see Plate 51309 Trouble Shooting

Lack of starter power - Main pipework choked or is bore Check entire pipework for correct
is less than stipulated for the bore and replace if incorrect
starter
- Insufficient air pressure Increase pressure in receiver
- Badly worn rotors Disassemble, replace and reassem-
ble

08028-0D/H5250/94.08.12

00.13 - ES0
MAN Diesel & Turbo
Description 503.06
Page 1 (1) Trouble shooting guide for air starter
Edition 05

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

L28/32S-DF
Trouble shooting guide for air starter
Trouble Possible cause, see work card Trouble shooting

1 Air always flow through A Relay valve improperly installed A Check typical installation dia-
exhaust gram and correct
B Relay valve not sealing properly B Check for damaged sealing
ring, replace relay valve or
damaged parts
C Solenoid is not sealing, pres- C Check solenoid potential at the
sure remains in APP port of lead to ground should be 0. If
relay valve not, fix ignition switch problem
2 Starter engages but does A Bad relay valve A Replace relay valve
not run
3 Starter does nut run, small A Nozzle blockage A Remove blockage or obstruc-
air flow from turbine tion from nozzles
exhaust or drive housing
4 Starter does not run. Nor- A Excessive bends in the supply A Shorten length or straighten
mal air flow from exhaust line supply air line
5 Pinion does not engage A Air pressure is too low A Increase air pressure to min.
according to "Operation data &
set points"
B Control lines to starter ports B Check installation diagram and
reversed correct
C Solenoid valve not operating or C Check wiring and solenoid
plugged operation. Correct wiring,
remove blockage, or replace
solenoid valve as needed
D Damaged pinion teeth D Replace pinion or starter drive
as necessary
6 Starter runs but engine A Air pressure too low A Increase air pressure to min.
cranks slowly or not at all according to "Operation data &
set points"
B Excessive back pressure B Check Exhaust Closure Plate
C Nozzle blocked or damaged C Remove blockage or replace
damaged parts
7 Starter continues to oper- A Solenoid valve is not sealing A See 1C above
ate after start button is correctly
released
B Relay valve is not sealing cor- B See 1B above
rectly
8 Air tank pressure decays A Air connections are not tight A Tighten loose fittings. Repair or
after extended shut down replace damaged fittings
B Damaged air lines: crushed, B Replace damaged lines
frayed, and kinked
C Relay valve is not sealing cor- C See 1B above
rectly
D Solenoid valve is stuck open D See 1C above

2014.03.31 - TDI
MAN Diesel & Turbo

Description 503.06
Page 1 (1) Trouble Shooting Guide for Air Starter Edition 06H

L27/38

Trouble Possible cause, see pl. 51309 Trouble shooting

On pressing push-button, starter does not - Empty air receiver(s) Charge receiver(s)
respond and no air flow seems to exist in - Flow valve(s) close Open flow valve(s)
control circuit. - Control circuit blocked Disconnect and clean out

On pressing push-button, starter does not - Leak in control duct Repair or replace
respond, although air flows through control - Insufficient air pressure Increase pressure in receiver
circuit. - Push button stuck Remove and clean same
- Excessive length of main air pipework Approach push-button to starter or install
a solenoid valve near the latter.

Pinion revolves and advances, but does - Ring gear and/or pinion burrs or damage Clean burrs or replace if necessary
not engage the ring gear. - Lack of clearance between pinion and Replace pinion by a more adequate one.
ring gear Check for distortion of ring gear

Pinion revolves but does not advance. - Follower Item 20 inoperative Disassemble, check, smoothen guide
diameter, clean or replace if rusted.
- Insufficient air pressure Increase pressure in receiver.
- Splined shaft Item 17 sticking Disassemble, clean, check spring Item 16
- Excessive length of control pipe and reassemble.
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
matters between teeth and for possible
wear of gears.
- Check valve Item 45 Clean and reassemble.
Replace worn parts.
Disassemble, clean and reassemble.

Pinion engages gear ring, but will not turn - Main valve Item 133 blocked Disassemble, clean and reassemble or
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 it if it
insufficient bore necessary

Starter starts working upon opening the - Incorrect connection of control pipes Connect control pipes as per installation
flow valve of the feed line, although push- (with separate solenoid valve) instruction
button (or solenoid valve) are not actuated. - Main valve Item 133 blocked and open Disassemble, clean and replace joint if
instruction needed

Lack of starter power - Main pipework choked or is bore is less Check entire pipework for correct bore
than stipulated for the starter and replace if incorrect
- Insufficient air pressure Increase pressure in receiver
- Badly worn rotors Disassemble, replace and reassemble

02.37 - ES0-b/c
MAN Diesel & Turbo

Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1) Edition 03

General

Description The pump bearings are lubricated automatically with

oil from the lubricating oil system of the engine.
The built-on fresh water pumps in the high and low
temperature circuits are of the centrifugal type. They If the pump leaks and the shaft sealing rings are
are mounted in the front end box and are driven worn, it is recommended to replace the shaft seal,
through the gearing. see Working card 516-02.00.

Trouble Possible cause Troubleshooting

Oil or water flows out of the inspec- Worn rotating sealing. See working card 502-05.00.
tion holes.

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

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

Air cannot escape on delivery side. Vent the system.

Leaking shaft seal. Check the shaft seal.

Pump capacity drops after normal Air leakages from shaft seal. Overhaul the shaft seal.
operation.
Fouled impeller. Clean the impeller.

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

Worn impeller and worn wear rings. Overhaul the pump.

Note: Running trouble with the pump, apart from

mechanical faults, is most often due to leaks in the
suction line. It is therefore essential that all pack­ings
and gaskets are in order and that they are renewed
when necessary. Even a tiny hole in the suction line
will reduce the pump capacity.

98.20 - ES0
MAN Diesel & Turbo

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

Trouble Possible cause Troubleshooting

Leakage. Too high pressure. Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operating
Data & Set Points".

Leakage. Insufficient tightening. Tighten up the plate heat exchanger, but

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

If the plate heat exchanger is still leaky,

proceed to phase 2.

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

Leakage. Gaskets. Separate the plate heat exchanger.

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

Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the 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 & Turbo

503.10 Description
Edition 01 Troubleshooting for Lubricating Oil Cooler Page 2 (2)

General

Non-Visible Leakage

Trouble Possible cause Troubleshooting

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

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

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

Leakage. Holes in plates. Close down the plate heat exchanger.

(The fluids get mixed.) Corrosion or fatigue fracture. Separate the plate heat exchanger.
(Phase 2) Put all plates to dry. Suspend the plates
in the plate heat exchanger again and
tighten it.
Circulate medium at full capacity on one
plate side (every second plate channel).
Keep the other plate channels unpres-
surised and free from liquid!
Stop the circulation after a few minutes
of operation and open the plate heat ex-
changer again. Take care to avoid water
spraying onto the dry plate side!
By a careful study of the plates it will be
possible to find moist areas, if any, on the
otherwise dry plate sides.
Check these areas with a dye penetrant!
Replace defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
Assemble the plate heat exchanger and
check to find more defective plates, if any,
by putting one side under press.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!

98.20 - ES0
Media specification

504/604
 MAN Diesel & Turbo 010.000.023-11

Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)

Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
General
The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Medium alkalinity lubricating oils have a proven track record as lubricants for
the moving parts and turbocharger cylinder and for cooling the pistons.
Lubricating oils of medium alkalinity contain additives that, in addition to
other properties, ensure a higher neutralisation reserve than with fully com-
pounded engine oils (HD oils).
International specifications do not exist for medium alkalinity lubricating oils.
A test operation is therefore necessary for a corresponding long period in
accordance with the manufacturer's instructions.
Only lubricating oils that have been approved by MAN Diesel & Turbo may be
used. These are listed in the table entitled "Lubricating oils approved for use
in heavy fuel oil-operated MAN Diesel & Turbo four-stroke engines".

Specifications
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the limit values in the table below, particularly
in terms of its resistance to ageing:
Properties/Characteristics Unit Test method Limit value
Make-up - - Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 -15
Flash point (Cleveland) °C ASTM D 92 > 200

Lubricating oil (SAE 40) - Specification for heavy fuel

Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of heating - MAN ageing oven * -
up to 135 °C
Insoluble n-heptane Weight % ASTM D 4055 < 0.2
or DIN 51592
Evaporation loss Weight % - <2
Spot test (filter paper) - MAN Diesel test Precipitation of resins or
asphalt-like ageing products
must not be identifiable.
Table 1: Base oils - target values

* Works' own method

2013-05-23 - de

operation (HFO)

Medium alkalinity lubricating The prepared oil (base oil with additives) must have the following properties:
oil
Additives The additives must be dissolved in the oil and their composition must ensure
General

that after combustion as little ash as possible is left over, even if the engine is
provisionally operated with distillate oil.

D010.000.023-11-0001 EN 1 (5)
 010.000.023-11 MAN Diesel & Turbo

The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
osition in the combustion chamber will be higher, particularly at the outlet
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)

valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
ting of the valve seats, and causes valve burn-out, it also increases mechani-
cal wear of the cylinder liners.
Additives must not increase the rate, at which the filter elements in the active
or used condition are blocked.
Washing ability The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion. The lubricating oil must not
absorb the deposits produced by the fuel.
Dispersion capability The selected dispersibility must be such that commercially-available lubricat-
ing oil cleaning systems can remove harmful contaminants from the oil used,
i.e. the oil must possess good filtering properties and separability.
Neutralisation capability The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
For tips on selecting the base number, refer to the table entitled “Base num-
ber to be used for various operating conditions".
Evaporation tendency The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
Additional requirements The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.

Lubricating oil selection

Engine SAE class
16/24, 21/31, 27/38, 28/32S, 32/40, 32/44, 40/54, 48/60, 58/64, 40
51/60DF
Table 2: Viscosity (SAE class) of lubricating oils
Lubricating oil (SAE 40) - Specification for heavy fuel

Neutralisation properties Lubricating oils with medium alkalinity and a range of neutralization capabili-
(BN) ties (BN) are available on the market. According to current knowledge, a rela-
tionship can be established between the anticipated operating conditions
and the BN number as shown in the table entitled "Base number to be used
for various operating conditions". However, the operating results are still the
overriding factor in determining which BN number provides the most efficient
engine operation.
Approx. BN Engines/Operating conditions
of fresh oil
(mg KOH/g oil)
20 Marine diesel oil (MDO) of a lower quality and high sulphur content or heavy fuel oil with a sulphur
content of less than 0.5 %
30 generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating conditions.
2013-05-23 - de

For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
operation (HFO)

51/60DF for exclusively HFO operation only with a sulphur content < 1.5 %.
General

2 (5) D010.000.023-11-0001 EN
 MAN Diesel & Turbo 010.000.023-11

Approx. BN Engines/Operating conditions

Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
of fresh oil
(mg KOH/g oil)
40 Under unfavourable operating conditions 23/30A, 28/32A and 28/32S, and where the corre-
sponding requirements for the oil service life and washing ability exist.
In general 16/24, 21/31, 27/38, 32/40, 32/44CR, 32/44K, 40/54, 48/60 as well as 58/64 and
51/60DF for exclusively HFO operation providing the sulphur content is over 1.5 %.
50 32/40, 32/44CR, 32/44K, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is
insufficient with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil
consumption).
Table 3: Base number to be used for various operating conditions
Operation with low-sulphur To comply with the emissions regulations, the sulphur content of fuels used
fuel nowadays varies. Fuels with a low-sulphur content must be used in environ-
mentally-sensitive areas (SECA). Fuels with a higher sulphur content may be
used outside SECA zones. In this case, the BN number of the lubricating oil
selected must satisfy the requirements for operation using fuel with a high-
sulphur content. A lubricating oil with low BN number may only be selected if
fuel with a low-sulphur content is used exclusively during operation.
However, the results obtained in practiсe that demonstrate the most efficient
engine operation are the factor that ultimately determines, which additive
fraction is permitted.
Cylinder lubricating oil In engines with separate cylinder lubrication systems, the pistons and cylin-
der liners are supplied with lubricating oil via a separate lubricating oil pump.
The quantity of lubricating oil is set at the factory according to the quality of
the fuel to be used and the anticipated operating conditions.
Use a lubricating oil for the cylinder and lubricating circuit as specified above.
Speed governor Multigrade oil 5W40 should ideally be used in mechanical-hydraulic control-
lers with a separate oil sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not available when filling,
15W40 oil may be used instead in exceptional cases. In this case, it makes
no difference whether synthetic or mineral-based oils are used.
The military specification for these oils is O-236.

Lubricating oil (SAE 40) - Specification for heavy fuel

Experience with the drive engine L27/38 has shown that the operating tem-
perature of the Woodward controller UG10MAS and corresponding actuator
for UG723+ can reach temperatures higher than 93 °C. In these cases, we
recommend using synthetic oil such as Castrol Alphasyn HG150. The
engines supplied after March 2005 are already filled with this oil.
Lubricating oil additives The use of other additives with the lubricating oil, or the mixing of different
brands (oils by different manufacturers), is not permitted as this may impair
the performance of the existing additives which have been carefully harmon-
ised with each another, and also specially tailored to the base oil.
Selection of lubricating oils/ Most of the mineral oil companies are in close regular contact with engine
warranty manufacturers, and can therefore provide information on which oil in their
specific product range has been approved by the engine manufacturer for
the particular application. Irrespective of the above, the lubricating oil manu-
facturers are in any case responsible for the quality and characteristics of
2013-05-23 - de

operation (HFO)

their products. If you have any questions, we will be happy to provide you
with further information.
Oil during operation There are no prescribed oil change intervals for MAN Diesel & Turbo medium
General

speed engines. The oil properties must be regularly analysed. The oil can be
used for as long as the oil properties remain within the defined limit values
(see table entitled "Limit values for used lubricating oil“). An oil sample must

D010.000.023-11-0001 EN 3 (5)
 010.000.023-11 MAN Diesel & Turbo

be analysed every 1-3 months (see maintenance schedule). The quality of the
oil can only be maintained if it is cleaned using suitable equipment (e.g. a
Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)

separator or filter).
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-
ing oil with a BN of 20 must be used. If the BN 20 lubricating oil from the
same manufacturer as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the
changeover. It will be sufficient to use BN 20 oil when replenishing the used
lubricating oil.
If you wish to operate the engine with HFO once again, it will be necessary to
change over in good time to lubricating oil with a higher BN (30 – 55). If the
lubricating oil with higher BN is by the same manufacturer as the BN 20 lubri-
cating oil, the changeover can also be effected without an oil change. In
doing so, the lubricating oil with higher BN (30 – 55) must be used to replen-
ish the used lubricating oil roughly 2 weeks prior to resuming HFO operation.
Limit value Procedure
Viscosity at 40 ℃ 110 - 220 mm²/s ISO 3104 or ASTM D 445
Base number (BN) at least 50 % of fresh oil ISO 3771
Flash point (PM) At least 185 ℃ ISO 2719
Water content max. 0.2 % (max. 0.5 % for brief peri- ISO 3733 or ASTM D 1744
ods)
n-heptane insoluble max. 1.5 % DIN 51592 or IP 316
Metal content depends on engine type and operat-
Lubricating oil (SAE 40) - Specification for heavy fuel

ing conditions
Guide value only .
Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Table 4: Limit values for used lubricating oil

Tests
Regular analysis of lube oil samples is very important for safe engine opera-
2013-05-23 - de

tion. We can analyse fuel for customers at our laboratory (PrimeServLab).

operation (HFO)

Base Number (mgKOH/g)

Manufacturer
20 30 40 50
General

AEGEAN —— Alfamar 430 Alfamar 440 Alfamar 450

AGIP —— Cladium 300 Cladium 400 ——

4 (5) D010.000.023-11-0001 EN
 MAN Diesel & Turbo 010.000.023-11

Base Number (mgKOH/g)

Lubricating oil (SAE 40) - Specification for heavy fuel operation (HFO)
Manufacturer
20 30 40 50

BP Energol IC-HFX 204 Energol IC-HFX 304 Energol IC-HFX 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
CHEVRON Taro 20DP40 Taro 30DP40 Taro 40XL40 Taro 50XL40
(Texaco, Caltex) Taro 20DP40X Taro 30DP40X Taro 40XL40X Taro 50XL40X
EXXON MOBIL —— Mobilgard M430 Mobilgard M440 Mobilgard M50
—— Exxmar 30 TP 40 Exxmar 40 TP 40
LUKOIL Navigo TPEO 20/40 Navigo TPEO 30/40 Navigo TPEO 40/40 Navigo TPEO 50/40
Navigo TPEO 55/40
PETROBRAS Marbrax CCD-420 Marbrax CCD-430 Marbrax CCD-440 ——
REPSOL Neptuno NT 2040 Neptuno NT 3040 Neptuno NT 4040 ——
SHELL Argina S 40 Argina T 40 Argina X 40 Argina XL 40
Argina XX 40
TOTAL LUBMAR- —— Aurelia TI 4030 Aurelia TI 4040 Aurelia TI 4055
INE
Table 5: Approved lubricating oils for heavy fuel oil-operated MAN Diesel & Turbo four-stroke engines.

No liability assumed if these oils are used

MAN Diesel & Turbo SE does not assume liability for problems that
occur when using these oils.

Lubricating oil (SAE 40) - Specification for heavy fuel

2013-05-23 - de

operation (HFO)
General

D010.000.023-11-0001 EN 5 (5)
 MAN Diesel & Turbo 010.000.023-07

Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil

Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
(MGO/MDO) and biofuels
General
The specific output achieved by modern diesel engines combined with the
use of fuels that satisfy the quality requirements more and more frequently
increase the demands on the performance of the lubricating oil which must
therefore be carefully selected.
Doped lubricating oils (HD oils) have a proven track record as lubricants for
the drive, cylinder, turbocharger and also for cooling the piston. Doped lubri-
cating oils contain additives that, amongst other things, ensure dirt absorp-
tion capability, cleaning of the engine and the neutralisation of acidic com-
bustion products.
Only lubricating oils that have been approved by MAN Diesel & Turbo may be
used. These are listed in the tables below.

Specifications
Base oil The base oil (doped lubricating oil = base oil + additives) must have a narrow
distillation range and be refined using modern methods. If it contains paraf-
fins, they must not impair the thermal stability or oxidation stability.
The base oil must comply with the following limit values, particularly in terms
of its resistance to ageing.
Properties/Characteristics Unit Test method Limit value
Make-up - - Ideally paraffin based
Low-temperature behaviour, still flowable °C ASTM D 2500 -15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02

Specification of lubricating oil (SAE 40) for operation with

Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of heating - MAN ageing oven * -
up to 135 °C
Insoluble n-heptane Weight % ASTM D 4055 < 0.2
or DIN 51592 gas oil, diesel oil (MGO/MDO) and biofuels
Evaporation loss Weight % - <2
Spot test (filter paper) - MAN Diesel test Precipitation of resins or
asphalt-like ageing products
must not be identifiable.
Table 1: Base oils - target values

* Works' own method

Compounded lubricating oils The base oil to which the additives have been added (doped lubricating oil)
(HD oils) must have the following properties:
2013-04-11 - de

Additives The additives must be dissolved in the oil, and their composition must ensure
that as little ash as possible remains after combustion.
General

D010.000.023-07-0001 EN 1 (5)
 010.000.023-07 MAN Diesel & Turbo

The ash must be soft. If this prerequisite is not met, it is likely the rate of dep-
osition in the combustion chamber will be higher, particularly at the outlet
Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels

valves and at the turbocharger inlet housing. Hard additive ash promotes pit-
ting of the valve seats, and causes valve burn-out, it also increases mechani-
cal wear of the cylinder liners.
Additives must not increase the rate, at which the filter elements in the active
or used condition are blocked.
Washing ability The washing ability must be high enough to prevent the accumulation of tar
and coke residue as a result of fuel combustion.
Dispersion capability The selected dispersibility must be such that commercially-available lubricat-
ing oil cleaning systems can remove harmful contaminants from the oil used,
i.e. the oil must possess good filtering properties and separability.
Neutralisation capability The neutralisation capability (ASTM D2896) must be high enough to neutral-
ise the acidic products produced during combustion. The reaction time of
the additive must be harmonised with the process in the combustion cham-
ber.
Evaporation tendency The evaporation tendency must be as low as possible as otherwise the oil
consumption will be adversely affected.
Additional requirements The lubricating oil must not contain viscosity index improver. Fresh oil must
not contain water or other contaminants.

Lubricating oil selection

Engine SAE class
16/24, 21/31, 27/38, 28/32S, 32/40, 32/44, 40/54, 48/60, 58/64, 40
51/60DF
Table 2: Viscosity (SAE class) of lubricating oils
Doped oil quality We recommend doped lubricating oils (HD oils) according to international
specifications MIL-L 2104 or API-CD with a base number of BN 10 – 16 mg
KOH/g. Military specification O-278 lubricating oils may be used.
Specification of lubricating oil (SAE 40) for operation with

The operating conditions of the engine and the quality of the fuel determine
the additive fractions the lubricating oil should contain. If marine diesel oil is
used, which has a high sulphur content of 1.5 up to 2.0 weight %, a base
number of appr. 20 should be selected. However, the operating results that
ensure the most efficient engine operation ultimately determine the additive
content.
gas oil, diesel oil (MGO/MDO) and biofuels

Cylinder lubricating oil In engines with separate cylinder lubrication systems, the pistons and cylin-
der liners are supplied with lubricating oil via a separate lubricating oil pump.
The quantity of lubricating oil is set at the factory according to the quality of
the fuel to be used and the anticipated operating conditions.
Use a lubricating oil for the cylinder and lubricating circuit as specified above.
Speed governor Multigrade oil 5W40 should ideally be used in mechanical-hydraulic control-
lers with a separate oil sump, unless the technical documentation for the
speed governor specifies otherwise. If this oil is not available when filling,
15W40 oil may be used instead in exceptional cases. In this case, it makes
2013-04-11 - de

no difference whether synthetic or mineral-based oils are used.

The military specification for these oils is O-236.
General

2 (5) D010.000.023-07-0001 EN
 MAN Diesel & Turbo 010.000.023-07

Experience with the drive engine L27/38 has shown that the operating tem-
perature of the Woodward controller UG10MAS and corresponding actuator

Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
for UG723+ can reach temperatures higher than 93 °C. In these cases, we
recommend using synthetic oil such as Castrol Alphasyn HG150. The
engines supplied after March 2005 are already filled with this oil.
Lubricating oil additives The use of other additives with the lubricating oil, or the mixing of different
brands (oils by different manufacturers), is not permitted as this may impair
the performance of the existing additives which have been carefully harmon-
ised with each another, and also specially tailored to the base oil.
Selection of lubricating oils/ Most of the mineral oil companies are in close regular contact with engine
warranty manufacturers, and can therefore provide information on which oil in their
specific product range has been approved by the engine manufacturer for
the particular application. Irrespective of the above, the lubricating oil manu-
facturers are in any case responsible for the quality and characteristics of
their products. If you have any questions, we will be happy to provide you
with further information.
Oil during operation There are no prescribed oil change intervals for MAN Diesel & Turbo medium
speed engines. The oil properties must be regularly analysed. The oil can be
used for as long as the oil properties remain within the defined limit values
(see table entitled "Limit values for used lubricating oil“). An oil sample must
be analysed every 1-3 months (see maintenance schedule). The quality of the
oil can only be maintained if it is cleaned using suitable equipment (e.g. a
separator or filter).
Temporary operation with Due to current and future emission regulations, heavy fuel oil cannot be used
gas oil in designated regions. Low-sulphur diesel fuel must be used in these regions
instead.
If the engine is operated with low-sulphur diesel fuel for less than 1,000 h, a
lubricating oil which is suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
If the engine is operated provisionally with low-sulphur diesel fuel for more
than 1,000 h and is subsequently operated once again with HFO, a lubricat-

Specification of lubricating oil (SAE 40) for operation with

ing oil with a BN of 20 must be used. If the BN 20 lubricating oil from the
same manufacturer as the lubricating oil is used for HFO operation with
higher BN (40 or 50), an oil change will not be required when effecting the
changeover. It will be sufficient to use BN 20 oil when replenishing the used
lubricating oil.
If you wish to operate the engine with HFO once again, it will be necessary to
gas oil, diesel oil (MGO/MDO) and biofuels
change over in good time to lubricating oil with a higher BN (30 – 55). If the
lubricating oil with higher BN is by the same manufacturer as the BN 20 lubri-
cating oil, the changeover can also be effected without an oil change. In
doing so, the lubricating oil with higher BN (30 – 55) must be used to replen-
ish the used lubricating oil roughly 2 weeks prior to resuming HFO operation.

Tests
Regular analysis of lube oil samples is very important for safe engine opera-
2013-04-11 - de

tion. We can analyse fuel for customers at our laboratory (PrimeServLab).

General

D010.000.023-07-0001 EN 3 (5)
 010.000.023-07 MAN Diesel & Turbo

Improper handling of operating fluids

Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels

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

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

Approved lubricating oils SAE 40

Manufacturer Base number 10 - 16 1) (mgKOH/g)
AGIP Cladium 120 - SAE 40
Sigma S SAE 40 2)
BP Energol DS 3-154
CASTROL Castrol MLC 40
Castrol MHP 154
Seamax Extra 40
CHEVRON Texaco Taro 12 XD 40
(Texaco, Caltex) Delo 1000 Marine SAE 40
Delo SHP40
EXXON MOBIL Exxmar 12 TP 40
Mobilgard 412/MG 1SHC
Mobilgard ADL 40
Delvac 1640
PETROBRAS Marbrax CCD-410
Marbrax CCD-415
Q8 Mozart DP40
REPSOL Neptuno NT 1540
Specification of lubricating oil (SAE 40) for operation with

SHELL Gadinia 40
Gadinia AL40
Sirius X40 2)
Rimula R3+40 2)
STATOIL MarWay 1540
gas oil, diesel oil (MGO/MDO) and biofuels

MarWay 1040 2)
TOTAL LUBMARINE Caprano M40
Disola M4015
Table 3: Lubricating oils approved for use in MAN Diesel & Turbo four-stroke Diesel engines that run on gas oil and
diesel fuel
If marine diesel oil is used, which has a very high sulphur content of 1.5 up
1)

to 2.0 weight %, a base number of appr. 20 should be selected.

2)
With a sulphur content of less than 1 %
2013-04-11 - de

No liability assumed if these oils are used

MAN Diesel & Turbo SE does not assume liability for problems that
General

occur when using these oils.

4 (5) D010.000.023-07-0001 EN
 MAN Diesel & Turbo 010.000.023-07

Limit value Procedure

Specification of lubricating oil (SAE 40) for operation with gas oil, diesel oil
(MGO/MDO) and biofuels
Viscosity at 40 ℃ 110 - 220 mm²/s ISO 3104 or ASTM D445
Base number (BN) at least 50 % of fresh oil ISO 3771
Flash point (PM) At least 185 ℃ ISO 2719
Water content max. 0.2 % (max. 0.5 % for brief peri- ISO 3733 or ASTM D 1744
ods)
n-heptane insoluble max. 1.5 % DIN 51592 or IP 316
Metal content depends on engine type and operat-
ing conditions
Guide value only .
Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
When operating with biofuels: max. 12 % FT-IR
biofuel fraction
Table 4: Limit values for used lubricating oil

Specification of lubricating oil (SAE 40) for operation with

gas oil, diesel oil (MGO/MDO) and biofuels
2013-04-11 - de

General

D010.000.023-07-0001 EN 5 (5)
MAN Diesel & Turbo
Description 504.03
Page 1 (7) Treatment and maintenance of lubricating oilD
Edition 08

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

General Operation on Heavy Fuel Oil (HFO)

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

2013.10.04
 MAN Diesel & Turbo
504.03 Description
Treatment and maintenance of lubricating oilD Page 2 (7)
Edition 08

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

The most appropriate type of equipment for a par- Lubricating oil preheating
ticular application depends on the engine output,
the type and amount of combustion residues, the The installed heater on the separator unit ensures
annual operating time and the operating mode of correct lubricating oil temperature during separa-
the plant. Even with a relatively low number of oper- tion. When the engine is at standstill, the heater can
ating hours there can be a great deal of combustion be used for two functions:
residues if, for instance, the engine is inadequately ▪ The oil in the sump is preheated to 95 – 98 °C
preheated and quickly accelerated and loaded. by the heater and cleaned continuously by the
separator unit.
Separator unit ▪ The heater can also be used to maintain an oil
temperature of at least 40 °C, depending on
Continuous lubricating oil cleaning during engine
installation of the lubricating oil system.
operation is mandatory. An optimal lubricating oil
treatment is fundamental for a reliable working con-
dition of the engine. Cleaning capacity
If the lubricating oil is circulating without a separator Normally, it is recommended to use a self-cleaning
unit in operation, the lubricating oil will gradually be filtration unit in order to optimize the cleaning period
contaminated by products of combustion, water and thus also optimize the size of the filtration unit.
and/or acid. In some instances cat-fines may also Separator units for manual cleaning can be used
be present. when the reduced effective cleaning time is taken
In order to prolong the lubricating oil lifetime and into consideration by dimensioning the separator
remove wear elements, water and contaminants unit capacity.
from the lubricating oil, it is mandatory to use a by-
pass separator unit. The required operation and design flow
The separator unit will reduce the carbon residue
content and other contaminants from combustion In order to calculate the required operation flow
on engines operated on HFO, and keep the amount through the separator unit, MDT's recommendation
within MDT’s recommendation, on condition that must be followed.
the separator unit is operated according to MDT's As a guidance, the following formula should form
recommendations. the basis for calculating the required operation flow
When operating a cleaning device, the following through the separator unit:
recommendations must be observed:
▪ The optimum cleaning effect is achieved by
keeping the lubricating oil in a state of low vis-
cosity for a long period in the separator bowl.
Q = required operation flow [l/h]
▪ Sufficiently low viscosity is obtained by preheat-
ing the lubricating oil to a temperature of 95°C - P = MCR (Maximum Continuous Rat-
98°C, when entering the separator bowl. ing) [kW]

▪ The capacity of the separator unit must be t = actual effective separator unit sep-
arating time per day [hour]
adjusted according to MDT's recommenda-
(23.5 h separating time and 0.5 h
tions. for sludge discharge = 24 h/day)
Slow passage of the lubricating oil through the sep-
n = number of turnovers per day of the
arator unit is obtained by using a reduced flow rate theoretical oil volume correspond-
and by operating the separator unit 24 hours a day, ing to 1.36 [l/kW] or 1 [l/HP]
stopping only for maintenance, according to mak-
er's recommendation. The following values for "n" are recommended:
n = 6 for HFO operation (residual)
n = 4 for MDO operation
n = 3 for distillate fuel

2013.10.04
MAN Diesel & Turbo
Description 504.03
Page 3 (7) Treatment and maintenance of lubricating oilD
Edition 08

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

Example 1
For multi-engine plants, one separator unit per
engine in operation is recommended.

In order to obtain sufficient cleaning of the lubricat-

ing oil, the operation flow through the separator unit
must be around 15-25% of the design flow.
The design flow for selection of separator unit size
will then be in the range 1806-3009 l/h.
With an average power demand above 50% of the
installed GenSet power, the operation flow must be
based on 100% of the installed GenSet power.

Figure 1: Example 1

One 1000 kW engine operating on HFO connected

to a self-cleaning separator unit with a daily effective
separating period of 23.5 hours:

In order to obtain sufficient cleaning of the lubricat-

ing oil, the operation flow through the separator unit
must be around 15-25% of the design flow.
The design flow for selection of separator unit size
will then be in the range 1389-2315 l/h.

Example 2
As alternative one common separator unit can be
installed, with one in reserve if possible, for multi- 1 Interconnected valves
engine plants (maximum 3 engines per separator
unit). Figure 2: Example 2

The experienced load profile for the majority of mer-

chant vessels is that the average power demand is
around 43-50% of the installed GenSet power. With
three identical engines this corresponds to 1.3-1.5
times the power of one engine.
▪ Bulk Carrier and tankers : ~1.3 times the power
of one engine
▪ Container vessel : ~1.5 times the power of one
engine
Three 1000 kW engines operating on HFO connec-
ted to a common self-cleaning separator unit with a
daily effective separating period of 23.5 hours:

2013.10.04
 MAN Diesel & Turbo
504.03 Description
Treatment and maintenance of lubricating oilD Page 4 (7)
Edition 08

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

Density and viscosity are important parameters for
Separator unit installation efficient separation. The greater the difference in
density between the particle and the lubricating oil,
With multi-engine plants, one separator unit per the higher the separation efficiency. The settling
engine in operation is recommended (see figure 1), velocity increases in inverse proportion to viscosity.
but if only one separator unit is in operation, the fol- However, since both density and viscosity vary with
lowing layout can be used: temperature, separation temperature is the critical
▪ A common separator unit (see figure 2) can be operating parameter.
installed, with one in reserve, if possible, for Particle size is another important factor. The settling
operation of all engines through a pipe system, velocity increases rapidly with particle size. This
which can be carried out in various ways. The means that the smaller the particle, the more chal-
aim is to ensure that the separator unit is only lenging the separation task. In a centrifuge, the term
connected to one engine at a time. Thus there (rω2) represents the centrifugal force which is sev-
will be no suction and discharging from one eral thousand times greater than the acceleration
engine to another. due to gravitational force. Centrifugal force enables
It is recommended that inlet and outlet valves are the efficient separation of particles which are only a
connected so that they can only be changed over few microns in size.
simultaneously. The separation efficiency is a function of:
With only one engine in operation there are no
problems with separating, but if several engines are
in operation for some time it is recommended to
split up the separation time in turns on all operating
engines.
With 2 out of 3 engines in operation the 23.5 hours
separating time must be split up in around 4-6
hours intervals between changeover.

Stokes' law
The operating principles of centrifugal separation
are based on Stokes’ Law.

V = settling velocity [m/sec]

rω 2
= acceleration in centrifgal field [m/sec2]
d = diameter of particle [m]
ρp = density of particle [kg/m3]
ρl = density of medium [kg/m3]
µ = viscosity of medium [kg/m, sec.]

The rate of settling (V) for a given capacity is deter-

mined by Stokes’ Law. This expression takes into
account the particle size, the difference between
density of the particles and the lubricating oil, and
the viscosity of the lubricating oil.

2013.10.04
MAN Diesel & Turbo
Description 504.03
Page 5 (7) Treatment and maintenance of lubricating oilD
Edition 08

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

tor unit. In order to ensure that the centrifugal forces
separate the heavy contaminants in the relatively
limited time that they are present in the separator
bowl, the separator unit must always be operated
with an inlet temperature of 95-98°C for lubricating
oil.
A control circuit including a temperature transmitter
and a PI-type controller with accuracy of ±2°C must
be installed. If steam-heated, a correctly sized
steam valve should be fitted with the right KvS
value. The steam trap must be a mechanical float
type. The most common heaters on board are
steam heaters. This is due to the fact that steam in
most cases is available at low cost.
Most ships are equipped with an exhaust boiler uti-
lizing the exhaust gases to generate steam.
A large proportion of smaller tonnage does, how-
ever, use electric heaters.
It is essential to keep the incoming oil temperature
to the separator unit steady with only a small varia-
tion in temperature allowed (maximum ±2°C).
The position of the interface between oil and water
in the separator bowl is a result of the density and
the viscosity of the oil, which in turn depends on the
temperature.

Flow rate
It is known that separation efficiency is a function of
the separator unit’s flow rate. The higher the flow
rate, the more particles are left in the oil and there-
fore the lower the separation efficiency. As the flow
rate is reduced, the efficiency with which particles
are removed increases and cleaning efficiency thus
Operating parameters improves. It is, however, essential to know at what
capacity adequate separation efficiency is reached
Various operating parameters affect separation effi-
in the specific case.
ciency. These include temperature, which controls
both lubricating oil viscosity and density, flow rate In principle, there are three ways to control the flow:
and maintenance. ▪ Adjustment of the built-in safety valve on the
pump.
Temperature of lubricating oil before This method is NOT recommended since the
separator unit built-on valve is nothing but a safety valve.
It is often seen that the lubricating oil pre-heaters The opening pressure is often too high and its
are undersized, have very poor temperature control, characteristic far from linear.
the steam supply to the pre-heater is limited or the In addition, circulation in the pump may result in
temperature set point is too low. oil emulsions and cavitation in the pump.
Often the heater surface is partly clogged by depos- ▪ A flow regulating valve arrangement on the
its. These factors all lead to reduced separation pressure side of the pump, which bypasses the
temperature and hence the efficiency of the separa- separator unit and re-circulates part of the

2013.10.04
 MAN Diesel & Turbo
504.03 Description
Treatment and maintenance of lubricating oilD Page 6 (7)
Edition 08

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

untreated lubricating oil back to the treated oil oxidation of the oil itself (TAN) or to the presence of
return line, from the separator unit and NOT inorganic acids (SAN). In both cases the presence
directly back to the suction side of the pump. of water will multiply the effect, especially sea water
The desired flow rate is set manually by means as the chloride ions act as an inorganic acid.
of the flow regulating valve. Further, the require-
ment for backpressure in the clean oil outlet Signs of deterioration
MUST also be fulfilled, helping to maintain the
If circulating oil of inferior quality is used and the oxi-
correct interface position.
dative influence becomes grave, prompt action is
▪ Speed control of the pump motor with a fre- necessary as the last stages in the deterioration will
quency converter or a 2-speed motor. develop surprisingly quickly, within one or two
This is a relatively cheap solution today and is a weeks. Even if this seldomly happens, it is wise to
good alternative for flow control. be acquainted with the signs of deterioration.
These may be some or all of the following:
Maintenance ▪ Sludge precipitation in the separator unit multi-
Proper maintenance is an important, but often over- plies
looked operating parameter that is difficult to quan- ▪ Smell of oil becomes acrid or pungent
tify. If the bowl is not cleaned in time, deposits will ▪ Machined surfaces in the crankcase become
form on the bowl discs, the free channel height will coffee-brown with a thin layer of lacquer
be reduced, and flow velocity increases. This further
tends to drag particles with the liquid flow towards ▪ Paint in the crankcase peels off or blisters
the bowl’s centre resulting in decreased separation ▪ Excessive carbon is formed in the piston cool-
efficiency. ing chamber
In a grave case of oil deterioration the system must
Check of lubricating oil system be cleaned thoroughly and refilled with new oil.
For cleaning of the lubricating oil system after over-
hauls and inspection of the lubricating oil piping Oxidation of oils
system the following checks must be carried out:
At normal service temperature the rate of oxidation
1. Examine the piping system for leaks. is insignificant, but the following factors will acceler-
2. Retighten all bolts and nuts in the piping sys- ate the process:
tem. High temperature
3. Move all valves and cocks in the piping system. If the coolers are ineffective, the temperature level
Lubricate valve spindles with graphite or similar. will generally rise. A high temperature will also arise
in electrical pre-heaters if the circulation is not con-
4. Blow through drain pipes. tinued for 5 minutes after the heating has been
5. Check flexible connections for leaks and dam- stopped, or if the heater is only partly filled with oil.
ages. Catalytic action
6. Check manometers and thermometers for pos- Oxidation of the oil will be accelerated considerably
sible damages. if catalytic particles are present in the oil. Wear par-
ticles of copper are especially harmful, but also fer-
Deterioration of oil rous particles and rust are active. Furthermore, the
lacquer and varnish oxidation products of the oil
Oil seldomly loses its ability to lubricate, i.e. to form itself have an accelerating effect. Continuous clean-
a friction-decreasing oil film, but it may become cor- ing of the oil is therefore important to keep the
rosive to the steel journals of the bearings in such a sludge content low.
way that the surface of these journals becomes too
rough and wipes the bearing surface.
Water washing
In that case the bearings must be renewed, and the
journals must also be polished. The corrosiveness Water washing of HD oils (heavy duty) must not be
of the lubricating oil is either due to far advanced carried out.

2013.10.04
MAN Diesel & Turbo
Description 504.03
Page 7 (7) Treatment and maintenance of lubricating oilD
Edition 08

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

Water in the oil

If the TAN is low, a minor increase in the fresh water
content of the oil is not immediately detrimental
while the engine is in operation. Naturally, it should
be brought down again as quickly as possible
(below 0.2% water content, which is permissible,
see description "B 12 15 0/504.04 criteria for
exchange of lube oil”). If the engine is stopped while
corrosion conditions are unsatisfactory, the crank-
shaft must be turned ½ - ¾ revolution once every
hour by means of the turning gear. Please make
sure that the crankshaft stops in different positions,
to prevent major damage to bearings and journals.
The lubricating oil must be circulated and separated
continuously to remove water.
Water in the oil may be noted by steam formation
on the sight glasses, by appearance, or ascertained
by immersing a piece of glass or a soldering iron
heated to 200-300°C in an oil sample. If there is a
hissing sound, water is present. If a large quantity of
water has entered the lubricating oil system, it has
to be removed. Either by sucking up sediment
water from the bottom, or by replacing the oil in the
sump. An oil sample must be analysed immediately
for chloride ions.

2013.10.04
MAN Diesel & Turbo
Description 504.04
Page 1 (2) Criteria for cleaning/exchange of lubricating oil
Edition 07

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

Replacement of lubricating oil 2. Flash point

The expected lubricating oil lifetime in operation is Min. value : 185° C
difficult to determine. The lubricating oil lifetime is
depending on the fuel oil quality, the lubricating oil Possible test : ASTM D-92, ISO 2719
method
quality, the lubricating oil consumption, the lubricat-
ing oil cleaning equipment efficiency and the engine Normally used to indicate fuel dilution.
operational conditions.
In order to evaluate the lubricating oil condition a 3. Water content
sample should be drawn on regular basis at least
once every three month or depending on the latest Max. value : 0.2 %
analysis result. The lubricating oil sample must be Unit : Weight %
drawn before the filter at engine in operation. The
sample bottle must be clean and dry, supplied with Possible test : ASTM D4928, ISO 3733
method
sufficient indentification and should be closed
immediately after filling. The lubricating oil sample Water can originate from contaminated fuel oil, an
must be examined in an approved laboratory or in engine cooling water leak or formed as part of the
the lubricating oil suppliers own laboratory. combustion process. If water is detected also
A lubricating oil replacement or an extensive lubri- Sodium, Glycol or Boron content should be
cating oil cleaning is required when the MAN Diesel checked in order to confirm engine coolant leaks.
& Turbo exchange criteria's have been reached.
4. Base number
Evaluation of the lubricating oil condition
Min. value : The BN value should not be lower
Based on the analysis results, the following guid- than 50% of fresh lubricating oil value,
ance are normally sufficient for evaluating the lubri- but minimum BN level never to be
cating oil condition. The parameters themselves can lower than 10-12 at operating on HFO!
not be jugded alonestanding, but must be evalu- Unit : mg KOH/g
ated together in order to conclude the lubricating oil
Possible test : ASTM D-2896, ISO 3771
condition. method

1. Viscosity The neutralization capacity must secure that the

acidic combustion products, mainly sulphur origi-
Limit value: nate from the fuel oil, are neutralized at the lube oil
consumption level for the specific engine type.
Normal min. max.
value value value
Gradually the BN will be reduced, but should reach
an equilibrium.
SAE 30 [cSt@40° C] 95 - 125 75 160
SAE 30 [cSt@100° C] 11 - 13 9 15 5. Total acid number (TAN)
SAE 40 [cSt@40° C] 135 - 165 100 220
Max. value : 3.0 acc. to fresh oil value
SAE 40 [cSt@100° C] 13.5 - 15.0 11 19
Unit : mg KOH/g
Possible test : ASTM D-664
Unit : cSt (mm2/s) method
Possible test : ASTM D-445, DIN51562/53018, ISO TAN is used to monitor oil degradation and is a
method 3104 measure of the total acids present in the lubricating
Increasing viscosity indicates problems with insolu- oil derived from oil oxidation (weak acids) and acidic
bles, HFO contamination, water contamination, oxi- products of fuel combustion (strong acids).
dation, nitration and low load operation. Decreasing
viscosity is generally due to dilution with lighter vis-
cosity oil.

2007.03.12
 MAN Diesel & Turbo
504.04 Description
Criteria for cleaning/exchange of lubricating oil Page 2 (2)
Edition 07

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

6. Insolubles content
Max. value : 1.5 % generally, depending upon
actual dispersant value and the
increase in viscosity
Unit : Weight %
Possible test : ASTM D-893 procedure B in Heptane,
method DIN 51592
Additionally : If the level in n-Heptane insolubles is
test considered high for the type of oil and
application, the test could be followed
by a supplementary determination in
Toluene.

Total insolubles is maily derived from products of

combustion blown by the piston rings into the
crankcase. It also includes burnt lubricating oil,
additive ash, rust, salt, wear debris and abrasive
matter.

7. Metal content
Metal content Remarks Attention limits
Iron Depend upon max. 50 ppm
Chromium engine type and max. 10 ppm
Copper operating condi- max. 15 ppm
Lead tions max. 20 ppm
Tin max. 10 ppm
Aluminium max. 20 ppm
Silicon max. 20 ppm

2007.03.12
 MAN Diesel

Description
Page 1 (1) Lubricating Points 504.05
Edition 03

General
Lubricating Oil Types Used in the Engine

Description Lub. Oil Type

Engine system lubricating oil SAE 40 oil according to lubricating oil specification on page 504.01.

Turbocharger Engine system lubricating oil.

Governor See governor instructions in section 509.

Alternator (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 03H

L27/38

Type L27/38 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.

Min. level alarm H1 (mm) 325 325 325 325 325

Min. level H2 (mm) 335 335 335 335 335

Max. level H3 (mm) 425 425 425 425 425

08028-0D/H5250/94.08.12

Max. level alarm H4 (mm) 440 440 440 440 440

Min. litre (H2) 1150 1314 1477 1639 1802

Max. litre (H3) 1471 1679 1887 2096 2304

99.25 - ES0
MAN Diesel & Turbo
Description 504.07
Page 1 (2) Specific lubricating oil consumption - SLOC
Edition 03

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

Description
Engine type RPM SLOC [g/kWh]
L16/24 1000/1200 0.4 - 0.8
L21/31 900/1000 0.4 - 0.8
L23/30H 720/750/900 0.6 - 1.0
L27/38 720/750 0.4 - 0.8
L28/32H 720/750 0.6 - 1.0
L28/32DF 720/750 0.6 - 1.0
V28/32H 720/750 0.6 - 1.0
V28/32S 720/750 0.4 - 0.8
L32/40 720/750 0.8 - 1.0
The lubricating oil density, ρ @ 15°C must be
Please note that only maximum continuous rating known in order to convert ρ to the present lubricat-
(PMCR (kW)) should be used in order to evaluate the ing oil temperature in the base frame. The following
formula is used to calculate ρ:
SLOC.
ρlubricating oil [kg/m3] =
Please note, during engine running-in the SLOC
may exceed the values stated.
The following formula is used to calculate the
SLOC:
SLOC [g/kWh] =

The engine maximum continuous design rating

(PMCR) must always be used in order to be able to
compare the individual measurements, and the run-
ning hours since the last lubricating oil adding must
be used in the calculation. Due to inaccuracy *) at
adding lubricating oil, the SLOC can only be evalu-
In order to evaluate the correct engine SLOC, the ated after 1,000 running hours or more, where only
following circumstances must be noticed and sub- the average values of a number of lubricating oil
tracted from the engine SLOC: addings are representative.
A1: Note!
▪ Desludging interval and sludge amount from the *) A deviation of ± 1 mm with the dipstick measure-
lubricating oil separator (or automatic lubricating ment must be expected, which corresponds uptill
oil filters). The expected lubricating oil content of ± 0.1 g/kWh, depending on the engine type.
the sludge amount is 30%.
The following does also have an influence on the
SLOC and must be considered in the SLOC evalua-
tion:
A2:
▪ Lubricating oil evaporation
Lubricating oil leakages
Lubricating oil losses at lubricating oil filter
exchange

2013.04.17
 MAN Diesel & Turbo
504.07 Description
Specific lubricating oil consumption - SLOC Page 2 (2)
Edition 03

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

2013.04.17
 MAN Diesel & Turbo 3.3.3

Specification for heavy fuel oil (HFO)

6680 3.3.3-01
Prerequisites
MAN four-stroke diesel engines can be operated with any heavy fuel oil
obtained from crude oil that also satisfies the requirements in Table "The fuel
specification and corresponding characteristics for heavy fuel oil", providing
the engine and fuel processing system have been designed accordingly. To
ensure that the relationship between the fuel, spare parts and repair / main-
tenance costs remains favorable at all times, the following points should be
observed.

Heavy fuel oil (HFO)

Origin/Refinery process The quality of the heavy fuel oil largely depends on the quality of crude oil
and on the refining process used. This is why the properties of heavy fuel oils
with the same viscosity may vary considerably depending on the bunker
positions. Heavy fuel oil is normally a mixture of residual oil and distillates.
The components of the mixture are normally obtained from modern refinery
processes, such as Catcracker or Visbreaker. These processes can
adversely affect the stability of the fuel as well as its ignition and combustion
properties. The processing of the heavy fuel oil and the operating result of
the engine also depend heavily on these factors.
Bunker positions with standardised heavy fuel oil qualities should preferably
be used. If oils need to be purchased from independent dealers, also ensure
that these also comply with the international specifications. The engine oper-
ator is responsible for ensuring that suitable heavy fuel oils are chosen.
Specifications Fuels intended for use in an engine must satisfy the specifications to ensure
sufficient quality. The limit values for heavy fuel oils are specified in Table
„The fuel specification and corresponding characteristics for heavy fuel oil“.
The entries in the last column of this table provide important background
information and must therefore be observed.
Different international specifications exist for heavy fuel oils. The most impor-
tant specifications are ISO 8217-2010 and CIMAC-2003, which are more or
less identical. The ISO 8217 specification is shown in Figure „ISO 8217-2010
specification for heavy fuel oil“. All qualities in these specifications up to K700 Specification for heavy fuel oil (HFO)
can be used, providing the fuel preparation system has been designed
accordingly. To use any fuels, which do not comply with these specifications
(e.g. crude oil), consultation with Technical Service of MAN Diesel & Turbo in
Augsburg is required. Heavy fuel oils with a maximum density of 1,010 kg/m3
may only be used if up-to-date separators are installed.
Important Even though the fuel properties specified in the table entitled "The fuel speci-
fication and corresponding properties for heavy fuel oil" satisfy the above
requirements, they probably do not adequately define the ignition and com-
bustion properties and the stability of the fuel. This means that the operating
behaviour of the engine can depend on properties that are not defined in the
2013-02-13 - de

specification. This particularly applies to the oil property that causes forma-
tion of deposits in the combustion chamber, injection system, gas ducts and
exhaust gas system. A number of fuels have a tendency towards incompati-
bility with lubricating oil which leads to deposits being formed in the fuel
General

delivery pump that can block the pumps. It may therefore be necessary to
exclude specific fuels that could cause problems.

6680 3.3.3-01 EN 1 (12)

 3.3.3 MAN Diesel & Turbo

Blends The addition of engine oils (old lubricating oil, ULO –used lubricating oil) and
additives that are not manufactured from mineral oils, (coal-tar oil, for exam-
6680 3.3.3-01

ple), and residual products of chemical or other processes such as solvents

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

Ash content 0.15 Heavy fuel oil processing

Vanadium content mg/kg 450 Heavy fuel oil processing
Water content Vol. % 0.5 Heavy fuel oil processing
Sediment (potential) Weight % 0.1
Aluminium and silicium mg/kg max. 60 Heavy fuel oil processing
content (total)
Acid number mg KOH/g 2.5
2013-02-13 - de

Hydrogen sulphide mg/kg 2

General

2 (12) 6680 3.3.3-01 EN

 MAN Diesel & Turbo 3.3.3

Used lubricating oil mg/kg The fuel must be free of lubri-

6680 3.3.3-01
(ULO) cating oil (ULO = used lubricat-
ing oil, old oil). Fuel is consid-
ered as contaminated with
lubricating oil when the follow-
ing concentrations occur:
Ca > 30 ppm and Zn > 15
ppm or Ca > 30 ppm and P >
15 ppm.
Asphaltene content Weight % 2/3 of coke residue Combustion properties
(according to Conradson)
Sodium content mg/kg Sodium < 1/3 Vanadium, Heavy fuel oil processing
Sodium < 100
The fuel must be free of admixtures that cannot be obtained from mineral oils, such as vegetable or coal-tar oils. It
must also be
free of tar oil and lubricating oil (old oil), and also chemical waste products such as solvents or polymers.
Table 1: The fuel specification and corresponding characteristics for heavy fuel oil

Specification for heavy fuel oil (HFO)

2013-02-13 - de

General

6680 3.3.3-01 EN 3 (12)

 3.3.3 MAN Diesel & Turbo
6680 3.3.3-01
Specification for heavy fuel oil (HFO)

2013-02-13 - de
General

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

4 (12) 6680 3.3.3-01 EN

 MAN Diesel & Turbo 3.3.3

6680 3.3.3-01
Specification for heavy fuel oil (HFO)
2013-02-13 - de

General

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

6680 3.3.3-01 EN 5 (12)

 3.3.3 MAN Diesel & Turbo
6680 3.3.3-01

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

precleaning process will be (maximum preheating temperature of 75 °C to

prevent the formation of asphalt in heavy fuel oil). A settling tank is sufficient
for heavy fuel oils with a viscosity of less than 380 mm2/s at 50 °C. If the
heavy fuel oil has a high concentration of foreign matter, or if fuels in accord-
ance with ISO-F-RM, G/H/K380 or H/K700 are to be used, two settling tanks
will be required one of which must be sized for 24-hour operation. Before the
content is moved to the service tank, water and sludge must be drained from
the settling tank.
Separators A separator is particularly suitable for separating material with a higher spe-
cific density – water, foreign matter and sludge, for example. The separators
2013-02-13 - de

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

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

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

6 (12) 6680 3.3.3-01 EN

 MAN Diesel & Turbo 3.3.3

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

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

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

Application in ships and stationary use: parallel installation

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

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

The separators must be arranged according to the manufacturers' current
recommendations (Alpha Laval and Westfalia). The density and viscosity of
the heavy fuel oil in particular must be taken into account. If separators by
other manufacturers are used, MAN Diesel & Turbo should be consulted.
If processing is carried out in accordance with the MAN Diesel & Turbo spec-
ifications and the correct separators are chosen, it may be assumed that the
results stated in the table entitled "Achievable proportion of foreign matter
and water" for inorganic foreign matter and water in the heavy fuel oil will be
achieved at the engine inlet.
Results obtained during operation in practiсe show that the wear occurs as a
result of abrasion in the injection system and the engine will remain within
acceptable limits if these values are complied with. In addition, an optimum Specification for heavy fuel oil (HFO)
lubricating oil treatment process must be ensured.
Definition Particle size Quantity
Inorganic foreign matter < 5 µm < 20 mg/kg
including catalyst particles
Al+Si content -- < 15 mg/kg
Water content -- < 0.2 % by vol. %
Table 2: Achievable proportion of foreign matter and water (after separation)
Water It is particularly important to ensure that the water separation process is as
2013-02-13 - de

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

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

6680 3.3.3-01 EN 7 (12)

 3.3.3 MAN Diesel & Turbo

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

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

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

(ASTM D 97) (pumpable). As the pour point of many low-viscosity heavy fuel oils is higher
than 0 °C, the bunker facility must be preheated, unless fuel in accordance
with RMA or RMB is used. The entire bunker facility must be designed in
such a way that the heavy fuel oil can be preheated to around 10 °C above
the pour point.
Pump characteristics If the viscosity of the fuel is higher than 1,000 mm2/s (cST), or the tempera-
ture is not at least 10 °C above the pour point, pump problems will occur.
For more information, also refer to "Low-temperature behaviour (ASTM D
97)".
Combustion properties If the proportion of asphalt is more than two thirds of the coke residue (Con-
2013-02-13 - de

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

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

8 (12) 6680 3.3.3-01 EN

 MAN Diesel & Turbo 3.3.3

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

6680 3.3.3-01
increased deposition of asphalt (see "Compatibility").
Ignition quality Nowadays, to achieve the prescribed reference viscosity, cracking-process
products are used as the low viscosity ingredients of heavy fuel oils although
the ignition characteristics of these oils may also be poor. The cetane num-
ber of these compounds should be > 35. If the proportion of aromatic hydro-
carbons is high (more than 35 %), this also adversely affects the ignition
quality.
The ignition delay in heavy fuel oils with poor ignition characteristics is longer;
the combustion is also delayed which can lead to thermal overloading of the
oil film at the cylinder liner and also high cylinder pressures. The ignition delay
and accompanying increase in pressure in the cylinder are also influenced by
the end temperature and compression pressure, i.e. by the compression
ratio, the charge-air pressure and charge-air temperature.
The disadvantages of using fuels with poor ignition characteristics can be
limited by preheating the charge air in partial load operation and reducing the
output for a limited period. However, a more effective solution is a high com-
pression ratio and operational adjustment of the injection system to the igni-
tion characteristics of the fuel used, as is the case with MAN Diesel & Turbo
piston engines.
The ignition quality is one of the most important properties of the fuel. This
value does not appear in the international specifications because a standar-
dised testing method has only recently become available and not enough
experience has been gathered at this point in order to determine limit values.
The parameters, such as the calculated carbon aromaticity index (CCAI), are
therefore aids that are derived from quantifiable fuel properties. We have
established that this method is suitable for determining the approximate igni-
tion quality of the heavy fuel oil used.
A testing instrument has been developed based on the constant volume
combustion method (fuel combustion analyser FCA) and is currently being
tested by a series of testing laboratories.
The instrument measures the ignition delay to determine the ignition quality
of a fuel and this measurement is converted into a an instrument-specific
cetane number (FIA-CN or EC). It has been established that in some cases,
heavy fuel oils with a low FIA cetane number or ECN number can cause
operating problems. Specification for heavy fuel oil (HFO)
As the liquid components of the heavy fuel oil decisively influence the ignition
quality, flow properties and combustion quality, the bunker operator is
responsible for ensuring that the quality of heavy fuel oil delivered is suitable
for the diesel engine. (Also see illustration entitled "Nomogram for determin-
ing the CCAI – assigning the CCAI ranges to engine types").
2013-02-13 - de

General

6680 3.3.3-01 EN 9 (12)

 3.3.3 MAN Diesel & Turbo
6680 3.3.3-01

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

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

straight line through the density

and viscosity of the heavy fuel
oils.

Figure 4: Nomogram for determining the CCAI – assigning the CCAI ranges to engine
types
The CCAI can be calculated using the following formula:
CCAI = D - 141 log log (V+0.85) - 81
Sulphuric acid corrosion The engine should be operated at the cooling water temperatures prescribed
in the operating handbook for the relevant load. If the temperature of the
2013-02-13 - de

components that are exposed to acidic combustion products is below the

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

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

10 (12) 6680 3.3.3-01 EN

 MAN Diesel & Turbo 3.3.3

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

6680 3.3.3-01
are mixed, this can lead to separation and the associated sludge formation in
the fuel system during which large quantities of sludge accumulate in the
separator that block filters, prevent atomisation and a large amount of resi-
due as a result of combustion.
This is due to incompatibility or instability of the oils. Therefore heavy fuel oil
as much as possible should be removed in the storage tank before bunker-
ing again to prevent incompatibility.
Blending the heavy fuel oil If heavy fuel oil for the main engine is blended with gas oil (MGO) to obtain
the required quality or viscosity of heavy fuel oil, it is extremely important that
the components are compatible (see "Compatibility").
Additives to heavy fuel oils MAN Diesel & Turbo engines can be operated economically without addi-
tives. It is up to the customer to decide whether or not the use of additives is
beneficial. The supplier of the additive must guarantee that the engine opera-
tion will not be impaired by using the product.
The use of heavy fuel oil additives during the warranty period must be avoi-
ded as a basic principle.
Additives that are currently used for diesel engines, as well as their probable
effects on the engine's operation, are summarised in the table below „Addi-
tives for heavy fuel oils – classification/effects“.
Precombustion additives ▪ Dispersing agents/stabil-
isers
▪ Emulsion breakers
▪ Biocides
Combustion additives ▪ Combustion catalysts
(fuel savings, emissions)
Post-combustion additives ▪ Ash modifiers (hot corro-
sion)
▪ Soot removers (exhaust-
gas system)
Table 3: Additives for heavy fuel oils – Classification/effects
Heavy fuel oils with low From the point of view of an engine manufacturer, a lower limit for the sul-
sulphur content phur content of heavy fuel oils does not exist. We have not identified any Specification for heavy fuel oil (HFO)
problems with the low-sulphur heavy fuel oils currently available on the mar-
ket that can be traced back to their sulphur content. This situation may
change in future if new methods are used for the production of low-sulphur
heavy fuel oil (desulphurisation, new blending components). MAN Diesel &
Turbo will monitor developments and inform its customers if required.
If the engine is not always operated with low-sulphur heavy fuel oil, corre-
sponding lubricating oil for the fuel with the highest sulphur content must be
selected.
2013-02-13 - de

Improper handling of operating fluids

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

6680 3.3.3-01 EN 11 (12)

 3.3.3 MAN Diesel & Turbo
6680 3.3.3-01

Tests
Sampling To check whether the specification provided and/or the necessary delivery
conditions are complied with, we recommend you retain at least one sample
of every bunker oil (at least for the duration of the engine's warranty period).
To ensure that the samples taken are representative of the bunker oil, a sam-
ple should be taken from the transfer line when starting up, halfway through
the operating period and at the end of the bunker period. "Sample Tec" by
Mar-Tec in Hamburg is a suitable testing instrument which can be used to
take samples on a regular basis during bunkering.
Analysis of samples To ensure sufficient cleaning of the fuel via the separator, perform regular
functional check by sampling up- and downstream of the separator.
Analysis of HFO samples is very important for safe engine operation. We can
analyse fuel for customers at our laboratory (PrimeServLab).
Specification for heavy fuel oil (HFO)

2013-02-13 - de
General

12 (12) 6680 3.3.3-01 EN

 MAN Diesel & Turbo 010.000.023-04

Marine diesel oil (MDO) specification

D010.000.023-04-0001
Marine diesel oil
Other designations Marine diesel oil, marine diesel fuel.
Origin Marine diesel oil (MDO) is supplied as heavy distillate (designation ISO-F-
DMB) exclusively for marine applications. MDO is manufactured from crude
oil and must be free of organic acids and non-mineral oil products.

Specification
The suitability of fuel depends on the design of the engine and the available
cleaning options, as well as compliance with the properties in the following
table that refer to the as-delivered condition of the fuel.
The properties are essentially defined using the ISO 8217-2010 standard as
the basis. The properties have been specified using the stated test proce-
dures.
Properties Unit Testing method Designation
ISO-F specification DMB
Density at 15 °C kg/m 3
ISO 3675 < 900
Kinematic viscosity at 40 °C mm2/s ≙ cSt ISO 3104 > 2.0
< 11 *
Pour point (winter quality) °C ISO 3016 <0
Pour point (summer quality) °C <6
Flash point (Pensky Martens) °C ISO 2719 > 60
Total sediment content weight % ISO CD 10307 0.10
Water content vol. % ISO 3733 < 0.3
Sulphur content weight % ISO 8754 < 2.0
Ash content weight % ISO 6245 < 0.01
Coke residue (MCR) weight % ISO CD 10370 < 0.30
Cetane index - ISO 4264 > 35
Hydrogen sulphide mg/kg IP 570 <2
Marine diesel oil (MDO) specification
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation resistance g/m3 ISO 12205 < 25
Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Other specifications:
British Standard BS MA 100-1987 Class M2
ASTM D 975 2D
2013-07-03 - de

ASTM D 396 No. 2

Table 1: Marine diesel oil (MDO) – characteristic values to be adhered to
* For engines 27/38 with 350 resp. 365 kW/cyl the viscosity must not exceed
6 mm2/s @ 40 °C, as this would reduce the lifetime of the injection system.
General

D010.000.023-04-0001 EN 1 (2)
 010.000.023-04 MAN Diesel & Turbo
D010.000.023-04-0001

Additional information
During transshipment and transfer, MDO is handled in the same manner as
residual oil. This means that it is possible for the oil to be mixed with high-
viscosity fuel or heavy fuel oil – with the remnants of these types of fuels in
the bunker ship, for example – that could significantly impair the properties of
the oil.
Lubricity Normally, the lubricating ability of diesel oil is sufficient to operate the fuel
injection pump. Desulphurisation of diesel fuels can reduce their lubricity. If
the sulphur content is extremely low (< 500 ppm or 0.05%), the lubricity may
no longer be sufficient. Before using diesel fuels with low sulphur content,
you should therefore ensure that their lubricity is sufficient. This is the case if
the lubricity as specified in ISO 12156-1 does not exceed 520 μm.
You can ensure that these conditions will be met by using motor vehicle die-
sel fuel in accordance with EN 590 as this characteristic value is an integral
part of the specification.
The fuel must be free of lubricating oil (ULO – used lubricating oil, old oil).
Fuel is considered as contaminated with lubricating oil when the following
concentrations occur:
Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and P > 15 ppm.
The pour point specifies the temperature at which the oil no longer flows. The
lowest temperature of the fuel in the system should be roughly 10 °C above
the pour point to ensure that the required pumping characteristics are main-
tained.
A minimum viscosity must be observed to ensure sufficient lubrication in the
fuel injection pumps. The temperature of the fuel must therefore not exceed
45 °C.
Seawater causes the fuel system to corrode and also leads to hot corrosion
of the exhaust valves and turbocharger. Seawater also causes insufficient
atomisation and therefore poor mixture formation accompanied by a high
proportion of combustion residues.
Solid foreign matter increase mechanical wear and formation of ash in the
cylinder space.
We recommend the installation of a separator upstream of the fuel filter. Sep-
aration temperature: 40 – 50°C. Most solid particles (sand, rust and catalyst
Marine diesel oil (MDO) specification

particles) and water can be removed, and the cleaning intervals of the filter
elements can be extended considerably.

Improper handling of operating fluids

If operating fluids are improperly handled, this can pose a danger to
health, safety and the environment. The relevant safety information by
the supplier of operating fluids must be observed.
2013-07-03 - de

Analyses
Analysis of fuel samples is very important for safe engine operation. We can
General

analyse fuel for customers at our laboratory (PrimeServLab).

2 (2) D010.000.023-04-0001 EN
 MAN Diesel & Turbo 010.000.023-01

Gas oil / diesel oil (MGO) specification

D010.000.023-01-0001
Diesel oil
Other designations Gas oil, marine gas oil (MGO), diesel oil
Gas oil is a crude oil medium distillate and therefore must not contain any
residual materials.

Specification
The suitability of fuel depends on whether it has the properties defined in this
specification (based on its composition in the as-delivered state).
The DIN EN 590 and ISO 8217-2010 (Class DMA or Class DMZ) standards
have been extensively used as the basis when defining these properties. The
properties correspond to the test procedures stated.
Properties Unit Test procedure Typical value
Density at 15 °C ≥ 820.0
kg/m3 ISO 3675 ≤ 890.0
Kinematic viscosity 40 °C ≥2
mm2/s (cSt) ISO 3104 ≤ 6.0
Filterability*
in summer and °C DIN EN 116 ≤0
in winter °C DIN EN 116 ≤ -12
Flash point in closed cup °C ISO 2719 ≥ 60
Sediment content (extraction method) weight % ISO 3735 ≤ 0.01
Water content Vol. % ISO 3733 ≤ 0.05
Sulphur content ISO 8754 ≤ 1.5
Ash weight % ISO 6245 ≤ 0.01
Coke residue (MCR) ISO CD 10370 ≤ 0.10
Hydrogen sulphide mg/kg IP 570 <2
Acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m 3
ISO 12205 < 25 Gas oil / diesel oil (MGO) specification
Lubricity μm ISO 12156-1 < 520
(wear scar diameter)
Cetane index - ISO 4264 ≥ 40
Other specifications:
British Standard BS MA 100-1987 M1
ASTM D 975 1D/2D
Table 1: Diesel fuel (MGO) – properties that must be complied with.

* The process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining
2013-07-03 - de

the cloud point in accordance with ISO 3015

General

D010.000.023-01-0001 EN 1 (2)
 010.000.023-01 MAN Diesel & Turbo
D010.000.023-01-0001

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

Improper handling of operating fluids

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

Analyses
Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at our laboratory (PrimeServLab).
Gas oil / diesel oil (MGO) specification

2013-07-03 - de
General

2 (2) D010.000.023-01-0001 EN
 MAN Diesel & Turbo 3.3.1

Bio fuel specification

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

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

Iodine number < 125g/100g DIN EN 14111

TAN (total acid number) < 5 mg KOH/g DIN EN ISO 660
Filterability < 10 °C below the lowest temper- EN 116
2013-02-07 - de

ature in the fuel system

Table 1: Non-transesterified bio-fuel - Specifications
General

6680 3.3.1-02 EN 1 (2)

 3.3.1 MAN Diesel & Turbo

Improper handling of operating fluids

6680 3.3.1-02

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

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

Analyses
Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at our laboratory (PrimeServLab).
Bio fuel specification

2013-02-07 - de
General

2 (2) 6680 3.3.1-02 EN

 MAN Diesel & Turbo 3.3.1

Bio fuel specification

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

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

Iodine number < 125g/100g DIN EN 14111

TAN (total acid number) < 5 mg KOH/g DIN EN ISO 660
Filterability < 10 °C below the lowest temper- EN 116
2013-02-07 - de

ature in the fuel system

Table 1: Non-transesterified bio-fuel - Specifications
General

6680 3.3.1-02 EN 1 (2)

 3.3.1 MAN Diesel & Turbo

Improper handling of operating fluids

6680 3.3.1-02

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

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

Analyses
Analysis of fuel samples is very important for safe engine operation. We can
analyse fuel for customers at our laboratory (PrimeServLab).
Bio fuel specification

2013-02-07 - de
General

2 (2) 6680 3.3.1-02 EN

MAN Diesel & Turbo

Description
Crude oil specification 504.24
Page 1 (1) Edtioon 01

General

Crude Oil Our four-stroke medium-speed engines are well

proven in operation on crude oil taken directly from
Crude oil is a naturally occurring flammable liquid oil wells and conditioned on site.
consisting of a complex mixture of hydrocarbons of
various molecular weights and other liquid organic Exploiting crude oil to feed the large consumers
compounds, that are found in geologic formations involved in oil and gas exploration and production
beneath the Earth's surface. is both an economical solution and saves the con-
siderable CO2 emissions involved in the refining of
The flash point of crude oil is low, typically below distillate fuels and their transport via pumping sta-
ambient temperature. tions from and to the oil field.

Properties/Characteristics Unit Limit Test method

Viscosity, before injection pumps, min. cSt 3
Viscosity, before injection pumps, max. cSt 14 1)
Viscosity @ 50°C, max. cSt 700 ISO 3104
Density @ 15°C, max. kg/m 3
1010.0 ISO 3675 or ISO 12185
CCAI, max. - 870 ISO 8217
Water before engine, max. % volume 0.2 ISO 3733
Sulphur, max. % mass 4.5 ISO 8754 or ISO 14596
Ash, max. % mass 0.15 ISO 6245
Vanadium, max. mg/kg 600 ISO 14597 or IP 501 or IP 470
Sodium + Potassium before engine, mg/kg
1/3 Vanadium content ISO 10478
max.
Aluminium + Silicon before engine, max. mg/kg 15 ISO 10478 or IP 501 or IP 470
Carbon residue, max. % mass 20 ISO 10370
2/3 of carbon residue
Asphaltenes, max. % mass ASTM D3279
(according to Conradson)
Reid vapour pressure (RVP), max. kPa @ 37.8°C 65 ASTM D323
Lubricity (wear scar diameter) µm < 520 ISO 12156-1
Pour point, max. °C 30 ISO 3016
Cold filter plugging point °C 2)
IP 309
Total sediment potential, max. % mass 0.10 ISO 10307-2
Hydrogen sulphide, max. mg/kg 2 IP 570
AN (acid number), max. mg KOH/g 2.5 ASTM D664
Table 1 Crude oil - specifications.

1) Viscosity, before injection pumps, max. 18 cSt for 2) Minimum 10°C below the lowest temperature in
GenSets L23/30H, L28/32H and V28/32S the entire fuel system

12.36 - ES1
MAN Diesel & Turbo

Description
Page 1 (1) Firing Pressure Comparison 504.28
Edition 05

L27/38

Engine type, 5 - 9L27/38, GenSet

Output kW/cyl 320

Engine speed rpm 750

210

200

190

180

170
indicator cock [ bar ]

160

150

140

130

120

110

100
100 110 120 130 140 150 160 170 180 190 200 210
combustion chamber [ bar ]

Stated values under ISO reference conditions:

Air temperature compressor inlet °C 25
Cooling water temperature intercooler LT stage °C 32
Ambient air pressure mbar 1000
Ambient humidity abs. 5.96 g/kg, rel. 30%

11.33 - ES1 - Tier I

 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

Table 1. Cleaning of HFO.

97.40 - ES0
 MAN Diesel

504.30 Description
Edition 01 Fuel Oil Cleaning Page 2 (2)

General

To determine centrifuging capacity we generally

advise to follow the recommendations of the cen- Flow Rate
trifuge maker, but the curves in fig. 1, can be used Related to Rated Capacity of Centrifuge
as a guideline. %
100

A homogenizer may be installed in the fuel oil sys- 80

tem as a supplement to the centrifuges in order to 60
homogenize possible water and sludge still present 40
in the fuel after centrifuging. 20

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

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

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

Fig. 1 Flow rate through centrifuge related to nominal capa-

city of centrifuge.

08028-0D/H5250/94.08.12

97.40 - ES0
 010.000.023-13

Engine cooling water specifications

D010.000.023-13-0001
Preliminary remarks
As is also the case with the fuel and lubricating oil, the engine cooling water
must be carefully selected, handled and checked. If this is not the case, cor-
rosion, erosion and cavitation may occur at the walls of the cooling system in
contact with water and deposits may form. Deposits obstruct the transfer of
heat and can cause thermal overloading of the cooled parts. The system
must be treated with an anticorrosive agent before bringing it into operation
for the first time. The concentrations prescribed by the engine manufacturer
must always be observed during subsequent operation. The above especially
applies if a chemical additive is added.

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

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

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

Testing equipment The MAN Diesel water testing equipment incorporates devices that deter-
mine the water properties directly related to the above. The manufacturers of
anticorrosive agents also supply user-friendly testing equipment. Notes for
cooling water check see in 010.005 Engine – Work Instructions
010.000.002-03.

Additional information
Engine cooling water specifications

Distillate If distilled water (from a fresh water generator, for example) or fully desalina-
ted water (from ion exchange or reverse osmosis) is available, this should
ideally be used as the engine cooling water. These waters are free of lime
and salts which means that deposits that could interfere with the transfer of
heat to the cooling water, and therefore also reduce the cooling effect, can-
not form. However, these waters are more corrosive than normal hard water
as the thin film of lime scale that would otherwise provide temporary corro-
sion protection does not form on the walls. This is why distilled water must
be handled particularly carefully and the concentration of the additive must
2013-06-20 - de

be regularly checked.
Hardness The total hardness of the water is the combined effect of the temporary and
permanent hardness. The proportion of calcium and magnesium salts is of
General

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

nate content of the calcium and magnesium salts. The permanent hardness

D010.000.023-13-0001 EN 1 (7)
 010.000.023-13

is determined by the amount of remaining calcium and magnesium salts (sul-

phates). The temporary (carbonate) hardness is the critical factor that deter-
D010.000.023-13-0001

mines the extent of limescale deposit in the cooling system.

Water with a total hardness of > 10°dGH must be mixed with distilled water
or softened. Subsequent hardening of extremely soft water is only necessary
to prevent foaming if emulsifiable slushing oils are used.

Damage to the cooling water system

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

Processing of engine cooling water

Formation of a protective The purpose of treating the engine cooling water using anticorrosive agents
film is to produce a continuous protective film on the walls of cooling surfaces
and therefore prevent the damage referred to above. In order for an anticor-
rosive agent to be 100 % effective, it is extremely important that untreated
water satisfies the requirements in the section "Requirements".
Protective films can be formed by treating the cooling water with an anticor-
rosive chemical or an emulsifiable slushing oil.
Emulsifiable slushing oils are used less and less frequently as their use has
been considerably restricted by environmental protection regulations, and
because they are rarely available from suppliers for this and other reasons.
Engine cooling water specifications

Treatment prior to initial Treatment with an anticorrosive agent should be carried out before the
commissioning of engine engine is brought into operation for the first time to prevent irreparable initial
damage.

Treatment of the cooling water

The engine must not be brought into operation without treating the
cooling water first.
2013-06-20 - de

Additives for cooling water

General

Only the additives approved by MAN Diesel & Turbo and listed in the tables
under the section entitled „Approved cooling water additives“ may be used.

2 (7) D010.000.023-13-0001 EN
 010.000.023-13

Required approval A cooling water additive may only be permitted for use if tested and
approved as per the latest directives of the ICE Research Association (FVV)

D010.000.023-13-0001
"Suitability test of internal combustion engine cooling fluid additives.” The test
report must be obtainable on request. The relevant tests can be carried out
on request in Germany at the staatliche Materialprüfanstalt (Federal Institute
for Materials Research and Testing), Abteilung Oberflächentechnik (Surface
Technology Division), Grafenstraße 2 in D-64283 Darmstadt.
Once the cooling water additive has been tested by the FVV, the engine
must be tested in the second step before the final approval is granted.
In closed circuits only Additives may only be used in closed circuits where no significant consump-
tion occurs, apart from leaks or evaporation losses. Observe the applicable
environmental protection regulations when disposing of cooling water con-
taining additives. For more information, consult the additive supplier.

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

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

Anti-freeze agents
If temperatures below the freezing point of water in the engine cannot be
excluded, an anti-freeze solution that also prevents corrosion must be added
to the cooling system or corresponding parts. Otherwise, the entire system
must be heated.
Engine cooling water specifications
Sufficient corrosion protection can be provided by adding the products listed
in the table entitled „Anti-freeze solutions with slushing properties“ (Military
specification: Sy-7025) while observing the prescribed minimum concentra-
tion. This concentration prevents freezing at temperatures down to -22 °C
and provides sufficient corrosion protection. However, the quantity of anti-
freeze solution actually required always depends on the lowest temperatures
that are to be expected at the place of use.
Anti-freezes are generally based on ethylene glycol. A suitable chemical anti-
corrosive agent must be added if the concentration of the anti-freeze solution
2013-06-20 - de

prescribed by the user for a specific application does not provide an appro-
priate level of corrosion protection, or if the concentration of anti-freeze solu-
tion used is lower due to less stringent frost protection requirements and
does not provide an appropriate level of corrosion protection. Considering
General

that anti-freeze agents listed in the table „Anti-freeze solutions with slushing

D010.000.023-13-0001 EN 3 (7)
 010.000.023-13

properties“ also contain corrosion inhibitors and their compatibility with other
anticorrosive agents is generally not given, only pure glycol may be used as
D010.000.023-13-0001

anti-freeze agent in such cases.

Simultaneous use of anticorrosive agent from the table „Chemical additives –
nitrite free” together with glycol is not permitted, because monitoring the anti-
corrosive agent concentration in this mixture is not more possible.
Anti-freeze solutions may only be mixed with one another with the consent of
the manufacturer, even if these solutions have the same composition.
Before an anti-freeze solution is used, the cooling system must be thoroughly
cleaned.
If the cooling water contains an emulsifiable slushing oil, anti-freeze solution
must not be added as otherwise the emulsion would break up and oil sludge
would form in the cooling system.

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

Prerequisite for effective use of an anticorrosive agent

Clean cooling system

As contamination significantly reduces the effectiveness of the additive, the
tanks, pipes, coolers and other parts outside the engine must be free of rust
and other deposits before the engine is started up for the first time and after
repairs of the pipe system. The entire system must therefore be cleaned with
the engine switched off using a suitable cleaning agent (see 010.005 Engine
– Work Instructions 010.000.001-01.010.000.002-04).
Engine cooling water specifications

Loose solid matter in particular must be removed by flushing the system

thoroughly as otherwise erosion may occur in locations where the flow veloc-
ity is high.
The cleaning agents must not corrode the seals and materials of the cooling
system. In most cases, the supplier of the cooling water additive will be able
to carry out this work and, if this is not possible, will at least be able to pro-
vide suitable products to do this. If this work is carried out by the engine
operator, he should use the services of a specialist supplier of cleaning
agents. The cooling system must be flushed thoroughly after cleaning. Once
2013-06-20 - de

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

4 (7) D010.000.023-13-0001 EN
 010.000.023-13

Regular checks of the cooling water condition and cooling water

D010.000.023-13-0001
system
Treated cooling water may become contaminated when the engine is in
operation, which causes the additive to loose some of its effectiveness. It is
therefore advisable to regularly check the cooling system and the cooling
water condition. To determine leakages in the lube oil system, it is advisable
to carry out regular checks of water in the compensating tank. Indications of
oil content in water are, e.g. discoloration or a visible oil film on the surface of
the water sample.
The additive concentration must be checked at least once a week using the
test kits specified by the manufacturer. The results must be documented.

Concentrations of chemical additives

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

Excessively low concentrations can promote corrosion and must be avoided.

If the concentration is slightly above the recommended concentration this will
not result in damage. Concentrations that are more than twice the recom-
mended concentration should be avoided.
Every 2 to 6 months send a cooling water sample to an independent labora-
tory or to the engine manufacturer for integrated analysis.
Emulsifiable anticorrosive agents must generally be replaced after abt. 12
months according to the supplier's instructions. When carrying this out, the
entire cooling system must be flushed and, if necessary, cleaned. Once filled
into the system, fresh water must be treated immediately.
If chemical additives or anti-freeze solutions are used, cooling water should
be replaced after 3 years at the latest.
If there is a high concentration of solids (rust) in the system, the water must
be completely replaced and entire system carefully cleaned.
Deposits in the cooling system may be caused by fluids that enter the cool-
ing water, or the break up of emulsion, corrosion in the system and limescale
deposits if the water is very hard. If the concentration of chloride ions has
Engine cooling water specifications
increased, this generally indicates that seawater has entered the system. The
maximum specified concentration of 50 mg chloride ions per kg must not be
exceeded as otherwise the risk of corrosion is too high. If exhaust gas enters
the cooling water, this may lead to a sudden drop in the pH value or to an
increase in the sulphate content.
Water losses must be compensated for by filling with untreated water that
meets the quality requirements specified in the section Requirements. The
concentration of the anticorrosive agent must subsequently be checked and
adjusted if necessary.
2013-06-20 - de

Subsequent checks of cooling water are especially required if the cooling

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

D010.000.023-13-0001 EN 5 (7)
 010.000.023-13
D010.000.023-13-0001

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

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

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

Permissible cooling water additives

Nitrite-containing chemical additives

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

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

Maxigard 40 l 40,000 1,330 2,000
Wilhelmsen (Unitor) Rocor NB Liquid 21.5 l 21,500 2,400 3,600
Dieselguard 4.8 kg 4,800 2,400 3,600
Engine cooling water specifications

Nalfleet Marine Nalfleet EWT Liq 3l 3,000 1,000 1,500

(9-108)
Nalfleet EWT 9-111 10 l 10,000 1,000 1,500
Nalcool 2000 30 l 30,000 1,000 1,500
Nalco Nalcool 2000 30 l 30,000 1,000 1,500
TRAC 102 30 l 30,000 1,000 1,500
TRAC 118 3l 3,000 1,000 1,500
Maritech AB Marisol CW 12 l 12,000 2,000 3,000
2013-06-20 - de

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

Colorcooling 24 l 24,000 2,000 3,000
Marichem – Marigases D.C.W.T. - 48 l 48,000 2,400 -
Non-Chromate
General

6 (7) D010.000.023-13-0001 EN
 010.000.023-13

Manufacturer Product designation Initial dosing for Minimum concentration ppm

D010.000.023-13-0001
1,000 litres
Product Nitrite Na-Nitrite
(NO2) (NaNO2)

Marine Care Caretreat 2 16 l 16,000 4,000 6,000

Vecom Cool Treat NCLT 16 l 16,000 4,000 6,000
Table 2: Nitrite-containing chemical additives

Nitrite-free additives (chemical additives)

Manufacturer Product designation Initial dosing Minimum concentration
for 1,000 litres
Arteco Havoline XLI 75 l 7.5 %
Total WT Supra 75 l 7.5 %
Q8 Oils Q8 Corrosion Inhibitor 75 l 7.5 %
Long-Life
Table 3: Chemical additives - nitrite free

Emulsifiable slushing oils

Manufacturer Product
(designation)
BP Diatsol M
Fedaro M
Castrol Solvex WT 3
Shell Oil 9156
Table 4: Emulsifiable slushing oils

Anti-freeze solutions with slushing properties

Manufacturer Product designation Minimum concentration
BASF Glysantin G 48
Glysantin 9313
Glysantin G 05
Castrol Radicool NF, SF
Engine cooling water specifications
Shell Glycoshell 35%

Mobil Frostschutz 500

Arteco Havoline XLC
Total Glacelf Auto Supra
Total Organifreeze
Table 5: Anti-freeze solutions with slushing properties
2013-06-20 - de

General

D010.000.023-13-0001 EN 7 (7)
 010.000.002-03

Cooling water

M010.000.002-03-0001
inspecting
Summary
Acquire and check typical values of the operating media to prevent or limit
damage.
The fresh water used to fill the cooling water circuits must satisfy the specifi-
cations. The cooling water in the system must be checked regularly in
accordance with the maintenance schedule.
The following work/steps is/are necessary:
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the concentration of the anti-
corrosive agent.

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

Testing the typical values of water

Short specification
Typical value/property Water for filling Circulating water
and refilling (without additive) (with additive)
Water type Fresh water, free of foreign matter Treated cooling water
Total hardness ≤ 10°dGH 1) ≤ 10°dGH 1)
pH value 6.5 - 8 at 20 °C ≥ 7.5 at 20 °C
Chloride ion content ≤ 50 mg/l ≤ 50 mg/l 2)
Table 1: Quality specifications for cooling water (abbreviated version)
1)
dGH German hardness
1°dGh = 10 mg/l CaO
= 17.9 mg/l CaCO3
= 0.179 mmol/L
2)
1mg/l = 1 ppm
2013-04-11 - de

Cooling water
General

M010.000.002-03-0001 EN 1 (2)
 010.000.002-03
M010.000.002-03-0001

Testing the concentration of rust inhibitors

Brief specification
Anticorrosive agent Concentration
Chemical additives in accordance with quality specification in Volume 010.005 Engine – operating manual
010.000.023-14
Anti-freeze agents in accordance with quality specification in Volume 010.005 Engine – operating manual
010.000.023-14
Table 2: Concentration of the cooling water additive
Testing the concentration of The concentration should be tested every week, and/or according to the
chemical additives maintenance schedule, using the testing instruments, reagents and instruc-
tions of the relevant supplier.
Chemical slushing oils can only provide effective protection if the right con-
centration is precisely maintained. This is why the concentrations recommen-
ded by MAN Diesel & Turbo (quality specifications in Volume 010.005 Engine
– operating manual 010.000.023-14) must be complied with in all cases.
These recommended concentrations may be other than those specified by
the manufacturer.
Testing the concentration of The concentration must be checked in accordance with the manufacturer's
anti-freeze agents instructions or the test can be outsourced to a suitable laboratory. If in
doubt, consult MAN Diesel & Turbo.
Testing We can analyse fuel for customers at our laboratory (PrimeServ Lab).

2013-04-11 - de
Cooling water
General

2 (2) M010.000.002-03-0001 EN
 MAN Diesel & Turbo 010.000.002-04

Cooling water system

M010.000.002-04-0001
Summary
Remove contamination/residue from operating fluid systems, ensure/re-
establish operating reliability.
Cooling water systems containing deposits or contamination prevent effec-
tive cooling of parts. Contamination and deposits must be regularly elimina-
ted.
This comprises the following:
Cleaning the system and, if required,
removal of limescale deposits,
flushing the system.

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

nents being cooled.

Rust that has been flushed out may have an abrasive effect on other parts of
the system, such as the sealing elements of the water pumps. Together with
2012-08-20 - de

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

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

M010.000.002-04-0001 EN 1 (3)
 010.000.002-04 MAN Diesel & Turbo

other manufacturers can be used providing they have similar properties. The
manufacturer's instructions for use must be strictly observed. Prior to clean-
M010.000.002-04-0001

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

Only carry out the cleaning operation once the engine has
cooled down
Start the cleaning operation only when the engine has cooled down.
2012-08-20 - de

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

2 (3) M010.000.002-04-0001 EN
 MAN Diesel & Turbo 010.000.002-04

Cleaning products can cause damage

M010.000.002-04-0001
The products to be used can endanger health and may be harmful to
the environment.
Follow the manufacturer's handling instructions without fail.

The applicable regulations governing the disposal of cleaning agents or acids

must be observed.

Cooling water system

2012-08-20 - de

General

M010.000.002-04-0001 EN 3 (3)
 MAN Diesel & Turbo 010.000.023-16

Water specification for fuel-water emulsions

Water specification for fuel-water emulsions

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

Specifications
Limit values The characteristic values of the water used must be within the following limit
values:
Properties/ Characteristic value Unit
Characteristic
Water type Distillate or fresh water, free of foreign matter. -
Total hardness max. 10 ºdH*
pH value 6.5 - 8 -
Chloride ion content max. 50 mg/l
Table 1: Fuel-water emulsion - characteristic values to be observed

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

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

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

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

Treatment with anticorrosive agents not required

Treatment with anticorrosive agents is not required and must be
omitted.
2012-08-20 - de

General

D010.000.023-16-0001 EN 1 (1)
 MAN Diesel & Turbo 010.000.023-17

Specifications for intake air (combustion air)

Specifications for intake air (combustion air)

General
The quality and condition of intake air (combustion air) have a significant
effect on the power output, wear and emissions of the engine. In this regard,
not only are the atmospheric conditions extremely important, but also con-
tamination by solid and gaseous foreign matter.
Mineral dust in the intake air increases wear. Chemicals and gases promote
corrosion.
This is why effective cleaning of intake air (combustion air) and regular main-
tenance/cleaning of the air filter are required.
When designing the intake air system, the maximum permissible overall pres-
sure drop (filter, silencer, pipe line) of 20 mbar must be taken into considera-
tion.
Exhaust turbochargers for marine engines are equipped with silencers
enclosed by a filter mat as a standard. The quality class (filter class) of the
filter mat corresponds to the G3 quality in accordance with EN 779.

Requirements
Fuel oil engines: As minimum, inlet air (combustion air) must be cleaned in a
filter of the G3 class as per EN779. For engine operation in the environment
with a risk of higher inlet air contamination (e.g. due to sand storms, due to
loading the grain crops cargo vessels or in the surroundings of cement
plants) additional measures must be taken.
Gas engines and dual-fuel engines: As minimum, inlet air (combustion air)
must be cleaned in a filter of the G3 class as per EN779. Gas engines or
dual-fuel engines must only be equipped with a dry filter. Oil bath filters are
not permitted because they enrich the inlet air with oil mist. This is not per-
missible for gas operated engines. For engine operation in the environment
with a risk of higher inlet air contamination (e.g. due to sand storms, due to
loading the grain crops cargo vessels or in the surroundings of cement
plants) additional measures must be taken.
In general, the following applies: The concentration downstream of the air fil-
ter and/or upstream of the turbocharger inlet must not exceed the following Specifications for intake air (combustion air)
limit values.
Properties Typical value Unit *
Dust (sand, cement, CaO, Al2O3 etc.) max. 5 mg/Nm3
Chlorine max. 1.5
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 5
Salt (NaCl) max. 1
2013-02-04 - de

* One Nm corresponds to one cubic meter of

3

gas at 0 °C and 101.32 kPa.

Table 1: Intake air (combustion air) - typical values to be observed
General

D010.000.023-17-0001 EN 1 (2)
 010.000.023-17 MAN Diesel & Turbo

Intake air shall not contain any flammable gases

Specifications for intake air (combustion air)

Intake air shall not contain any flammable gases. Make sure that the
combustion air is not explosive.
Specifications for intake air (combustion air)

2013-02-04 - de
General

2 (2) D010.000.023-17-0001 EN
 MAN Diesel & Turbo 010.000.023-21

Specification for compressed air

D010.000.023-21-0001
General
For compressed air quality observe the ISO 8573-1:2010. Compressed air
must be free of solid particles and oil (acc. to the specification).

Requirements
Compressed air quality of Starting air must conform to the following quality acc. to the ISO
starting air system 8573-1:2010 as minimum.
Purity with respect to solid particles Quality class 6
Particle size > 40µm max. concentration < 5 mg/m3
Purity with respect to humidity Quality class 7
Residual water content < 5 mg/m3
Purity with respect to oil Quality class 5

Additional requirements are:

▪ The layout of the starting air system must prevent the initiation of corro-
sion.
▪ The starting air system starting air receivers must be equipped with devi-
ces for removing condensed water.
▪ The formation of a dangerous explosive mixture of compressed air and
lube oil must be prevented securely through the devices in the starting air
system and through system components maintenance.
Compressed air quality for Please remember that control air is used for activation of the engine safety
control air system functions, therefore the compressed air quality in this system is of great
importance.
Control air must conform to the following quality acc. to the ISO
8573-1:2010 as minimum.
▪ Purity with respect to solid parti- Quality class 5
cles
▪ Purity with respect to humidity Quality class 4
▪ Purity with respect to oil Quality class 3

For catalysts For catalysts, unless otherwise stated by relevant sources, the following
specifications are applicable:
Specification for compressed air

Compressed air quality for Starting air for soot blowing must conform to the following quality acc. to the
soot blowing ISO 8573-1:2010 as minimum.
▪ Purity with respect to solid parti- Quality class 2
cles
▪ Purity with respect to humidity Quality class 3
▪ Purity with respect to oil Quality class 2
2013-07-04 - de

Compressed air quality for Starting air for atomisation of reducing agents must conform to the following
atomisation of reducing quality acc. to the ISO 8573-1:2010 as minimum.
agents

D010.000.023-21-0001 EN 1 (2)
 010.000.023-21 MAN Diesel & Turbo

▪ Purity with respect to solid parti- Quality class 2

D010.000.023-21-0001

cles
▪ Purity with respect to humidity Quality class 3
▪ Purity with respect to oil Quality class 2

Clogging of catalyst
To prevent clogging of catalyst and catalyst lifetime shortening, the
compressed air specification must always be observed.
Specification for compressed air

2013-07-04 - de

2 (2) D010.000.023-21-0001 EN
Cylinder head

505/605
MAN Diesel & Turbo
Description 505.01
Page 1 (1) Cylinder head and water jacket
Edition 03

L27/38
Cylinder head
The cylinder head is of cast iron with an integrated
charge air receiver, made in one piece. It has a
bore-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 the nozzle tip area made it possible
to omit direct nozzle cooling. The valve pattern is
turned about 20° to the axis and achieves a certain
intake swirl.
The cylinder head is tightened by means of 4 nuts
and 4 studs which are screwed into the engine
frame. The nuts are tightened by means of hydraulic
jacks.
The cylinder head has a screwed-on top cover. It
has two basic functions: oil sealing of the rocker
chamber and covering of the complete head top
face.

Air inlet and exhaust valves

The valve spindles are made of heat-resistant mate-
rial and the spindle seats are armoured with wel-
ded-on hard metal.
All valve spindles are fitted with valve rotators which
turn the spindles each time the valves are activated.
The turning of the spindles ensures even tempera-
ture levels on the valve discs and prevents deposits
on the seating surfaces.
The cylinder head is equipped with replaceable
valve seat rings. The exhaust valve seat rings are
water cooled in order to assure low valve tempera-
tures.
The seat rings are made of heat-resistant steel. The
seating surfaces are hardened in order to minimize
wear and prevent dent marks.

1999.04.26 - ES0
MAN Diesel & Turbo
Work Card 505-01.00
Page 1 (4) Dismantling of cylinder unit from engine
Edition 12

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 038
52000 212
Shut off cooling water 52001 107
Shut off fuel oil 52000 334
Shut-off cooling oil 52000 060
- and hydraulic tools
Stop lub. oil circulation according to working
Press Blocking - Reset card 520-01.06

Short Description
Dismantling of cylinder unit from engine for inspec-
tion and/or overhaul.

Starting Position Hand Tools

Engine stopped and cooled down. Unbraco top
Ratchet
Extension

Related Procedure
Valve rotator 505-01.15
Disassembly of cylinder unit 505-01.01
Fuel injection valve 514-01.10
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2

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

2011.10.03. - Tier II, WB II

 MAN Diesel & Turbo
505-01.00 Work Card
Dismantling of cylinder unit from engine Page 2 (4)
Edition 12

L27/38

Tool
Warning!
Use original tool!

Preparations before Dismantling

1) Drain off the cooling water from the engine.
2) Remove the top cover.
3) Remove the side covers on both sides of the
engine.
4) Remove the exhaust gas cover.

Disassembling of connectings
1) Disconnect the clamp for connecting cylinder
head and exhaust gas receiver. 1 Charge air connection 2 Cooling water connection
2) Disconnect the fuel oil high pressure pipe.
Figure 1: Clip on/off
3) Disassembly the 4 clamps for locking the FW
connection between the cylinder heads by
removing the locking bolts for the clamps.
4) Push the FW connections inside the cylinder Removal of connecting rod shaft
heads, which are to be removed. 1) Mount the turning bracket between the marine
5) Disconnect the 2 clamps for locking the charge head and counter weight, see fig 2.
air connections by removing the locking bolts 2) Loosen the piston rod shaft by means of the
for the clamps. hydraulic jacks, see working card 506-01.25.
6) Push the charge air connections inside the cyl- 3) Remove the piston rod shaft nuts by hand.
inder head which are to be removed.
7) Turn the piston to top position.

2011.10.03. - Tier II, WB II

MAN Diesel & Turbo
Work Card 505-01.00
Page 3 (4) Dismantling of cylinder unit from engine
Edition 12

L27/38
2) Remove the cylinder head nuts by means of the
hydraulic jacks, see working card 520-01.05.
3) Mount the lifting tool on the cylinder head.

Removal of cylinder unit from engine

1) Carefully lift the cylinder unit out of the engine.
Note! Be careful not to scratch the thread on the
hydraulic bolts when lifting the cylinder unit.
2) Pull out the push rods from the engine frame.
3) Land and fasten the cylinder unit upon the spe-
cial work table, or on the floor upon wooden
supports and remove the lifting tool.

Figure 2: Mount the turning bracket between the marine head

and counterweight

Mounting of support tools

1) Mount the fixing tool for locking the connecting
rod shaft to the cylinder liner by means of the
mounting bolt, see fig 3.

1 Hydraulic tool 2 Ass. tension screw

3 Pressure part, long 4 Cylinder head
5 Cylinder head nut 6 Cylinder head bolt

Figure 4: Hydraulic tools for dismounting of cylinder head nuts

1 Lifting tool 2 Cylinder unit

3 Fixing tool

Figure 3: Mounting of fixing tool

2011.10.03. - Tier II, WB II

 MAN Diesel & Turbo
505-01.00 Work Card
Dismantling of cylinder unit from engine Page 4 (4)
Edition 12

L27/38

1 Cylinder unit 2 Work table

Figure 5: Cylinder unit placed in work table

2011.10.03. - Tier II, WB II

MAN Diesel & Turbo
Work Card 505-01.01
Page 1 (3) Disassembly of cylinder unit
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 212
52000 104
Shut off cooling water 52000 038
Shut off fuel oil 52000 021
Shut-off cooling oil 52000 082
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismounting of cylinder head, water jacket, cylin-
der liner and piston for inspection/overhaul

Starting Position Hand Tools

Measuring tools
Dismantling of cylinder unit 505-01.00
Allen key, 8 mm
Ratchet
Extension
Serrated fork

Related Procedure
Reconditioning of valve spindle 505-01.10
seat and valve seat ring
Valve rotator 505-01.10
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35
Inspection of piston 506-01.10
Cylinder liner 506-01.35
Separation of piston and connet- 506-01.05
ing rod
Fuel injection valve 514-01.10
Replacement and wearing parts
Qualified Manpower
Plate No. Item No. Quantity
Duration in h : 1
Number : 1

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

2003.01.27.
 MAN Diesel & Turbo
505-01.01 Work Card
Disassembly of cylinder unit Page 2 (3)
Edition 03

L27/38

Disassembly of cylinder unit 2) Mount the lifting tool on the cylinder head, see
fig 2.
Before starting to dismantle the cylinder unit it must
be placed on the working table. 3) Remove the cylinder head by means of the lift-
ing tool .
Removal of piston and connecting rod
1) Turn the unit upside down.
2) Remove the supporting tool from the cylinder
liner and piston rod shaft.
3) Mount the eye bolt at the bottom of the piston
rod shaft.
4) Pull out the piston and the connecting rod shaft
with the aid of the eye bolt and tackle.
5) Turn the unit back to it's starting position.

1 Lifting tool 2 Cylinder head

Figure 2: Removal of cylinder head

Removal of cylinder liner from the water

jacket
1) Lift the cylinder liner out of the water jacket by
means of the lifting tool as shown in fig 3.
2) Remove the flame ring from the cylinder liner by
means of the tool as shown in fig 4. Use a
used/scrapped piston ring.

Figure 1: Removal of piston and piston rod

Removal of cylinder head

1) Remove the four allen screws keeping the cool-
ing water jacket to the cylinder head.

2003.01.27.
MAN Diesel & Turbo
Work Card 505-01.01
Page 3 (3) Disassembly of cylinder unit
Edition 03

L27/38

1 Removal device for flame 2 Flame ring

ring
3 Scrapped piston ring

Figure 4: Removal of flame ring

1 Lifting tool for cylinder 2 Cylinder liner

liner

Figure 3: Removal of cylinder liner from water jacket

2003.01.27.
MAN Diesel & Turbo
Work Card 505-01.05
Page 1 (3) Inspection of inlet valve, exhaust valve and valve guide
Edition 04

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 014
52001 107
Shut off cooling water 52001 012
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismounting of inlet and exhaust valve, inspection
of valve guide and mounting of inlet and exhaust
valve.

Starting Position Hand Tools

Disassembly of cylinder unit 505-01.01

Related Procedure
Reconditioning of valve spindle 505-01.10
seat and valve seat ring
Valve rotator 505-01.15
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2001.07.23.
 MAN Diesel & Turbo
505-01.05 Work Card
Inspection of inlet valve, exhaust valve and valve guide Page 2 (3)
Edition 04

L27/38

Tool
Warning!
Use original tool!

Dismantling of inlet and exhaust valve

spindles
1) Land and fasten the cylinder head upon a spe-
cial work table and remove the lifting tool.
Or as an Alternative:
Land the cylinder head on the floor upon
wooden supports and remove the lifting tool.
2) Turn back the rocker arm and remove the valve
bridge over the valve spindles.
3) Install the tool for mounting of valves (B), see fig
1.
Figure 2: Mounting of compression tool
4) Compress valve springs by tightening nut A,
see fig 2.

Figure 1: Mounting of compression tool

5) Remove cone rings, see fig 3.

Figure 3: Removal of cone rings - valve spring pressed down
6) Release springs again by loosening nut A.
7) Remove a valve rotator and springs.
8) Push out the valve spindle.
9) Repeat point 4 - 8 to remove other valve spin-
dles.

2001.07.23.
MAN Diesel & Turbo
Work Card 505-01.05
Page 3 (3) Inspection of inlet valve, exhaust valve and valve guide
Edition 04

L27/38

x Max (see page 500.35)

Figure 5: Measurement of valve guide wear

Figure 4: Valve spring reliefed complete

Mounting of valve spindle
1) For mounting the valve spindle, follow the
instructions in "Dismantling of inlet and exhaust
Inspection of valves/valve seats valve spindles" point 3-8 in reverse order.
If the valve seat is burnt or scarred, it should be
ground using a valve seat grinder, please see work-
ing card 505-01.10.

Inspection of valve guide

Too much clearance between the valve spindle and
the valve guide may cause:
- increased lub. oil consumption.
- fouling up of the valve guide and thus give the risk
of the sticking of the valve spindle.
1) Clean the valve guide.
2) Inspect and measure for wear.
If the inner diameter of the valve guide meas-
ured below the O-ring exceeds the tolerance,
please see page 500.35, the valve guide must
be replaced. Please see working card
505-01.20.
Too much clearance also means insufficient
guidance of the valve spindle, and thus bad
alignment between the spindle head and the
valve seat ring.
3) Change the O-ring inside the valve guide, see
working card 505-01.20.

2001.07.23.
MAN Diesel & Turbo
Work Card Reconditioning of Valve Spindle Seat and Valve Seat 505-01.10
Page 1 (3)
Ring Edition 04

L21/31

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52001 119
52001 120
Shut off cooling water 52001 156
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Reconditioning of valve spindle seat and valve seat
ring, with special grinding machine.

Starting Position Hand Tools

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
Inspection of inlet valve, exhaust 505-01.05
valve and valve guide

Qualified Manpower Replacement and wearing parts

Duration in h : 3 Plate No. Item No. Quantity
Number : 1

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

2003.09.08.
 MAN Diesel & Turbo
505-01.10 Reconditioning of Valve Spindle Seat and Valve Seat Work Card
Page 2 (3)
Edition 04 Ring

L21/31

Reconditioning of Valve Seat Ring

Reconditioning of valve seat rings by machining is
carried out by means of a grinding machine, the
pilot spindle of which must be mounted in the valve
spindle guide. For operation of the grinding
machine, see separate instructions.

Grinding of Valve Seats

Warning!
Use safety glasses!
The area around the engine must be clean and
tidy!
Grinding of valve seat rings should be carried out in
the following order:
1) Grind the seating surface with a feed at an
angle "A" of 30° +0.05° / -0° .
2) Continue grinding until a clean and uniform sur-
face is obtained.
3) Carry out final grinding with a feed in direction
from inside to outwards. Normally, the best sur-
face quality is obtained this way. Figure 1: Valve seat ring

Scraping of Valve Seat Rings

Reconditioning of Valve Spindle
Normally, the valve seat ring can be reconditioned
several times. Reconditioning by machining is carried out with the
valve spindle being rotated in a turning lathe and a
However, when seat "S" is ground to such an special grinding machine mounted on the tool post
extent that recess "R" disappears, see fig 1, the of the turning latch.
valve seat ring must be scrapped and a new one
must be installed, please see working card
505-01.35 Grinding of Valve Spindle
This is only valid for the exhaust valve seat. The inlet For operation of the grinding machine, see separate
valve seat has no recess due to less wear of the instructions.
inlet valve seat. 1) Grind the seating surface with a feed at an
angle "A" of 30° +0° / -0.1°
2) Continue grinding until a clean and uniform sur-
face is obtained.
3) Check height "H"1 upon completion of the
grinding, see fig 2.

2003.09.08.
MAN Diesel & Turbo
Work Card Reconditioning of Valve Spindle Seat and Valve Seat 505-01.10
Page 3 (3)
Ring Edition 04

L21/31
"H"1 must be no less than indicated on page
500.35.
If less, the spindle must be scrapped.

Figure 2: Valve spindle

2003.09.08.
MAN Diesel & Turbo
Work Card 505-01.15
Page 1 (2) Valve Rotator
Edition 05

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismantling, inspection and mounting of valve
rotator.

Starting Position Hand Tools

Valve spindle has been removed 505-01.05 Small screwdriver
Ring and open-end spanner, 24 mm.

Related Procedure
Inspection of inlet valve, exhaust 505-01.05
valve and valve guide.

Qualified Manpower Replacement and wearing parts

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

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

2003.01.27.
 MAN Diesel & Turbo
505-01.15 Work Card
Valve Rotator Page 2 (2)
Edition 05

L21/31, L27/38

Procedure
Valve rotators are installed on all 4 valves in the cyl-
inder head. The function of the valve rotators is of
greatest importance for the lifetime of the valves.
Non-functioning valve rotators must be exchanged.
At every overhaul of the cylinder head, the valve
rotators must be checked.

Function Test
1) Remove the valve covers from the cylinder
heads.
2) Start the engine and let it run idle speed to
avoid oil splash.
3) Watch the indicator mark on top of the valve
rotator and see that it moves a little each time
the valve is activated. See fig 1.
4) Stop the engine, an re-install the valve covers
with new seals.

Figure 1: Valve rotator

2003.01.27.
MAN Diesel & Turbo
Work Card 505-01.20
Page 1 (2) Replacement of Valve Guide
Edition 10

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52001 120
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismantling and mounting of valve guide for inlet
and exhaust valve.

Starting Position Hand Tools

Valve spindle has been removed 505-01.05 Hammer / Lead hammer
Liquid Nitrogen (LN2) or equivalent
E7 reamer, 16 mm (L21/31)
H7 reamer, 20 mm (L27/38)

Related Procedure
Inspection of inlet valve, exhaust 505-01.05
valve and valve guide.

Qualified Manpower Replacement and wearing parts

Duration in h : 3/4 Plate No. Item No. Quantity
Number : 1 50501 076 4/cyl
(L27/38)
50502 536 4/cyl
Data (L21/31)
Data for pressure and tolerance (Page 500.35) 50501 088 4/cyl
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2011.01.24.
 MAN Diesel & Turbo
505-01.20 Work Card
Replacement of Valve Guide Page 2 (2)
Edition 10

L21/31, L27/38

When to Replace the Valve Guide 6) Insert a new O-ring in the top of the valve guide,
see fig 3.
If the diameter exceeds the max. limit, see page
500.35, the valve guide must be replaced.

Dismounting of Valve Guide

1) Remove the old valve guide, through the top of
the cylinder head using a drift inserted through
the valve seat, see fig 1.
This is easiest if the cylinder head is inverted, as
shown on fig 1.

Figure 2: Mounting of valve guide

Figure 1: Dismounting of valve guide

Mounting of Valve Guide

1) Clean the bore in the cylinder head carefully.
2) The new valve guide must be cooled down to
approx. -70°C with liquid nitrogen (LN2) or
equivalent.
3) Insert the valve guide in the bore, see fig 2.
Figure 3: Inserting a new O-ring in the valve guide
4) Ensure that the valve guide is fully seated, if
necessary by light blows to the drift.
Tool for valve guides is not a part of the standard
5) After the guide has been fitted and has returned tool kit.
to room temperature, it is essential that it be
reamed to final size using the specified reamer.
Please see page 500.35 for tolerances.

2011.01.24.
MAN Diesel & Turbo
Work Card 505-01.25
Page 1 (2) Check/adjustment of safety valve opening pressure
Edition 01

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air - Calibrated high pressure
testing equipment (not
Shut off cooling water supplied)
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismantling, inspection, reassembling and pres-
sure testing of safety valve.

Starting Position Hand Tools

Engine stopped.Respective side covers on engine
manoeuvre side dismounted.

Related Procedure
Indicator valve 505-01.26

Qualified Manpower Replacement and wearing parts

Duration in h : 1/2 Plate No. Item No. Quantity
Number : 1 50501 338 1/cyl

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

2001.09.03.
 MAN Diesel & Turbo
505-01.25 Work Card
Check/adjustment of safety valve opening pressure Page 2 (2)
Edition 01

L27/38

Check/adjustment of safety valve opening

pressure
For safety reasons, the safety valves are normally
checked/adjusted at an authorised workshop in
connection with overhaul of cylinder heads.
However, it is possible to check/adjust the valves
on board if calibrated high pressure testing equip-
ment is available.
Note: In connection with check of safety valves, do
not increase the test pressure to more than 250
bar.
1) Dismount the safety valve.
2) Connect the safety valve to a calibrated high
pressure testing device.
3) Slowly increase the pressure until the safety
valve blows off. Observe the blow-off pressure
and compare with the factory setting.
4) If necessary, adjust the blow off pressure, see
fig 1.
5) Remove lead seal (2) and securing wire (3).
6) Loosen and remove locking screw (4).
7) Adjust the blow off pressure by turning the
outer bushing (1).
8) Repeat step 3) until the correct blow off pres-
sure is reached.
9) Drill a securing bore for locking screw (4).
10) Mount locking screw (4).
11) Secure locking screw with locking wire and lead
seal. Figure 1: Safety valve

12) Mount the safety valve with a new gasket.

13) Mount the side covers.

2001.09.03.
MAN Diesel & Turbo
Work Card 505-01.26
Page 1 (2) Indicator Valve
Edition 05

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismounting, inspection and mounting of indicator
valve.

Starting Position Hand Tools

Ring and open-end spanner 10 mm
Ring and open-end spanner 27 mm
Steel brush

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/2 Plate No. Item No. Quantity
Number : 1 Molykote HSC

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

2005.08.08.
 MAN Diesel & Turbo
505-01.26 Work Card
Indicator Valve Page 2 (2)
Edition 05

L21/31, L27/38

Description
Under normal working conditions the indicator
valves require very little maintenance. However, to
minimize toxic gasses in the engine room and to
keep the engine and engine room clean, it is neces-
sary to keep the indicator valves tight.
Also, when taking combustion pressures/diagrams,
it is important that the mechanical connection
between the indicator valve and the indicator is tight
so that the parts are not overheated and damaged.
It is therefore important that the valve connecting
surface is in good condition.
Warning!
In connection with check of indicator valves, be
aware of hot surfaces and possible discharge of hot
gasses.
The insulation glove has to be placed over the indi-
cator valve at any time when the engine is running,
to prevent that fuel and oil will cause fi re when in
contact with hot surfaces. Exception will be taken
when measuring the max. pressure. Figure 1: Indicator valve.

Check of Indicator Valve By replacement of indicator valve all parts have to

See fig. 1 be fully cleaned and greased with molykote HSC to
prevent that the parts will seize.
1) Visually inspect the valve cone for damage.
2) Ensure that all indicator valves are closed.
3) Start and run the engine.
4) Observe that the indicator valve is not leaking.
5) Shortly open the valve and close it again.
6) Observe if ther is a leakage from the indicator
valve.
7) If the indicator is leaking, stop the engine and
replace the indicator valve.

2005.08.08.
MAN Diesel & Turbo
Work Card 505-01.35
Page 1 (2) Replacement of Valve Seat Ring
Edition 04

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52001 181
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Replacement of valve seat ring for inlet and
exhaust valve.

Starting Position Hand Tools

Inlet and exhaust valves have been removed Hammer
505-01.05 Loctite, 648
Lub. oil.

Related Procedure
Mounting of valve spindles 505-01.10

Qualified Manpower Replacement and wearing parts

Duration in h : 1 1/2 Plate No. Item No. Quantity
Number : 1 50501 123 2/cyl.
50501 172 2/cyl.
50501 184 2/cyl.
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2003.09.01.
 MAN Diesel & Turbo
505-01.35 Work Card
Replacement of Valve Seat Ring Page 2 (2)
Edition 04

L21/31, L27/38

Dismounting of Valve Seat Rings Mounting of Valve Seat Rings

When reconditioning of a valve seat ring no longer is 1) Prior to mounting of a new valve seat ring, the
possible due to dimensions exceeding the scrap- bore must be cleaned thoroughly and inspected
ping criteria, the valve seat ring has to be replaced. for marks. Marks that can hinder mounting of
Dismounting of a valve seat ring is carried out by the valve seat ring must be removed.
means of a special extractor tool set comprising the 2) Cool down the valve seat ring to a max. of -25°
components, see fig 1. C before mounting, otherwise the O-ring can be
damaged.
3) Place the O-ring on the valve seat ring and coat
with oil/loctite as shown in fig 2, just before
positioning it in the bore.

Figure 1: Extraction of valve seat ring

Dismounting of a Valve Seat Ring is

Carried out According to the Following
Procedure Figure 2: Coat with oil/loctite
1) Weld approx. 5 seconds at 3 places around the
old valve seat ring with electrode. 4) Prior to mounting of the valve spindle, the valve
Use welding helmet. seat ring must be grind to ensure correct cen-
tering at the valve guide and the valve seat ring.
2) Wait 60 seconds while the seat is cooling down
This can be done according to working card
and the shrink fit compression is relieved.
505-01.10.
3) Mount the extraction tool and pull out the used
valve seat ring. (If the waiting time is not
observed the tool might be damaged).
4) The valve seat ring is easy removed by turning
the handle.

2003.09.01.
MAN Diesel & Turbo
Work Card Inspection of Cylinder Head and Water Jacket Cooling 505-01.45
Page 1 (2)
Water Space Edition 03

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Inspection of cylinder head cooling water space.

Starting Position Hand Tools

Steel brush
The cylinder head dismantled 505-01.00
from engine

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2003.01.27.
 MAN Diesel & Turbo
505-01.45 Inspection of Cylinder Head and Water Jacket Cooling Work Card
Page 2 (2)
Edition 03 Water Space

L21/31, L27/38

Inspection of Cylinder Head Cooling Water

Space
1) Inspect the cooling water inlet and outlet of the
cylinder head, see fig 1.
2) Remove all possible deposits.
3) If necessary, clean the cooling water inlet and
cooling water outlet, see fig 1, with a steel
brush. Flush the cooling water space after
cleaning.
4) If the cylinder head cooling water space, con-
trary to expectation, is blocked with deposits,
please contact MAN Diesel for further instruc-
tions.

Figure 1: Cooling water spaces to be inspected

Inspection of Water Jacket Cooling Water

Space
1) Inspect the cooling water connections and the
cooling water space, see fig 1.
2) Remove all possible deposits.
Flush the cooling water space after cleaning.

2003.01.27.
MAN Diesel & Turbo
Work Card 505-01.50
Page 1 (3) Assembly of cylinder unit
Edition 04

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52001 107
52000 082
Shut off cooling water 52000 045
Shut off fuel oil 52000 212
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Mounting of cylinder head, cooling water jacket,
cylinder liner and piston after inspection/overhaul.

Starting Position Hand Tools

Cylinder unit, dismantled 505-01.01

Related Procedure
Mounting of cylinder unit in engine 505-01.55
Inspection of valve roller guides 508-01.00

Qualified Manpower Replacement and wearing parts

Duration in h : 1½ Plate No. Item No. Quantity
Number : 1 50501 111 1/cyl
50501 135 2/cyl
50501 196 1/cyl
Data 50610 031 1/cyl
Data for pressure and tolerance (Page 500.35) 50610 043 1/cyl
Data for tightening torque (Page 500.40) 50610 055 1/cyl
Declaration of weight (Page 500.45) 50610 092 1/cyl
50601 093 1/cyl
50601 103 2/cyl
50601 127 1/cyl

2001.07.23.
 MAN Diesel & Turbo
505-01.50 Work Card
Assembly of cylinder unit Page 2 (3)
Edition 04

L27/38

Preparing before mounting

1) Place the water jacket on the table.
2) Place a new o-ring on the cylinder liner and
slightly lubricate with oil.
3) Mount the cylinder liner, with a new flame ring,
in the water jacket by means of the lifting tool
for the liner, see fig 1.

x Mark for allignment with water jacket

Figure 2: Marking on the cylinder liner

Mounting of cylinder head

1) Place a new o-ring at the bottom of the cylinder
head and slightly lubricate with oil.
2) Mount the cylinder head by means of the lifting
tool (plate 52000, item no 38).
1 Flame ring 2 Tool 3) Mount the four allen screws in the cylinder head
3 Cylinder liner and tighten up all the screws, please see page
500.40.
Figure 1: Mounting of new flame ring
Mounting the piston
Note:
Be sure the marking on the cylinder liner is aligned Before mounting the piston turn around the cylinder
with the water jacket. unit.

4) Fit a new sealing ring on the cylinder liner. Note:

After an overhaul the cylinder liner must always be
5) Place a new o-ring on the top of the cylinder honed and the piston must be fitted with new piston
liner. rings, see Working Card 506-01.35.
6) Place a new sealing for the push rods on the 1) Mount the piston guide bush around the cylin-
water jacket. der liner.
7) Place a new o-ring for the cooling water con- 2) Screw an eye bolt in the bottom of the piston
nection on the water jacket. rod and lift the piston and piston rod.

2001.07.23.
MAN Diesel & Turbo
Work Card 505-01.50
Page 3 (3) Assembly of cylinder unit
Edition 04

L27/38
3) Lubricate the piston rings and the cylinder liner
with oil.
4) Slowly lower the piston into the cylinder liner.
Note:
Make sure that the “AS” mark at the top of the pis-
ton is placed to the exhaust gas side.
5) Mount the locking tools for the piston rod and
cylinder liner.
6) Remove the lifting eye bolt from the piston rod.

2001.07.23.
MAN Diesel & Turbo
Work Card 505-01.55
Page 1 (4) Mounting of cylinder unit in engine
Edition 10

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 038
52000 060
Shut off cooling water 52000 212
Shut off fuel oil 52000 334
Shut-off cooling oil - and hydraulic tools
according to working
Stop lub. oil circulation card 520-01.06
Press Blocking - Reset

Short Description
Mounting of cylinder unit after inspection and/or
overhaul.

Starting Position Hand Tools

Cylinder unit is completely assembled. Valve gear Lub oil and copaslip.
of respective cylinder is in the proper position
(valve closed). Control of the surface of the engine.

Related Procedure
Adjustment of valve clearance 508-01.10
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2 50501 135 1
50501 243 1
51630 033 8
Data 51230 027 4
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2011.10.03. - Tier II, WB II

 MAN Diesel & Turbo
505-01.55 Work Card
Mounting of cylinder unit in engine Page 2 (4)
Edition 10

L27/38

The area around the engine

Warning!
The area around the engine must be clean and
tidy!

Tool and wire

Warning!
Use original tool!
Use original wire for lifting!

Preparing before Mounting

Before the cylinder unit is mounted in the engine, be
sure to clean the joint faces carefully.

Placing of the cylinder unit in engine

1) Place a sealing ring around the push rods on
the frame.
2) Mount a new o-ring for the lub.oil connection to
the rocker arms. 1 Lifting tool 2 Cylinder unit
3) Lower the cylinder unit slowly into the engine by 3 Fixing tool
means of the lifting tool; (plate 52000 item 038).
Figure 1: Lifting tool

Mounting of the piston rod and marine

head
1) Make sure the crank throw is in the top posi-
tion. This must be checked on the flywheel.
2) Slowly land the piston rod on the top of the
marine head.
NOTE:
Be careful not to scratch the thread on the hydraulic
bolts.
3) Remove the locking tool for the piston rod and
the cylinder liner. (plate 52000 item 212).

2011.10.03. - Tier II, WB II

MAN Diesel & Turbo
Work Card 505-01.55
Page 3 (4) Mounting of cylinder unit in engine
Edition 10

L27/38
Note:
Check that the marks “AS” are placed at the same
side on both the piston rod and the marine head
against the exhaust side.

Tightening of piston rod

1) Lubricate threads and the contact face of the
hydraulic bolts with molycote paste or the like.
2) Mount the nuts and tighten them firmly with a
tommy bar.
For tightening hydraulic piston rod bolts, please
see working card 506-01.25.

Tightening of cylinder head nuts

1) Coat the cylinder stud threads and contact
faces with copaslip or the like.
2) Fit the cylinder head nuts and make sure that
they run easily and that they bear on their entire
contact surfaces.
3) Tighten the nuts lightly with a tommy bar.
4) Place the spacer ring around the nuts with a
slot in such a position that the tommy bar can
be used.
1 Hydraulic tool 2 Assembling tension screw
5) Tighten the hydraulic jacks and make sure that
the cylinder of the jacks bears firmly on the 3 Pressure part, long 4 Cylinder head
spacer ring. Tighten up all the nuts, see 5 Cylinder head nut 6 Cylinder head bolt
description 500.40. For usage of the hydraulic
tools, please see working card 520-01.05. Figure 2: Hydraulic tools for mounting of cylinder head nuts

Note:
If new studs or nuts are fit, the nuts must be tight-
ened and loosened three times, in order to com- Mounting of the Push Rods
pensate for deformation of the thread and in order
1) Loosen and remove the bolt on the top of the
to ensure a safe minimum load of the studs through
rocker arm shaft.
the tightening.
2) Push out the rocker arm shaft and remove the
rocker arms.
3) Place the push rods on the rollers.
4) Remount the rocker arms and rocker arm shaft.
5) Fit and tighten the bolt on the top of the rocker
arm shaft again.

Assembling of connections
1) Mount the exhaust clamp between the cylinder
head and the exhaust pipe.
Note:
Turn clamps correctly as they are not symmetrical,
see fig 3.

2011.10.03. - Tier II, WB II

 MAN Diesel & Turbo
505-01.55 Work Card
Mounting of cylinder unit in engine Page 4 (4)
Edition 10

L27/38
However, to avoid problems in the ship’s installa-
tion, we recommend ventilating. This can be done
in the following way:
1) Open connection G1, L.T. fresh water - inlet.
2) Bleed air from the venting screws on the charge
air cooler.
3) Bleed air from the venting screws on the water
jacket drain cock, or by the connection F3,
venting to expansion tank.
4) Open connection G2, L.T. fresh water - outlet.
5) Check for leakage.
Figure 3: Correct mounting of clamps
Adjustment of Valve Clearance
2) Place new O-rings on water connections and 1) Adjust the valve clearance, see working card
push the connections into the cylinder head. 508-01.10.
3) Secure the water connections with clamps and 2) Mount the side and top covers.
tighten bolts on the clamp.
4) Place new O-rings on the charge air connection
and push the connections into the next cylinder
head.
5) Secure the charge air connection with a clamp
and tighten the bolt on the clamp.
6) Mount the high pressure fuel oil pipe, please
see working card 514-01.05.

A Front of engine

Figure 4: Clip on/off

Ventilation
The GenSet is self-ventilating. This means that it is
not necessary for the engine to vent the system
before start.

2011.10.03. - Tier II, WB II

MAN Diesel & Turbo

Plate
Page 1 (2) Cylinder Head 50501-24

L27/38

040 See plate 50502

015 052

064 088

See plate 50507

See plate 50508

027

280
172

184
123
111 196

243

135

422

See plate 50507

11.23 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50501-24 Cylinder Head Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

015 2/C Guide for Styr for

valve bridge ventilbro

027 1/C Cylinder head Cylinderdæksel

040 1/C O-ring O-ring

052 1/C Sleeve Foring

064 2/C O-ring O-ring

088 4/C Valve guide Ventilstyr

111 1/C O-ring O-ring

123 2/C Valve seat ring, Ventilsædering,

inlet indstrømning

135 1/C O-ring O-ring

172 2/C O-ring O-ring

184 2/C Valve seat ring, Ventilsædering,

exhaust udstødning

196 1/C O-ring O-ring

243 1/C O-ring O-ring

280 6/C Closing cover Frostprop

422 1/C Cylinder head incl. Cylinderdæksel inkl.

items 015, 027, 040, items 015, 027, 040,
052, 064, 088, 123, 172, 052, 064, 088, 123, 172,
184, plate 50502 items 184, plate 50502 items
010, 022, 130, 178, 191, 010, 022, 130, 178, 191,
201, 213, 237, 249, 250, 201, 213, 237, 249, 250,
262, 274, 644 262, 274, 644

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

11.23 - ES0 - Tier II

MAN Diesel & Turbo

Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-15

L27/38

058
010
105 071
022 083
034 095
142
046
117 071
129 154
130
166

178

178 191

191 201
213
201
632
490-500 237
512 632
524 249

250

Cylinder Head,
see plate 50501

644

262

274

11.23 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50502-15 Valve Spindles and Valve Gear Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

010 1/C Rocker arm, exhaust Vippearm, udstøds, 490 24/C Spring Fjeder
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 083 046, 058, 071, 083 500 24/C Ball Kugle

022 1/C Rocker arm, inlet Vippearm, indsugning 512 4/C Spring washer Fjederskive
complete, incl. item komplet inkl. item 034,
034, 046, 071, 083, 105 046, 071, 083, 105 524 4/C Retainer ring Låsering

034 2/C Bolt Bolt 632 4/C Valve cap Ventilkappe

046 2/C Bearing bush Leje 644 4/C O-ring O-ring

058 1/C Rocker arm, exhaust Vippearm, udstøds

071 4/C Nut Møtrik

083 2/C Adjusting screw com­ Justérbar skrue komplet

plete, incl. item 095, inkl. item 095, 117, 142
117, 142

095 2/C Circlip Fjederring

105 1/C Rocker arm, inlet Vippearm, indsugning

117 2/C Thrust piece Trykstykke

129 2/C Thrust piece Trykstykke

130 2/C Valve bridge com- Ventilbro komplet, inkl.

plete, incl. item 071, item 071, 129, 154, 166
129, 154, 166

142 2/C Adjusting screw Justérbar skrue

154 2/C Adjusting screw Justérbar skrue

166 2/C Valve bridge Ventilbro

178 4/C Conical ring 2/2 Konisk ring 2/2

191 4/C Rotocap complete Rotationsgiver, komplet

201 4/C Spring Fjeder

213 1/C Screw Skrue

237 1/C O-ring O-ring

249 1/C Shaft Aksel

250 1/C O-ring O-ring

262 2/C Valve spindle, Ventilspindel, udstøds

exhaust

274 2/C Valve spindle, inlet Ventilspindel, indsugn.

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

11.23 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
Page 1 (2) Water Guide Jacket 50507-04

L27/38

018

See plate 50501

031
080
114
079
080 102

043
08028-0D/H5250/94.08.12

See plate 50610

11.23 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50507-04 Water Guide Jacket Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

018 4/C Screw Skrue

031 1/C Water guide jacket Kølekappe

043 1/C Gasket Pakning

079 1/C Connecting piece Forbindelsesstykke

080 2/C O-ring O-ring

102 1/C Seal ring Tætning

114 1/C Plug screw Propskrue

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 /
not avail separately ikke tilgængelig alene
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/I = Qty/Individual Antal/I = Antal/individuelt

11.23 - ES0 - Tier II

MAN Diesel & Turbo

Plate
Page 1 (2) Safety valve & Indicator Valve 50508-03

L27/38

050

049
228

013
194
204

121
108

See plate 50501

11.23 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50508-03 Safety Valve & Indicator Valve Page 2 (2)

L27/38
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

013 1/C Connecting socket Forbindelsesstykke

049 1/C Indicator valve Indikatorventil

050 1/C Insulation glove Beskyttelseshætte

108 1/C Safety valve Sikkerhedsventil

121 1/C Gasket Pakning

194 1/C Threaded socket Gevindstuds

204 1/C Union nut Omløbermøtrik

228 1/C Pipe Rør

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 Antal/C = Antal/Cylinder

11.23 - ES0 - Tier II

MAN Diesel & Turbo
Plate
Page 1 (2) Cylinder head, top cover P50510-09

L27/38

2011.05.30
 MAN Diesel & Turbo
Plate
P50510-09 Cylinder head, top cover Page 2 (2)

L27/38
Item No. Qty Item Designation Item No. Qty Item Designation

014 1/C O-ring

026 5/C Screw
038 5/C Washer
051 1/C Top cover

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder

2011.05.30
MAN Diesel & Turbo

Plate
Page 1 (2) Cylinder Unit 50515-18

L27/38

011

12.47 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50515-18 Cylinder Unit Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

011 1/C Cylinder unit, complete Plate 50515 Item 011

consisting of:

1/C Cylinder head Plate 50501

1/C Valve spindle and valve gear Plate 50502

1/C Piston and connecting rod Plate 50601

1/C Cylinder liner Plate 50610

Qty/C = Qty/Cylinder

12.47 - ES0 - Tier II

Piston/connecting rod

506/606
 MAN Diesel
Description 506.01
Page 1 (2) Piston, Connecting Rod and Cylinder Liner Edition 03H

L27/38

Piston

The piston, which is oil-cooled and of the composite

type, has a body made of nodular cast iron and a
crown made of forged deformation resistant steel. It
is fitted with 2 compression rings and 1 oil scraper
ring in hardened ring grooves.

Fig. 2 Connecting rod

The piston pin is fully floating and kept in position in

the axial direction by two circlips.

Connecting Rod
Fig. 1 Piston
The connecting rod is of the marine head type.

By the use of compression rings with different barrel- The joint is above the connecting rod bearing. This
shaped profiles and chrome-plated running surfaces, means that it is not nessesary to open the big-end
the piston ring pack is optimized for maximum sealing bearing when pulling the piston. This is of advantage
effect and minimum wear rate. for the operational safety (no positional changes/no
new adaption), and this solution also reduces the
The piston has a cooling oil space close to the piston height dimension required for piston assembly /
crown and the piston ring zone. The heat transfer, removal.
and thus the cooling effect, is based on the shaker
08028-0D/H5250/94.08.12

effect arising during the piston movement. The Connecting rod and bearing body consist of CrMo
cooling medium is oil from the engine's lubricating steel. They are die-forged products.
oil system.
The bearing shells are identical to those of the crank-
Oil is supplied to the cooling oil space through chan- shaft bearing. Thin-walled bearing shells having an
nels from the oil grooves in the piston pin bosses. Oil AISn running layer are used.
is drained from the cooling oil space through ducts
situated diametrically to the inlet channels. The bearing caps and bearing blocks are bolted
together by waisted bolts.

98.27 - ES0
 MAN Diesel

506.01 Piston, Connecting Rod and Cylinder Liner Description

Edition 03H Page 2 (2)

L27/38
Cylinder Liner

The cylinder liner is made of special centrifugal cast

iron and fitted in a bore in the engine frame. The
liner is clamped by the cylinder head and rests by
its flange on the water jacket.

The liner can thus expand freely downwards when

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

The gas sealing between liner and cylinder head

consists of an iron ring.

To reduce bore polishing and lube oil consumption

a slip-fit-type flame ring is arranged on the top side
of the liner.

Fig. 3 Cylinder liner

08028-0D/H5250/94.08.12

98.27 - ES0
MAN Diesel & Turbo
Work Card Separation/assembly of Piston and Connecting Rod 506-01.05
Page 1 (3)
and Fitting of Piston Rings Edition 09

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 177
52000 190
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Separation of piston and connecting rod for
inspection or/and overhaul. Assembly of the piston
and connecting rod after inspection or/and over-
haul.
Hand Tools
Starting Position Wooden wedge, 2 pieces
Wooden support
Disassembly of cylinder unit 505-01.01
Wire

Related Procedure
Inspection or/and overhaul of pis- 506-01.10
ton
Inspection or/and overhaul of con- 506-01.15
necting rod
Inspection of connecting rod big- 506-01.16
end bearing
Assembly of cylinder unit 505-01.50

Replacement and wearing parts

Qualified Manpower
Plate No. Item No. Quantity
Duration in h : 1 50601 127 1
Number : 1 50601 296 1
50601 414 1
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2011.07.11. - Tier II
 MAN Diesel & Turbo
506-01.05 Separation/assembly of Piston and Connecting Rod Work Card
Page 2 (3)
Edition 09 and Fitting of Piston Rings

L27/38

Separation of Piston and Connecting Rod Ascertain correct assembling by checking the back
clearance. The back clearance is sufficient when the
1) Take out the securing ring (Seeger circlips) with face of the ring is below the groove edge when the
the plier (Plate 52000, Item 177). Push out the ring is pressed against the bottom of the groove.
piston pin and lift the connecting rod away.
When installed on the piston, the rings should be
pushed back and forth in the grooves to make sure
Assembly of Piston and Connecting Rod that they can move freely. It is also advisable to
1) Lubricate the piston pin before assembling. insert a feeler gauge of adequate thickness
2) For assembly of piston and connecting rod, see between ring and groove.
point 1), but in the opposite direction. Adequate clearance is present if the feeler gauge
can be moved all the way around.
To prevent gas leakage through coinciding ring
joints, the piston rings should be turned into posi-
tions offsetting the ring joint 180° to each other.

Figure 1: Joint coil spring to be placed opposite to ring joint

Fitting of piston rings

The piston rings should only be fitted to the piston
by the use of a special tool; the so-called piston ring
opener.
If the rings are opened further than necessary, there
is a risk of overstressing which means that the rings
will become permanently distorted and will not fit to
the cylinder liner's inner running surface.
The piston rings should be installed with the identifi-
cation mark which is stamped into the ring close to
the ring joints, facing upwards, see fig 2.
Before fitting the coil spring loaded scraper ring, the
coil spring is dismantled from the ring by removal of
the joint pin. The coil spring is placed and assem-
bled in the ring groove. The scraper ring then is fit-
ted in the groove in such a way that the ring joint is
approximately 180° offset to the spring joint.

2011.07.11. - Tier II
MAN Diesel & Turbo
Work Card Separation/assembly of Piston and Connecting Rod 506-01.05
Page 3 (3)
and Fitting of Piston Rings Edition 09

L27/38

Figure 2: Marking of piston and scraper ring

2011.07.11. - Tier II
MAN Diesel & Turbo
Work Card 506-01.10
Page 1 (3) Piston
Edition 21

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 153
52000 165
Shut off cooling water 52000 190
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Cleaning and inspection of piston. Replacement of
piston ring, scraper ring and control of ring
grooves.

Starting Position Hand Tools

Tools for cleaning of piston, steel brush, scraper
Piston has been dismantled from 506-01.05
connecting rod etc.
Torque spanner

Related Procedure
Mounting of piston and connect- 506-01.20
ing rod

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2013.08.29 - Tier II
 MAN Diesel & Turbo
506-01.10 Work Card
Piston Page 2 (3)
Edition 21

L27/38
5) the tightening of the piston bolts with a torque
of 40 Nm in the piston head must be controlled.
6) Pretighten the nuts crosswise with joint moment
of 20 Nm.
7) Turn the nuts cross wise with joint moment of
20 Nm.
8) Turn the nuts further 90 degrees.
Inspection of piston Check the piston bolt tension, see "Check of piston
1) Remove the piston and scraper rings. bolt tension".
2) Clean the piston on the outside and on the
inside.
3) Inspect the piston ring and scraper ring grooves
for wear, see page 3.

Check of piston bolt tension

1) Apply a torque spanner to the piston bolts,
adjusted to 54 Nm.
2) Turn the torque spanner.
Note: It may turn out that the bolts do not turn dur-
ing the test:
If Then
The bolts do not turn during The tension are ok
the test
The bolts can turn during the Loosen the bolts and tighten
test as described for the process
of "Mounting of piston
crown"

Inspection of piston crown

For cleaning and inspection of the piston crown, it
must be disassembled.
1) Loosen the bolts and remove the piston crown.
2) Clean carefully the piston shirt and piston bolts.

Mounting of piston crown

Note: always use new bolts when assembling the
piston.
1) Lubricate the threads and bearing surface with
"molycote-paste G-n Plus".
2) Tighten the piston bolts with a torque of 40 Nm
in the piston head.
3) Tighten the nuts crosswise with 67 Nm.
4) Loosen the nuts again.

2013.08.29 - Tier II
MAN Diesel & Turbo
Work Card 506-01.10
Page 3 (3) Piston
Edition 21

L27/38

Figure 1: Wear limits for ring grooves

Piston and oil New ring Ring grooves
scraper ring grooves Max. wear
Nominal size Tolerances limit (mm)
(mm) (mm)
Piston ring 1 7 7.17 +0.03 7.42
Piston ring 2 6 6.12 +0.03 6.42
Scraper ring 8 8.04 +0.03 8.42
Table 1: Nominal size, new ring groove tolerance and wear limit
for ring grooves
The piston crown must be scrapped if:
A) The wear limit on the testing mandrel is excee-
ded, see fig 1A
or
B) The clearance between the new piston / scraper
ring and the ring groove is exceeded, see fig 1B
Note: At each piston overhaul:
▪ The piston and the scraper ring must be
replaced
▪ The cylinder liner must be honed according
to the instructions
▪ For position and fittings of piston rings,
please see working card 506-01.05

2013.08.29 - Tier II
MAN Diesel & Turbo
Work Card 506-01.15
Page 1 (5) Connecting Rod
Edition 09

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 177
52001 252
Shut off cooling water
Shut off fuel oil and hydraulic tools according to working card
520-01.06
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Cleaning, inspection and test measurement of
connecting rod.

Starting Position Hand Tools

Inside micrometer (140 mm)
Connecting rod has been disman- 506-01.05
tled from piston Feeler gauge 0.15 - 0.20 mm.

Related Procedure
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06

Qualified Manpower Replacement and wearing parts

Duration in h : 3/4 Plate No. Item No. Quantity
Number : 1

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

2013.08.28
 MAN Diesel & Turbo
506-01.15 Work Card
Connecting Rod Page 2 (5)
Edition 09

L21/31, L27/38

If bolts/nuts Then

have seizures in threads or renew the bolts/screws

pittings on contact surface
cannot be turned onto bot- renew the bolts/screws
tom position by hand

Cleaning of Piston Rod and Marine Head

1) Clean all machined surfaces on the piston rod
and marine head.
2) Degrease the joint faces, holes, piston rod and
marine head screws with a volatile solvent and
blow dry with working air.

Visual Inspection of Faces

1) Inspect the joint faces.
Damages, in the form of visible wear marks and
pittings or even cracks, may be in the joint faces
due to relative movements between the surfa-
ces.
Wear marks and cracks are visible, but not per-
ceptible with a fingernail. Pittings and impact
marks are both visible and perceptible.
Note: Handle the piston rod and marine head
with care. In case of damaged joint faces
caused by improper handling, the marine head
bearing caps can no longer be tightened with-
out ovalness of the big-end bore.
2) Register observed damages in the scheme
„Marine Head Inspection“ for historic use only.
Please see page 4.
3) Carefully smooth single raised spots in the joint
faces caused by pitting and impact marks with
Figure 1: Point of measurement
a filesmall.

Inspection of Piston rod and Marine Head

Measurement of Big-end Bore
bolts
For check of ovalness, the upper and lower bearing
1) Inspect the hydraulic nuts for seizures in the caps have to be assembled without bearing shells.
threads and pittings on the contact surfaces of
the screwheads. Note: The IMO No on the bearing caps and the
piston rod must always be the same, see fig 3.
2) Turn the hydraulic nuts onto bottom position of
the bolts. Note:The Ident No on the upper and lower bearing
caps must always be the same.
1) Mount the upper and lower bearing caps by
means of the hydraulic bolts.

2013.08.28
MAN Diesel & Turbo
Work Card 506-01.15
Page 3 (5) Connecting Rod
Edition 09

L21/31, L27/38
2) Tighten the bolts with the prescribed pressure,
please see working card 506-01.25.
Note: Connecting rod must be installed.
3) Measure five different diameters in the groove of
the boring, see fig 1.
4) Register the measurements in the scheme
„Marine Head Inspection“. Please see page 4.
5) Calculate the maximum ovalness as the differ-
ence between largest and smallest diameter
measured.
6) Check if maximum ovalness is exceeded,
please see page 500.35.
If Then
maximum ovalness is excee- renew the complete marine
ded head, piston rod, screws
and bearing shells
maximum ovalness is not reuse the marine head
exceeded

Example of Measurement Results

The example, see fig 2, shows measurements and
damage observations for two marine heads in the
scheme „Marine Head Inspection“ (in case the
specified maximum ovalness is exceeded, contact
MAN Diesel for overhaul.
For marine head No 1 in the example, the maximum
ovalness is 0,02 mm and thus reuse is acceptable.
For marine head No 2 in the example, the maximum
ovalness is 0,125 mm and therefore the marine Figure 2: "marine Head Inspection"
head is rejected.

Inspection of Piston Rod Bush

1) Inspect the surface of the piston pin and the
piston rod bush.
2) Measure the clearance between the piston pin
and bush.
3) Check if max. clearance is exceeded, see page
500.35.
If the specified clearance is exceeded, contact MAN
Diesel for replacement.

Inspection of Bearing Shells for Big-end

Criteria for replacement of connecting rod big-end
bearing, see working card 506-01.16.

2013.08.28
 MAN Diesel & Turbo
506-01.15 Work Card
Connecting Rod Page 4 (5)
Edition 09

L21/31, L27/38

Figure 3: The IMO No on the marine head must always be the

same

2013.08.28
MAN Diesel & Turbo
Work Card 506-01.15
Page 5 (5) Connecting Rod
Edition 09

L21/31, L27/38

2013.08.28
MAN Diesel & Turbo
Work Card Criteria for Replacement of Connecting Rod Big-end 506-01.16
Page 1 (5)
and Main Bearing Shells Edition 02

L16/24, L23/30H, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Inspection of bearing shells.

Starting Position Hand Tools

Magnifier
Bearing shells removed from
engine:
Big-end bearing 506-01.30
Main bearing and guide bearing 510-01.05

Related Procedure
Big-end bearing, 506-01.30
Main bearing and guide bearing 510-01.05

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2002.06.24. - Miba
 MAN Diesel & Turbo
506-01.16 Criteria for Replacement of Connecting Rod Big-end Work Card
Page 2 (5)
Edition 02 and Main Bearing Shells

L16/24, L23/30H, L21/31, L27/38

The area around the engine Bearing Surface

Warning! Standard Miba bimetal bearings have no tin flash.
Oil is used for protective coating.
The area around the engine must be clean and
tidy! In new condition the bearing has a silvery, bright
color.
The running surface might become dull silvery after
General
only a short time of operation.
This paper gives information about the evaluation of
the connecting rod big-end and main bearing shells Criteria for bimetal bearing replacement
when wear appears on the running surface under
normal operating conditions. Actual wear can be determined by measuring wall
thickness or via clearance measurements in com-
Bearing damages caused by incorrect running con-
parison to the specification for a bearing in new
ditions, like
condition.
- Corrosion
A bearing should be replaced if the wear limit, as
- Overloading, overheating a.s.o. specified by the engine manufacturer, is reached or
are not described in this paper. can be expected to be reached during the next
period of operation.
In these cases, the bearing shells must be
exchanged, of course, and in order to avoid further Another method is to specify a certain time limit for
bearing failures, the cause of the failure must be the useful service life of the bearing.
found and eliminated. The individual time limit (recommended maximum
time in operation) specified by the engine manufac-
New Condition turer is based on the calculated bearing load, mini-
mum oil film thickness and load profile.
The running surface has a silvery, bright color, see
fig 1. The useful service life of a bearing is also deter-
mined by the fatigue strength of the lining material
under the respective load profile.

Usual running pattern

Typical running pattern after completion of running:

Bearings to be reused
Following pictures shows the typical running pattern
where bearing shells are reusable.
1) Normal wear
Slightly polished zones and symmetrical running
pattern in the most loaded zone of the bearing.
Minor scoring. See fig 2.
Figure 1: Without flash

2002.06.24. - Miba
MAN Diesel & Turbo
Work Card Criteria for Replacement of Connecting Rod Big-end 506-01.16
Page 3 (5)
and Main Bearing Shells Edition 02

L16/24, L23/30H, L21/31, L27/38

4) Minor cavitation after long time in operation
Minor and shallow material removal outside the
most loaded zone. See fig 5.

Figure 2: Reusable

2) Minor edge loading

and usual running pattern. Slightly polished
stripes along the side faces. See fig 3.
Figure 5: Reusable

Bearings to be replaced
Following pictures shows abnormal wear or dam-
ages that require replacement of bearing shells i.e.
investigation of reasons.
1) Localized heavy smearing of lining material
due to local disturbance of the oil film. See fig 6.

Figure 3: Reusable

3) Damage due to foreign particles

Shallow scoring and / or imprints that are few in
number. See fig 4.

Figure 6: Replace

2) More extensive area of damage with seizure

locally smeared lining material
caused by a severe disturbance of the oil film.
See fig 7.

Figure 4: Reusable

2002.06.24. - Miba
 MAN Diesel & Turbo
506-01.16 Criteria for Replacement of Connecting Rod Big-end Work Card
Page 4 (5)
Edition 02 and Main Bearing Shells

L16/24, L23/30H, L21/31, L27/38

4) Deep punctual cavitation
In severe cases the cavitation extends to the
steel shell, spreads along the interface between
steel shell and lining material, and undermines
the AISn20 lining. See fig 10.

Figure 7: Replace

3) Damage due to foreign particles

Many scores or multiple deep grooves and / or
imprints. See fig 8 and fig 9.

Figure 10: Replace

5) Deep cavitation
Cavitation at the end of the oil groove.

Figure 8: Replace - deep scoring, imprints. Lining material locally

smeared

Figure 11: Replace - deep cavitation

6) Fatigue rupture of the lining material

Mechanism:
- Development of fine cracks in the lining material
- Network of cracks (crazing)
- Parts of the lining material break out

Figure 9: Replace - many deep imprints

2002.06.24. - Miba
MAN Diesel & Turbo
Work Card Criteria for Replacement of Connecting Rod Big-end 506-01.16
Page 5 (5)
and Main Bearing Shells Edition 02

L16/24, L23/30H, L21/31, L27/38

Figure 12: Fatigue rupture

2002.06.24. - Miba
MAN Diesel & Turbo
Work Card Criteria for Replacement of Connecting Rod Big-end 506-01.16
Page 1 (5)
and Main Bearing Shells Edition 04

L23/30H, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Inspection of bearing shells.

Starting Position Hand Tools

Magnifier (x30)
Bearing shells removed from
engine:
Big-end bearing 506-01.30
Main bearing and guide bearing 510-01.05

Related Procedure
Big-end bearing 506-01.30
Main bearing and guide bearing 510-01.05

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2011.01.24. - Daido
 MAN Diesel & Turbo
506-01.16 Criteria for Replacement of Connecting Rod Big-end Work Card
Page 2 (5)
Edition 04 and Main Bearing Shells

L23/30H, L21/31, L27/38

The area around the engine mately the capacity of the engine oil pump will be
reached. Hydrodynamic oil film formation is also a
Warning! function of clearance, very large values resulting in
reduction of film thickness. Additionally, as clear-
The area around the engine must be clean and
ance increases, all bearing materials become more
tidy!
prone to suction cavitation erosion.

General
This Working Card gives information about the eval-
uation of the connecting rod big-end and main
bearing shells when wear appears on the running
surface under normal operating conditions.
Bearing damages caused by incorrect running con-
ditions, like
- Corrosion
- Overloading, overheating a.s.o.
are not described in this Working Card.
In these cases, the bearing shells must be
exchanged, of course, and in order to avoid further
bearing failures, the cause of the failure must be
found and eliminated. Figure 1: Suction cavitation erosion due to high clearance.

Inspection and replacement criteria for Under normal engine operating conditions, surface
aluminium tin bi-metal bearings wear of un-plated tin-based aluminium alloy bearing
alloys, such as A20 & A104, should be negligible.
Compared with overlay plated, or tri-metal, bearing The surface hardness is significantly higher than
construction, aluminium tin bi-metal bearings have a overlay plated (tri-metal) bearings and affords as
homogeneous construction throughout the lining much reduced wear rate.
layer. Thus surface wear will never change the oper-
ating characteristics of the bearing unless the lining The bedding-in process will produce a moderate
is completely removed. The lining thickness is typi- initial wear rate, while geometric inaccuracies in
cally of the order of 0.4 to 1.0 mm for medium crank journals, housings and the bearings them-
speed diesel engine bearings. This level of thickness selves are being accomodated. Once bedding-in is
would not be lost by conventional wear and would completed, wear rate usually becomes immeasura-
only be removed by virtue of major operating prob- ble.
lems causing high temperature generation at the
bore surface, or by fatigue.
Although conventional wear will never change the
properties of the surface of the lining, the resulting
increase in clearance can have several effects.
These will all limit the acceptable level of wear,
regardless of the lining material. The oil flow require-
ment through the bearing will increase, and ulti-

2011.01.24. - Daido
MAN Diesel & Turbo
Work Card Criteria for Replacement of Connecting Rod Big-end 506-01.16
Page 3 (5)
and Main Bearing Shells Edition 04

L23/30H, L21/31, L27/38

Figure 2: A104 bearing after 22.000 hours. Can refit.

Direct measurement of bearing wall thickness is the

simplest way of assessing the level of wear. The
most common procedure would be to use a ball
ended micrometer. However, at the low levels of
wear that will usually occur, measurement inaccur-
acy can mask the true wear rate, but since it is only Figure 3: Acceptable level of contaminant. Can refit.
gross wear that will become the limitation, this
method is acceptable. It should be noted that some
bearings are deliberately bored eccentric to counter
housing distortion, and this must be taken into
account when assessing wall thickness measure-
ments. Alternatively, Plastigauge, or other soft
material, may be used for direct measurement of
diametral clearance. The engine manufacturers'
advice on maximum diametral clearance should be
sought. If no such advice is available, a general rule
is that the maximum clearance should not increase
by more than 50% of the minimum design clear-
ance.
A significant rate of wear would only be anticipated Figure 4: Multiple scoring due to excessive fine debris. Do not
under severe adverse conditions, most commonly refit.
where oil entrained hard debris is present. Fine deb-
ris would be evidenced by an abraded appearance
of the bore surface, while coarse debris would pro-
duce deep scoring with raised edges, often pol-
ished an eventually bedded-in. Large debris may
not become completely embedded in the lining
material, and would also score the shaft. Severe
scoring of the bearing could cause overheating, tin
melt and eventually seizure. However, aluminium tin
bearing materials, such as A20 and A104, are toler-
ant of a significant level of contaminant, and can
absorb it without detriment, and such bearings can
be refitted.
Figure 5: Large embedded debris. Do not refit.

Replacement frequency for un-plated bi-metal bear-

ings depends upon visual appearance and/or oper-
ating time. If, on removal and examination, the bore
surface appears overheated, significantly scored,
debris contaminated or showing other signs of dis-
tress, then the bearings should be renewed. It is

2011.01.24. - Daido
 MAN Diesel & Turbo
506-01.16 Criteria for Replacement of Connecting Rod Big-end Work Card
Page 4 (5)
Edition 04 and Main Bearing Shells

L23/30H, L21/31, L27/38

often the case that bearings operate satisfactorily
even though damaged, particularly if the damage
progresses slowly. However, if such parts are refit-
ted after inspection or overhaul they may be less
tolerant to slight geometric variations introduced
during the rebuild.
If significant debris has been present in the oil, over
a long time interval, differential wear of the crank
surface may have occurred. This is termed cam
wear and is characterised by wear or wiping of the
bearing surface between the ends of partial
grooves. If this is evident, the bearings should be
replaced, and the differential wear of the crank sur-
face eliminated.

Figure 7: Carbonised oil behind bearing, causing overloading. Do

not refit.

Figure 6: Cam wear. Do not refit.

Any indication of loss of lining is an obvious reason

not to refit the bearings. However, the cause for
such damage should be investigated, and correc-
ted where possible. The two most likely causes are
fatigue and cavitation erosion. Provided the engine
has been running at its design rating, fatigue should
not occur unless some introduced defect is present.
Possibilities include oil or debris trapped between
the bearing and its housing, mechanical damage to
the housing bore, the bearing back or bearing bore,
or lack of support behind the bearing. Figure 8: Lack of support behind bearing back results in fatigue
in the bore. Do not refit.

Aluminium tin bearings are resistant to corrosion in

a normal engine environment, but can suffer dam-
age due to water if the engine has been shut down
for a long time. If all the oil has drained away, the
bore surface and bond lines can oxidise. Such
bearings should not be refitted.

2011.01.24. - Daido
MAN Diesel & Turbo
Work Card Criteria for Replacement of Connecting Rod Big-end 506-01.16
Page 5 (5)
and Main Bearing Shells Edition 04

L23/30H, L21/31, L27/38

Figure 9: Corrosion due to water (in this case, outside the

engine). Do not refit.

As with any bearing material, if the interface

between the bearing back and the housing bore
shows signs of fretting, the bearing should be
renewed, and any damage to the housing rectified.
Even if the bearing bore surface has not been dam-
aged, refitting in such a condition may still result in
later damage.

Figure 10: Fretting pits on bearing back. Do not refit.

If bearings are in otherwise good condition, they

should be checked for the presence of positive
freespread before re-fitting. Some loss of free-
spread is normal, but bearings without positive free-
spread, possibly caused by high temperature oper-
ation, cannot be refitted correctly and must be dis-
carded. Such bearings would have continued to
operate successfully had the assembly not been
dismantled, as freespread loss only occurs when
the clamping bolts are released.

2011.01.24. - Daido
MAN Diesel & Turbo
Work Card Criteria for replacement of connecting rod big-end and 506-01.16
Page 1 (8)
main bearing shells Edition 05

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

Safety precautions Special tools

Engine stopped Plate No. Item No. Note

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

Short Description
Inspection of bearing shells.

Hand Tools
Starting Position
Magnifier (x30)
Bearing shells removed from
engine:
Big-end bearing 506-01.30
or Main bearing 510-01.05
Guide bearing 510-01.10

Related Procedure
Mounting of bearing shells:
Big-end bearing 506-01.30
Main bearing 510-01.05
Guide bearing 510-01.10

Replacement and wearing parts

Qualified Manpower
Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2014.04.02
 MAN Diesel & Turbo
506-01.16 Criteria for replacement of connecting rod big-end and Work Card
Page 2 (8)
Edition 05 main bearing shells

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

A new bearing shell has a running surface with
approx. 75 % galvanic overlay and approx. 25 %
light-alloy metal, see fig. 1.
Wear of the bearings running surface starts primarily
in the soft overlay, where the overlay in the slots is
reduced approx. 0.001 mm. The difference
between the light-alloy metal and the overlay is by
further wear almost constant, i.e. approx. 0.005
The area around the engine mm.
Warning! The gravity of the running surface’s wear must be
determined with a magnifier (x30), hereby the over-
The area around the engine must be clean and lay can be seen as the dark area and the light-alloy
tidy! metal as the light area.
The ratio between the width of the light-alloy metal
General and the width of the slot as well as the dimension of
the worn area are important for determining the
This paper gives information about the evaluation of
wear of the bearing.
the connecting rod big-end and main bearing shells
when wear appears on the running surface under The bearing can also operate although part of the
normal operating conditions. overlay is missing in the slots. Practice has shown,
that bearings with partly empty slots can run with-
Bearing damages caused by incorrect running con-
out any negative influence on the operation of the
ditions, like
bearing.
- Scoring of the running surface due to foreign parti-
By determining the condition of the bearing shell,
cles in the lubricating oil
the overlay at a minor stressed area must be used
- Cavitation as comparison.
- Corrosion The valuation of the bearing shell condition is divi-
- Overloading, overheating a.s.o. ded into 5 groups:
are not described in this paper. 1. Re-use
In these cases, the bearing shells must be 2. Limiting case - wear
exchanged, of course, and in order to avoid further 3. Limiting case - local levelling
bearing failures, the cause of the failure must be
4. Limiting case - permanent breakage on the over-
found and eliminated.
lay
5. Empty slots
In case of a combination of the above mentioned
conditions, the lowest possible limits are valid.

1 Overlay (~75%) 2 Light metal (~25%)

3 Nickel strike (max. 5%)

Figure 1: Running surface of the bearing shell.

2014.04.02
MAN Diesel & Turbo
Work Card Criteria for replacement of connecting rod big-end and 506-01.16
Page 3 (8)
main bearing shells Edition 05

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

Dark spots are mainly oil coke remains.
1.1.Bearing Shells for Re-use Valuation: Due to worn running surface the light-
alloy strips are slightly widened. Re-use!
Condition: The slot geometry corresponds to a
new bearing shell. The overlay in the slots is fully
preserved, see fig. 2.
Dark spots are mainly oil coke remains.
Valuation: The ratio between light-alloy metal and
overlay is 75 % to 25 %. Re-use!

Figure 3: .

1.3. Bearing Shells for Re-use

Condition: Small particles all over the overlay. The
light- alloy metal shows no changes of importance,
Figure 2: .
see fig. 4.
Valuation: Re-use of the shell, as the particles are
1.2. Bearing Shells for Re-use wedged in the slots.

Condition: The overlay is equally worn, approx.

0.005 mm in the slots. The light-alloy strips show
no wear, see fig. 3.

2014.04.02
 MAN Diesel & Turbo
506-01.16 Criteria for replacement of connecting rod big-end and Work Card
Page 4 (8)
Edition 05 main bearing shells

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

Figure 4: . Figure 5: .

1.4. Bearing Shells for Re-use

Condition: The overlay has been dragged and
smudged over the light-alloy metal. These are only
partly visible, see fig. 5.
Valuation: Re-use of the shell.

2014.04.02
MAN Diesel & Turbo
Work Card Criteria for replacement of connecting rod big-end and 506-01.16
Page 5 (8)
main bearing shells Edition 05

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

metal has increased from 100 % (new bearing shell)
2. Limiting Case - Wear up to 175 %. In the slots some overlay is still left,
see fig. 7.
Valuation: The bearing can operate with wear of
the below listed size, see fig. 8 og 9. If the wear lim-
its are exceeded the bearing shells must be
exchanged due to safety precausions.

Figure 8: .

Figure 6: .

Figure 9: .

Figure 7: . 3. Limit Case - Levelling

Condition: The slots are locally totally levelled as
Condition: The bearing shell is locally so worn, that shown in fig. 10.
the ratio between the light-alloy metal and the over-
lay is 1:1, see fig. 6. The width of the light-alloy

2014.04.02
 MAN Diesel & Turbo
506-01.16 Criteria for replacement of connecting rod big-end and Work Card
Page 6 (8)
Edition 05 main bearing shells

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

4. Limit Case - Permanent Breakage of the

Running Surface

Figure 10: .

Figure 11: .

Valuation: If the limits shown in fig. 11 and 12 are

exceeded the bearing shells must be exchanged.

Figure 13: .

Figure 14: .

Condition: Breakage in the overlay due to local

overload, as shown in fig. 13 and 14.
Valuation: If the limits as shown below in fig. 15
and 16 below are exceeded with totally or partially
empty slots, the bearing shells must be exchanged.
Figure 12: .

2014.04.02
MAN Diesel & Turbo
Work Card Criteria for replacement of connecting rod big-end and 506-01.16
Page 7 (8)
main bearing shells Edition 05

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

Figure 15: .

Figure 16: .

2014.04.02
 MAN Diesel & Turbo
506-01.16 Criteria for replacement of connecting rod big-end and Work Card
Page 8 (8)
Edition 05 main bearing shells

V28/32S, L27/38, L28/32DF, V28/32DF, L27/38S, L28/32S-DF

5. Limit Case - Empty Slots

Condition: In some areas there is no overlay in the
slots, see fig. 17.

Figure 17: .

Figure 19: .

Figure 18: .

Valuation: If the limits shown in the below fig. 18

and 19, are exceeded, the bearing shells must be
exchanged.

2014.04.02
MAN Diesel & Turbo
Work Card 506-01.24
Page 1 (6) Removal / Mounting of Marine Head from Engine
Edition 01

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 060 52000
069 52000
Shut off cooling water
Shut off fuel oil and hydraulic tools according to working card
520-01.06
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Removal of marine head from engine.

Starting Position Hand Tools

Engine out of operation.

Related Procedure

Qualified Manpower Replacement and wearing parts

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

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

2003.07.30.
 MAN Diesel & Turbo
506-01.24 Work Card
Removal / Mounting of Marine Head from Engine Page 2 (6)
Edition 01

L21/31, L27/38

Removal / Mounting of Marine Head from

Engine
Condition : Piston and connecting rod has been
removed and the fixation tool is installed, see fig. 1.

Figure 1: Fixation of connecting rod bearing

2003.07.30.
MAN Diesel & Turbo
Work Card 506-01.24
Page 3 (6) Removal / Mounting of Marine Head from Engine
Edition 01

L21/31, L27/38
1) Turn the crank through to about TDC.
2) Install the brackets in the lower end of the
crankcase opening, see fig. 2.

Figure 2: Bracket installed

2003.07.30.
 MAN Diesel & Turbo
506-01.24 Work Card
Removal / Mounting of Marine Head from Engine Page 4 (6)
Edition 01

L21/31, L27/38
3) Place the guide beam on the brackets and
secure it by means of the screws, see fig 3.

Figure 3: Placing of guide beam

2003.07.30.
MAN Diesel & Turbo
Work Card 506-01.24
Page 5 (6) Removal / Mounting of Marine Head from Engine
Edition 01

L21/31, L27/38

Warning!
Use safety glasses and protective gloves!
4) Turn the crankshaft to the position shown in fig
4 and remove the nuts by means of the
hydraulic tool.

Figure 4: Removal of nuts

2003.07.30.
 MAN Diesel & Turbo
506-01.24 Work Card
Removal / Mounting of Marine Head from Engine Page 6 (6)
Edition 01

L21/31, L27/38

Warning!
Use safety shoes and protective gloves!
5) Install the slide piece as shown in fig. 5 and
remove the bracket.
6) Turn the crankshaft to make the marine head
rest against the beam, see fig. 5..
7) Pull out the two halves of the marine head.
8) Remove the bearing shells from each marine
head half.

Figure 5: Marine head with slide piece

Mounting of Marine Head

Mounting is carried out in reverse order of the
above.

2003.07.30.
MAN Diesel & Turbo
Work Card Hydraulic Tightening of Piston and Marine Head 506-01.25
Page 1 (3)
Screws Edition 06

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 011
52000 096
Shut off cooling water 52000 167
Shut off fuel oil 52000 180
Shut-off cooling oil 52000 202
52000 334
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Tightening procedure for connecting rod screws.
Check of connecting rod screws, tightening condi-
tion.

Starting Position Hand Tools

Piston, connecting rod, bearing
shells and bearing cap preassem-
bled

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : ½ Plate No. Item No. Quantity
Number : 2

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

2002.09.23.
 MAN Diesel & Turbo
506-01.25 Hydraulic Tightening of Piston and Marine Head Work Card
Page 2 (3)
Edition 06 Screws

L27/38

Tightening Sequence 3) Connect the hoses and pressure pump to the

hydraulic tool.
The following sequence is the same for both the
connecting rod screws (item 211) and the marine
head screws (item 152), see plate 50601. Measuring instruction for extension of
1) Mount the hydraulic tightening bolts and be hydraulic tightened bolts
sure that the studs are screwed home. Tighten 1) Mount the two dial gauges on the hydraulic
the nuts by hand (step 1). tools, fig 2.
2) Mount the hydraulic tools, fig. 1, on both con- Note: For a correct measuring the dial gauge has to
necting rod bolts. be mounted with the magnetic bracket on the
housing of the hydraulic tool.
2) Tension both bolts simultaneously to a pressure
of:
connecting rod screw: ..100 bar
marine head screw: ......600 bar
by use of the hydraulic tightening tool.
3) Set the dial gauges to "0".
4) Check by feeler gauge 0.01 mm. It is not
allowed that there is clearance between the
assembled components.
5) Load the bolts to the specified pressure, see
description 500.40.
6) Tension both the nuts hand-tight.
7) Release the pressure.

A Tightening order B Hydraulic tool

1 Dial gauge 2 Hydraulic tightening tool

Figure 1: Hydraulic tool for tightening of connecting rod screws
3 Nut 4 Screw
Be aware of the max. lifting height of the tool and
Figure 2: Hydraulic tool for tightening of connecting rod screws
adjust the distance between the piston and the cyl-
inder before adding pressure to the tool, please see
working card 520-01.05.

2002.09.23.
MAN Diesel & Turbo
Work Card Hydraulic Tightening of Piston and Marine Head 506-01.25
Page 3 (3)
Screws Edition 06

L27/38
8) Tension the bolts to a pressure of:
connecting rod screw: ..100 bar
marine head screw: ......600 bar
again.
9) Read elongation of the screw Δl on the dial
gauge and compare with the value in table.
Note: The bolts should be tightened to the speci
fied tensioning pressure, not according to the elon-
gation. The elongation only serves as a means of
control. In case of excessive deviations, repeat the
tensioning procedure and check the measuring
instruments and / or pressure gauges.
10) Release the pressure and remove the hydraulic
tensioning tools.
Note: For general instruction about hydraulic tight-
ening, please see working card 520-01.05.

2002.09.23.
MAN Diesel & Turbo
Work Card 506-01.30
Page 1 (3) In-situ Inspection of Connecting Rod Big-end Bearing
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 069
Shut off cooling water and hydraulic tools according to working card
Shut off fuel oil 520-01.06
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
In situ inspection and/or replacement of connect-
ing rod big-end bearing, dismounting and mount-
ing.

Starting Position Hand Tools

Open-end spanner, 24 mm
Crankcase opened

Related Procedure
Inspection of connecting rod big- 506-01.16
end bearing
Tightening and check of connect- 506-01.25
ing rod screws
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06

Qualified Manpower Replacement and wearing parts

Duration in h : 1½ Plate No. Item No. Quantity
Number : 1

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

2001.07.23.
 MAN Diesel & Turbo
506-01.30 Work Card
In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
Edition 03

L27/38

Removal of the connecting rod bearing

cap
1) Turn the crankshaft into the top position.
2) Mount the holder on the marine head. Please
see fig 1.
3) Loosen the two marine head nuts with the
hydraulic tools.
4) Remove the nuts and bolts.
5) Mount the supporting pipes. Please see fig 2.
6) Remove the upper screws of the holder.
7) Lowering the lower marine head cap by means
of the pipes until the pipes rest at the frame,
see fig 2.
8) Remove the bearing shell.

1 Support pipes

Figure 2: Mounting of the supporting pipes

Mounting of the inspection bracket

1) Mount the inspection bracket. Please see fig 3.
2) Slowly turn the crankshaft clockwise until the
marine head is resting on the inspection
bracket.
3) Fix the marine head and inspection bracket with
screw.

1 Holder 2 Hydraulic device

Figure 1: Mounting of holders on the marine head

2001.07.23.
MAN Diesel & Turbo
Work Card 506-01.30
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing
Edition 03

L27/38
1) Slowly turn the crankshaft clockwise until it is
possible to remove the upper marine head
bearing shell. Please see fig 4.
2) Remove the upper marine head bearing shell.

Inspection of bearing shells

1) Inspect the bearing shells; please see working
card 506-01.16.

Cleaning of components before mounting

1) Clean carefully the joint faces, the bore and the
bearing shells.

Mounting of upper bearing shell

1) The bearing shell is placed in the bore, and the
contact surfaces of the shells must be parallel
to the contact surface of the marine head and
the bearing cap respectively.
1 Inspection bracket 2 Screw for fitting marine
head and inspection 2) Coat the journal with clean lubricating oil.
bracket
3) Slowly turn the crankshaft anti-clockwise until it
Figure 3: Mounting of the inspection bracket rests in the marine head.
4) Remove the inspection bracket.

Removal of the upper marine head bearing Mounting of lower bearing shell
shell 1) Turn the crankshaft anti-clockwise until it is in
the top position.
2) The bearing shell is placed in the bore, and the
contact surfaces of the shells must be parallel
to the contact surface of the marine head and
the bearing cap respectively.
3) Coat the journal with clean lubricating oil.

Mounting of bearing cap

1) Lift the lower bearing cap by means of the pipes
and mount the upper screws of the holder.
2) Mount the two bolts and nuts for hydraulic
tightening of the marine head.
3) Mount the hydraulic tool and tighten the nuts
according to working card 506-01.25.
4) Remove the holder from the marine head.

Figure 4: Removal of the upper marine head bearing shell

2001.07.23.
MAN Diesel & Turbo
Work Card 506-01.35
Page 1 (7) Inspection and Honing of Cylinder Liner
Edition 09

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air A MAN approved equipment: Honing stone
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Inspection and honing of cylinder liner

Starting Position Hand Tools

Honing liquid
Cylinder head removed 505-01.00
Piston and connecting rod shank 506-01.00 Gas oil
removed

Related Procedure
Grinding of seal face on cylinder 506-01.45
head and cylinder liner

Qualified Manpower Replacement and wearing parts

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

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

2011.09.26.
 MAN Diesel & Turbo
506-01.35 Work Card
Inspection and Honing of Cylinder Liner Page 2 (7)
Edition 09

L27/38

Inspection and honing of cylinder liner

Use only a MAN approved equipment and always
read the manufacturer-supplied instructions.

Brief description
Carry out the work in good time according to the
maintenance schedule, check the components as
to their wear, restore running surface to operational
state, ensure the tasks are carried out correctly.
The cylinder liners are to be checked at regular
intervals and the original running surface geometry
is to be restored to how it was.
The work / working steps consists of:
▪ Honing the reversal point of the piston rings.
▪ Honing the entire running surface.

Preliminary remarks
Cylinder liners must be rehoned when the piston Figure 1: Honing device for cylinder liner - tool not supplied.
Stones can be replaced with brush.
rings are replaced or once the maintenance interval
has elapsed. Through honing, the original rough-
ness or the cylinder liner running surface is restored. In case of lacquering of the liner surface first clean
This roughness is necessary to ensure a sufficiently the liner with mild acid to remove lacquer. Honing is
thick and adhesive lubricating film. While for the done to restore liner surface – not to clean for lac-
most part the microgeometry can be returned to its quer.
original state, it is not possible to influence the wear
profile, i.e. the macrogeometry of the cylinder liner. Set-up and mode of operation
Typically during the first work step the TDC area of The stroke speed and the honing head speed are
the piston rings is honed. In the second work step preadjusted as is the contact pressure of the honing
work is performed to the entire piston ring running sticks using the control valves on the compressed
surface. air outlet. The rope tackle engine is activated for lift-
Honing the cylinder liner does not take very long. ing and lowering movements using the buttons on
Operating the device and the work itself, as well as the remote control.
correctly assessing the results, however, does
require concentration and a certain amount of Work sequence 1
experience. We thus recommend having this task
performed at least once for instruction purposes by
- honing the piston ring reversal point in
MAN Diesel SE staff.
the top dead centre (gusset area)
Starting position

2011.09.26.
MAN Diesel & Turbo
Work Card 506-01.35
Page 3 (7) Inspection and Honing of Cylinder Liner
Edition 09

L27/38
Cylinder head has been removed, piston with con- The crankcase is adequately covered. The funnel is
necting rod shank removed, the connecting rod attached on the lower part of the cylinder liner and
bearing with the turning stirrup attached to the bal- the hose is facing outwards into a collecting tank.
ance weight and turned towards the side far The honing device has been set up as per its sepa-
enough for a funnel to be mounted. The cylinder rate instructions and has been set.
liner has been cleaned (free of coke and lube oil) Notice
and measured. If measurement is above limit the The piston ring reversal points are to be honed as a
liner must be scrapped. first work step using short coarse honing stones
before the entire running surface of the piston ring is
honed during a subsequent work step.
Working steps
1) Clip honing stones (20 mm long) into each
grinding strip at the same level close to the cen-
tre of the grinding strip.
Notice
Lengths can be broken off the longer honing stones
to make short honing stones. To do so, notch the
honing stone using a steel saw blade, clamp it into
a vice and break off.
2) Insert the honing head carefully into the cylinder
liner.
3) Set the stroke movement of the honing head in
the cylinder liner with stops in such a way that
the upper edge of the honing stones comes to
rest approx. 10 mm above the top dead centre
of the first piston ring resulting in a stroke of
1 Cylinder liner 2 Funnel 40-50 mm.
3 Hose 4 Collecting tank 4) Set the spray nozzles so that the lubricant coats
the honing area upon exit.
Figure 2: Honing the cylinder liner
5) Close the stop cock on the tank and fill it with
adequate honing lubricant (diesel oil, gas oil or
kerosene). Be aware that some liquids are pro-
hibited in some places.

Warning!
No smoking. Do not use an open flame - fire haz-
ard!
6) Open the stop-cock on the tank. Check that
lubricant is coming out of the spray nozzles and
is coating the area to be honed. Check whether
lubricant is flowing through the funnel into the
collecting tank without leaking.
Notice
For the honing process of one cylinder liner, approx.
4-6 litres of lubricant are needed. Always use ade-
quate lubricant for the honing process. It is to be
Figure 3: Honing the cylinder liner recommended that the abrasion products are

2011.09.26.
 MAN Diesel & Turbo
506-01.35 Work Card
Inspection and Honing of Cylinder Liner Page 4 (7)
Edition 09

L27/38
flushed away immediately. The lubricant may be 2) Insert the honing head carefully into the cylinder
used several times if it flows into the collecting tank liner.
through a fleece mat. For the final cleaning process, 3) Set the stroke movement of the honing head
after the actual honing process, use a clean lubri- with stops in such a way that the honing stones
cant / cleaning agent to clean the cylinder liner. range in the upper half of the stroke area of the
7) Activate the honing device using a setting that piston (running area of the piston rings), mean-
has been tested in advance. Take the honing ing that the upper and lower edges of the stone
stones to the installation. Using slight upward protrude approx. 100 mm beyond it.
and downward strokes. Hone the surface until 4) Set the spray nozzles so that the lubricant coats
the surface is within the required tolerance. It the honing area upon exit. Fill the tank with
can be necessary to use more than one stone. lubricant (diesel oil, gas oil or kerosene).
This takes approx. 1-1.5 minutes. In so doing,
the honing head speed is approx. 35 RPM con- Warning!
tact pressure 2.5 bar.
The short stroke means that only a minimum No smoking. Do not use an open flame - fire haz-
honing angle is achieved. If in the TDC area of ard!
the first piston ring honing grooves become visi- 5) Open the stop-cock on the tank. Check that
ble, the honing process should be stopped. A lubricant is coming out of the spray nozzles and
remaining, rounded protrusion at the reversal is coating the area to be honed. Check whether
point of the first piston ring is acceptable. If nec- lubricant is flowing through the funnel into the
essary, a second set of honing stones should collecting tank without leaking.
be inserted and the process should be repea-
ted. Notice
Approx. 10 litres of lubricant are needed for the
8) As soon as a satisfactory abrasion pattern has honing process of one cylinder liner. Always use
been achieved, terminate the honing process adequate lubricant for the honing process. It is to
and stop the flow of lubricant. be recommended that the abrasion products are
9) Pull the honing head out of the cylinder liner and flushed away immediately.
secure it in the upper position. 6) Activate the honing device using a setting that
has been tested in advance. Take the honing
Work sequence 2 stones to the installation. For honing one cylin-
der liner, 40-80 upward and downward strokes
each are necessary at a stroke speed of
- honing the entire running surface of the
approx. 18 double strokes per minute. The
cylinder liner overall honing time for one cylinder is typically
Starting position 3.5-4 minutes. In so doing, the honing head
speed is approx. 35 RPM. Contact pressure 2.5
The piston ring reversal point in the top dead centre
bar. Control the stroke movement so that a
has been honed or the cylinder liner shows mini-
honing angle (a) of 45-60° (± 22.5-30° to the
mum wear points in the TDC area.
horizontal) is achieved. A surface roughness
Notice depth Rz of 10-15 µm is to be aimed at.
This task is intended to roughen up the upper area
7) Stop the honing device. Evaluate the rough-
of the cylinder liner on which no further honing
ness, honing angle and honing pattern. If the
grooves are visible after many operating hours. In
evaluation proves to be satisfactory, execute
the lower area, the surface should be honed as little
two double strokes over the entire running sur-
as possible, however upon completing the work,
face of piston rings. To do so, set the stops so
two double strokes should be carried out over the
that the honing blocks partially move outside
entire running surface of the piston rings.
the cylinder liner. In the process, ensure that the
Working steps honing head does not knock into the funnel.
1) Fit six long coarse honing stones onto the hon- Repeat the honing sequence 2 with fine honing
ing head. stones.

2011.09.26.
MAN Diesel & Turbo
Work Card 506-01.35
Page 5 (7) Inspection and Honing of Cylinder Liner
Edition 09

L27/38
Repeat the honing sequence 1 (top of the liner) with
fine honing stones.
8) After finishing the honing process, measure the
cylinder liner. If the maximum allowable wear
has beeen exceeded in the top dead centre of
the first piston ring, or the maximum allowable
ovality (for threshold values see 500.35), the cyl-
inder liner will need to be replaced.
9) Check surface roughness, to be within toler-
ance:
RK = 2.5 - 5.0
Rpk = 0.6 - 2.0
10) Replace the grinding strips with hard cleaning
brushes.
11) Pull back the honing head and using reduced
contact pressure of 0.5-1.0 bar, carefully
remove (dissolve / rinse) all abrasion residue at
an unchanged number of revolutions and stroke
speed. If necessary, repeat the process with a
soft cleaning brush. Plenty of lubricant should
be used for cleaning. A total of approx. 50 dou-
ble strokes should be carried out. The last run
should be carried out using fresh lubricant. No
abrasion residue should remain (use your finger-
tips to check).
12) Remove the honing device. Place it onto the
next cylinder or store it safely after it has been
cleaned or store it in its packaging.
13) Remove the funnel, in the process ensure that
no dirt particles get into the running gear.
14) Finally, manually clean the cylinder liner and cor-
rosion protect the liner with clean oil.

2011.09.26.
 MAN Diesel & Turbo
506-01.35 Work Card
Inspection and Honing of Cylinder Liner Page 6 (7)
Edition 09

L27/38

Figure 4: Template to control honing angle. Copy and use at liner in situ

2011.09.26.
MAN Diesel & Turbo
Work Card 506-01.35
Page 7 (7) Inspection and Honing of Cylinder Liner
Edition 09

L27/38

2011.09.26.
MAN Diesel & Turbo
Work Card Grinding of Seal Face on Cylinder Liner and Cylinder 506-01.45
Page 1 (2)
Head Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 087
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Grinding of seal face on cylinder liner, cylinder
head and engine frame by hand with grinding tool
and grinding paste.

Starting Position Hand Tools

Grinding paste.
Disassembly of cylinder unit 505-01.01

Related Procedure
Assembling of cylinder unit 505-01.50

Qualified Manpower Replacement and wearing parts

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

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

2003.10.20.
 MAN Diesel & Turbo
506-01.45 Grinding of Seal Face on Cylinder Liner and Cylinder Work Card
Page 2 (2)
Edition 03 Head

L27/38

Grinding
Note: The grinding tool, see fig 1, is used for both
grinding the groove in the sealing surface on the
cylinder head (1), the cylinder liner flange (2) and the
surface of the engine frame (3).
If severe damage or corrosion is observed, a
machining of the sealing faces may be required.

Figure 3: Grinding tool at engine frame

1 Cylinder head 2 Cylinder liner

3 Engine frame

Figure 1: Grinding tool

1) Loosen the sealing ring in liner flange and take it

out.
2) Face-grind the sealing grooves in the cylinder
liner flange, see fig 2, the surface of the engine
Figure 4: Grinding tool at cylinder head
frame, see fig 3 and the sealing surface on the
cylinder head, see fig 4 with the use of grinding
paste and the grinding tool. 3) Move back and forth the tool and lift it out from
time to time.
4) After grinding, carefully remove all traces of
abrasives and grinding compound.
5) When having ground the contact faces between
cylinder head and cylinder liner, it must be
observed that the sealing minimum height
above the cylinder liner is according to 500.35.

Figure 2: Grinding tool at cylinder liner

2003.10.20.
MAN Diesel & Turbo
Work Card Dismantling of Piston and Cylinder Liner at Low 506-01.50
Page 1 (3)
Overhaul Height Edition 06

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 060
52000 082
Shut off cooling water 52000 104
Shut off fuel oil
and hydraulic tools according to working card
Shut-off cooling oil 520-01.06
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismounting of cylinder unit for inspection and/or
overhaul.

Starting Position Hand Tools

Engine stopped and cooled down.

Related Procedure
Inlet + exh. valve - overhaul / 505-01.10
regrinding of spindel + valve seat
Valve rotator 505-01.15
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35
Inspection of piston 506-01.10
Cylinder liner 506-01.35
Sep. of piston and connection rod 506-01.05
Fuel injection valve 514-01.10
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06
Replacement and wearing parts
Qualified Manpower Plate No. Item No. Quantity
Duration in h : 2½
Number : 2

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

2007.08.27.
 MAN Diesel & Turbo
506-01.50 Dismantling of Piston and Cylinder Liner at Low Work Card
Page 2 (3)
Edition 06 Overhaul Height

L27/38

Preparing before dismantling 5) Disconnect the 2 clamps for locking the charge
air connections by removing the locking bolts
1) Drain off the water from the engine. for the clamps, see fig 1.
2) Take off the top cover. 6) Push the charge air connections inside the cyl-
3) Take off the side covers on both sides of the inder head which are to be removed.
engine. 7) Remove the cylinder head nuts by means of the
4) Remove the exhaust gas cover. hydraulic jacks, see working card 520-01.05.
8) Remove the bolts, which hold the cylinder head
Disassembling of connectings and water jacket together, see fig 2.
1) Disconnect the clamp for connecting cylinder Note: This means that the cylinder head now can
head and exhaust gas receiver. be removed from the cylinder unit.
2) Disconnect the fuel oil high pressure pipe.
3) Disconnect the 4 clamps for locking the FW
connection between the cylinder heads.
4) Push the FW connections inside the cylinder
heads, which are to be removed.

A Bolts to be removed

Figure 2: Remove bolts, which hold the cylinder head and water
jacket together

9) Mount the lifting tool on the cylinder head.

10) Lift the cylinder head and land it carefully on
wooden support.
11) Remove the push rods by hand.

Removal of piston rod, cylinder liner and

water jacket
A Charge air connection B Cooling water connection
1) Turn the piston into top dead centre.
Figure 1: Push the cooling water connection and charge air con-
nections inside the cylinder heads, which are to be removed 2) Mount the turning bracket to the marine head
and counterweight, see fig 3.

2007.08.27.
MAN Diesel & Turbo
Work Card Dismantling of Piston and Cylinder Liner at Low 506-01.50
Page 3 (3)
Overhaul Height Edition 06

L27/38
6) Mount the lifting tool for the cylinder liner, see
fig 5 and lift the cylinder liner out of the engine.
7) Mount the eye bolt in water jacket and lift it off
the engine.

Figure 3: Turning bracket mounted to the marine head and coun-

terweight

3) Loosen the four bolts for the piston rod by

means of the hydraulic tools and remove the
nuts.
4) Mount the tool for lifting the piston, see fig 4.

1 Lifting tool for cylinder 2 Cylinder liner

liner
Figure 4: Lifting tool for piston
3 Lifting tool

5) Carefully lift the piston and piston rod out of the

Figure 5: Lifting tool for cylinder liner
cylinder liner and land it on wooden support.

2007.08.27.
MAN Diesel & Turbo

Plate
Page 1 (2) Piston and Connecting Rod 50601-33

L27/38

414

296 306
414 127
296
355**
127
367**

379**

081
019

176**
032
318**
331**

380**
392**
056
380**
402** 188

211
188

211

272
140

139 284
343

152

164

11.23 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50601-33 Piston and Connecting Rod Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

019 1/C Piston pin Stempelpind 380** 2/C Support disc Støtteskive

032 2/C Retaining ring Sikringsring 392** 1/C Pressure spring Trykring

056 1/C Bush for connecting Plejlstangsbøsning 402** 1/C Slide shoe Glidesko
rod
414 1/C Piston ring Stempelring
081 1/C Piston 2/2, Stempel 2/2,
incl. item 176, 318, inkl. item 176, 318,331
331

127 1/C Oil scraper ring Olieskrabering

139 1/C Connecting rod Plejlstangsleje 2/2,

bearing 2/2, Daido Daido

140 4/C Cylindrical pin Cylindrisk stift

152 2/C Screw Plejlstangsskrue

for connecting rod

164 2/C Nut Møtrik

176** 4/C Bolt Bolt

188 4/C Nut Møtrik

211 4/C Screw for Plejlstangsskrue **

For illustration only;
connecting rod – only available to MAN Service Centers
and Hubs.
272 1/C Connecting rod shaft, Plejlstangsskaft, – piston only available as complete.
incl. item 056 inkl. item 056

284 1/C Marine head, Marinehovede, ** Kun til illustration;

complete incl. item komplet inkl. item – kun tilgængelig for MAN Service Centre.
140, 152, 164, 188, 211 140, 152, 164, 188, 211 – stempel kun tilgængelig som komplet.
296 1/C Piston ring Stempelring

306 1/C Set of piston rings and Sæt af stempelringe og

oil scraper ring, incl. olieskrabering, inkl. item
item 127, 296 and 414 127, 296 og 414

318** 4/C Distance sleeve Afstandsskive

331** 4/C Nut Møtrik

343 1/C Connecting rod Plejlstangsleje 2/2,

bearing 2/2, Miba Miba

355** 1/C O-ring O-ring

367** 1/C Retaining ring Sikringsring

379** 1/C Spring pin Fjedertap

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

11.23 - ES0 - Tier II

 MAN Diesel
Plate
Page 1 (2) Cylinder Liner 50610-11H

L27/38
08028-0D/H5250/94.08.12

06.29 - ES0
 MAN Diesel
Plate
50610-11H Cylinder Liner Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

018 1/C Cylinder liner Cylinderforing

031 1/C Sealing ring Tætningsring

043 1/C O-ring O-ring

055 1/C O-ring O-ring

092 1/C Flame ring Flammering

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

06.29 - ES0
Camshaft

507/607
MAN Diesel & Turbo
Description 507.01
Page 1 (1) Camshaft and camshaft drive
Edition 03

L27/38

Camshaft and camshaft drive

The inlet and exhaust valves as well as the fuel
pumps of the engine are actuated by two cam-
shafts.
Due to the two-camshaft design an optimal adjust-
ment of the gas exchange is possible without inter-
rupting the fuel injection timing. It is also possible to
adjust the fuel injection without interrupting the gas
exchange.
The two camshafts are located in the engine frame.
On the exhaust side, in a very high position, the
valve camshaft is located to allow a short and stiff
valve train and to reduce moving masses.
The injection camshaft is located at the service side
of the engine.
Both camshafts are designed as cylinder sections
and bearing sections in such a way that disassem-
bly of single cylinder sections is possible through
the side openings in the crankcase.
The two camshafts and the governor are driven by Figure 1: Twin camshafts
the main gear train which is located at the flywheel
end of the engine. They rotate with a speed which
is half that of the crankshaft.
The camshafts are located in bearing bushes which
are fitted in bores in the engine frame; each bearing
is replaceable and locked in position in the engine
frame by means of a locking screw.
The gear wheel for driving the camshaft as well as a
gear wheel connection for the governor drive are
screwed on to the aftmost section.
The lubricating oil pipes for the gear wheels are
equipped with nozzles which are adjusted to apply
the oil at the points where the gear wheels are in
mesh.

1998.06.29
MAN Diesel & Turbo
Work Card 507-01.00
Page 1 (2) Check of camshaft and camshaft drive
Edition 05

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Checking of gear wheels, bolted connections and
lubricating system.

Starting Position Hand Tools

Unbraco top, 14 mm
Ratchet
Extension
Top, 24 mm
Serrated fork

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 1 51106 142 1/cyl

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

2002.11.18.
 MAN Diesel & Turbo
507-01.00 Work Card
Check of camshaft and camshaft drive Page 2 (2)
Edition 05

L27/38

Check of Camshaft- and Camshaft Drive

1) Dismount the covers which give access to the
gear wheels, camshaft and crankcase.
2) Examine all gear wheels for cracks, wear and
deformations while turning the engine to enable
inspection all over the circumference of the gear
wheels.
3) Check all screws, nuts and bolted connections,
including locking devices everywhere in the gear
wheel housing, camshaft housing and crank
case to check that they have not loosend.
Tightening torques, please see page 500.40.
4) Examine all lubricating oil spray pipe nozzles.
5) Mount the covers.

2002.11.18.
MAN Diesel & Turbo
Work Card 507-01.05
Page 1 (3) Inspection and replacement of camshaft bearing
Edition 04

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air Hydraulic tools according to Working Card
Shut off cooling water 520-01.06
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of roller path of cams and check of cam-
shaft bearing. Replacement of camshaft bearing.

Starting Position Hand Tools

Screwdriver
Cover for camshaft and gear
wheel has been removed. Supporting tool for camshaft bearing

Related Procedure
Camshaft and camshaft drive 507-01.00
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06

Qualified Manpower Replacement and wearing parts

Duration in h : 3 Plate No. Item No. Quantity
Number : 2 50705 350 1/eng
50705 648 1/eng
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2002.10.07.
 MAN Diesel & Turbo
507-01.05 Work Card
Inspection and replacement of camshaft bearing Page 2 (3)
Edition 04

L27/38

To check roller path of cams Note: To prevent the lower rocker arm from push-
ing downward at the camshaft section to be
1) While turning the engine, examine the cam removed, place a screwdriver in the sloth of the
discs and in particular, check the roller path of rocker arm and lift the lower rocker arm free from
all cams for cracks, crackles and ruffle. Also the camshaft section, see fig 1.
examine the rollers of the lower rocker arms.
Note: If there are flat spots on the roller and if some
of the rollers may be blocked, the roller must be
replaced by a new one, please see working card
508-01.00.

To Check Camshaft Bearings

1) The wearing surface of the camshaft bearings
cannot be checked without dismounting the
camshaft. However, abnormal wear of one or
more bearings will become apparent in the form
of burrs of white metal at the circumference of
the camshaft journal, and in that case the bear-
ing will in no doubt be discoloured, as well.
The bearing clearance is measured with a feeler
Figure 1: Place a screwdriver in the sloth of the lower rocker arm
gauge, please see data sheet 500.35.
5) Remove the spur wheel and the bearing plate,
To replace camshaft bearing for injection see fig 2 so the camshaft can be moved
or valve camshaft towards the alternator.
Remember to mark the spur wheel. It must be
If one or several of the camshaft bearings should be
placed exactly at the same spot. Otherwise, the
replaced, the camshaft must be wholly or partly dis-
timing will be changed.
mantled.
6) Dismantle the camshaft section aft (towards the
1) The camshaft sections are marked in relation to
alternator) of the bearing that is to be replaced.
each other.
7) Place a screwdriver between the camshaft sec-
2) Dismantle the camshaft section for (towards
tions aft of the bearing and push the camshaft
engine front) of the bearing that is to be
aft towards the alternator.
replaced.
8) Dismantle the same camshaft section at the aft
3) Place a screwdriver between the camshaft sec-
end and remove the camshaft section from the
tions forward of the bearing and push the cam-
engine.
shaft forward.
The bearing to be removed is now free.
4) Dismantle the same camshaft section at the
9) Mount the supporting tool for removing the
front end and remove the camshaft section
camshaft bearing, see fig 3.
from the engine.
10) Turn the nut clockwise until the bearing is
removed from the frame hole.
11) Remove the supporting tool.

2002.10.07.
MAN Diesel & Turbo
Work Card 507-01.05
Page 3 (3) Inspection and replacement of camshaft bearing
Edition 04

L27/38

Mounting of the camshaft bearing

1) For fitting the bearing it must be cooled down
with CO2 to -90° C below crankcase tempera-
ture.
2) Insert the bearing in the frame. Make sure that
the oil bores in the bearing shell are turned 90°
according to the oil bores in the frame.
Note: Check that the bearing is placed in the
middle of the frame.
3) 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.
4) Assemble the sections and fit the bolts (coated
with molycote or similar).
5) Tighten the nuts with a torque spanner, see
data sheet 500.40.

1 Spur wheel

Figure 2: Removing of spur wheel and the bearing plate

1 Tool 2 Bearing

Figure 3: Supporting tool for removing the camshaft bearing

Inspection of Sleeve and Oil Bore

1) Check that the oil bore for the bearing is free for
oil flow. Inspect the camshaft journal for seiz-
ures.

2002.10.07.
MAN Diesel & Turbo
Work Card 507-01.20
Page 1 (4) Adjustment of camshaft for valve and injection timing
Edition 18

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Nominal adjustment of camshaft. (Adjustment of
camshaft in relation to crankshaft).

Starting Position Hand Tools

Camshaft assembled as per timing order, moun-
ted in frame and roller gear house. If intermediated
gearwheel must be changed, the generator must
be dismounted.

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : -

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

2013.06.19
 MAN Diesel & Turbo
507-01.20 Work Card
Adjustment of camshaft for valve and injection timing Page 2 (4)
Edition 18

L27/38

Assembly of gear wheels for valve

camshaft and injection valve camshaft,
without mounted flywheel
Following description is for mounting the gear-
wheels in the control drive when alternator, flywheel
and cover on coupling side are dismantled from the
engine.

Mounting of the intermediate spur gear

wheels
1) Turn the crankshaft to top dead centre for the
last cylinder (the cylinder nearest to the coupling
side).
2) Mount the upper intermediate spur gearwheel.

1 Upper intermediate spur 2 Small holes

wheel
3 Lower intermediate spur 4 Crankshaft
wheel

Figure 2: Position of small holes in the circumference of the two

intermediated gearwheels

Note: The punch mark on the crankshaft gearwheel

is placed between teeth 12 and 13 counting coun-
ter clockwise from the joint of the gearwheel, see fig
3.

Figure 1: Marks on gearwheels

3) Mount the lower intermediate spur gearwheel

so the marks on the lower intermediate spur
gearwheel are corresponding with the mark on
the crankshaft gearwheel, see fig 1(E2). At the
same time turn the upper intermediate spur
gearwheel so that the small holes in the circum-
ference of the two intermediate spur gear-
wheels are corresponding, see fig 2.

2013.06.19
MAN Diesel & Turbo
Work Card 507-01.20
Page 3 (4) Adjustment of camshaft for valve and injection timing
Edition 18

L27/38
Note: Adjustment of injection valve camshaft is now
needed, please see separately chapter “Adjustment
of Fuel Injection Camshaft / Injection Timing”.

Measure of fuel pump lead

1) Dismantle covers for fuel camshaft and fuel
pump.
2) Check the mobility of the regulating device.
3) Position the support of the measuring tool on
the two bolts of the camshaft covering. Slip on
the distance sleeves and fasten to the cylinder
crankcase by means of hexagon nuts.
Note: During attaching, pay attention to the correct
fitting position of the contact point.

a 13 teeth

Figure 3: 13 teeth counter-clockwise from the joint of the gear-

wheel

4) Tighten up the intermediate spur gearwheels,

please see page 500.40.

Mounting of gearwheel for valve camshaft

1) Before mounting of the gearwheel, the marks
on the crankshaft and the lower intermediate
gearwheel must correspond, see fig 1 (E2).
Futher, the small holes on both intermediate
gearwheels must correspond.
2) Turn the valve camshaft, until the mark on the
gearwheel for valve camshaft corresponds with
the 2 marks on upper intermediate gearwheel,
see fig 1 (E1).
3) Tighten up the gearwheel. Tightening torque,
please see page 500.40.
1 Contact point 2 Fixing screws
3 Lever 4 Measuring gauge
Mounting the gearwheel for injection
camshaft Figure 4: Measure of fuel pump lead
1) Before mounting the gearwheel, must marks for
crankshaft and lower intermediate gearwheel 4) Insert the dial gauge into the support.
correspond, see fig 1(E2). Secondly must the 5) Turn the engine until the cam base circle is
small holes for both intermediate gearwheels be reached (approx 40° BTDC).
corresponding.
6) Set the dial gauge to "Zero".
2) Turn the injection valve camshaft, until the mark
on the gearwheel for valve camshaft corre- 7) Turn the engine until the TDC mark (ignition DC)
spond with the 2 marks on upper intermediate for the actual cylinder is reached.
gearwheel, see fig 1 (E1). Read the dial gauge and note down the gauge
value in sheet.

2013.06.19
 MAN Diesel & Turbo
507-01.20 Work Card
Adjustment of camshaft for valve and injection timing Page 4 (4)
Edition 18

L27/38
8) Determine the values for the other cylinders in
the same way.
Calculate the average value of all measure-
ments.
9) Compare the calculated value determined with
the value mentioned below.
10) If the values exceeds the limits, an adjustment
must be done in order to correct the errors.
11) Remove the complete measuring tool.
12) Mount all camshaft covers.
13) Plunger lift (average value), please see descrip-
tion 500.35.

2013.06.19
MAN Diesel & Turbo

Plate
Page 1 (2) Intermediate Wheel 50701-06

L27/38

107
119

073

085

132

061
036 107
073

085
085
132

061

012

097 085

10.48 - ES0
 MAN Diesel & Turbo

Plate
50701-06 Intermediate Wheel Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

012 1/E Stepped spur gear, Tandhjul, komplet

complete incl. item 061 inkl. item 061

036 1/E Spur gear, complete Tandhjul, komplet

incl item 061 inkl. item 061

061 2/E Control drive bearing Lejebøsning

073 2/E Bolt Bolt

085 4/E Axial bearing ring Lejering

097 2/E Axle Aksel

107 2/E Washer Skive

119 2/E Nut Møtrik

132 2/E Snap ring Låsering

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor

10.48 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Camshaft bearing P50704-01

L27/38

2013.04.22 - valve camshaft

 MAN Diesel & Turbo
Plate
P50704-01 Camshaft bearing Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

019 /I Camshaft bearing (valve camshaft) 1)

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

5 cyl. - 6/E, 6 cyl. - 7/E, 7 cyl. - 8/E, 8 cyl. - 9/E, 9 cyl.
- 10/E
* = Only available as part of a spare parts kit/not
available separately
Qty/I = Qty/Individual

2013.04.22 - valve camshaft

MAN Diesel & Turbo
Plate
Page 1 (2) Camshaft bearing P50704-02

L27/38

2013.04.22 - Injection camshaft

 MAN Diesel & Turbo
Plate
P50704-02 Camshaft bearing Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

032 /I Camshaft bearing (injection camshaft) 1)

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

5 cyl. - 6/E, 6 cyl. - 7/E, 7 cyl. - 8/E, 8 cyl. - 9/E, 9 cyl.
- 10/E
* = Only available as part of a spare parts kit/not
available separately
Qty/I = Qty/Individual

2013.04.22 - Injection camshaft

 MAN Diesel
Plate
Page 1 (2) Camshaft (Injection Camshaft) 50705-21H

L27/38

278 266
362
362
278
266
673
291
266 636
278 291
590 589
600
362
291
685
697

5 cyl.
313* 301 374 386
386 374

6 cyl.
Item nos for 408 433
bearing disks 398 421 445

7 cyl.
08028-0D/H5250/94.08.12

457 470 469

469 470 457

8 cyl.
494 421 528
482 504 516 541

9 cyl.
553 433 577 565
565 577 433 553

06.33 - ES0
MAN Diesel
Plate
50705-21H Camshaft (Injection Camshaft) Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

266 Screw Skrue 469 2/E Bearing disk, Lejesøle,

160/E 5 cyl. engine 5 cyl. motor 7 cyl. engine 7 cyl. motor
192/E 6 cyl. engine 6 cyl. motor
224/E 7 cyl. engine 7 cyl. motor 470 2/E Bearing disk, Lejesøle,
256/E 8 cyl. engine 8 cyl. motor 7 cyl. engine 7 cyl. motor
288/E 9 cyl. engine 9 cyl. motor
482 1/E Bearing disk, Lejesøle,
278 Washer Skive 8 cyl. engine 8 cyl. motor
160/E 5 cyl. engine 5 cyl. motor
192/E 6 cyl. engine 6 cyl. motor 494 1/E Bearing disk, Lejesøle,
224/E 7 cyl. engine 7 cyl. motor 8 cyl. engine 8 cyl. motor
256/E 8 cyl. engine 8 cyl. motor
288/E 9 cyl. engine 9 cyl. motor 504 1/E Bearing disk, Lejesøle,
8 cyl. engine 8 cyl. motor
291 Cylindrical pin Cylindrisk stift
10/E 5 cyl. engine 5 cyl. motor 516 1/E Bearing disk, Lejesøle,
12/E 6 cyl. engine 6 cyl. motor 8 cyl. engine 8 cyl. motor
14/E 7 cyl. engine 7 cyl. motor
16/E 8 cyl. engine 8 cyl. motor 528 1/E Bearing disk, Lejesøle,
18/E 9 cyl. engine 9 cyl. motor 8 cyl. engine 8 cyl. motor

301 1/E Bearing plate, com- Lejeplade, komplet 541 1/E Bearing disk, Lejesøle,
plete incl. item 313 inkl item 313 8 cyl. engine 8 cyl. motor

313* 4/E Expander plug Ekspansionsprop 553 2/E Bearing disk, Lejesøle,
9 cyl. engine 9 cyl. motor
362 1/C Camshaft part Styreakselsektion
piece 565 2/E Bearing disk, Lejesøle,
9 cyl. engine 9 cyl. motor
374 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 577 2/E Bearing disk, Lejesøle,
9 cyl. engine 9 cyl. motor
386 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 589 1/E Axial bearing disk Aksial lejesøle

398 1/E Bearing disk, Lejesøle, 590 1/E Bearing segment Lejesøle, ende
6 cyl. engine 6 cyl. motor end

408 1/E Bearing disk, Lejesøle, 600 1/E Spur wheel Cylindrisk tandhjul
6 cyl. engine 6 cyl. motor
636 1/E Flange Flange
421 Bearing disk Lejesøle
1/E 6 cyl. engine 6 cyl. motor 673 16/E Bolt Bolt
1/E 8 cyl. engine 8 cyl. motor
685 2/E Screw Skrue
433 Bearing disk Lejesøle
1/E 6 cyl. engine 6 cyl. motor 697 2/E Washer Skive
2/E 9 cyl. engine 9 cyl. motor

445 1/E Bearing disk, Lejesøle,

08028-0D/H5250/94.08.12

6 cyl. engine 6 cyl. motor

457 2/E Bearing disk, Lejesøle,

7 cyl. engine 7 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

06.33 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Camshaft P50705-28

L27/38, L27/38S

2014.03.18 - Tier II, Stationary

 MAN Diesel & Turbo
Plate
P50705-28 Camshaft Page 2 (2)

L27/38, L27/38S
Item No. Qty Item Designation Item No. Qty Item Designation

014 1/C Camshaft part piece 697 2/E Washer

026 2/E Bearing disk 707 1/E Ring
038 2/E Bearing disk 719 1/E Additional mass
051 1/E Bearing disk, 6 cyl. engine 720 8/E Screw
063 1/E Bearing disk, 6 cyl. engine 732 1/E Cylindrical pin
075 1/E Bearing disk, 6 and 8 cyl. engine
087 Bearing disk, 6 and 9 cyl. engine 1)
099 1/E Bearing disk, 6 cyl. engine
109 2/E Bearing disk, 7 cyl. engine
110 2/E Bearing disk, 7 cyl. engine
122 2/E Bearing disk, 7 cyl. engine
134 1/E Bearing disk, 8 cyl. engine
146 1/E Bearing disk, 8 cyl. engine
158 1/E Bearing disk, 8 cyl. engine
171 1/E Bearing disk, 8 cyl. engine
183 1/E Bearing disk, 8 cyl. engine
195 1/E Bearing disk, 8 cyl. engine
205 2/E Bearing disk, 9 cyl. engine
217 2/E Bearing disk, 9 cyl. engine
229 2/E Bearing disk, 9 cyl. engine
230 1/E Axial bearing disk
242 1/E Bearing segment end
254 1/E Spur wheel
266 Screw 2)
278 Washer 2)
291 Cylindrical pin 3)
301 1/E Bearing plate complete
313 4/E Expander plug*
685 2/E Screw

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

6 Cyl. 1/E, 9 Cyl. 2/E
ace. 2)
5 Cyl. 88/E, 6 Cyl. 96/E, 7 Cyl. 112/E, 8 Cyl. 128/E, 9
Cyl. 144/E
* = Only available as part of a spare parts kit/not 4)
5 Cyl. 10/E, 6 Cyl. 11/E, 7 Cyl. 13/E, 8 Cyl. 15/E, 9 Cyl.
available separately 17/E
Qty/C = Qty/Cylinder
Qty/E = Qty/Engine

2014.03.18 - Tier II, Stationary

Operating gear

508/608
 MAN Diesel
Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition 03H

L27/38
Roller Guides Valve Actuating Gear

The fuel injection pumps and rocker arms for inlet The push rods for the inlet and exhaust valves are
and exhaust valves are operated by the cams on the activated by the camshaft via a cam follower.
camshafts through roller guides. The roller guides for
inlet and exhaust valves are located in bores in the The push rod movement is in the cylinder head
water jacket for each cylinder. transmitted to short rockers, and from these to a
guided, spring-loaded yoke. This yoke operates two
The roller runs on a bush fitted on a pin that is equal valves each.
pressed into the roller guide and secured by means
of a lock screw. The pillow supporting the rocking levers (the rocking-
lever casing) is bolted to the cylinder head.

Operating Gear for Fuel Injection Pumps Bearing bushes, ball pans and yokes are lubricated
by means of a fitting in the pillow.
The injection pumps which are mounted directly on
the frame are activated via thrust pieces from the
roller guide. The roller guide is incorporated in the
fuel pump as one unit.
08028-0D/H5250/94.08.12

98.27 - ES0
MAN Diesel & Turbo
Work Card 508-01.00
Page 1 (3) Inspection of valve roller guide
Edition 17

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismounting, inspection and/or overhaul, and
mounting of valve roller guides.

Starting Position Hand Tools

Related Procedure
Control and adjusting of valve 508-01.10
clearance

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2012.01.16.
 MAN Diesel & Turbo
508-01.00 Work Card
Inspection of valve roller guide Page 2 (3)
Edition 17

L27/38

Inspection of valve camshaft lower and

upper rocker arms
1) To be able to inspect the cam followers it can
be necessary to gain access by removing the
exhaust arrangement, water pipes and top
cover.

1 Locking screw for rocker arm shaft

Figure 2: Locking screw for rocker arm shaft

1 Rocker arm 2 Lock screw for cam fol-

lower

Figure 1: Lower and upper rocker arm

2) The cam followers can be dismantled after the

rocker arms in the cylinder head have been
removed.
3) To remove the rocker arms, the crankshaft 1 Locking screw for cam follower shaft
must be turned to a position where the cam fol-
lowers are on the circular part of the cams for Figure 3: Locking screw for cam follower shaft
the cylinder unit in question.

2012.01.16.
MAN Diesel & Turbo
Work Card 508-01.00
Page 3 (3) Inspection of valve roller guide
Edition 17

L27/38
4) Untighten the locking screw for rocker arm
shaft, see fig 2 and push out the shaft for rocker
arm.
5) After the rocker arms have been removed, the
push rods can be pulled out.
6) Check the condition of the bushings in the
rocker arms and the condition of the rocker arm
shaft, see fig 2. Max clearance please see
description 500.35.
7) To get access to the cam follower, the cover for
the valve camshaft must be removed.
8) Dismantle the shaft for the cam followers by
removing the locking screw, see fig 3, and push
the shaft out of the console.
9) Check the tolerance between the shaft and the
bushing in the shaft end of the cam follower.
Max clearance please see description 500.35.
10) Check of roller, bushing and shaft: While press-
ing in the spring loaded guide pin, the roller
shaft can be pressed out, see fig 4.
11) Max total tolerance between shaft, bushing and
roller please see description 500.35.
12) If all parts appear in good condition, they can
be reused, otherwise defective parts are to be
replaced.

1 Roller 2 Roller pin

3 Guide pin

Figure 4: Remove the locating pin for the roller shaft

2012.01.16.
MAN Diesel & Turbo
Work Card 508-01.10
Page 1 (3) Control and adjusting of valve clearance
Edition 14

L16/24, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Control and/or adjustment of inlet and exhaust
valve clearance

Starting Position Hand Tools

Cover for valve camshaft is removed. Cover for Socket wrench
cylinder top is removed. Feeler gauge
Torque spanner

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1½ Plate No. Item No. Quantity
Number : 1 See plate -
50502
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2012.02.20.
 MAN Diesel & Turbo
508-01.10 Work Card
Control and adjusting of valve clearance Page 2 (3)
Edition 14

L16/24, L21/31, L27/38

Control and adjusting of valve clearance

1) Shut-off starting air and fuel oil.
2) Stop the lubricating oil circulation.
3) Dismantle the cylinder top cover.
4) Dismantle the clamp for non-turning bridge, if
mounted (L16/24).
5) Turn the crankshaft until the cylinder is in igni-
tion TDC (both valves closed).
6) Check that the surfaces are clean.
7) Loosen the counter nut, pos. 1, and the adjust-
ing screw, pos. 2, on the valve bridge.

Figure 2: .

11) Adjust the screw, pos. 2, on the valve bridge

until the feeler gauge makes slightly more resist-
ance, but it must still be possible to move the
feeler gauge.
Figure 1: . 12) Tighten the counter nut, pos. 1, on the valve
bridge with torque. Re-check that the feeler
8) Loosen the counter nut, pos. 3, and the adjust- gauge clearance has not changed.
ing screw, pos. 4, on the rocker arm and insert
the feeler gauge between valve bridge and
rocker arm, pos. 5.
9) Adjust the screw , pos. 4, on the rocker arm
until the feeler gauge makes only slight resist-
ance.
10) Tighten the counter nut, pos. 3, on the rocker
arm with torque. Re-check that the feeler gauge
clearance has not changed.

Figure 3: .

2012.02.20.
MAN Diesel & Turbo
Work Card 508-01.10
Page 3 (3) Control and adjusting of valve clearance
Edition 14

L16/24, L21/31, L27/38

▪ Sharp-edged feeler gauge can cause injuries.
▪ Be careful not to put fingers between adjusting
screw and valve.
▪ Wrong torque can cause injuries.
▪ Damaged parts must not be reused.

Figure 4: .

13) The adjustment is completed.

14) Install the clamp for the non-turning bridge, if
mounted (L16/24).
15) Install the cylinder head cover.
Please note:
▪ The engine must be cold or cooled down for at
least 30 minutes.
▪ Ensure to have a firm stand before working on
the engine.
▪ It is not allowed to turn during the adjustment
process.
▪ The torque spanner must be positioned com-
pletely on the coupling.
▪ Attach the socket wrench straight on the hexa-
gon nut before screwing.
▪ Adjust the torque correctly, see values for tight-
ening in description 500.40.
▪ Tools consisting of several part, can fall into
pieces.
▪ All bolted joints to be re-established.
Caution:
▪ Engine parts can be hot; watch out for burns.
▪ Slipping can cause injuries.
▪ Injuries such as crushing of fingers, hands or
similar.
▪ Slipping of torque spanner or similar tools can
cause injuries.
▪ Falling down from working position and/or hit-
ting engine parts can cause injuries.
▪ Damaging of socket wrench, hexagon nut or
screw can cause injuries.

2012.02.20.
MAN Diesel & Turbo
Plate
Page 1 (2) Roller guide and push rods P50801-05

2013.08.28
 MAN Diesel & Turbo
Plate
P50801-05 Roller guide and push rods Page 2 (2)

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

016 4/C Ball seat

028 2/C Push rod incl. item 016
090 1/C O-ring
100 4/C Screw
112 2/C Cylindrical pin
124 1/C Bracket
136 1/C Shaft
148 2/C Bearing bush
161 2/C Roller pin
173 2/C Thrust piece
185 2/C Bush
197 2/C Roller
220 2/C Rocker arm complete, incl. item
161, 185, 197
232 1/C Threaded pin
244 2/C Spring
256 2/C Locating pin

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder

2013.08.28
Control/safety

509/609
MAN Diesel & Turbo

Description
Safety, Control and Monitoring System 509.01
Page 1 (7) edition 16

L16/24, L21/31
L27/38
General information Furthermore, the Control Unit is equipped with a
Display Module. This module consists of a touch-
The document is valid for the following engine screen and a integrated PLC for the safety system.
types: L16/24, L21/31, and L27/38. The Display Module also acts as safety system for
over speed, low lubrication oil pressure and high
The monitoring and safety system SaCoSone serves cooling water temperature.
for complete engine operation, control, monitoring
and safety of GenSets. All sensors and operating The Display Module provides the following func-
devices are wired to the engine-attached units. tions:

The SaCoSone design is based on high reliable and • safety system

approved components as well as modules specially • visualisation of measured values and opera-
designed for installation on medium speed engines. ting values on a touchscreen
The used components are harmonised to a homo- • engine operation via touchscreen
genously system. The whole system is attached to
the engine cushioned against vibration. The safety system is electrically separated from the
control system due to requirements of the classifi-
cation societies.

For engine operation, additional hardwired switches

are available for relevant functions.

The system configuration can be edited via an

Ethernet interface at the Display Module.

SaCoSone GenSet mounted on a L16/24 GenSet

(Probable Layout)

Control Unit

The Control Unit includes a highly integrated

Control Module for engine control, monitoring and Prototype of the SaCoSone GenSet
alarm system (alarm limits and delay). The module
collects engines measuring data and transfers the
most measurements and data to the ship alarm Connection Box
system via Modbus.
The Connection Box is the central connecting and
distribution point for the 24VDC power supply of the
whole system.

10.12 - ES1 - Tier II

 MAN Diesel & Turbo

509.01 Safety, Control and Monitoring System Description

edition 16 Page 2 (7)

L16/24, L21/31
L27/38
Furthermore it connects the Control Unit with the
GenSet, the ship alarm system and the optional
crankcase monitoring.

System bus

The SaCoSone system is equipped with a redundant The control module operates directly with electro-
bus based on CAN. The bus connects all system hydraulic actuator.
modules. This redundant bus system provides the
basis data exchange between the modules.

el.-hydraulic
governor

• engine control control

control RS422/RS485 ship alarm
• speed control
• alarm system module system
control bus

display system
• display
• operation module Ethernet configuration
• safety system (via SaCoSone
EXPERT)
safety system

10.12 - ES1 - Tier II

MAN Diesel & Turbo

Description
Safety, Control and Monitoring System 509.01
Page 3 (7) edition 16

L16/24, L21/31
L27/38
Technical data

Example shows the dimensions of L16/24

L16/24 L21/31 L27/38

Width (mm) 400 400 400
Height (mm) 480 565 480
Length (mm) 869 1168 1323
Length overall (mm) 902 1201 1356
Weight (kg) 60 60 65

10.12 - ES1 - Tier II

 MAN Diesel & Turbo

509.01 Safety, Control and Monitoring System Description

edition 16 Page 4 (7)

L16/24, L21/31
L27/38
System Description Alarm/Monitoring System

Safety System Alarming

The alarm function of SaCoSone supervises all
Safety functions necessary parameters and generates alarms to
The safety system monitors all operating data of the indicate discrepancies when required. The alarms
engine and initiates the required actions, i.e. engine will be transferred to ship alarm system via Modbus
shut-down, in case the limit values are exceeded. data communication.
The safety system is integrated the Display Module.
The safety system directly actuates the emergency Self-monitoring
shut-down device and the stop facility of the speed SaCoSone carries out independent self-monitoring
governor. functions. Thus, for example the connected sensors
are checked constantly for function and wire break.
Auto shutdown In case of a fault SaCoSone reports the occurred
Auto shutdown is an engine shutdown initiated by malfunctions in single system components via sys-
any automatic supervision of engine internal para- tem alarms.
meters.
Control
Emergency stop SaCoSone controls all engine-internal functions as
Emergency stop is an engine shutdown initiated by well as external components, for example:
an operator manual action like pressing an emer-
gency stop button. An emergency stop button is  Start/stop sequences:
placed at the Control Unit on engine. For connection  Local and remote start/stop sequence for
of an external emergency stop button there is one the GenSet.
input channel at the Connection Box.  Activation of start device. Control (auto
start/stop signal) regarding prelubrication
Engine shutdown oil pump.
If an engine shutdown is triggered by the safety  Monitoring and control of the acceleration
system, the emergency stop signal has an immedi- period.
ate effect on the emergency shut-down device and
the speed control. At the same time the emergency  Jet system:
stop is triggered, SaCoSone issues a signal resulting  For air fuel ratio control purposes, com-
in the generator switch to be opened. pressed air is lead to the turbocharger at
start and at load steps.
Shutdown criteria
• Engine overspeed  Control signals for external functions:
• Failure of both engine speed sensors  HT cooling water preheating unit
• Lube oil pressure at engine inlet low  Prelubrication oil pump control
• HT cooling water temperature outlet too high
• High bearing temperature/deviation from  Redundant shutdown functions:
Crankcase Monitoring System. (optional)  Engine overspeed
• High oilmist concentration in crankcase.  Low lub. oil pressure inlet engine
(optional)  High cooling water temperature outlet
• Remote Shutdown. (optional) engine
o Differential protection (optional)
o Earth connector closed (optional)
o Gas leakage (optional)

10.12 - ES1 - Tier II

MAN Diesel & Turbo

Description
Safety, Control and Monitoring System 509.01
Page 5 (7) edition 16

L16/24, L21/31
L27/38
Speed Control System Remote speed setting is either possible via 4-20mA
signal or by using hardwired lower/raise commands.
Governor
The engine electronic speed control is realized Speed adjustment range
by the Control Module. As standard, the engine is Between -5% and +10% of the nominal speed at
equipped with an electro-hydraulic actuator. idle running.

Engine speed indication is carried out by means of Droop

redundant pick-ups at the camshaft. Adjustable by parameterisation tool from 0-5%
droop.
Instead of electronic speed governing the system
can optionally be equipped with a mechanical Load distribution
governor. By droop setting.

Speed adjustment Engine stop

Local, manual speed setting is possible at the con- Engine stop can be initiated local at the display
trol unit with a turn switch. module and remote via a hardware channel or the
bus interface.

10.12 - ES1 - Tier II

 MAN Diesel & Turbo

509.01 Safety, Control and Monitoring System Description

edition 16 Page 6 (7)

L16/24, L21/31
L27/38
Interfaces to External Systems

Overview

A detailed signal description is available on the GS Product page in the document “B 19 00 0, Interface
Description"

10.12 - ES1 - Tier II

MAN Diesel & Turbo

Description
Safety, Control and Monitoring System 509.01
Page 7 (7) edition 16

L16/24, L21/31
L27/38
Data Machinery Interface Generator Control

This interface serves for data exchange to ship SaCoSone provides inputs for all temperature signals
alarm systems or integrated automation systems for the temperatures of the generator bearings and
(IAS). generator windings.

The status messages, alarms and safety actions, Power Management

which are generated in the system, can be transfer-
red. All measuring values and alarms acquired by Hardwired interface for remote start/stop, speed
SaCoSone GenSet are available for transfer. setting, alternator circuit breaker trip etc.

The following MODBUS protocols are available: Remote Control

• MODBUS RTU (Standard) For remote control several digital inputs are avail-
• MODBUS ASCII (for retrofits) able.

For a detailed description of these protocols see Ethernet Interface

the document “B 19 00 0, Communication from the
GenSet”. The Ethernet interface at the Display Module can
be used for the connection of SaCoSone EXPERT.
main emergency
switchboard switchboard Serial Interface

CoCoS-EDS can be connected to a serial RS485

AC 24VDC
AC interface.
Yard supply

DC DC Power Supply

24VDC uninterruptible
power supply
The plant has to provide electric power for the
automation and monitoring system. In general a
redundant, uninterrupted 24V DC (+20% -30%
and max ripple 10%) power supply is required for
10 A

16 A

SaCoSone.

Crankcase Monitoring Unit (optional)

MAN supply

Control Module
SaCoSone GenSet provides an interface to an opti-
onal Crankcase Monitoring Unit. This unit is not part
Display Module of SaCoSone GenSets and is not standard scope
of supply. If applied, it is delivered as stand-alone
Connection Box Control Unit
system in an extra control cabinet.

10.12 - ES1 - Tier II

MAN Diesel & turbo

Description
Communication from the GenSet 509.55
Page 1 (4) Edition 14

L16/24, L21/31
L27/38
Data Bus Interface (Machinery Alarm Sys- �Settings
tem)
The communication parameters are set as follows:
This interface serves for data exchange to ship alarm
systems or integrated automation systems (IAS). Modbus Slave SaCoS
Modbus Master Machinery alarm system
The status messages, alarms and safety actions, Slave ID (default) 1
which are generated in the system, can be trans-
Data rate (default) 57600 baud
ferred. All measuring values and alarms acquired by
SaCoSone GenSet are available for transfer. Data rate (optionally available) 4800 baud
9600 baud
19200 baud
The following Modbus protocols are available: 38400 baud
115200 baud
• Modbus RTU (Standard) Data bits 8
Stop bits 1
• Modbus ASCII
Parity None
Transmission mode Modbus RTU
The Modbus RTU protocol is the standard protocol
used for the communication from the GenSet. For
the integration in older automation system, Modbus
ASCII is also available. Function Codes

The following function codes are available to gather

Modbus RTU Protocol data from the SaCoSone controllers:

The Modbus RTU protocol is the standard protocol

Func- Function
used for the communication from the GenSet. tion Code (hexa- Description
Code decimal)
The bus interface provides a serial connection. The 1 0x01 read coils
protocol is implemented according to the following
3 0x03 read holding registers
definitions:
5 0x05 write coil
• Modbus application protocol specification, 6 0x06 write single register
Modbus over serial line specification and im- 15 0x0F write multiple coils
plementation guide, 16 0x10 write multiple registers
22 0x16 mask write register
There are two serial interface standards available:
23 0x17 read write multiple registers

• RS422 – Standard, 4 + 2 wire

(cable length <= 100m), cable type as speci-
fied by the circuit diagram, Message Frame Separation
line termination: 150 Ohms
Message frames shall be separated by a silent in-
• RS485 – Standard, 2 + 2 wire terval of at least 4 character times.
(cable length <= 100m), cable type as speci-
fied by the circuit diagram,
line termination: 150 Ohms Provided Data

Provided data includes measured values and alarm

or state information of the engine.

10.48 - ES1 (02.08.2010) - Tier II

 MAN Diesel & Turbo

509.55 Communication from the GenSet Description

Edition 14 Page 2 (4)

L16/24, L21/31
L27/38
Measured values are digitized analogue values of Pre-alarms, shutdowns and state information from
sensors, which are stored in a fixed register of the the SaCoSone system are available as single bits in
Control Module Small. Measured values include fixed registers. The data type used is unsigned of
media values (pressures, temperatures) where, ac- size 16 bit. The corresponding bits of alarm or state
cording to the rules of classification, monitoring has information are set to the binary value „1“, if the
to be done by the machinery alarm system. The data event is active.
type used is signed integer of size 16 bit. Measured
values are scaled by a constant factor in order to Contents of List of Signals
provide decimals of the measured.
For detailed information about the transferred data,
please refer to the ”list of signals“ of the engine’s
documentation set. This list contains the following
information:

Field Description
Address The address (e.g.: MW15488) is the software address used in the Control Module Small.
HEX The hexadecimal value (e.g.: 3C80) of the software address that has to be used by the MODBUS master
when collecting the specific data.
Bit Information of alarms, reduce load, shutdown, etc. are available as single bits. Bits in each register are counted
0 to 15.
Meas. Point The dedicated denomination of the measuring point or limit value as listed in the „list of measuring and control
devices“.
Description A short description of the measuring point or limit value.
Unit Information about how the value of the data has to be evaluated by the Modbus master (e.g. „°C/100“ means:
reading a data value of „4156“ corresponds to 41,56 °C).
Origin Name of the system where the specific sensor is connected to, or the alarm is generated.
Signal range The range of measured value.

Life Bit

In order to enable the alarm system to check whether

the communication with SaCoS is working, a life bit is
provided in the list of signals (MW15861; Bit2). This
Bit is alternated every 10 seconds by SaCoS. Thus,
if it remains unchanged for more than 10 seconds,
the communication is down.

10.48 - ES1 (02.08.2010) - Tier II

MAN Diesel & turbo

Description
Communication from the GenSet 509.55
Page 3 (4) Edition 14

L16/24, L21/31
L27/38
Modbus ASCII Protocol FCT = 03H: Read n words
The master transmits an inquiry to the slave (CMS)
General to read a number (n) of datawords from a given
address. The slave (CMS) replies with the required
The communication setup is: 9600 baud, 8 databits, number (n) of datawords. To read a single register
1 stopbit, no parity. (n) must be set to 1. To read block type register (n)
must be in the range 1...32.
The Modbus protocol accepts one command (Func-
tion Code 03) for reading analogue and digital input Request (master):
values one at a time, or as a block of up to 32 inputs. [DATA] = [ADR][n]
[ADR]=Word stating the address in HEX.
The following chapter describes the commands in [n]=Word stating the number of words to
the Modbus protocol, which are implemented, and be read.
how they work.
Answer (slave-CMS):
Protocol Description [DATA] = [bb][1. word][2. word]....[n. word]
[bb]=Byte, stating number of subsequent
bytes.
The ASCII and RTU version of the Modbus protocol
[1. word]=1. dataword
is used, where the CMS/DM works as Modbus slave.
[2. word]=2. dataword
[n. word]=No n. dataword
All data bytes will be converted to 2-ASCII charac-
ters (hex-values). Thus, when below is referred to
FCT = 10H: Write n words
“bytes“ or “words“, these will fill out 2 or 4 characters,
The master sends data to the slave (CMS/DM) start-
respectively in the protocol. The general “message
ing from a particular address. The slave (CMS/DM)
frame format“ has the following outlook:
returns the written number of bytes, plus echoes
the address.
[:] [SLAVE] [FCT] [DATA] [CHECKSUM] [CR] [LF]
– [:] 1 char. Begin of frame
Write data (master):
– [SLAVE] 2 char. Modbus slave ad-
[DATA] = [ADR][n] [bb][1. word][2. word]....[n word]
dress (Selected on DIP-
[ADR] = Word that gives the address in
switch at Display Module)
HEX.
– [FCT] 2 char. Function code
[n] = Word indicating number of words to
– [DATA] n X 2 chars data.
be written.
– [CHECKSUM] 2 char checksum (LRC)
[bb] = Byte that gives the number of bytes
– [CR] 1 char CR
to follow (2*n)
– [LF] 1 char LF (end of frame)
Please note that 8bb9 is byte size!
[1. word]=1. dataword
The following function codes (FCT) is accepted:
[2. word]=2. dataword
– 03H: Read n words at specific address.
[n. word]=No n. dataword
– 10H: Write n words at specific address.

In response to the message frame, the slave (CMS)

Answer (slave-CMS/DM):
must answer with appropriate data. If this is not pos-
[DATA] = [ADR][bb*2]
sible, a package with the most important bit in FCT
[ADR]= Word HEX that gives the address
set to 1 will be returned, followed by an exception
in HEX
code, where the following is supported:
[bb*2]=Number of words written.
– 01: Illegal function
[1. word]=1. dataword
– 02: Illegal data address
[2. word]=2. dataword
– 03: Illegal data value
[n. word]=No n. dataword
– 06: BUSY. Message rejected

10.48 - ES1 (02.08.2010) - Tier II

 MAN Diesel & Turbo

509.55 Communication from the GenSet Description

Edition 14 Page 4 (4)

L16/24, L21/31
L27/38
Data Format MODBUS block addresses

The following types of data format have been cho- In order to be able to read from the different I/O
sen: and data areas, they have to be supplied with an
„address“. In the MODBUS protocol each address
Digital: Consists of 1 word (register): refers to a word or „register“. For the GenSet there
1 word: [0000H]=OFF are following I/O registers:
[FFFFH]=ON
• Block (multiple) I/O registers occupying up to
Integer: Consists of 1 word (register): 32 word of registers
1 word: 12 bit signed data
(second complement): This list specifies the addresses assigned for MOD-
[0000H]=0 BUS Block data, which enables the user to read up
[0FFFH]=100% of range to 32 signals/alarms/inputs in a single MODBUS
[F000H]=-100% of range request.

Notice: 12 bit data format must be used no matter General) All alarm signals are already performed
what dissolution a signal is sampled with. All meas- with necessary time delay. F.ex. lub. oil level
uring values will be scaled to 12 bit signed. alarms (LAL/LAH28) includes 30 sec. alarm
delay. Start air alarm (PAL70) includes 15 sec.
alarm delay. No further delay are needed.

10.48 - ES1 (02.08.2010) - Tier II

MAN Diesel & Turbo
Work Card 509-01.05
Page 1 (3) Function test of shutdown
Edition 11

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

Safety precautions Special tools

Engine stopped Plate No. Item No. Note

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

Short Description
Functional test of overspeed trip. Functional test of
low lubricating oil pressostate trip. Functional test
of high fresh water thermostat.
Hand Tools
Starting Position
Allen key 4 mm
Functional test and adjustment of 509-01.00 Allen key 2 mm
safety alarm and mounting equip- Manometer or test pump
ment Large spanner
Small screwdriver

Related Procedure

Replacement and wearing parts

Qualified Manpower
Plate No. Item No. Quantity
Duration in h : 1
Number : 1

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

2014.03.18
 MAN Diesel & Turbo
509-01.05 Work Card
Function test of shutdown Page 2 (3)
Edition 11

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

Function Test of Shutdown
It is of the upmost importance that the shutdown
function is working properly. Therefore, the shut-
down function must be tested at regular intervals
according to the planned maintenance programme
500.25.

Function Test of Overspeed Shutdown

1) Start the engine locally and keep it at no load,
at nominal rpm:
Engine Type / rpm
L16/24 / 1000 or 1200
L27/38 / 720 or 750
L21/31 / 900 or 1000
L23/30DF / 720, 750 or 900
L28/32DF / 720 or 750
2) Take a large spanner and put it on the link
between fuel-rack and actuator. Slowly force
the engine rpm over the setpoint, see Descrip-
tion 500.30 and the overspeed will release.
3) Overspeed can also be simulated by activting
test bed operation and overspeed test. Then
overspeed setpoint is changed to 85% of 1 Cable connection to ter- 2 Protection cover
minal
nominell speed.
Warning: Do not raise the speed over 120% of 3 Test coupling 4 Test block
nominal speed because this could damage the 5 Valve 6 System pressure
valves and pistons.
The engine must stop.
Figure 1: Pressure controller
4) Reset the overspeed shutdown on the display
module.

Function Test of Low Lubricating Oil

Adjustment
Pressure Shutdown
Correct detection of RPM (counting of teeths)
depends on the size of the gap between the mova- 1) Start the engine and keep it at no load.
ble flywheel and the front of the pick-up sensor. If 2) Mount the manometer/test pump on the test
no or wrong signal is detected by the sensor, the valve outlet, situated right under the pressos-
measuring gap must be adjusted or cleaned. tate PSL 22, fig 1.
The gap is expected to be 2.0 mm ± 0.3 mm (the 3) Close oil pressure valve, fig 1.
pitch of the thread on the pick-up is 1.0 mm). The
4) Relieve the pressure slowly and check that the
number of teeth relative speed values/limits can be
switch changes back to the pressure stated as
found in the Engine Automatic diagram, section 509
the shutdown point, see 500.30.
and description 500.30 in section 500.
The engine must stop.
The overspeed shutdown limits can not be adjusted Note: If adjustment is needed, turn the screw
by the user. clockwise or anticlockwise, see fig 2.
5) Disconnect the manometer/test pump.
6) Open the oil pressure valve on the pressure
block.

2014.03.18
MAN Diesel & Turbo
Work Card 509-01.05
Page 3 (3) Function test of shutdown
Edition 11

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

7) Reset the low lubricating oil pressure shutdown
on the operation box.

1 Protection cap 2 Temp. sensor

Figure 2: Adjustment of pressostate and thermostate

Figure 3: Thermostate

Function Test of High Fresh Water

Temperature Shutdown Alarm System
The functional test of the thermostat, is to be car- It is important that all alarms lead to prompt investi-
ried out according to the following procedure. gation and remedy of the error.
1) Take the sensor out of the pocket. No alarm is insignificant. It is therefore important
2) Test the sensor in a water bath, which is con- that all engine crew members are familiar with and
trolled by the temperature or a special testing well trained in the use and importance of the alarm
device. system.
3) Start the engine and keep it at no load. The most serious alarms are equipped with slow-
down and/or shutdown functions.
4) Raise the temperature until the switch changes
and check that it happens at the stated shut-
down point, see 500.30.
The engine must stop.
Note: If adjustment is needed, remove the
thermostat cover. Locking screw pos. 5, fig 3,
is loosened, and the range can be set with the
spindle, pos. 1, while the scale, pos. 2, is read
at the same time.
5) The sensor is mounted again.
6) Reset the high H.T. water temperature shut-
down on the display module.

2014.03.18
 MAN Diesel & Turbo

Plate
Page 1 (2) Actuator and Actuator Drive 50901-28

L27/38

For actuator, 476

see special
instruction book 464
511
403 488

415

141
153
165
190
177
200
356
069 094

082
070
427
045 212
08028-0D/H5250/94.08.12

033
236
319
332 320
297
273 307
261 285

10.29 - ES0 - Tier II - RE2800

 MAN Diesel & Turbo

Plate
50901-28 Actuator and Actuator Drive Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

033 1/E Plug screw Propskrue 452 2/E Screw Skrue

045 1/E Gasket Pakning 464 1/E Governor arm Regulatorarm

069 4/E Screw Skrue 476 1/E Screw Skrue

070 1/E O-ring O-ring 488 1/E Spring loaded pull rod Trækstang

082 1/E Castle nut Kronemøtrik 511 1/E Nut Møtrik

094 1/E Split pin Split

141 1/E Shim (set 0.1 - Mellemlæg (sæt 0,1 -

0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)

153 1/E Disc Skive

165 1/E Ball bearing Kugleleje

177 1/E Bevel gear wheel Konisk tandhjul

190 1/E Castle nut Kronemøtrik

200 1/E Split pin Split

212 1/E Housing Hus

236 2/E Pin Stift

261 1/E Screw Skrue

273 1/E Axle journal Akseltap

285 1/E Bush Bøsning

297 1/E Bevel gear wheel Konisk tandhjul

307 1/E Gear wheel Tandhjul

319 1/E Screw Skrue

320 1/E Wear disc Slidskive

332 1/E Key Feder

356 /I Silastene Silastene

403 1/E Actuator, electronic Elektronisk aktuator

415 4/E Screw Skrue

08028-0D/H5250/94.08.12

427 1/E O-ring O-ring

439 3/E Disc spring Fjederskive

440 2/E Nut Møtrik

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

10.29 - ES0 - Tier II - RE2800

 MAN Diesel & Turbo

Plate
Page 1 (2) Actuator and Actuator Drive 50901-29

L27/38

For actuator,
see special
instruction book
476
464
511
403 488

415

141
153
165
190
177
200
356
069 094

082
070
427
045 212
08028-0D/H5250/94.08.12

033
236
319
332 320
297
273 307
261 285

10.29 - ES0 - Tier II - UG25+

 MAN Diesel & Turbo

Plate
50901-29 Actuator and Actuator Drive Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

033 1/E Plug screw Propskrue 452 2/E Screw Skrue

045 1/E Gasket Pakning 464 1/E Governor arm Regulatorarm

069 4/E Screw Skrue 476 1/E Screw Skrue

070 1/E O-ring O-ring 488 1/E Spring loaded pull rod trækstang

082 1/E Castle nut Kronemøtrik 511 1/E Nut Møtrik

094 1/E Split pin Split

141 1/E Shim (set 0.1 - Mellemlæg (sæt 0,1 -

0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)

153 1/E Disc Skive

165 1/E Ball bearing Kugleleje

177 1/E Bevel gear wheel Konisk tandhjul

190 1/E Castle nut Kronemøtrik

200 1/E Split pin Split

212 1/E Housing Hus

236 2/E Pin Stift

261 1/E Screw Skrue

273 1/E Axle journal Akseltap

285 1/E Bush Bøsning

297 1/E Bevel gear wheel Konisk tandhjul

307 1/E Gear wheel Tandhjul

319 1/E Screw Skrue

320 1/E Wear disc Slidskive

332 1/E Key Feder

356 /I Silastene Silastene

403 1/E Actuator, electronic Elektronisk aktuator

415 4/E Screw Skrue

08028-0D/H5250/94.08.12

427 1/E O-ring O-ring

439 3/E Disc spring Fjederskive

440 2/E Nut Møtrik

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

10.29 - ES0 - Tier II - UG25+

 MAN Diesel

Plate
Page 1 (2) Regulating Device 50902-05H

L27/38
399 280
387 409
434* Pick-up, see plate 50907/276

410

375 292
302

255 243 279

135 674
172 159
160 231 686
147 674 267

088 184 206

196 218
08028-0D/H5250/94.08.12

111
123
064
314 338 363 027 040 076 088
326 351 015 039 052

06.05 - ES0
MAN Diesel

Plate
50902-05H Regulating Device Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

015 Bearing bracket, com- Konsol, komplet inkl. 279 1/C Ball joint Kugleled
plete incl. bush bøsning
6/E 5 cyl. engine 5 cyl. motor 280 5/E Nut Møtrik
7/E 6 cyl. engine 6 cyl. motor
8/E 7 cyl. engine 7 cyl. motor 292 1/E Bracket Konsol
9/E 8 cyl. engine 8 cyl. motor
10/E 9 cyl. engine 9 cyl. motor 302 4/E Screw Skrue

027 Screw Skrue 314 1/E Shaft, 5 cyl. engine Aksel, 5 cyl. motor
12/E 5 cyl. engine 5 cyl. motor
14/E 6 cyl. engine 6 cyl. motor 326 1/E Shaft, 6 cyl. engine Aksel, 6 cyl. motor
16/E 7 cyl. engine 7 cyl. motor
18/E 8 cyl. engine 8 cyl. motor 338 1/E Shaft, 7 cyl. engine Aksel, 7 cyl. motor
20/E 9 cyl. engine 9 cyl. motor
351 1/E Shaft, 8 cyl. engine Aksel, 8 cyl. motor
039 1/E Setting ring Justerring
363 1/E Shaft, 9 cyl. engine Aksel, 9 cyl. motor
040 1/E Spring pin Fjederstift
375 4/E Lock washer Låseskive
052 1/E Sleeve Bøsning
387 1/E Cylinder, complete Cylinder, komplet
064 1/E Lever Arm
399 4/E Screw Skrue
076 1/E Screw Skrue
409 1/E Stop screw Stopskrue
088 2/E Spring pin Fjederstift
410 1/E Lever, complete Arm, komplet
111 1/E Screw Skrue
434* 1/E Repair kit for item Reservedelssæt til item
123 1/E Nut Møtrik 387, 387, bestående af:
consisting of: 1 stk. fjeder
135 2/C Bult strap Bøjle 1 pc spring 2 stk. pakning til stempel
2 pcs gasket f/piston 2 stk. pakning til ende-
147 1/C Clamping piece Spændestykke 2 pcs end cover dæksel
gasket 1 stk. kombineret
159 1/C Screw Skrue 1 pc combined scraper skrabe- og tætningsring
and sealing ring 1 stk pakning uden krave
160 2/C Spring pin Fjederstift 1 pc gasket without col-
lar
172 1/C Spring pin Fjederstift
674 2/C Nut Møtrik
184 1/C Sleeve Bøsning
686 1/C Nut Møtrik
196 2/C Sleeve Bøsning

206 1/C Screw Skrue

218 2/C Screw Skrue

231 2/C Self locking nut Selvlåsende møtrik

08028-0D/H5250/94.08.12

243 1/C Screw Skrue

255 1/C Tension spring Trækfjeder

267 1/C Articulated head Svinghoved

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

06.05 - ES0
MAN Diesel & Turbo

Plate
Page 1 (9) Instruments 50907-21

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

0.1 - 35 kHz SE89 012

Speed pick-up, TC speed, TCR12

0.1 - 35 kHz SE89 048

Speed pick-up, TC speed, TCR14

0.1 - 35 kHz SE89 061

Speed pick-up, TC speed, TCR16/18

0.1 - 35 kHz SE89 073

Speed pick-up, TC speed, TCR20/22

0 - 1 kHz SE89 085

Speed pick-up, TC speed, NR29/S

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

 MAN Diesel & Turbo

Plate
50907-21 Instruments Page 2 (9)

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

0.1 - 35 kHz SE89 097

Speed pick-up, TC speed, NR34/S

SE90-1
0 - 20 kHz 107
SE90-2

Speed pick-up, engine speed

TE29-1
TE29-2
TE29-3
TE29-4
TE29-5
0 - 120° C TE29-6 119
TE29-7
TE29-8
TE29-9
Temp. sensor, eng. main bearing TE29-10
L16/24, L21/31, L27/38 TE29-11

TE29-1
TE29-2
TE29-3
TE29-4
TE29-5
0 - 120° C TE29-6 120
TE29-7
TE29-8
TE29-9
Temp. sensor, eng. main bearing TE29-10
L32/40 (1 pc) TE29-11

TE29-1
TE29-2
TE29-3
TE29-4
TE29-5
0 - 120° C TE29-6 132
TE29-7
TE29-8
TE29-9
Temp. sensor, eng. main bearing TE29-10
L32/40 TE29-11

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

MAN Diesel & Turbo

Plate
Page 3 (9) Instruments 50907-21

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

On/Off ZS75 144

Limit switch, turning gear disengaged

PT21
0 - 10 bar 156
PT22

Pressure transmitter

TE21
-20 - 200° C 168
TE31

Temperature sensor

1 - 10 bar PSL22 181

Pressure switch

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

 MAN Diesel & Turbo

Plate
50907-21 Instruments Page 4 (9)

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

On/Off FE94 193

Limit switch

PT23
0-4 bar 203
PT31

Pressure transmitter

LAH28
On/Off LAL28 215
LAH42

Level switch

PT10
0 - 6 bar 227
PT01

Pressure transmitter

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

MAN Diesel & Turbo

Plate
Page 5 (9) Instruments 50907-21

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

TE58-1
TE58-2
TE58-3
TE58-4
0 - 120° C TE58-5 252
TE58-6
TE58-7
TE58-8
TE58-9

Temperature sensor
L16/24, L27/38, L32/40

TE58-1
TE58-2
TE58-3
TE58-4
0 - 120° C TE58-5 264
TE58-6
TE58-7
TE58-8
TE58-9

Temperature sensor
L21/31

-20 - 200° C TE10 276

Temperature sensor

-20 - 200° C TE12 288

Temperature sensor

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

 MAN Diesel & Turbo

Plate
50907-21 Instruments Page 6 (9)

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

70 - 120° C 311

Temperature switch

-20 - 200° C TE01 323

Temperature sensor
L16/24, L21/31

-20 - 200° C TE01 335

Temperature sensor
L27/38

-20 - 200° C TE01 347

Temperature sensor
L32/40

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

MAN Diesel & Turbo

Plate
Page 7 (9) Instruments 50907-21

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

0 - 16 bar PT40 360

Pressure transmitter

0 - 700° C TE60-1 396

TE60-2
TE60-3
TE60-4
TE60-5
TE60-6
TE60-7
TE60-8
TE60-9
Temperature sensor Pocket for sensor 397
L16/24

0 - 700° C TE60-1 406

TE60-2
TE60-3
TE60-4
TE60-5
TE60-6
TE60-7
TE60-8
TE60-9
Temperature sensor Pocket for sensor 407
L21/31, L27/38

0 - 700° C TE60-1 418

TE60-2
TE60-3
TE60-4
TE60-5
TE60-6
TE60-7
TE60-8
TE60-9
Temperature sensor Pocket for sensor 419
L32/40

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

 MAN Diesel & Turbo

Plate
50907-21 Instruments Page 8 (9)

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

0 - 700° C TE62 443

Pocket for sensor 444

Temperature sensor, TC in
L16/24

0 - 700° C TE62 455

Pocket for sensor 456

Temperature sensor, TC in
L21/31, L27/38

0 - 700° C TE62 467

Pocket for sensor 468

Temperature sensor, TC in
L32/40

0 - 700° C TE61 480

Pocket for sensor 481

Temperature sensor, TC out

L16/24

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

MAN Diesel & Turbo

Plate
Page 9 (9) Instruments 50907-21

L16/24
L21/31, L27/38
Length Item
Figure Range Code
L mm L1 mm no

0 - 700° C TE61 492

Pocket for sensor 456

Temperature sensor, TC out

L21/31, L27/38

0 - 700° C TE61 502

Pocket for sensor 503

Temperature sensor, TC out

L32/40

0 - 40 bar PT70 526

Pressure transmitter

13.33 - ES0 - Tier II - SaCoS - same content as 60907-22H

 MAN Diesel

Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-03H

L27/38
08028-0D/H5250/94.08.12

02.11 - ES0
MAN Diesel

Plate
50920-03H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

049 4/E Screw Skrue

050 2/E Nut Møtrik

062 1/E Plate Plade

098 1/E Pipe for level switch Rør for nivaeukontakt

108 1/E Level switch Niveaukontakt

121 1/E Pipe for level switch Rør for nivaeukontakt

133 1/E Level switch Niveaukontakt

157 1/E O-ring O-ring

169 1/E Dipstick, complete Pejlestok, komplet

incl. item 157 inkl. item 157

170 1/E Gasket Pakning

182 2/E Red. adaptor Red. adapter

194 /I Glue Lim

204 1/E Cable union Kabelforskruning

216 1/E Terminal box Klemkasse

228 2/E Screw Skrue

241 1/E Parts for terminal Dele for klemrække

strip

253 2/E Screw Skrue

265 1/E Pipe Rør

277 2/E Angle union Vinkelforskruning

289 1/E Pipe Rør

290 1/E Pipe Rør

300 1/E Pipe Rør

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

02.11 - ES0
 MAN Diesel

Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-07

L21/31, L27/38
V28/32S

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

06.47 - ES0
MAN Diesel

Plate
50925-07 Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)

L21/31, L27/38
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

010 1/E Fuel oil leakage Br.olielækagealarm

alarm

022 1/E Flange Flange

034 1/E Gasket Pakning

046 1/E Level switch Niveaukontakt

058 1/E Hose connection Slangeforbindelse

178 1/E Repair kit for Reparationssæt for

running in filter indkørselsfilter

286 4/E Screw Skrue

333 2/E O-ring O-ring

345 1/E Packing ring Pakningsring

357 1/E Plug screw Propskrue

369 1/E Packing ring Pakningsring

370 1/E Plug screw Propskrue

382 1/E Packing ring Pakningsring

394 1/E Plug screw Propskrue

404 1/E Plug screw Propskrue

416 /I Glue Lim

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

06.47 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Prelubricating oil pump starter P50951-07

L27/38

2013.11.05 - 1 engine
 MAN Diesel & Turbo
Plate
P50951-07 Prelubricating oil pump starter Page 2 (2)

L27/38
Item No. Qty Item Designation Item No. Qty Item Designation

012 1/E Panel 396 2/E Circuit breaker, 2 amp

024 1/E Name plate 406 12/E Terminal
073 1/E Name plate 418 2/E Earth terminal
085 4/E Screw M3 455 11/E End angle
097 4/E Nut M3 467 1/E Auxilliary relay
107 1/E Pilot lamp, green 479 1/E Socket
119 1/E Lamp holder
120 1/E Glow lamp
132 1/E Label, pump on
144 1/E Head
156 1/E Body
168 1/E No contact block
181 1/E Label, M-0-A
193 1/E Selector switch
227 4/E Bracket
239 4/E Screw M8
240 4/E Nut M8
252 2/E Cable union M20
264 2/E Nut M20
276 2/E Cable union M25
288 2/E Nut M25
311 1/E Transformer, 400/440 V
323 4/E Screw M5
335 2/E Contactor
347 2/E Thermal relay
359 /I Channel track
360 /I Conduit
372 1/E Circuit breaker, 10 amp
384 1/E Auxilliary switch

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine
Qty/I = Qty/Individual

2013.11.05 - 1 engine
MAN Diesel & Turbo

Plate
Page 1 (2) Main Bearing Monitoring 50961-06

L27/38
Coupling side

Free end
CL crankshaft
Locating
Outside
bearing

bearing

bearing
Main

091

078 101
042 054
066

Item 066 glued in

030 item 054 with Loctite
item 101

017 042 029 005

11.39 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
50961-06 Main Bearing Monitoring Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

005 Temperature sensor Temperaturføler 091 Seal ring Tætningsring

7/E 5 cyl. engine 5 cyl. motor 7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor 8/E 6 cyl. engine 6 cyl. motor
9/E 7 cyl. engine 7 cyl. motor 9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor 10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor 11/E 9 cyl. engine 9 cyl. motor

017 Screw Skrue 101 /I Loctite 243 Loctite 243

7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

029 Nut Møtrik

7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

030 Screw Skrue

14/E 5 cyl. engine 5 cyl. motor
16/E 6 cyl. engine 6 cyl. motor
18/E 7 cyl. engine 7 cyl. motor
20/E 8 cyl. engine 8 cyl. motor
22/E 9 cyl. engine 9 cyl. motor

042 Circlip Sikringsring

21/E 5 cyl. engine 5 cyl. motor
24/E 6 cyl. engine 6 cyl. motor
27/E 7 cyl. engine 7 cyl. motor
30/E 8 cyl. engine 8 cyl. motor
33/E 9 cyl. engine 9 cyl. motor

054 Plug screw Propskrue

7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

066 Threaded piece Rørforskruning

7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

078 Clamping ring Sikringsring

7/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
9/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 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/I = Qty/Individual Qty/I = Qty/Individuelt

11.39 - ES0 - Tier II

MAN Diesel & Turbo

Plate
Page 1 (2) Crankcase Oil Temperature Monitoring / Oil Splash 50962-03

L27/38

012

024

036

048
107
119

061
120
132

073 085 097

11.41 - ES0
 MAN Diesel & Turbo

Plate
50962-03 Crankcase Oil Temperature Monitoring / Oil Splash Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

012 1/C Resistance thermo- Modstandstermo-

meter, PT1000 meter, PT1000

024 1/C Seal ring Tætningsring

036 1/C Cable, Kabel,

teflon armoured teflonbelagt

048 1/E Cable tray, Kabelbakke,

5 cyl. engine 5 cyl. motor

061 1/E Cable tray, Kabelbakke,

7 cyl. engine 7 cyl. motor

073 Clamping plate Beslag

6/E 5 cyl. engine 5 cyl. motor
7/E 6 cyl. engine 6 cyl. motor
8/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

085 Lock washer Låseskive

6/E 5 cyl. engine 5 cyl. motor
7/E 6 cyl. engine 6 cyl. motor
8/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

097 Cylindrical screw Cylindrisk skrue

6/E 5 cyl. engine 5 cyl. motor
7/E 6 cyl. engine 6 cyl. motor
8/E 7 cyl. engine 7 cyl. motor
10/E 8 cyl. engine 8 cyl. motor
11/E 9 cyl. engine 9 cyl. motor

107 1/E Cable tray, Kabelbakke,

6 cyl. engine 6 cyl. motor

119 1/E Cable tray, Kabelbakke,

7-8-9 cyl. engines 7-8-9 cyl. motor

120 1/E Cable tray, Kabelbakke,

8 cyl. engine 8 cyl. motor

132 1/E Cable tray, Kabelbakke,

9 cyl. engine 9 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

11.41 - ES0
 MAN Diesel & Turbo

SaCoS_one GENSET
Operating Instructions

Revision ............................................. 1.9

Date ................................................... 2013-04-17
2013-04-17 - 1.9

Translation of the original instructions

EN
 MAN Die

MAN Diesel & Turbo SE

2013-04-17 - 1.9

86224 Augsburg
Phone +49 (0) 821 322-0
Fax +49 (0) 821 322-3382
www.mandieselturbo.com

Copyright © 2013 MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.

EN
 MAN Diesel & Turbo

Table of contents

Table of contents
1 Introduction ........................................................................................................................................... 8
1.1 General information ....................................................................................................................8
1.1.1 Validity .................................................................................................................... 8
1.1.2 System identification ............................................................................................... 8
1.2 Comments on the manual ...........................................................................................................8
1.2.1 Contents ................................................................................................................. 8
1.2.2 Structure of this manual .......................................................................................... 9
1.2.3 Revision history ..................................................................................................... 10
1.3 Structure and use of operating manual ...................................................................................12
1.4 Contact ......................................................................................................................................13

2 Safety regulations ............................................................................................................................... 15

2.1 Intended Use .............................................................................................................................15
2.2 Requirements to be met by operating personnel ....................................................................15
2.3 Structure of warning messages ...............................................................................................15
2.4 Symbols and warning information ...........................................................................................16
2.5 General safety information .......................................................................................................17

3 Description of the system ................................................................................................................... 19

3.1 General information ..................................................................................................................19
3.1.1 Area of application ................................................................................................ 19
3.1.2 System architecture .............................................................................................. 19
3.1.3 System components ............................................................................................. 20
3.1.3.1 Overview ............................................................................................................... 20
3.1.3.2 Control Module S .................................................................................................. 20
3.1.3.3 Display Module ..................................................................................................... 21
3.1.3.4 Gateway Module ................................................................................................... 21
3.1.3.5 System bus CAN .................................................................................................. 21
3.2 Control functions .......................................................................................................................22
3.2.1 Engine control ....................................................................................................... 22
3.2.1.1 Basic functions of the engine control ..................................................................... 22
3.2.1.2 Safety monitors and functions ............................................................................... 23
3.2.2 Speed control ....................................................................................................... 23
3.2.2.1 Basic functions of speed control ........................................................................... 23
3.2.2.2 Monitoring of speed governor functions ................................................................ 24
3.2.3 Alarm system ........................................................................................................ 24
3.2.3.1 Alarm monitoring systems ..................................................................................... 24
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3.2.3.2 Redundant safety monitoring of alarm system ....................................................... 25

3.2.4 Safety system ....................................................................................................... 25
3.2.4.1 Safety monitoring systems .................................................................................... 25
3.2.4.2 Safety functions .................................................................................................... 25
3.2.5 HMI - Local Operating Panel ................................................................................. 26

3 (136)
 MAN Diesel & Turbo

3.3 Options ......................................................................................................................................26

Table of contents

3.4 System design for L16/24, L21/31 and L27/38 ........................................................................26

3.4.1 Control Unit ........................................................................................................... 27
3.4.2 Connection Box .................................................................................................... 27
3.4.3 Versions ................................................................................................................ 28
3.4.4 Block diagrams ..................................................................................................... 29
3.5 System design for L32/40 .........................................................................................................33
3.5.1 Control Unit ........................................................................................................... 33
3.5.2 VIT Cabinet ........................................................................................................... 34
3.5.3 Versions ................................................................................................................ 34
3.5.4 Block diagrams ..................................................................................................... 35

4 Installation .......................................................................................................................................... 37
4.1 Installation requirements .........................................................................................................37
4.1.1 Storage and transport conditions .......................................................................... 37
4.1.2 Cable installation ................................................................................................... 37
4.1.3 Installation ............................................................................................................. 37
4.2 Technical data ...........................................................................................................................38
4.2.1 Operating prerequisites ......................................................................................... 38
4.2.2 SaCoSone GENSET for L16/24 .............................................................................. 38
4.2.3 SaCoSone GENSET for L21/31 .............................................................................. 39
4.2.4 SaCoSone GENSET for L27/38 .............................................................................. 39
4.2.5 SaCoSone GENSET for L32/40 .............................................................................. 40
4.3 Connecting the SaCoSone GENSET .............................................................................................42
4.3.1 Modbus connection to ship's alarm system .......................................................... 42
4.3.2 Connection with other external systems ................................................................ 42
4.3.3 Connecting the power supply ............................................................................... 43
4.4 Adjusting the speed governor servo-drive ...............................................................................44
4.4.1 Mechanical settings .............................................................................................. 44
4.4.2 Electronic settings ................................................................................................. 44

5 Software & parameters ....................................................................................................................... 47

5.1 Loading software on modules ..................................................................................................47
5.1.1 Preparation phase ................................................................................................. 47
5.1.2 Load software on the module ................................................................................ 47
5.1.3 Troubleshooting .................................................................................................... 49
5.2 Adjusting the speed governor parameters ..............................................................................50
5.3 Configuring the Gateway Module .............................................................................................52
5.3.1 Configuration of the Ethernet interface .................................................................. 53
2013-04-17 - 1.9

5.3.2 Configuration of the serial interface ....................................................................... 54

5.4 Software and parameter backup ..............................................................................................54

6 Configuration and tests ...................................................................................................................... 56

6.1 Configuration of the modbus interface ....................................................................................56

4 (136)
 MAN Diesel & Turbo

6.2 Documentation of engine configuration ..................................................................................59

Table of contents
6.2.1 Parameters on page 1 of 4 .................................................................................... 60
6.2.2 Parameters on page 2 of 4 .................................................................................... 60
6.2.3 Parameters on page 3 of 4 (governor parameters) ................................................ 62
6.2.4 Parameters on page 4 of 4 (PLC parameters) ....................................................... 63
6.2.5 Parameters for CoCoS-EDS via Gateway .............................................................. 64
6.3 Project-specific documents .....................................................................................................64
6.3.1 General ................................................................................................................. 64
6.3.2 Checking the documents ...................................................................................... 65
6.3.3 Tests ..................................................................................................................... 65
6.3.4 Documents for class approval ............................................................................... 66

7 Operation of the engine ...................................................................................................................... 67

7.1 Operating stations .....................................................................................................................67
7.1.1 Local operation ..................................................................................................... 67
7.1.2 Operation at the VIT cabinet .................................................................................. 68
7.1.3 External control (remote-controlled) ....................................................................... 69
7.2 Transfer of operating rights .....................................................................................................69
7.3 Engine start ...............................................................................................................................70
7.3.1 Before starting the engine ..................................................................................... 70
7.3.2 Starting block ........................................................................................................ 70
7.3.3 Start menu ............................................................................................................ 70
7.4 Engine stop ................................................................................................................................72
7.5 Safety functions ........................................................................................................................73
7.5.1 Alarms .................................................................................................................. 73
7.5.2 Automatic shutdown ............................................................................................. 73
7.5.3 Emergency stop .................................................................................................... 74
7.5.4 Request for a load reduction ................................................................................. 74
7.5.5 Emergency Generator Mode ................................................................................. 75
7.5.5.1 Activation of Emergency Generator Mode ............................................................. 76
7.5.5.2 Deactivation of Emergency Generator Mode ......................................................... 77
7.6 Speed control ............................................................................................................................78
7.6.1 At the Control Unit ................................................................................................ 78
7.6.2 At an external control ............................................................................................ 78

8 Functions of the touchscreen ............................................................................................................. 79

8.1 Layout of the display .................................................................................................................79
8.1.1 Header .................................................................................................................. 79
8.1.2 Status line ............................................................................................................. 80
2013-04-17 - 1.9

8.1.3 Info panel .............................................................................................................. 81

8.1.4 Alarm line .............................................................................................................. 81
8.1.5 Horizontal navigation bar ....................................................................................... 81
8.2 Buttons and display elements ..................................................................................................81
8.2.1 General information ............................................................................................... 81
8.2.2 Buttons in the navigation bar ................................................................................. 81

5 (136)
 MAN Diesel & Turbo

8.2.3 Displaying measured values .................................................................................. 82

Table of contents

8.2.4 Status display ....................................................................................................... 83

8.2.5 Input fields and on-screen keypad ........................................................................ 83
8.3 Main Overview ...........................................................................................................................83
8.3.1 Info panel .............................................................................................................. 84
8.3.2 Start status ........................................................................................................... 85
8.3.3 Status line ............................................................................................................. 85
8.4 Main Menu .................................................................................................................................85
8.5 Main functions ..........................................................................................................................86
8.5.1 Exhaust gas .......................................................................................................... 87
8.5.2 VIT ........................................................................................................................ 90
8.5.3 Fuel ....................................................................................................................... 91
8.5.4 Cooling water ........................................................................................................ 92
8.5.5 Air ......................................................................................................................... 93
8.5.6 Lube Oil ................................................................................................................ 94
8.5.7 Media overview ..................................................................................................... 95
8.5.8 Engine status ........................................................................................................ 97
8.5.9 Equipment attached to the engine ........................................................................ 98
8.5.10 Cylinder lubrication (L32/40) .................................................................................. 99
8.5.11 Generator ........................................................................................................... 101
8.6 MISC ........................................................................................................................................102
8.6.1 Overview ............................................................................................................. 103
8.6.2 Date / Time ......................................................................................................... 104
8.6.3 Diagnosis display ................................................................................................ 105
8.6.4 Screen brightness adjustment ............................................................................. 106
8.6.5 Project Info ......................................................................................................... 107
8.6.6 Parameters / Emission Identifier .......................................................................... 108
8.6.7 Simulation ........................................................................................................... 109
8.6.8 Parametrisation ................................................................................................... 111
8.6.9 Starting blocks and errors (optional) .................................................................... 114
8.6.10 PLC diagnosis ..................................................................................................... 115
8.6.11 Service screens ................................................................................................... 118
8.6.12 Language selection ............................................................................................. 121

9 Alarm handling .................................................................................................................................. 123

9.1 Alarm line ................................................................................................................................123
9.1.1 Display of alarms ................................................................................................. 123
9.1.2 Acknowledgement of alarms in the alarm line ...................................................... 123
9.2 List of all alarms .....................................................................................................................123
2013-04-17 - 1.9

9.2.1 Accessing the list ................................................................................................ 123

9.2.2 Resetting alarm messages .................................................................................. 126
9.2.3 History ................................................................................................................ 126
9.2.4 Troubleshooting .................................................................................................. 127
9.3 Common Alarm .......................................................................................................................129
9.4 Alarm messages .....................................................................................................................130

6 (136)
 MAN Diesel & Turbo

9.5 Abbreviations in the alarm messages ....................................................................................130

Table of contents
10 Repairs and cleaning ........................................................................................................................ 132

11 Spare parts ........................................................................................................................................ 133

11.1 Ordering spare parts ...............................................................................................................133
11.1.1 Identification of spare parts ................................................................................. 133
11.1.2 Contact ............................................................................................................... 134
11.2 Spare parts list for SaCoSone GENSET V1.1.X .........................................................................134
2013-04-17 - 1.9

7 (136)
 1 MAN Diesel & Turbo

1 Introduction
1.2 Comments on the manual

1.1 General information

This manual describes operation of MAN Diesel & Turbo GenSets with the
SaCoSone GENSET monitoring and control system. The manual is valid for
the following GenSet types:
▪ L16/24
▪ L21/31
▪ L27/38
▪ L32/40

1.1.1 Validity
This manual is valid for the following SaCoSone GENSET version(s):
▪ SaCoSone GENSET V1.1.x

In addition to this description, please also observe the relevant chapter in the
operating instructions for the engine.

1.1.2 System identification

The SaCoSone GENSET type plate is on the right-hand panel of the Control
Unit.
1 Introduction

1.2 Comments on the manual

2013-04-17 - 1.9

1.2.1 Contents
Chapter 1 Preface: Description of how the manual is structured and how to use it and
also Service contacts.

8 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 1

1.2 Comments on the manual

Chapter 2 Safety regulations: This chapter explains the purposes of the control system,
requirements to be met by the operator, presentation and meaning of warn-
ings and general safety information.

Chapter 3 Description of the system: Overview of the system and its

components.

Chapter 4 Installation: In addition to the installation prerequisites, technical data and

assembly instructions, this chapter describes connections to external sys-
tems and the power supply.

Chapter 5 Software handling: All procedures in relation to the installation of software,

programming, data backup and configuration documentation are described
here.

Chapter 6 Commissioning: This chapter explains the GenSet configuration and corre-
sponding documentation.

Chapter 7 Engine operation: This chapter contains descriptions of the operating sta-
tions, transfer of operating rights, starting and stopping a GenSet and emer-
gency measures and alarms.

Chapter 8 Touchscreen functions: Description of menu structure and functions.

Chapter 9 Alarm handling: This chapter describes alarm displays and resetting of
alarms and shutdowns.

Chapter 10 Repairs and cleaning: Description of changing the module and notes on
cleaning.

Chapter 11 Spare parts: Information on the spare parts catalogues for different engine
types

1.2.2 Structure of this manual

Handling instructions The handling instructions in this description are numbered. The handling
instruction is always followed by the result of the work step.
Example:
1 Introduction

1. Step 1.
2013-04-17 - 1.9

Result of step 1 or other operator controls.

2. Step 2.
…
Button designations, menu
titles and text Texts from the display and other texts that have been adopted from the dis-
play (e.g. button designations or menu titles) are displayed in capital letters.

SaCoS_one GENSET, Operating Instructions, EN 9 (136)

 1 MAN Diesel & Turbo

Example:
1.2 Comments on the manual

1. Press DIVERSE button in MAIN MENU.

The DIVERSE menu appears.

2. …
Limit values Limit values (times, pressure, temperature, rotary speeds) are not included in
this description. These parameters can be obtained from the list of measur-
ing points.

1.2.3 Revision history

Revision Changes Date

1.0 First edition. 27.08.2010
1.1 ▪ Ch. 3.2.1: New inside view of the Control Unit. 16.11.2010
▪ Ch. 3.2.2: New inside view of the Connection
Box.
▪ Ch. 5.1.2:Title changed.
▪ Ch. 5.2: Information inserted.
▪ Ch. 7.3: Chapter revised.
▪ Ch. 7.4: Information added to the engine stop
operation.
▪ Ch. 7.5.4: Information about the load reduction.
▪ Ch. 8.1.1: New screenshots for service loca-
tions.
▪ Ch. 8.3.2: Startstatus corrected.
▪ Ch. 8.5: Several corrections and new Screen-
shots.
▪ Ch. 8.6: Several corrections and new Screen-
shots.
▪ Ch. 9.3: Alarm list updated.
▪ Ch. 11: Chapter revised.
1.2 ▪ Ch. 3.3.2: EZV-image corrected. 23.12.2010
▪ Ch. 5.3.2: Values to the new parameters added
to the table.
▪ Ch. 6.2: List adapted to new parameters.
▪ Ch. 7.2.2: EZV-image and -description
1 Introduction

changed.
2013-04-17 - 1.9

▪ Ch. 7.6.4: Description of the EZV requirement

corrected for load reduction.
▪ Ch. 8.6.8: Screenshots including of the new
parameters.

10 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 1

Revision Changes Date

1.2 Comments on the manual

1.3 ▪ Ch. 4.8.1: Value for backlash in millimeters and 27.01.2011
inches added.
▪ Ch. 6.1: Setting the node ID corrected.
▪ Ch. 9.2.1: Description of colors added to the
alarm line.
1.4 ▪ Ch. 8.6.10: Changed menu PLC Diagnose 07.03.2011
because the gateway module is now available
for connection.
▪ Ch. 9.3: Updated alarm list.
1.5 ▪ All Chapter: Menu title DIVERSE changed to 06.05.2011
MISC. All the relevant chapter and screenshots
corrected.
▪ Ch. 5.3.3: New parameters for the use of
CoCoS-EDS with the Gateway module.
▪ Ch. 5.5: New chapter describes the configura-
tion of the gateway module.
▪ Ch. 6.6.2: New notice about the responsibility
class approval.
▪ Ch. 7.6.4: Modified description of the load
reduction requirement.
▪ Ch. 9.1: Modified description of displayed alarm
lines.
▪ Ch. 9.2: Menu HISTOGRAM changed to HIS-
TORY.
▪ Ch. 9.3: Alarm list updated.
▪ Ch. 9.4: Corrected meaning of RED and OVRD
RED.
1.6 Total operating instructions revised. Main changes: 26.01.2012
▪ All Chapter: Pictures and drawings updated.
▪ All Chapter: Pictures and drawings updated.
▪ Ch. 3: Completely revised.
▪ Ch. 4.2.5: Drawing of the VIT Cabinet updated.
▪ Ch. 6.3: No document available to the system.
▪ Ch. 7.5.2: Note on the turbocharger lube oil
pressure added.
▪ Ch. 7.6.4: Load reduction added.
▪ Ch. 8.6.7: Description of Simulation menu
changed. Simulation of engine load is no longer
available. Description TESTBED OPERATION
corrected.
▪ Ch. 9.3: Dual alarms deleted. list updated.
1 Introduction
2013-04-17 - 1.9

▪ Ch. 10.2: New chapter for cleaning.

SaCoS_one GENSET, Operating Instructions, EN 11 (136)

 1 MAN Diesel & Turbo

Revision Changes Date

1.3 Structure and use of operating manual

1.7 ▪ Total document: screenshots replaced. 21.08.2012

▪ Ch. 3.1.2: System architecture corrected
▪ Ch. 4.7.1: Description for RS485 corrected
▪ Ch. 6: Renamed to Configuration.
▪ Ch. 7.2: Graphics replaced.
▪ Ch. 9.1.2: Acknowledgment of alarms in the
alarm line no longer possible.
▪ Ch. 9.2.2: Note added for reset in case of failure
Display Module.
▪ Ch. 9.4: Alarm message. List deleted and refer-
ence added.
1.8 ▪ Ch. 6.2.1: Parameter “Alternator Cooling Air 04.03.2013
Temp” (22015) added.
▪ Ch. 8.5.11: New screenshot due to parameter
22015.
▪ Ch. 8.6.8: New screenshot due to parameter
22015.
▪ Ch. 8.6.11: New screenshot due to parameter
22015.
1.9 ▪ Ch. 6.2.2: Parameter list completed 17.04.2013

1.3 Structure and use of operating manual

The manual contains information which is intended to assist the operator and
guarantee safe operation. This information is intended as support for experi-
enced and qualified employees who are responsible for operating and moni-
toring the engine.
This is why the operating manual must be available to employees at all times
and these persons must familiarise themselves with the structure of the man-
ual in order to be able to find the necessary information quickly.

Liability / Warranty MAN Diesel & Turbo Augsburg will not be held liable for damage to materials,
the environment or physical injury occurring as a result of partial or complete
disregard of the operating manual.
Interventions made by unauthorized persons will render the warranty null and
void.
Liability and warranty claims will not be recognised in the event of physical
injury or material damage if this is attributable to one of the following factors:

▪ if the damage is caused by the use of non-genuine spare parts.

1 Introduction

▪
2013-04-17 - 1.9

if the system is incorrectly operated or is not properly maintained or

repaired
▪ if the system is operated with poorly fitting, faulty or defective safety and
protective equipment.
▪ if operation, maintenance and repairs are not carried out as specified in
this manual.

12 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 1

▪ if the system is modified without the express permission of MAN Diesel &
Turbo Augsburg. The installation and removal of parts is expressly pro-

1.4 Contact
hibited.
▪ if plant components are not adequately monitored.
▪ if damage is caused by foreign bodies or force majeure.

Copyright MAN Diesel & Turbo Augsburg retains the data protection rights for these
operating instructions. These operating instructions are confidential and must
not be disclosed either in whole or in part to third parties.
Reproduction, disclosure, amendment, transfer or translation into other lan-
guages of the entire document or parts thereof using electronic, mechanical
or other means is only permitted with the express permission of MAN Diesel
& Turbo Augsburg.
Observe operating Thorough knowledge of the technical system documentation is essential for
instructions! ensuring the physical safety of employees, preventing faults and error-free
safe module operation.
▪ The operating instructions must be available at all times (in the control
room, for example).
▪ The operating instructions must be available to all persons responsible
for transporting, installing, testing, operating, maintaining or repairing the
plant.
▪ All requirements and directions in these operating instructions must be
observed.
▪ The description of adopted parts is an integral part of these operating
instructions. All safety-relevant information and other topics in these
operating instructions must be observed.
▪ All national regulations in relation to environmental protection and tech-
nology that are designed to ensure that work is carried out safely and
correctly must be complied with.

1.4 Contact

MAN Diesel & Turbo Group provides a 24-hour service 365 days a year
worldwide. In addition to the MAN Diesel & Turbo head offices in Augsburg,
Copenhagen, Stockport and St. Nazaire, service centres across all conti-
nents offer straightforward no fuss support at all times.
MAN Diesel & Turbo engines are renowned for their long service life which
means that a spare parts programme is required that guarantees availability
of components for decades to come. Thanks to their modern high-perform-
ance technical equipment, MAN Diesel & Turbo production facilities can deal
with specific customer requests flexibly and to a high degree of precision.
1 Introduction
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24-hour hotline
Tel: +49 1801 15 15 15

Technical service 24-hour hotline

SaCoS_one GENSET, Operating Instructions, EN 13 (136)

 1 MAN Diesel & Turbo

Tel: +49 821 322-1499

1.4 Contact

Fax: +49 821 322-3838

E-mail: [email protected]

Spare parts 24-hour hotline

Tel: +49 821 322-1799
Fax: +49 821 322-3574
E-mail: [email protected]

Turbocharger service 24-hour hotline

Spares sales
Tel: +49 821 322-4030

Technical Service (radial)

Tel: +49 821 322-4020

Technical Service (axial)

Tel: +49 821 322-4010
Fax: +49 821 322-3998

E-mail:
[email protected]
[email protected]
[email protected]
1 Introduction

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14 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 2

2 Safety regulations

2.3 Structure of warning messages

2.1 Intended Use
The control system has to be used according to the specifications in the
contract. Any other use will be considered improper use. For safety reasons,
any modification or alteration of the control system is strictly prohibited. MAN
Diesel & Turbo does not assume liability for resulting damages. The operator
bears all associated risks.

Operating and installing conditions!

The operating and installation requirements stipulated in this manual
strictly have to be met.
• The use of non-original parts with the control system is prohibited since
safe operation can otherwise not be guaranteed.
• Any action that could potentially lead to impairment of the safety of the
control system is prohibited.

2.2 Requirements to be met by operating personnel

Qualifications The personnel who carry out operation, maintenance and assembly work
must be qualified to do so. If they do not have the required knowledge they
must be trained and instructed accordingly. This can, if necessary, be carried
out by the manufacturer/supplier or at the request of the owner/operator.
Training Although when developing SaCoSone, particular attention has been paid at
MAN Diesel & Turbo SE to simplicity, reliability and safety the system must
always be operated carefully in compliance with all safety measures. The
operating instructions must be available at all times and must be worked
through carefully.

2.3 Structure of warning messages

The safety information and corresponding symbols that appear in this manual
to indicate a danger to life, the engine or its control system or to the environ-
ment. The system must always be operated carefully in compliance with all
safety measures. The operating instructions must be available at all times
and must be worked through carefully.
2 Safety regulations

The following examples show how the safety information in the manual is
structured (examples are used for ease of comprehensibility!). They may also
appear in conjunction with other symbols. The symbols denote the severity
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of the danger.

SaCoS_one GENSET, Operating Instructions, EN 15 (136)

 2 MAN Diesel & Turbo

Signal word "Danger", "Warning" or "Caution"

2.4 Symbols and warning information

(severity of danger).
Type of danger
• Possible consequences of non-observance.
• Preventative measure.

Important!
Description of the danger (type and origin, possible
consequences of non-observance, preventative measures).
Consequences

Note!
Description.
Consequences

2.4 Symbols and warning information

The following table describes the danger levels for warnings in the MAN Die-
sel & Turbo SE technical product information.
Icon Title Description
DANGER Danger level 1
If the corresponding precautions are not
taken this poses an immediate danger:
▪ Death or severe physical injury.
▪ Total loss of engine/system.
▪ Grave environmental damage.
WARNING Danger level 2
If the corresponding precautions are not
taken, this may give rise to a danger with
the following consequences:
▪ Death or severe physical injury.
▪ Serious material damage.
2 Safety regulations

▪ severe environmental damage.

CAUTION Danger level 3
If the corresponding precautions are not
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taken, this will give rise to a danger with

the following consequences:
▪ Minor physical injury.
▪ Possible material damage.

16 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 2

Icon Title Description

2.5 General safety information

CAUTION Danger level 4
Indicates the origins of faults and improper
handling.
▪ Material damage may occur.
NOTE No danger level
Additional references, information and tips.

2.5 General safety information

Provide sufficient information!

A lack or neglect of information may lead to severe personal or
material damage! Therefore:
• Always obey the operating instructions!
• Always keep the operating instructions available!

Unqualified staff!
The procedures described in the following chapters require a certain
degree of electrical knowledge. Unqualified staff could cause severe
injuries or material damage!
• Cabling and service inspection are to be carried out by qualified
electricians only.
• Do not take on tasks that exceed your knowledge.
• Deny access/participation to any unauthorized person.

Hazard of electric shock!

When working with electrical systems, direct contact with live
components or flash-over voltage may lead to an electric shock and
subsequently to cardiac arrhythmia. Other consequences may be
severe burnings as well as injuries caused by uncontrolled body
movements.
Apply the five safety rules (according to DIN EN 50110) before
commencing work in order to eliminate this hazard.
2 Safety regulations

• Disconnect (all poles!).

• Prevent from reconnecting.
• Ensure there is no live voltage.
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• Ground and short-circuit.

• Cover and protect against adjacent live components.

SaCoS_one GENSET, Operating Instructions, EN 17 (136)

 2 MAN Diesel & Turbo

Scope of technical documentation.

2.5 General safety information

Technical documents are always valid for specific systems! If

information on a different system is used, this could lead to
malfunctions or damage!
• Use only the relevant information, and never information from other
sources!
2 Safety regulations

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18 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

3 Description of the system

3.1 General information

3.1 General information
State-of-the-art control technology that undertakes comprehensive control
and monitoring of all auxiliary units, components and core functions of the
diesel engine is required in order to ensure modern diesel engines operate
efficiently and safely. The SaCoSone control system which has been devel-
oped in-house by MAN Diesel & Turbo SE has a modular concept and offers
the following core control and monitoring functions:
▪ Engine control
▪ Speed control
▪ Alarm system
▪ Safety system

3.1.1 Area of application

Due to the system architecture and control modules used, this line of prod-
ucts can only be used for the following engines and applications:
▪ In-line engines with a maximum of 10 cylinders in the L16/24, L21/31,
L27/38 and L32/40 series.
▪ Only suitable for engines with PT1000 exhaust gas sensors.
▪ Only for "Auxiliary GenSets" (auxiliary units), not for main machines.

3.1.2 System architecture

3 Description of the system

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SaCoS_one GENSET, Operating Instructions, EN 19 (136)

 3 MAN Diesel & Turbo
3.1 General information

3.1.3 System components

3.1.3.1 Overview

The control modules are listed below with information on their essential con-
trol functions in abridged form:
Device Basis Functions
Display ▪ Expert-Gateway functionality
Module
▪ HMI functionality for display and
operation
▪ Safety system incl. the necessary
digital I/O signal coupling
▪ Configuration interface for speed
governor and engine control system
parameters
Control ▪ Engine control
Module
▪ Alarm system incl. necessary digital
S
and analogue I/O signal acquisition
▪ Data link with EDS via serial inter-
face (only possible with PT1000
sensors at the alternator)
▪ Speed control
Gateway Option ▪ EDS connection, Databox and
Module Online Service
▪ Redundant coupling with plant
alarm system

Wago I/ Option ▪ For connection of alternators with

O PT100 measuring points
CCM Option ▪ Crankcase Monitoring Unit
unit
▪ Main bearing and splash oil moni-
toring equipment with dedicated
display and control system (off-
3 Description of the system

engine)
VIT Option ▪ Variable Ignition Timing
(32/40
only)

3.1.3.2 Control Module S

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The Control Module S was specially developed for use with GenSets and is a
compact unit that in addition to the control unit (PLC) contains the entire I/O
package that is required to connect the sensors and actuators. The Control
Module S is characterised by the following salient features:
▪ PLC system with real time operating system and 3S-PLC software.
▪ 2 serial RS422/485 interfaces for connection to external systems.

20 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

▪ 3 CAN: 2 bus interfaces for redundant connection to the system bus and
1 bus interface for connection of external I/O extensions.

3.1 General information

▪ 4 frequency inputs for speed sensors.
▪ 24 digital inputs.
▪ 3 analogue outputs for 4-20 mA signals.
▪ 12 analogue inputs for 4-20 mA signals from pressure sensors, etc.
▪ 24 PT1000 inputs for analogue signals from temperature sensors.
▪ 8 digital outputs for activation of relay or for hard-wired signals to other
systems.
▪ 8 power outputs.

3.1.3.3 Display Module

Visual representation of connecting terminals:

▪ 2 CAN bus connections for redundant connection to system bus.
▪ 1 Ethernet interface.
▪ 1 USB port for data backup and software updates.
▪ 2 frequency inputs.
▪ 5 digital outputs for activation of relay or for hard-wired signals to other
systems.
▪ 1 power output (1 A).
▪ 8 digital inputs.

3.1.3.4 Gateway Module

Visual representation of connecting terminals:

▪ 4 CAN: 2 bus interfaces for redundant connection to the system bus and
2 bus interfaces for connection of external I/O extensions.
▪ 3 Ethernet interfaces for connection to the plant.
▪ 1 Ethernet interface for connection to SaCoSone EXPERT.
▪ 1 USB port for data backup and software updates.
▪ 1 serial RS422/485 interface for connection to external systems.

3.1.3.5 System bus CAN

3 Description of the system

The individual control modules in the system are connected via a communi-
cations interface (data bus) to facilitate the exchange of status information
between the individual sensors, data reconciliation and communication of
system messages and notifications. A CAN bus is used with SaCoSone and
this has been duplicated for redundancy reasons. This ensures that if one of
the two bus connections drops out, the modules can continue to communi-
cate with one another and that the requirements of the classification societies
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are met.

SaCoS_one GENSET, Operating Instructions, EN 21 (136)

 3 MAN Diesel & Turbo
3.2 Control functions

3.2 Control functions

3.2.1 Engine control

The engine control is executed as an integral part of the Control Module S
and fully controls the engine in all possible operating states:
▪ It controls and monitors the entire starting routine of the engine.
▪ It assumes full load-dependent control of the engine speed throughout
its entire operation.
▪ It assumes the control and monitoring of all auxiliary units and engine
parameters when the engine is in operation.
▪ It ensures that the engine's combustion process is optimised to minimise
pollutant emissions and consumption thus ensuring efficient and load-
optimised operation of the engine.
▪ It manages the controlled stopping routine of the engine.

3.2.1.1 Basic functions of the engine control

The individual functions of the engine control are described below:

Function Brief description
Start-Stop function ▪ Local and remote start/stop
▪ Activation of starting device
▪ Control and monitoring of start-up phase
▪ Monitoring of stopping routine
Jet-Assist Improvement in engine acceleration performance when run-
ning up to speed or during application of load
External Jet Assist Regulates with external speed control the activation of the Jet
Request Assist valve, as opposed to the regular Jet Assist function
Nozzle cooling Cooling of injection valves during HFO operation in order to
avoid thermal overloading
Target speed value Differentiation between droop (symmetrical) and isochronous
selection (asymmetric) load distribution during multi-engine operation
Charge air preheat- Heating of air downstream of turbocharger but upstream of
3 Description of the system

ing cylinder via HT cooling water heat exchanger at low load,

cooling via LT cooling water at high load
Cylinder lubrication the additional cylinder lubrication is activated with 32/40 at
high loads
IMO Identifier calculates and visualises the checksum of all parameters set
that are relevant to IMO
Pump control Control of priming pump and preheating pump in order to
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facilitate engine start at any time

22 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

Function Brief description

3.2 Control functions

VIT (Variable Injec- Fuel injection timer: the fuel injection timing or camshaft posi-
tion Timing) tion is changed in relation to engine load by adjusting the cam-
shaft; only possible with 32/40
Fuel detection The type of fuel is identified by analyzing the fuel temperature.
The fuel pressure alarm limit is adjusted and the fuel tempera-
ture alarm is enabled depending on the type and temperature

3.2.1.2 Safety monitors and functions

The safety functions integrated in the engine control effect an immediate

shutdown of the engine if required by resetting the speed governor release.
In this case, a shutdown request is also transmitted to the safety system via
the system bus. The following safety monitoring operations are performed by
the engine control:
▪ Shutdowns during serious speed governor alarms (double pickup error,
actuator error accompanied by target/actual signal deviation).
▪ Monitoring of manual emergency stop operation.

3.2.2 Speed control

The digital speed control is also executed as an integral part of the control
module. A separate speed governor module is therefore not required. The
electro-hydraulic actuator is activated directly via a power output at the con-
trol module.

3.2.2.1 Basic functions of speed control

The individual control functions of the speed control are listed below accom-
panied by a brief description:
Function Brief description
Speed measure- Importing and processing of speed signals received from pick-
ment ups
PID - speed gov- Each controller part is fully adjustable in order to achieve opti-
ernor mum controller characteristics at each engine operating point.
This allows adjustment of the static controller characteristics at
every operating point and dynamic adaptation of load applica-
3 Description of the system

tion.
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SaCoS_one GENSET, Operating Instructions, EN 23 (136)

 3 MAN Diesel & Turbo

Function Brief description

3.2 Control functions

Load distribution The controller can distinguish between two load distribution
types:
▪ P level: automatic uniform load distribution with multi-
engine installations when using the same P level
parameter. Application is suitable for stand-alone
operation and parallel operation with the grid.
▪ Isochronous load distribution: A load/speed setpoint
signal can be supplied to the relevant controller via an
upstream load distribution system. This application is
intended purely for multi-engine use in stand-alone
mode.
Limiter functions Different limiter functions (start fuel limiter, charge air limiter,
maximum fuel limiter, jump rate limiter, zero fuel limiter) ensure
that the filling is monitored in all engine operating states at all
times.

3.2.2.2 Monitoring of speed governor functions

If an error is detected, the speed governor switches off automatically (actua-

tor setpoint set to zero) and reports the error to the engine control.
▪ Monitors its actuating signal to the actuator (back measurement of cur-
rent setpoint)
▪ Monitoring of speed inputs for signal plausibility.

3.2.3 Alarm system

The engine alarm system is also executed as an integral part of the control
module. It monitors all necessary media parameters (temperatures, pres-
sures, etc.) and generates an alarm if critical changes (exceedance or under-
cutting) in the signal occur for limit values that are predefined using parame-
ters. This is displayed at the local control panel and forwarded to the higher-
level alarm system. The connection to the plant alarm system is normally
established via a serial interface.

3.2.3.1 Alarm monitoring systems

The alarm monitoring functions of the alarm system are listed individually
3 Description of the system

below:
▪ Engine speed and turbocharger speed
▪ Monitoring of pressure and temperature sensors for engine and turbo-
charger lube oil, LT and HT cooling water, fuel, starting air and ambient
air (optional)
▪ Main bearing and splash oil temperature (optional CCM, hard-wired sig-
nal connection)
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▪ Oil mist monitoring

▪ Monitoring of exhaust gas temperatures of individual cylinders and turbo-
charger (inlet / outlet)
▪ Monitoring of VIT positioning
▪ Monitoring of alternator winding and bearing temperatures
▪ Monitoring of communication with connected system components

24 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

3.2 Control functions

3.2.3.2 Redundant safety monitoring of alarm system

In addition, the alarm system as redundant system for the safety system also
triggers an engine shutdown if the limit values of the most important engine
operating parameters are out-of-spec. In these instances, as is the case with
the engine control, the speed governor release and therefore the filling of the
engine is reset to zero and a shutdown request is also transmitted to the
safety system via the system bus.
▪ Monitoring of engine speed for overspeed, implementation of redundant
overspeed protection
▪ Shutdown if lube oil pressure at engine entry point is too low
▪ Shutdown if HT cooling water temperature at engine exit point is too high

3.2.4 Safety system

The safety system is integrated into the Display Module as one of its func-
tions. It monitors all operating parameters of the engine that are connected
to the system via a separate sensor. If a critical limit value is violated (excee-
ded or undercut) the safety system initiates the necessary measures (load
reduction or, if required, engine stop).
The safety system features purely binary signal detection (apart from the
speed signals), analogue signals cannot be recorded and processed. The
pressure and temperature sensors that are connected to the safety system
therefore feature binary switching contacts that close when the limit values
are reached. The sensors must be set to the required limit values (switching
threshold). This setting is performed manually based on the limit values sta-
ted in the list of measuring points and cannot be monitored by the safety
system directly.

3.2.4.1 Safety monitoring systems

The individual control functions of the safety system are listed below accom-
panied by a brief description:
▪ Overspeed monitoring of engine.
▪ Lube oil pressure of engine.
▪ HT cooling water temperature.
3 Description of the system

▪ Oil mist concentration in crankcase.

▪ Main bearing and splash oil temperature (optional CCM, hard-wired sig-
nal connection).

3.2.4.2 Safety functions

The safety system performs the safety functions listed below by activating
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the emergency stop valve which sets the engine filling to zero and therefore
stops the engine:
▪ Auto shutdown
▪ Emergency stop

SaCoS_one GENSET, Operating Instructions, EN 25 (136)

 3 MAN Diesel & Turbo
3.4 System design for L16/24, L21/31 and L27/38

3.2.5 HMI - Local Operating Panel

The user interface comprises an "on-engine" touchscreen which is integrated
into the Display Module. This incorporates the following functions:
▪ Visualisation of the most important operating parameters of the engine.
▪ Display of operating status messages/alarms.
▪ Manual operation of the engine

3.3 Options
▪ Connection of alternators to PT100 sensors (in this case a GM must be
installed for the EDS connection as the CM-S is required for connection
of the PT-100 coupler).
▪ Connection of a splash oil and main bearing CCM unit. However, the
necessary hardware must be installed "off-engine".
▪ VIT unit.
▪ IM unit.

3.4 System design for L16/24, L21/31 and L27/38

The system comprises the Control Unit and a Connection Box both of which
are housed in the same casing.
3 Description of the system

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SaCoSone GENSET for L16/24

26 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

3.4 System design for L16/24, L21/31 and L27/38

3.4.1 Control Unit
The Control Unit contains a large-scale integrated Control Module which
controls and monitors the engine and manages the alarm system.

The Display Module is built into the door of the Control Unit. The engine can
be operated and operating values displayed via this touchscreen. A PLC for
the safety system is integrated into the Display Module.

1 Control Module S 2 Display Module

Figure 1: Internal view of Control Unit

Additional operator control buttons are built into the door for the purpose of
transferring operating rights and regulating the engine speed.

3.4.2 Connection Box

A 24 VDC voltage supply is connected inside the Connection Box.
3 Description of the system

Furthermore, the Connection Box is the interface between the Control Unit
and GenSet, the ship's alarm system and optional crankcase monitoring sys-
tem.
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SaCoS_one GENSET, Operating Instructions, EN 27 (136)

 3 MAN Diesel & Turbo
3.4 System design for L16/24, L21/31 and L27/38

Figure 2: Internal view of Connection Box

3.4.3 Versions
Different versions of the SaCoSone GENSET are available, depending on the
sensor equipment of the alternator used. Pt1000 or PT100 sensors can be
used to monitor the winding and bearing temperature of the alternator.
The optional CoCoS-EDS can be connected to the system via a serial inter-
face or Ethernet
The following table contains all available combinations for the engine types
L16/24:
SaCoSone GENSET

Sensors at alternator EDS L16/24 L21/31 L27/38

Pt1000 serial RTU X X X
Pt1000 Ethernet & serial o o o
interface
Pt100 without EDS o o o
Pt100 Ethernet o o o
3 Description of the system

X = standard o = optional
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28 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

3.4 System design for L16/24, L21/31 and L27/38

3.4.4 Block diagrams
Alternator with Pt1000, EDS
via serial interface

3 Description of the system

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SaCoS_one GENSET, Operating Instructions, EN 29 (136)

 3 MAN Diesel & Turbo

Alternator with Pt1000, EDS

3.4 System design for L16/24, L21/31 and L27/38

via Ethernet
3 Description of the system

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30 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

Alternator with Pt100,

3.4 System design for L16/24, L21/31 and L27/38

without EDS

3 Description of the system

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SaCoS_one GENSET, Operating Instructions, EN 31 (136)

 3 MAN Diesel & Turbo

Alternator with Pt100, EDS

3.4 System design for L16/24, L21/31 and L27/38

via Ethernet or serial

interface
3 Description of the system

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32 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

3.5 System design for L32/40

3.5 System design for L32/40

3.5.1 Control Unit

With the L32/40 engine, the SaCoSone GENSET is installed in a switch cabi-
net on the engine.

3 Description of the system

Figure 3: Control unit for L32/40

The Control Unit contains a large-scale integrated Control Module which
controls and monitors the engine and manages the alarm system.
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The Display Module is built into the door of the Control Unit. The engine can
be operated and operating values displayed via this touchscreen. A PLC for
the safety system is integrated into the Display Module.
Additional operator control buttons are built into the door for the purpose of
transferring operating rights and regulating the engine speed.

SaCoS_one GENSET, Operating Instructions, EN 33 (136)

 3 MAN Diesel & Turbo

The 24-VDC voltage supply for the entire system is connected inside the
Control Unit. The Control Unit acts as the interface between the GenSet,
3.5 System design for L32/40

external control and optional crankcase monitoring.

3.5.2 VIT Cabinet

The L32/40 features Variable Injection Timing (VIT) in order to reduce emis-
sions during partial load operation. Depending on the engine load or position
of the filling linkage, the VIT changes the fuel injection timing by adjusting the
injection camshaft.

Figure 4: VIT Cabinet

3.5.3 Versions
Different versions of the SaCoSone GENSET are available, depending on the
sensor equipment of the alternator used. Pt1000 or PT100 sensors can be
used to monitor the winding and bearing temperature of the alternator.
The optional CoCoS-EDS can be connected to the system via a serial inter-
face or Ethernet
The following table contains all available combinations for the engine type
L32/40:
SaCoSone GENSET

Sensors at alternator EDS L32/40

3 Description of the system

Pt1000 without EDS X

Pt1000 Ethernet & serial interface o
Pt100 without EDS o
Pt100 Ethernet & serial interface o
X = standard o = optional
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34 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 3

3.5 System design for L32/40

3.5.4 Block diagrams
Alternator with Pt1000,
without EDS

Alternator with Pt1000, EDS

via Ethernet

Alternator with Pt100,

without EDS 3 Description of the system
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SaCoS_one GENSET, Operating Instructions, EN 35 (136)

 3 MAN Diesel & Turbo

Alternator with Pt100, with

3.5 System design for L32/40

EDS
3 Description of the system

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36 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 4

4 Installation

4.1 Installation requirements

4.1 Installation requirements

4.1.1 Storage and transport conditions

The following prerequisites generally apply:
Ambient temperature: -10 ℃...+60 ℃
Relative humidity: < 96 %.
If these prerequisites cannot be met, measures must be taken to protect
against the effects of the climate on electronic components.

4.1.2 Cable installation

The connecting cable between the engine and SaCoSone GENSET must be
routed according to the rules of electromagnetic compatibility. The control
and voltage cables must be routed in separate cable guide rails.
Shielded cables must be used when wiring up the sensors. The cable shield-
ing must be installed as shown in the cable routing diagram. Unshielded
cables must be kept as short as possible.
The Control Unit must be earthed. An earthing strip must be used for this
(scope of supply, licensee).

For more details on the cable installation, refer to

▪ Cable installation guidelines
▪ Cable routing diagram

4.1.3 Installation
Make sure that the environmental conditions are also complied with during
the installation. The cabinets must be protected against water, dust and fire
when assembly is in progress.
Welding work must not be carried out near cabinets. If this is unavoidable,
the control stations, particularly the control desks, must be protected from
heat, current and electromagnetic interference. To protect against electrical
current, the entire cable installation must be isolated from the components
when welding work is in progress.
4 Installation
2013-04-17 - 1.9

The installation of additional components in the devices is not permitted.

SaCoS_one GENSET, Operating Instructions, EN 37 (136)

 4 MAN Diesel & Turbo
4.2 Technical data

4.2 Technical data

4.2.1 Operating prerequisites

The following prerequisites fundamentally apply:
▪ Ambient temperature: 0 ℃...+55 ℃
▪ Relative humidity:< 96 %
▪ Vibrations: < 4 g.

If the required ambient temperature cannot be achieved, the electronic com-

ponents must also be protected against climatic influences.

4.2.2 SaCoSone GENSET for L16/24

Dimensions and weight

System dimensions for L16/24

Width 400 mm
Height 480 mm
Length 869 mm
Overall length 902 mm
Weight 60 kg
4 Installation

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38 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 4

4.2 Technical data

4.2.3 SaCoSone GENSET for L21/31
Dimensions and weight

System dimensions for L21/31

Width 400 mm
Height 565 mm
Length 1,168 mm
Overall length 1,201 mm
Weight 60 kg

4.2.4 SaCoSone GENSET for L27/38

Dimensions and weight

System dimensions for L27/38

Width 400 mm
Height 480 mm
Length 1,323 mm
Overall length 1,354 mm
Weight 65 kg
4 Installation
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SaCoS_one GENSET, Operating Instructions, EN 39 (136)

 4 MAN Diesel & Turbo
4.2 Technical data

4.2.5 SaCoSone GENSET for L32/40

Dimensions and weight of
Control Unit
4 Installation

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System dimensions for L32/40

40 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 4

Width 380 mm

4.2 Technical data

Height 1000 mm
Length 210 mm
Overall length 243 mm
Weight 70 kg

Dimensions and weight of

VIT Cabinet

System dimensions for VIT Cabinet

Width 600 mm
Height 600 mm
Length 350 mm
Weight 50 kg
4 Installation
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SaCoS_one GENSET, Operating Instructions, EN 41 (136)

 4 MAN Diesel & Turbo
4.3 Connecting the SaCoS_one_ GENSET

4.3 Connecting the SaCoSone GENSET

Warning!
In order to carry out the procedures explained below, some prior
knowledge of electrical engineering is required. If this work is carried
out by unqualified persons, this could result in severe physical injury
and material damage!
• Cables must only be installed by qualified electricians.
• Never undertake tasks if you are not sure whether you have the
necessary personal knowledge or
experience.
• Access/participation must not be granted to unauthorized persons.

4.3.1 Modbus connection to ship's alarm system

SaCoSone GENSET features a Modbus interface with the ship's alarm system.
This interface can be configured as a RS485 (Modbus-RTU) or RS422 (Mod-
bus-ASCII). The standard configuration is RS485.

RS485 For an RS485 connection, contacts AE and AF must be bypassed with con-
tacts AG and AH respectively at the connecting plug.
Two wires (RX/TX H and RX/TX L) are required to establish the cable con-
nection between SaCoSone GENSET and the ship's alarm system. A termi-
nating resistor (120 Ω) must be applied between RX/TX H and RX/TX L.

RS422 For RS422, the connections between AE and AG and AF and AH must be
removed. Four wires (TX H, TX L, RX H, RX L) are required for the cable
installation between the SaCoSoneGENSET and the ship's alarm system. A
terminating resistor (120 Ω) must be applied between RX/TX H and RX/TX L.

For additional information see:

▪ Circuit diagram
▪ Terminal list
▪ Description of SaCoSone GENSET interface
4 Installation

2013-04-17 - 1.9

4.3.2 Connection with other external systems

The connection with the external system is explained in the following docu-
ments:
▪ Circuit diagram
▪ Terminal list

42 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 4

4.3 Connecting the SaCoS_one_ GENSET

4.3.3 Connecting the power supply

Unqualified staff!
The procedures described in the following chapters require a certain
degree of electrical knowledge. Unqualified staff could cause severe
injuries or material damage!
• Cabling and service inspection are to be carried out by qualified
electricians only.
• Do not take on tasks that exceed your knowledge.
• Deny access/participation to any unauthorized person.

Important!
The power supply must be established using a wire cross-section of at
least 16 mm².

SaCoSone GENSET requires two uninterruptible 24 V DC power supplies

(UPS), one for the Alarm System, one for the Safety System. The Alarm Sys-
tem and the Safety System must each be protected by a 8 A pre-fuse.

Additional information ▪ Circuit diagram

▪ SaCoSone GENSET interface description

Connecting the power supply

1. Unplug the power supply connector of the Display Module.
2. Unplug the power supply connector of the Control Module S.
3. Connect the uninterruptible power supply to the following clamps.
System Voltage Polarity Terminal clamp
Safety System 24 V ++ -X12/3
0V -- -X12/4
Alarm System 24 V ++ -X12/5
0V -- -X12/6

1. Check with a Multimeter, if the polarity of the polarity is connected cor-

4 Installation
2013-04-17 - 1.9

rectly.

SaCoS_one GENSET, Operating Instructions, EN 43 (136)

 4 MAN Diesel & Turbo

Risk of destroying modules by wrong polarity!

4.4 Adjusting the speed governor servo-drive

Wrong polarity may destroy SaCoSone modules.

• Check polarity before empowering SaCoSone with voltage!
• Do not supply power to any of the SaCoSone modules before you are
sure the polarity is correct.

2. Reconnect the power supply connector of the Display Module.

3. Reconnect the power supply connector of the Control Module S.

4.4 Adjusting the speed governor servo-drive

4.4.1 Mechanical settings

Once the actuator has been installed at the engine and the backlash has
been adjusted to 0.2 - 0.3 mm (0.008 - 0.012 inches) the filling linkage must
be adjusted.
The following conditions must be met in this case:
1. The fuel pump must be at "0" and the reading on the actuator display
must be "0 %".
2. The fuel pump must be at the 100 % load position and the indicator
reading on the actuator must be "80 %".

Caution!
If there is an elastic component between the actuator and the filling
linkage, this must not be compressed under any circumstances
whatsoever when the settings are being made!

4.4.2 Electronic settings

1. Start the engine and bring it up to the rated speed without applying a
load.
2. Press the MISC button in the MAIN MENU.
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The MISC menu appears.

44 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 4

3. Press the PARAMETERS SETTING button.

4.4 Adjusting the speed governor servo-drive

4. Press the "NEXT" button in the navigation bar twice.

The GOVERNOR PARAMETERS page appears.

5. Read off the value displayed under ACTUATOR SETPOINT.

6. Enter this value in the FUEL QUANTITY AT IDLE field via the on-screen
keypad.
7. Press ENTER on the on-screen keypad to confirm.
This value is saved automatically and the on-screen keypad disappears.
8. Bring the engine load up to 100 % of the rated output and speed.
9. Read off the value displayed under ACTUATOR SETPOINT.
10. Enter this value in the FUEL QUANTITY AT FULL LOAD field via the on-
screen keypad.
11. Press ENTER on the on-screen keypad to confirm.
This value is saved automatically and the on-screen keypad disappears.
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SaCoS_one GENSET, Operating Instructions, EN 45 (136)

 4 MAN Diesel & Turbo

Caution!
4.4 Adjusting the speed governor servo-drive

Once all settings have been made correctly, the FUEL INDEX displayed
in the status bar will be exactly 100 % at 100-% engine load and rated
speed.
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46 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 5

5 Software & parameters

5.1 Loading software on modules

5.1 Loading software on modules

5.1.1 Preparation phase

▪ Engine at a standstill.
▪ The restoration process should only be started if the module has been
disconnected from the system bus. To do so disconnect CAN1 and
CAN2 from the module.

Connecting the SaCoSone 1. Plug PCAN-USB adapter into a USB port on the notebook.
TOOLBOX Notebook to the 2. Connect the PCAN-USB adapter to CAN1 of the module via the CAN
module cable.
3. Switch on the notebook.

5.1.2 Load software on the module

1. Click on the desktop symbol for the SaCoSone DEVICE MANAGER
(licensee version).

2. Click SELECT DEVICE.

The following window appears. If a connection with the system bus has
not been established, only one module will be displayed.
3.
5 Software & parameters
2013-04-17 - 1.9

4. Select module.
5. Click OK.
The selected module is displayed in the line next to the SELECT
DEVICE button.

SaCoS_one GENSET, Operating Instructions, EN 47 (136)

 5 MAN Diesel & Turbo

6. Click SELECT SOURCE PATH.

The source path is the path to the location where the sdi files were
5.1 Loading software on modules

stored.
7. Select the source path.
8. Click OK.
9. Check whether the serial number in the SERIAL OF ORIGINAL DEVICE
and SERIAL OF SDI MASTER DEVICE input fields is 00.0.00000-0000
in both cases.
10. Click SELECT IMAGE FILE.
11. Select the corresponding sdi file for the engine type.

12. Click OK.

All preparatory tasks are now complete.
5 Software & parameters

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48 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 5

13. Click RESTORE IMAGE.

The restore process starts during which the RESTORE IMAGE button

5.1 Loading software on modules

remains red. The progress of the process is displayed in a status bar:

this takes a few minutes. The current work step is displayed in the log
window. Please wait until the Binary IMAGE SUCCESSFULLY
RESTORED message appears.

Caution!
The process takes several minutes. Nothing is displayed on a Display
Module when it is being updated. As soon as the update process is
complete, the Display Module is automatically restarted.

14. Close the SaCoSone DEVICE MANAGER.

5.1.3 Troubleshooting
Error 1 Problem:
The SELECT DEVICE window is not displaying a module.

5 Software & parameters

Solution:
▪ Check cable connection with module.
▪ Check power supply.
▪
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Error 2 Problem:
The connection broke down when uploading.

SaCoS_one GENSET, Operating Instructions, EN 49 (136)

 5 MAN Diesel & Turbo
5.2 Adjusting the speed governor parameters

Solution:
▪ Check cable connection with module.
▪ Check power supply.

Error 3 Problem:
sdi file error.

Solution:
▪ Download the latest sdi file from DieselPort and start the restore process
once again.

5.2 Adjusting the speed governor parameters

The engine manufacturer has the option of adjusting the touchscreen param-
eters of the speed governor.

Important!
• The speed governor parameters are preset. Only change these
parameters if it is absolutely necessary to do so!
• The parameters can also be changed when the engine is running.
5 Software & parameters

The following table contains an overview of the speed governor parameters.

Parameter PAR Category Description Values
ID
Rate: Auto-Up 52202 Start This parameter specifies the rate at which Min. = 0.1 rpm/
2013-04-17 - 1.9

the engine speed increases per second dur- s

ing the engine start-up operation. Max. = 50 rpm/
s
Start Fuel: Quantity 1 55111 Start This parameter specifies the quantity of fuel Min. = 0 %
(in percent) that is injected during the engine Max. = 60 %
start-up operation.

50 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 5

Parameter PAR Category Description Values

5.2 Adjusting the speed governor parameters

ID
Start Fuel: Quantity 2 55112 Start If the starting speed is not reached during Min. = 0 %
the specified period, the speed governor Max. = 100 %
changes to Start Fuel Quantity 2. The
engine accelerates up to this fuel quantity
until the starting speed is reached.
Speed Governor P Adjust- 54001 Speed gov- The actuator speed can be adjusted via this Min. = 50 %
ment ernor parameter. Max. = 150 %
dynamic Value <100 %: actuator responds more
slowly.
Value >100 %: actuator responds more
quickly.
Speed Governor I Adjust- 54011 Speed gov- The actuator speed can be adjusted via this Min. = 50 %
ment ernor parameter. Max. = 150 %
dynamic Value <100 %: actuator responds more
slowly.
Value >100 %: actuator responds more
quickly.
Rate: Digital Speed Setting 52214 Load sharing This parameter defines the rate at which the Min. = 0.1 rpm/
speed falls with digital speed control. s
Max. = 20 rpm/
s
Fuel Quantity at Idle 53001 Load sharing Defines the quantity of fuel injected at idle. Min. = 0 %
Max. = 40 %
Fuel Quantity at Full Load 53002 Load sharing Defines the quantity of fuel injected at full Min. = 60 %
load. Max. = 100 %
Droop Value Digital Speed 53101 Load sharing Defines the droop value for regulation of Min. = 1 %
Set engine speed in droop mode. Max. = 10 %
Droop Value Analog Speed 53102 Load sharing Defines the droop value for regulation of Min. = 1 %
Set engine speed in isochronous load sharing Max. = 10 %
mode.
As long as this value is set to 0, the engine
is operated in droop mode
Maximum fuel limit 55501 Limiter This parameter defines the maximum quan- Min. = 0 %
tity of fuel injected. Max. = 100 %
Jump Rate Limiter: Jump 55602 Limiter This parameter limits the maximum increase Min. = 5 %
Limit in quantity of fuel injected during a load
5 Software & parameters

Max. = 100 %
application step.
Jump Rate Limiter: Unlimit 55603 Limiter This parameter defines the rate at which the Min. = 5 % per
Rate fuel quantity increases in percent once the second
Jump Limit (55602) has been reached. Max. = 1000 %
per second
2013-04-17 - 1.9

Adjusting the speed governor 1. Press the PARAMETERS SETTING button in the MISC menu.
parameters

SaCoS_one GENSET, Operating Instructions, EN 51 (136)

 5 MAN Diesel & Turbo

2. Press NEXT until page 3/4 GOVERNOR PARAMETERS appears.

5.3 Configuring the Gateway Module

3. Press the parameter value to be changed.

The on-screen keypad appears.
4. Enter the applicable value (see table above).
5. Press ENTER.
The value is saved automatically.
Restoring the preset The preset parameters of the speed governor are easily restored by pressing
parameters the RESTORE DEFAULT SETTINGS button.
1. Press the RESTORE DEFAULT SETTINGS button in the PARAMETERS
menu.

2. Press YES in the window that appears next to confirm you wish to
restore the settings.

Special feature The RESTORE DEFAULT SETTINGS button always starts flashing when a
new parameter set is loaded using the SaCoSone EXPERT. The following
5 Software & parameters

steps must be carried out in order to apply the new parameters:

1. Press the RESTORE DEFAULT SETTINGS button.
2. Press YES in the display window to apply the new parameters.
or:
Press NO to keep the old values.
In both cases the button stops flashing.
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5.3 Configuring the Gateway Module

Before the Gateway Module is used, the interface must be configured. Vari-
ous parameters must therefore be set via the SaCoSone Expert.

52 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 5

Note

5.3 Configuring the Gateway Module

The standard parameter values are preset.

5.3.1 Configuration of the Ethernet interface

1. Connect SaCoSone EXPERT to Gateway Module.
2. Adjust the parameters as shown in the table below.

3. Press "Save to flash".

4. Disconnect the Gateway Module from the network.
5. Reconnect the Gateway Module to the network. The connection with
the IP address can now be established as specified under Point 2.
Parameter PAR-ID Description
IP ETH1_byte1 45513 IP address of Ethernet 1 interface: byte 1
IP ETH1_byte2 45514 IP address of Ethernet 1 interface: byte 2
IP ETH1_byte3 45515 IP address of Ethernet 1 interface: byte 3
IP ETH1_byte4 45516 IP address of Ethernet 1 interface: byte 4
Subnet ETH1_byte1 45517 Subnet mask of Ethernet 1 interface: byte 1
Subnet ETH1_byte2 45518 Subnet mask of Ethernet 1 interface: byte 2
Subnet ETH1_byte3 45519 Subnet mask of Ethernet 1 interface: byte 3
Subnet ETH1_byte4 45520 Subnet mask of Ethernet 1 interface: byte 4
5 Software & parameters

IP ETH2_byte1 45521 IP address of Ethernet 2 interface: byte 1

IP ETH2_byte2 45522 IP address of Ethernet 2 interface: byte 2
IP ETH2_byte3 45523 IP address of Ethernet 2 interface: byte 3
IP ETH2_byte4 45524 IP address of Ethernet 2 interface: byte 4
Subnet ETH2_byte1 45525 Subnet mask of Ethernet 2 interface: byte 1
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Subnet ETH2_byte2 45525 Subnet mask of Ethernet 2 interface: byte 1

Subnet ETH2_byte3 45527 Subnet mask of Ethernet 2 interface: byte 3
Subnet ETH2_byte4 45528 Subnet mask of Ethernet 2 interface: byte 4

SaCoS_one GENSET, Operating Instructions, EN 53 (136)

 5 MAN Diesel & Turbo
5.4 Software and parameter backup

5.3.2 Configuration of the serial interface

Note:
It is not possible to apply an "Offset Register" at the Gateway Module.
The start address MW0 must always be used.

1. Connect the SaCoSone EXPERT to the Gateway Module.

2. Adjust the parameters as described in the table below.
3. Press "Save to flash".
Parameter PAR-ID Description
ModusSlvAddr 45316 Modbus slave address of Gateway Module for
serial MODBUS communication
ModusBaudRat 45317 Baud rate used for serial MODBUS communica-
tion Gateway Modules
ModusPty 45318 Parity bits used for serial MODBUS communica-
tion Gateway Modules
ModusNrStpBits 45319 Stop bits used for serial MODBUS communication
Gateway Modules

5.4 Software and parameter backup

SaCoSone GENSET supports software backups via the SaCoSone DEVICE
MANAGER. The backups are saved as sdi files and a special USB stick is
required for this. This USB stick is an integral part of the SaCoSone TOOL-
BOX. The SaCoSone DEVICE MANAGER creates a separate image file for
each module that contains the module software and parameters.

Caution!
Loss of data can cause engine failure.
When a defective module is replaced, it may not be possible to restore
the latest parameters. As the parameters regulate the most important
engine functions, if any parameters are missing or incorrect this could
lead to engine trouble.
5 Software & parameters

By backing up the parameters, you have a guarantee that they will

easily be restored after a module is replaced.
• Document changes to the parameters in the tables in the chapter
"Documentation of engine configuration"!
• As soon as a parameter is changed, a backup is required.
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54 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 5

Important!

5.4 Software and parameter backup

The procedure described here will only work with the MAN Diesel
Service Stick.
Other data must not be saved on this USB stick!

Performing a backup Before you start the backup operation, you must ensure that all CAN cables
of the system bus are connected and that the power supply is switched on.
1. Plug the MAN Diesel Service Stick into the USB port on the underside
of the Display Module.
The system now automatically saves image files for all modules on the
stick in sdi format. This operation can take several minutes during which
the progress is displayed at the top right-hand side of the screen.
2. Once the process is complete, a corresponding message is displayed
and the MAN Diesel Service Stick can be removed.
3. Enter all parameters as displayed in the PARAMETERS menu in the
corresponding standard form (cp. chapter "Documentation of engine
configuration").

5 Software & parameters

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SaCoS_one GENSET, Operating Instructions, EN 55 (136)

 6 MAN Diesel & Turbo

6 Configuration and tests

6.1 Configuration of the modbus interface

6.1 Configuration of the modbus interface

The SaCoSone GENSET allows configuration of the interface with the ship's
alarm system via Modbus RTU or Modbus ASCII.

Selection of You can select the required Modbus protocol from the PARAMETERS SET-
Modbus protocol TING
menu.

1. Press the MISC button in the MAIN MENU.

The MISC menu appears.

2. Press the PARAMETER SETTING button.

The PARAMETER SETTING menu appears. This consists of four screen

pages.
6 Configuration and tests

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56 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 6

3. Press the NEXT button in the navigation bar to go to page 4/4.

6.1 Configuration of the modbus interface

The PLC PARAMETERS menu appears.

4. Press ASCII or RTU to select the required Modbus protocol.

The green LED indicates which Modbus protocol was selected. Mod-
bus RTU was selected in the above example.

Setting the Modbus The Modbus Node ID can be set via the on-screen keypad.
Node ID 1. Tap the white input field in the MODBUS NODE ID line. The on-screen
keypad appears.
2. Enter value.
3. Press the Enter button on the on-screen keypad to confirm your input.
6 Configuration and tests

The value is saved automatically.

Setting the parity bit The parity bit can be set via pushbuttons:
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SaCoS_one GENSET, Operating Instructions, EN 57 (136)

 6 MAN Diesel & Turbo

Push button to deactivate parity bit.

6.1 Configuration of the modbus interface

Push button to use even parity bit.

Push button to use odd parity bit.

Setting the baud rate The baud rate can be set via pushbuttons
Push the button to set the baud rate to 4800 bd.

Push the button to set the baud rate to 9600 bd.

Push the button to set the baud rate to 19200 bd.

Push the button to set the baud rate to 38400 bd.

Push the button to set the baud rate to 57600 bd.

Push the button to set the baud rate to 115200 bd.

6 Configuration and tests

Important!
Changes to the parameters must be entered in the table in the chapter
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"Documentation of engine configuration"!

58 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 6

6.2 Documentation of engine configuration

6.2 Documentation of engine configuration
The configuration of the engine parameters must be documented following
the factory acceptance test. The relevant parameters are displayed on the
parameter settings screen page.

DOCUMENTATIONS PARAMETERS
Incorrect parameters may lead to malfunction during engine operation.
It is therefore helpful to print the following pages (PARAMETER page
1-4) and note down the values shown on the Display Module.

Displaying the parameters The parameters are displayed in the PARAMETERS SETTING menu. To view
the parameters, press the PARAMETER SETTINGS button in the MISC
menu. The screen page 1/4 PARAMETERS will then displayed. Using the
NEXT button, the remaining 3 pages will be displayed.

6 Configuration and tests

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SaCoS_one GENSET, Operating Instructions, EN 59 (136)

 6 MAN Diesel & Turbo
6.2 Documentation of engine configuration

6.2.1 Parameters on page 1 of 4

Note the values displayed on the screen page!
Parameter Parameter Value
ID
Engine type 13902

Cyl. No. 13901

(number of cylinders) 29501
Engine application 13903
29503
Classification 13905
Nominal engine speed 13907
(rpm)
TC speed alarm limit 21531
(turbocharger speed alarm limit) (rpm)
Alt. front bearing temp. alarm limit 22004
(alarm limit temperature front alternator bearing)
(°C)
Alt. rear bearing temp. alarm limit 22007
(alarm limit temperature rear alternator bearing)
(°C)
Alt. winding temp. alarm limit 22024
(alarm limit
alternator winding temperature) (°C)
Fuel oil press. filter inlet alarm lim. 22096
(fuel oil pressure alarm limit, filter inlet) (bar)
Fuel oil SW-over time (s) 29349
Fuel oil engine in SW temp.(°C) 29350
Remote shutdown delay (ms) 11961
Pulses per revolution (Turbocharger speed sen- 29517
6 Configuration and tests

sor)
Alt. cooling air alarm lim. 22015
(alarm limit temperature alternator cooling air) (°C)

6.2.2 Parameters on page 2 of 4

2013-04-17 - 1.9

Mark the displayed status in this table! If the LED on the page is green, the
parameter is set to TRUE. If the LED is grey, the parameter is set to FALSE.

60 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 6

Parameter Parameter Value

6.2 Documentation of engine configuration

ID
OMD function 13929

CCMON function 13931

Charge air relief valve 13932

Charge air shut off flap 13933

Alt. cooling water leakage alarm 29256

Jet assist 29546

Analog speed setpoint 29573

MGO operation 29520

Power output: 350kW/cyl. 29575

6 Configuration and tests

Jet assist at start 29555

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Charge air blow-off flap #1 29547

SaCoS_one GENSET, Operating Instructions, EN 61 (136)

 6 MAN Diesel & Turbo

Parameter Parameter Value

6.2 Documentation of engine configuration

ID
Charge air blow-off flap #2 29548

External alt. temperatures 29567

29568

Charge air preheater 29565

Nozzle cooling 29527

TC speed pickup inductive type 29518

Gali starter used 29574

6.2.3 Parameters on page 3 of 4 (governor parameters)

Enter the values displayed on this screen page in this table!
Category: start Parameter Value
Rate: auto-up
(rpm/sec)
Start fuel: Quantity #1
6 Configuration and tests

(%)
Start fuel: Quantity #2
(%)

Category: load distribution Parameter Value

2013-04-17 - 1.9

Rate: Digital Speed Setting

(rpm/sec)
Fuel quantity at idle
(%)

62 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 6

Parameter Value

6.2 Documentation of engine configuration

Fuel quantity at full load
(%)
Droop #1 value
(%)
Droop #2 value
(%)

Category: speed governor Parameter Value

dynamics
P adjustment
(%)
I adjustment
(%)

Category: limiter Parameter Value

Max Limit (Gov. Scale)
(%)
Jump limiter: Jump limit
(%)
Jump limiter: Unlimit rate
(%/sec)

6.2.4 Parameters on page 4 of 4 (PLC parameters)

Enter the values displayed on this screen page in this table!
Category: communication Parameter Value
protocol
Modbus Node ID
Offset register
Stop bits
Data bits
Parity
6 Configuration and tests

OFF

EVEN

ODD
2013-04-17 - 1.9

Baud rate
Protocol type: ASCII or RTU
ASCII

RTU

SaCoS_one GENSET, Operating Instructions, EN 63 (136)

 6 MAN Diesel & Turbo

Category: static pressure Parameter Value

6.3 Project-specific documents

HT Cooling Water pressure

(bar)
LT Cooling Water pressure
(bar)

6.2.5 Parameters for CoCoS-EDS via Gateway

These parameters only have to be documented if a Gateway Module is con-
nected. The parameters are displayed in the PLC-DIAG: GATEWAY MODUL
(-GM-) menu. Follow the instructions provided in the chapter "PLC diagnosis"
to display the parameters.
Parameter Value
ModusSlvAddr
ModusBaudRat
ModusPty
ModusNrStpBits
IP ETH1_byte1
IP ETH1_byte2
IP ETH1_byte3
IP ETH1_byte4
Subnet ETH1_byte1
Subnet ETH1_byte2
Subnet ETH1_byte3
Subnet ETH1_byte4
IP ETH2_byte1
IP ETH2_byte2
IP ETH2_byte3
IP ETH2_byte4
Subnet ETH2_byte1
Subnet ETH2_byte2
6 Configuration and tests

Subnet ETH2_byte3
Subnet ETH2_byte4

6.3 Project-specific documents

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6.3.1 General
SaCoSone GENSET must be approved by the major classification societies
(ABS, BV, DNV, GL, LR, RINA). Environmental and EMC tests on the mod-
ules are now complete and function tests on the system have been carried

64 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 6

out by the major classification societies. The main components of the system
(sensors, actuators, etc.) have been tested and approved by the above clas-

6.3 Project-specific documents

sification societies.

6.3.2 Checking the documents

The approval of a project-specific SaCoSone system must be implemented by
presenting the documentation as described in the chapter "List of docu-
ments to be checked". The scope of documents can vary depending on the
rules of the relevant classification society. These can be submitted "electroni-
cally" via an Internet portal or as a printout. The method used depends on
the requirements of the local branch of the classification society.

IMPORTANT!
The licensee must submit the required approval documents to the
classification societies!

6.3.3 Tests
General Testing of the most important components of the system such as SaCoSone,
Control Module, Display Module or speed governor is already underway at
the manufacturers. SaCoSone GENSET is being tested at MAN Diesel &
Turbo. During this test, the system hardware is also tested for correct func-
tionality.
MAN Diesel & Turbo prepares a report to verify that the test has been suc-
cessfully concluded.
System test Each project-specific SaCoSone system must be tested. The following are
tested:
▪ Correctness of the cable installation at the engine (sensors, power sup-
ply, etc.)
▪ Correctness of the configuration and parameter settings
A template for compiling corresponding test instructions is available from
MAN Diesel & Turbo. It may be necessary for the tests to be carried out by
an expert on behalf of the classification society. This depends on what the
requirements of the local branch of the society are. The test can be com-
bined with the factory acceptance test of the engine.
6 Configuration and tests

Tests carried out during During the factory acceptance test for an engine, the main functions of the
approval testing of the SaCoSone system are tested in the presence of a local expert who represents
engine the classification society. These comprehensive tests normally cover the
most important safety functions (e.g. automatic shutdowns in the event of
overspeeding and excessively low lube oil pressure) and the speed governor
functions (e.g. load application and load shedding). The scope of these tests
2013-04-17 - 1.9

is agreed with the local classification society.

Tests carried out when When commissioning an engine on board a ship, the classification societies
commissioning the engine may require that the alarm and safety functions are tested. This depends on
on board what the requirements of the local branch of the classification society are.
The above tests are normally carried out by a local expert on behalf of the
society.

SaCoS_one GENSET, Operating Instructions, EN 65 (136)

 6 MAN Diesel & Turbo

Documentation The documentation of the tests carried out is signed by the expert responsi-
ble for acceptance on behalf of the classification society. A copy must be
6.3 Project-specific documents

archived at the manufacturer's premises. Depending on the requirements of

the local branch, it may be necessary to send a copy to the classification
society.
The type plate of the SaCoSone system is stamped by the expert responsible
for acceptance once the factory acceptance test for the engine is complete.

6.3.4 Documents for class approval

No. Description Document type/Comment

1 System overview and operation
Operating instructions Description (customer ver-
sion)
System block diagram Block diagram
Scope of supply List
2 Measuring points and setpoints
List of measuring and control devices List
3 Interfaces
Power supplies Block diagram
Machine alarm system (interface description) Description
Machine alarm system (list of signals) List
4 Units off engine
VIT Cabinet (VIT only available at
L32/40))
Cabinet design drawing Drawing
Circuit diagram Drawing
5 Cabling off engine
Cable plan Drawing
Terminal list List (also valid for the
cable installation at the
engine)
6 Units at the engine
6 Configuration and tests

Control Unit
Cabinet design drawing Drawing
Circuit diagram Drawing
7 Cabling on engine
Cable of electrical units on engine (terminal con- Drawing
2013-04-17 - 1.9

nection diagram)

66 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 7

7 Operation of the engine

7.1 Operating stations

7.1 Operating stations

7.1.1 Local operation

The operator has full control over the engine via the Control Unit. In addition
to the touchscreen, hard-wired buttons and switches are installed for con-
trolling the engine speed and transferring the operator rights. The hard-wired
control system also works even if the touchscreen is not working.

Important!
The layout of the control elements is the same for all GenSets.

Operation at the Control Unit

7 Operation of the engine

2013-04-17 - 1.9

SaCoS_one GENSET, Operating Instructions, EN 67 (136)

 7 MAN Diesel & Turbo

Operating elements at the Control Unit

7.1 Operating stations

1 Touchscreen
The purpose of the touchscreen is to display measured values and operating
statuses. The operator has full control over the engine via the touchscreen. The
functions are described in the chapter "Layout of display".
2 "LOCAL/REMOTE" selector switch
Position "1" = Local, operation takes place at Control Unit.
Position "2" = Controlled remotely by a higher-level control system.
3 Rotary switch "LOWER/RAISE"
Turn the rotary switch to position 1 and hold to decrease the speed of the
engine incrementally.
Turn the rotary switch to position 2 and hold to increase the speed of the
engine incrementally.
4 "EMERGENCY STOP" pushbutton
The engine must be stopped immediately if physical injury or damage to the
engine is directly iminent. The engine stops immediately when the EMER-
GENCY STOP pushbutton is pressed.
The pushbutton locks and must be turned to release it before the emergency
stop can be reset.

7.1.2 Operation at the VIT cabinet

(only with L32/40 GenSet)
7 Operation of the engine

2013-04-17 - 1.9

Operation at the VIT cabinet

68 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 7

1 Indicator light "24 V DC OK"

7.2 Transfer of operating rights

The indicator light illuminates to indicate that power is being supplied to the
VIT cabinet.

7.1.3 External control (remote-controlled)

Control can be passed to an external system that regulates the engine start/
stop and reference speed.
The touchscreen of the Control Unit displays detailed status, operation and
error messages.

7.2 Transfer of operating rights

This chapter explains how the operating rights can be passed between the
various control stations.
The following positions are defined as controls:
▪ Local: Control Unit of engine
▪ Remote-controlled: external control system
The operating rights can be passed over via a switch. When the operating
rights are passed over, the following control functions are transferred to the
relevant system:
▪ Engine start
▪ Engine stop
▪ Control of coupling
▪ Regulation of engine speed
▪ Acknowledge and reset alarms
These functions can always only be performed by the system with the oper-
ating rights. These settings exclude emergency stops. An emergency stop is
possible from every operating station.
Transferring the operating The operating rights can be easily transferred between the Control Unit and
rights external automation system via the LOCAL/REMOTE selector switch. The
operating rights are passed immediately without further acknowledgement as
soon as the switch is turned. 7 Operation of the engine
2013-04-17 - 1.9

When the switch is in position "1", the Control Unit has the operating rights.
When the switch is in position "2", the external control system has the oper-
ating rights.

SaCoS_one GENSET, Operating Instructions, EN 69 (136)

 7 MAN Diesel & Turbo
7.3 Engine start

7.3 Engine start

7.3.1 Before starting the engine

Possibility of serious engine damage!

If the engine is shut down in order to carry out maintenance or repair
work, it must be sufficiently warmed up and prelubricated before it is
restarted.

System test When the power supply is switched on, SaCoSone GENSET starts automati-
cally after performing a self-test. As soon as the starting routine is complete,
all error messages on the Local Operating Panel must be acknowledged and
reset.

For detailed information on preparing the engine start, refer to the operating
instructions for the engine.

7.3.2 Starting block

The engine start is monitored by SaCoSone GENSET. It is not possible to start
the engine if one or several of the following criteria apply:
▪ The turning gear is engaged.
▪ Low prelubrication oil pressure.
▪ Stop by safety system (automatic shutdown).
▪ Emergency stop is active.
▪ Remote-controlled stop sequence is active.

7.3.3 Start menu

The start can be performed at the LOP. The operator can start the engine by
selecting the menu item ENGINE START/STOP SEQUENCE.
7 Operation of the engine

The operator must follow the on-screen steps during the starting routine. If a
fault occurs when starting the engine, the start is cancelled and all start
releases are reset. The engine can be restarted as soon as the engine is at a
standstill and the starting block has been cancelled.
Engine start/stop menu The following functions are available via the menu buttons. In this case, only
the button for the necessary action is active at any time:
2013-04-17 - 1.9

▪ START
▪ STOP
▪ RESET
▪ SHOW BLOCKINGS
▪ CONFIRMATION

70 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 7

Start engine 1. Press the ENGINE START/STOP button in the MAIN MENU.

7.3 Engine start

The ENGINE START/STOP SEQUENCE menu item appears.

2. Make sure that the manual turning operation has been performed.
3. If starting blocks are present, press the SHOW BLOCKINGS button to
display the list of active blocks. If not, continue with step 7.

7 Operation of the engine

2013-04-17 - 1.9

4. Correct all starting blocks.

SaCoS_one GENSET, Operating Instructions, EN 71 (136)

 7 MAN Diesel & Turbo

5. Press the ENGINE START/STOP button in the START

BLOCKING/FAILURE menu.
7.4 Engine stop

6. Press the START button.

7. Press CONFIRMATION. The engine is started.

Starting error Possible faults that can lead to the starting operation being aborted are:
▪ Insufficient engine prelubrication pressure.
▪ Starting speed not reached.
▪ Minimum speed not reached within a specific period.
▪ Double Pickup Error: If both speed sensors malfunction, the engine will
not start. An error message will not be displayed!

7.4 Engine stop

The engine stop is triggered by the Control Unit or an external control. The
engine stopping routine is controlled by SaCoSone, which also monitors relu-
brication and post-cooling.
Stopping the engine. 1. Press the ENGINE START/STOP button in the MAIN MENU.

The ENGINE START/STOP SEQUENCE menu item appears.

7 Operation of the engine

2013-04-17 - 1.9

2. Press the STOP button.

3. Press the CONFIRMATION button in the menu.
Follow the on-screen instructions to stop the engine.

72 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 7

Stopping sequence The engine stopping sequence starts when the operator presses the STOP
button in the ENGINE START/STOP SEQUENCE menu. This action must be

7.5 Safety functions

confirmed with the CONFIRMATION button to prevent the stop command
from being executed unintentionally.
The filling is set to zero which interrupts the ignition routine. The engine can-
not be restarted while the engine speed is decreasing and before the engine
has come to a standstill.
Once the engine has reached the standstill speed, a monitoring period starts
to verify that the engine is actually at a standstill.

7.5 Safety functions

SaCoSone GENSET monitors the operating data of the engine and initiates the
necessary processes, e.g. alarms and automatic shutdown, if limit values are
exceeded.

7.5.1 Alarms
An alarm is the first level of a safety function and is triggered if the operating
values increase or fall below a specific alarm limit. Alarms are displayed as
messages on the touchscreen.
E.g.: if the main bearing temperature increases, an alarm is triggered once an
alarm limit has been reached. If the increase continues, an automatic shut-
down is initiated.

7.5.2 Automatic shutdown

The safety system of the SaCoSone GENSET monitors the engine operating
values and triggers an automatic shutdown as soon as a limit value is excee-
ded. The engine is then stopped immediately by actuating the stop valve. An
automatic shutdown by the plant control system via binary contacts can also
be configured. In contrast to an emergency stop, an automatic shutdown is
performed by SaCoSone GENSET and not by the user.
The engine is switched off immediately in any of the following cases.

Shutdown criteria The criteria that bring about an automatic engine stop by the safety system
are listed below.
7 Operation of the engine

▪ Engine overspeed.
▪ Failure of both speed transmitters.
▪ Lube oil pressure at the engine inlet too low.
▪ HT cooling water temperature at the outlet is high.
▪ High bearing temperature/temperature deviation from Crankcase Moni-
2013-04-17 - 1.9

toring System (optional).

▪ High oil mist concentration in crankcase (optional).
▪ Other optional remote-controlled shutdown processes:
- Differential protection.
- Earthing jumper closed.
- Gas leak.

SaCoS_one GENSET, Operating Instructions, EN 73 (136)

 7 MAN Diesel & Turbo

For additional information see list of measuring points (LMC).

7.5 Safety functions

Note:
Contrary to information in the turbocharger documentation which
states otherwise, an automatic shutdown does not occur with GenSets
if the turbocharger lube oil pressure is too low! Oil is also supplied to
the turbocharger via the lube oil supply to the engine which means
lube oil pressure is monitored at the engine entry point.

Shutdown routine If several parameters exceed defined values and this poses a risk of damage
(e.g.: overspeed, extremely low lube oil pressure), an engine stop is required.
The safety system stops the engine automatically.
Following an automatic shutdown, the operation must be acknowledged and
reset at the touchscreen.

7.5.3 Emergency stop

In cases where physical injury or engine damage is iminent, the engine must
be switched off immediately. The emergency stop effects an immediate shut-
down of the engine. The emergency stop does not depend on operating
rights and can be triggered from any operating station.

Location of emergency stop An EMERGENCY STOP pushbutton is mounted on the Control Unit. Addi-
devices tional emergency stop buttons (not included in the MAN Diesel & Turbo
scope of delivery) can be installed in machine or control rooms.

Emergency stop at Control Press the EMERGENCY STOP pushbutton on the Control Unit. The engine is
Unit switched off immediately.
The button engages and must be pressed again before the emergency stop
can be reset via the touchscreen.

7.5.4 Request for a load reduction

A load reduction is requested by the higher-level control system. This request
is transmitted via a potential-free binary contact. As soon as the higher-level
control system receives the signal, the engine load must reduce to 60 %.
7 Operation of the engine

Request by the VIT

Only applies for engine type L32/40

2013-04-17 - 1.9

The function described below only exists in engine type L32/40!

74 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 7

The actual position of the VIT servo-drive is monitored. If the signaled posi-
tion does not correspond to the target position of the VIT (a positioning delay

7.5 Safety functions

is also taken into account), the VIT automatically changes to emergency
mode. In emergency mode, the VIT is moved to a safe position (2GOS1028)
in which safe operation of the engine is guaranteed.
A load reduction is requested if:
▪ the VIT does not reach the safe position in emergency mode. This is indi-
cated by the on-screen message 40580 -RED: EMERGENCY MODE
ERROR.
▪ SaCoSone GENSET identifies a CAN communication error with the PLC
inside the VIT cabinet.
▪ there is no power supply to the VIT cabinet.
The positioning error, emergency mode error and communication error can
be acknowledged and reset at the touchscreen at any time. The VIT reverts
to normal operation and attempts to reach the target position. If this is not
possible, the error will occur again.

Request when exhaust gas temperature at turbocharger inlet is too

high

Applies only for engine types L27/38 and L32/40 with DNV
classification
The request for load reduction described below only applies for engine
types L27/38 and L32/40 and a DNV classification (Det Norske Veritas).
The function is activated automatically when the parameter for the
classification society is set to DNV.

As soon as the exhaust gas temperature at the turbocharger inlet exceeds

the corresponding limit, SaCoSone GENSET requests a load reduction from
the higher-level control system.
7 Operation of the engine

7.5.5 Emergency Generator Mode

In Emergency Generator Mode, the operator can override the safety func-
tions of SaCoSone GENSET in critical situations (when entering the port, when
navigating difficult passages, etc.). Emergency Generator Mode is available
for the following safety functions:
▪ Automatic shutdown.
2013-04-17 - 1.9

▪ Automatic load reduction.

SaCoS_one GENSET, Operating Instructions, EN 75 (136)

 7 MAN Diesel & Turbo

IMPORTANT!
7.5 Safety functions

Emergency Generator Mode must be activated as a preventative

measure before a safety function is triggered.
If Emergency Generator Mode is activated, this does not reset the
safety functions that have already been triggered

Sequence Emergency Generator Mode is activated from afar as a preventative measure

before carrying out difficult manoeuvres.
When the Emergency Generator Mode is activated, this is signalled via the
MODBUS and displayed at the LOP.
If an automatic stop or load reduction alarm is triggered in Emergency Gen-
erator Mode, this is signalled via the MODBUS and displayed at LOP.

7.5.5.1 Activation of Emergency Generator Mode

Total loss due to incorrect operation

The Emergency Generator Mode function represents a major
intervention in the safety system.
Safety functions that are otherwise implemented automatically to
protect the engine are suppressed.
Only a warning is displayed, the operator himself then decides what
action to take in relation to shutting down the engine or reducing the
load and, if this is necessary, does so manually. The operator therefore
assumes responsibility for all consequences and damage arising as a
result of these actions!

The Emergency Generator Mode button(s) (not included in the MAN Diesel &
Turbo scope) is (are) on the bridge. The Emergency Generator Mode is acti-
vated when the button is pressed.

If Emergency Generator Mode is already active when the engine is started,

the speed governor attempts to bring the engine up to its rated speed as
quickly as possible. This function is intended for use in emergencies, e.g.
black out.
7 Operation of the engine

The information that Emergency Generator Mode has been activated

appears in the MAIN MENU.
The corresponding alarm message appears in the Alarm Bar.
2013-04-17 - 1.9

76 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 7

7.5 Safety functions

7 Operation of the engine

7.5.5.2 Deactivation of Emergency Generator Mode

2013-04-17 - 1.9

Press the Emergency Generator Mode button again to cancel Emergency

Generator Mode.

SaCoS_one GENSET, Operating Instructions, EN 77 (136)

 7 MAN Diesel & Turbo
7.6 Speed control

7.6 Speed control

The operator can regulate the engine speed manually at the Control Unit
(CU). The engine speed can also be regulated using an external control sys-
tem.

Important!
Operating rights required. The speed of the engine can only be
controlled from the operating station if the operating rights have been
assigned to it.

7.6.1 At the Control Unit

The operator can control the speed of the engine via the LOWER/RAISE
rotary switch at the Control Unit.

Reducing the speed Turn the LOWER/RAISE rotary switch to LOWER and hold. The speed
reduces incrementally for as long as the switch is held at LOWER.

Increasing the speed Turn the LOWER/RAISE rotary switch to RAISE and hold. The speed increa-
ses incrementally for as long as the switch is held at RAISE.

7.6.2 At an external control

For information on regulating the speed via an external control, refer to the
manufacturer's operating instructions.
7 Operation of the engine

2013-04-17 - 1.9

78 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 8

8 Functions of the touchscreen

8.1 Layout of the display

8.1 Layout of the display

1 Header 4 Alarm line

2 Status line 5 Horizontal navigation bar
3 Info panel

8.1.1 Header
A brief description of the current page appears in the header.
If the contents take up more than one page, the page number and total
number of pages is displayed on the left.
8 Functions of the touchscreen
The addresses of PrimeServ facilities can be displayed via the MAN Logo.
2013-04-17 - 1.9

SaCoS_one GENSET, Operating Instructions, EN 79 (136)

 8 MAN Diesel & Turbo
8.1 Layout of the display

Additional service centres Press the relevant flag to display the information for service centres in Den-
mark, France or the United Kingdom.
Press the WORLDWIDE button in the navigation bar to display an overview of
service telephone numbers worldwide.
8 Functions of the touchscreen

2013-04-17 - 1.9

8.1.2 Status line

The status line is below the header. It contains the following data:
▪ engine speed in rpm
▪ filling in %.

80 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 8

8.2 Buttons and display elements

8.1.3 Info panel
The layout of the info panel is different on each page. Menus and overviews
of measured values are displayed.
You can jump to the required menu by pressing the relevant button in the
info panel, e.g. in the MAIN MENU (see above).

8.1.4 Alarm line

The alarm line is below the info panel. The most recent alarm is displayed
here. The alarm line is always in the same place.

8.1.5 Horizontal navigation bar

The horizontal navigation bar is below the alarm line and contains menu and
function buttons that vary depending on which menu is displayed.

8.2 Buttons and display elements

8.2.1 General information

Active & inactive Standard of a button in the
buttons info panel. Press the button to start the corresponding func-
tion.

If the text is greyed out, the function is not available.

8 Functions of the touchscreen

Empty buttons Buttons without text have no function assigned to them and
serve only as placeholders.
2013-04-17 - 1.9

8.2.2 Buttons in the navigation bar

Important menus Buttons for important menus can be found in the navigation bar.

SaCoS_one GENSET, Operating Instructions, EN 81 (136)

 8 MAN Diesel & Turbo

Press this button to display the MAIN MENU.

8.2 Buttons and display elements

Press this button to display the MAIN OVERVIEW.

Navigation The LAST SCREEN button appears in every menu.

You can scroll back through the last nine pages that were displayed.
Press the button once to go back on page.

The following buttons are displayed if the overview takes up more than one
page:
Press this button to go back to the previous page (only menus with
more than one page).

Press this button to go to the next page (only menus with more than
one page).

8.2.3 Displaying measured values

Speed indication The speed is displayed via a tachometer and as an absolute value
8 Functions of the touchscreen

Different colours are assigned to the speed ranges.

Colour Speed range
Green Rated engine speed.
Yellow Abnormal engine speed:
2013-04-17 - 1.9

Only during engine starts / stops.

Red Overspeed.

Temperatures and pressures Temperatures and pressures are displayed in the form of bar charts and as
an absolute value. The colour of the bar indicates the following states:

82 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 8

Green:

8.3 Main Overview

Sensor OK
Value OK
Yellow:
Alarm
Red:
Automatic shutdown or load reduction.

8.2.4 Status display

Pump status All electric pumps that are controlled and monitored by SaCoS are displayed
in a separate menu. The corresponding symbol is green while the pump is
running, otherwise it is grey.
Pump on

Pump off

Status LED The status of several functions is indicated by the colour of an LED:
Green:
▪ Automatic control
▪ Function OK
▪ Operation is active
Red:
▪ Alarm(s) (an error has occurred)
▪ Function suppressed / blocked
▪ Critical state
No colour:
▪ Operation is inactive. 8 Functions of the touchscreen

8.2.5 Input fields and on-screen keypad

The operator can modify a number of default values. Every value displayed
on a white background can be modified by touching the field.

The on-screen keypad via which new values can be entered appears. The
2013-04-17 - 1.9

on-screen keypad also shows the permissible range of the value selected.

8.3 Main Overview

When the SaCoSone GENSET is started, the display switches on automati-
cally and the MAIN OVERVIEW appears.

SaCoS_one GENSET, Operating Instructions, EN 83 (136)

 8 MAN Diesel & Turbo

It is possible to jump to the MAIN OVERVIEW from other menus by pressing

the button with the same name in the navigation bar.
8.3 Main Overview

The MAIN OVERVIEW shows the most important operating values:

1 Engine speed 4 Status line

2 Info panel 5 Alarm line
3 Start status 6 Navigation bar

The following functions are described in separate chapters and are therefore
not dealt with here:
▪ Engine speed (see chapter "Layout of display")
▪ Alarm line (see chapter "Layout of display")
8 Functions of the touchscreen

▪ Navigation bar (see chapter "Layout of display")

8.3.1 Info panel

Important operating values of the engine are displayed in the info panel.
Depending on the engine configuration, these include:
▪ ENGINE SPEED in rpm.
▪ SPEED TC (turbocharger speed) in rpm.
2013-04-17 - 1.9

▪ HT-COOL.WATER ENGINE INLET pressure in bar (psi).

▪ STARTING AIR pressure in bar (psi).
▪ LUBE OIL ENGINE INLET outlet pressure in bar (psi).
▪ LUBE OIL FILTER INLET pressure in bar (psi).
▪ LT-CW CA-COOLER INLET pressure after cooler in bar (psi).

84 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 8

▪ CHARGE AIR COOLER OUTLET in bar (psi).

8.4 Main Menu

▪ LUBE OIL TC INLET pressure in bar (psi).
▪ FUEL OIL ENGINE INLET pressure in bar (psi).
▪ ALTERNATOR POWER in KW.
▪ WORKING HOURS in h.

8.3.2 Start status

The START STATUS field is on the info panel. It shows current messages on
operations that are currently active in the engine.

▪ START PREPARATIONS
Engine prelubrication and preheating in progress.
▪ ACCELERATION
Engine starting routine in progress.
▪ RUNNING
Engine running; engine stop is blocked (e.g. by engaging clutch).
▪ ENGINE IS STOPPING
Engine stopping routine is in progress.
▪ STANDSTILL
Engine at standstill.

8.3.3 Status line

The status line shows the status of operations and settings.

8.4 Main Menu 8 Functions of the touchscreen

Access Press the MAIN MENU button to access the main menu. This button
appears on the bottom left of each screen page.

The main menu appears.

2013-04-17 - 1.9

Each button in the info panel provides a link to the corresponding submenu.

SaCoS_one GENSET, Operating Instructions, EN 85 (136)

 8 MAN Diesel & Turbo
8.5 Main functions

8.5 Main functions

This chapter describes the following functions of the MAIN MENU:
▪ Exhaust gas
▪ VIT
▪ Fuel
▪ Cooling water
▪ Air
▪ Lubricating oil
▪ Media overview
▪ Engine status
▪ Accessories on the engine
▪ Cylinder lubrication (L32/40)
8 Functions of the touchscreen

▪ Alternator (only if SaCoSone GENSET is monitoring the alternator temper-

ature).

The following menus are described in other chapters:

▪ Alarm groups
see chapter "Alarm handling".
▪ Misc
see chapter "MISC".
2013-04-17 - 1.9

▪ Engine start/stop
see chapter "Start menu".

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 MAN Diesel & Turbo 8

8.5 Main functions

8.5.1 Exhaust gas
Access Press the EXHAUST GAS button in the MAIN MENU.

Temperature values The EXHAUST GAS menu appears.

The exhaust gas temperature values are displayed as an absolute value and
in the form of a bar chart.

The exhaust gas temperature of every cylinder is displayed. The temperature

of the exhaust gas when it enters and exits the turbocharger is also dis-
played. Mean value deviations and the sensor status can also be displayed in
this menu by pressing the relevant buttons in the navigation bar.
8 Functions of the touchscreen
Mean value deviation To display mean value deviations of the measured values, press MEAN
VALUE DEVIATION in the navigation bar.

The exhaust gas temperature deviation is displayed per cylinder in the form
of a bar chart. The maximum permissible deviation appears at the top of the
2013-04-17 - 1.9

scale, the mean value appears below this and the minimum permissible devi-
ation appears at the bottom.

SaCoS_one GENSET, Operating Instructions, EN 87 (136)

 8 MAN Diesel & Turbo

Exhaust gas temperatures at the turbocharger inlet and outlet are not inclu-
ded in monitoring of the mean value deviation.
8.5 Main functions

Sensor Status Press the SENSOR STATUS button in the horizontal navigation bar.

The status of the exhaust gas temperature sensors is now displayed as text
on the screen.
8 Functions of the touchscreen

2013-04-17 - 1.9

The sensor status is indicated by the following messages:

88 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 8

Status message Meaning

8.5 Main functions

OK Sensor is working. No alarms due to wire break, etc.
SENSOR FAULT Sensor fault: wire break or malfunction.
PRE_ALARM MAX/MIN The value measured by the sensor is lower or higher
than the minimum or maximum pre-alarm value.
PRE_ALARM MVD The value measured by the sensor has exceeded the
maximum permissible mean value deviation. A pre-alarm
is triggered.
SLOW DOWN MAX/MIN The value measured by the sensor has exceeded the
maximum or minimum slow down value.
SLOW DOWN MVD The value measured by the sensor has exceeded the
minimum permissible mean value deviation. A pre-alarm
is triggered.
SHUTDOWN MAX/MIN The value measured by the sensor is lower or higher
than the minimum or maximum shutdown value.
SHUTDOWN MVD The value measured by the sensor has exceeded the
maximum permissible mean value deviation for shut-
down.
CUT-OFF The sensor has delivered an implausible value and is
therefore being excluded from the mean value calcula-
tion.

Important note:
Measured values are no longer displayed if a sensor error alarm or a
sensor cut-off alarm occurs. The value "0" is displayed instead. The
error messages for the sensor error alarm and sensor cut-off alarm
must therefore always be acknowledged and reset. Measured values
will only be displayed again once this has been done.

8 Functions of the touchscreen

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SaCoS_one GENSET, Operating Instructions, EN 89 (136)

 8 MAN Diesel & Turbo
8.5 Main functions

8.5.2 VIT
Access Press the VIT button in the MAIN MENU.

Example The VIT menu is displayed.

The overview shows all VIT relevant values and status, as well as the injection
position.

In addition, the VIT-reference value and the position feedback signal are dis-
8 Functions of the touchscreen

played.
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90 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 8

8.5 Main functions

8.5.3 Fuel
Access Press FUEL button in MAIN MENU.

Example The FUEL menu is displayed.

All measured values are absolute and are displayed graphically in the form of
a bar chart. The type of fuel (HFO / MDO) is also displayed.

The values displayed may vary depending on the engine configuration. 8 Functions of the touchscreen
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SaCoS_one GENSET, Operating Instructions, EN 91 (136)

 8 MAN Diesel & Turbo
8.5 Main functions

8.5.4 Cooling water

Access Press the COOL.WATER (cooling water) button in the MAIN MENU.

Example The COOL. WATER menu is displayed.

All measured values are absolute and are displayed graphically in the form of
a bar chart.

Display of A pump symbol indicates the status of the HT cooling water preheating:
HT cooling water preheating
8 Functions of the touchscreen

HT cooling water preheating requested. Pump is running.

No preheating request. Pump at standstill.

Status of thermostat The following status of the thermostat can be displayed:

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Normal operation

Thermostat (TSH12) at the engine inlet has triggered a shutdown (HT

cooling water temperature). An alarm message is displayed.

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8.5 Main functions

8.5.5 Air
Access Press the AIR button in the MAIN MENU.

Example The AIR menu is displayed.

All measured values are absolute and are displayed graphically in the form of
a bar chart.

The values displayed vary depending on the engine configuration.

8 Functions of the touchscreen
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SaCoS_one GENSET, Operating Instructions, EN 93 (136)

 8 MAN Diesel & Turbo
8.5 Main functions

8.5.6 Lube Oil

Access Press the LUBE OIL button in the MAIN MENU.

Example The LUBE OIL menu is displayed.

All measured values are absolute and are displayed graphically in the form of
a bar chart.

Display values vary depending on engine configuration.

Status of pressure switch The LED indicates whether the pressure triggered a shutdown due to insuffi-
cient lube oil pressure at the engine inlet.
8 Functions of the touchscreen

Normal operation

Pressure switch has triggered a shutdown. Lube oil pressure is too

low. An alarm message is indicated.

Lube oil pump request The status of the lube oil is represented by means of a pump symbol:
Pump is running.
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Pump is in standstill.

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8.5 Main functions

8.5.7 Media overview
Access Press the MEDIA OVERVIEW button in the MAIN MENU.

The MEDIA OVERVIEW menu appears.

Media overview - screen 1 of 2
▪ Fuel values
▪ Air values
▪ Cooling water values
▪ Lubricating oil values.

8 Functions of the touchscreen

Press the NEXT button to display MEDIA OVERVIEW screen 2 of 2.

Media overview - screen 2 of 2

▪ Charge air values
▪
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Alternator values
▪ Performance data
▪ Speed values.

SaCoS_one GENSET, Operating Instructions, EN 95 (136)

 8 MAN Diesel & Turbo
8.5 Main functions

Press BACK to go back to screen 1 of 2.

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 MAN Diesel & Turbo 8

8.5 Main functions

8.5.8 Engine status
Access Press the ENGINE STATUS button in the MAIN MENU.

Example The ENGINE STATUS menu appears.

This screen page provides an overview of the switching state of the engine's
digital outputs. If a status LED lights up, the corresponding signal is forwar-
ded to an external control system.

The LOAD REDUCTION REQUEST line is only displayed with L32/40 engines
8 Functions of the touchscreen
as these are the only models in which the VIT can trigger a request for load
reduction.
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SaCoS_one GENSET, Operating Instructions, EN 97 (136)

 8 MAN Diesel & Turbo
8.5 Main functions

8.5.9 Equipment attached to the engine

Access Press the ENGINE ATTACHED EQUIPMENT button in the MAIN MENU.

Example The ENGINE ATTACHED EQUIPMENT menu is displayed.

An overview of the accessories attached to the engine appears. If the LED
lights up, the component is installed.

The LED in the DROOP/ISOCHRON MODE line lights up green when the
engine is running with isochronous load distribution.
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 MAN Diesel & Turbo 8

8.5 Main functions

8.5.10 Cylinder lubrication (L32/40)
Access Press the MANUAL OPERATIONS button in the MAIN MENU.

Example
The MANUAL OPERATIONS menu appears. The content of the info panel
depends on the type of engine.
This function and corresponding buttons is not available for engine types
L16/24, L21/31 and L27/38.

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SaCoS_one GENSET, Operating Instructions, EN 99 (136)

 8 MAN Diesel & Turbo

Special feature of L32/40

8.5 Main functions

The buttons via which cylinder lubrication is manually controlled are only
available with L32/40. The operating status of the cylinder lubrication is also
displayed. The available buttons have the following functions:
Activation/deactivation of manual cylin-
der lubrication.

Cylinder lubrication: change to automatic

mode.
In automatic mode, the cylinder lubrica-
tion only operates when the engine load
is higher than 50 %.
Cylinder lubrication: change to run-in
mode.
8 Functions of the touchscreen

In run-in mode, the cylinder lubrication

operates continuously irrespective of the
engine load when the engine is started.
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 MAN Diesel & Turbo 8

8.5 Main functions

8.5.11 Generator
Access Press the ALTERNATOR button in the MAIN MENU.

Example The ALTERNATOR menu is displayed.

This display overview shows the bearing and winding temperatures of the
alternator if the sensors are connected to the SaCoSone.

The display values vary depending on the which sensors are installed with
the alternator.
8 Functions of the touchscreen
The values that are displayed depend on which sensors are installed with the
alternator.
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SaCoS_one GENSET, Operating Instructions, EN 101 (136)

 8 MAN Diesel & Turbo
8.6 MISC

8.6 MISC
The MISC menu and the following submenus are described in this chapter:
▪ Date / Time
▪ Diagnosis display
▪ Screen brightness adjustment
▪ Project info
▪ Parameters / Emission Identifier
▪ Parametrisation
▪ PLC diagnosis
▪ Service
▪ Language settings.

The ALL ALARMS menu and the processing of alarms is described in the
chapter "Alarm handling".
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 MAN Diesel & Turbo 8

8.6 MISC
8.6.1 Overview
Access Press the MISC button in the MAIN MENU.

Example The MISC menu which contains the following overview is displayed.

The individual menus can be accessed via the buttons in the info panel.
Cleaning the touchscreen Press the TOUCHSCREEN CLEANING button in the horizontal navigation
bar to obtain information on cleaning the display.
While this screen is active, all functions of the touchscreen are deactivated
8 Functions of the touchscreen
so it can be cleaned without a problem. The buttons are reactivated after 30
seconds and the MAIN OVERVIEW reappears.
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SaCoS_one GENSET, Operating Instructions, EN 103 (136)

 8 MAN Diesel & Turbo
8.6 MISC

8.6.2 Date / Time

Access Press the DATE & TIME button in the MISC menu.

Example The DATE & TIME menu where the date and time can be changed appears.

Current time display The date and time are displayed on the top right-hand side of the info panel.

Changing the date and time The user can change the date and time
8 Functions of the touchscreen

1. by tapping the value to be changed.

The on-screen keypad appears.

2. Enter the required value via the on-screen keypad.
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3. Press Enter to confirm the changes.

The on-screen keypad then disappears.
4. Press the ADJUSTMENT OF DATE/TIME button to save the changes.

The new values are saved and applied on the screen.

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8.6 MISC
8.6.3 Diagnosis display
Access Press the DISPLAY DIAGNOSTIC button in the MISC menu.

Example The DISPLAY DIAGNOSTIC menu which contains up-to-date information on

the PLC of the Display Module appears.

The following information is displayed:

▪ Type of application (e.g. Genset).
8 Functions of the touchscreen
▪ Load of PLC program
▪ CPU temperature.
▪ Firmware version.
▪ Serial no. of module.
▪ PLC software version of CM at the safety system.
▪ Date of programming of DM at the safety system.
▪ Engine information (engine type, number of cylinders, engine serial num-
ber).
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SaCoS_one GENSET, Operating Instructions, EN 105 (136)

 8 MAN Diesel & Turbo
8.6 MISC

8.6.4 Screen brightness adjustment

Access The brightness of the display can be modified as follows:
1. Press the DISPLAY BACKLIGHT CONTROL button in the MISC menu.

Example 1. The DISPLAY BACKLIGHT CONTROL menu with test image and sliding
switch appears.

2. Adjust the display brightness via the "+" or "-" button.

0 %= maximum brightness
100 %= minimum brightness.
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 MAN Diesel & Turbo 8

8.6 MISC
8.6.5 Project Info
Access Press the PROJECT INFO button in the MISC menu.

Example The PROJECT INFO menu which shows up-to-date information on the
engine and its software appears.

The following detailed information is shown in this menu:

▪ Type of plant (ship or stationary)
▪ Operating hours (during normal operation)
8 Functions of the touchscreen
▪ Operating hours with overload
▪ PLC Software versions
▪ Date when parameters were last set
▪ Version of display software
▪ Engine details
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SaCoS_one GENSET, Operating Instructions, EN 107 (136)

 8 MAN Diesel & Turbo
8.6 MISC

8.6.6 Parameters / Emission Identifier

Access Press the PARAMETERS / EMISSION IDENTIFIER button in the MISC menu.

Example The PARAMETERS / EMISSION IDENTIFIER menu with the IMO-Emission-

Identifier appears.
The time the parameters were last modified is also displayed.
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8.6 MISC
8.6.7 Simulation
Access Press the SIMULATION button in the MISC menu.

The SIMULATION menu is displayed. Different operating values can be simu-

lated in the Simulation menu for testing operation.

Deactivating the wire break Press the DISABLE REMOTE SIGNALS WIRE BRAKE SUPERVISION button
monitoring system to switch off the wire break monitoring of digital remote signals.
Test of engine overspeed The purpose of the TESTBED OPERATION function is to test the shutdown
8 Functions of the touchscreen
shutdown function if the engine is overspeeding. When testing the engine overspeed
shutdown, the overspeed shutdown limit is lowered to 85 %. This means the
shutdown is triggered before the engine reaches its rated speed and can be
tested without putting the engine in a potentially dangerous operating state.
1. Press the TESTBED OPERATION button to display the OVERSPEED
ENGINE TEST button.
2. Press the OVERSPEED ENGINE TEST OFF button to start the test.
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3. The appearance of the button changes while this function is active.

SaCoS_one GENSET, Operating Instructions, EN 109 (136)

 8 MAN Diesel & Turbo

Press the button again to deactivate the function.

8.6 MISC

Test of turbocharger The purpose of the TESTBED OPERATION function is to test the shutdown
overspeed shutdown function if the turbocharger is overspeeding. When testing the turbocharger
overspeed shutdown, the overspeed alarm limit is lowered to 20 %. This
means the shutdown is triggered before the turbocharger reaches its rated
speed and can be tested without putting the turbocharger in a potentially
dangerous operating state.
1. Press the TESTBED OPERATION button to display the OVERSPEED
TC TEST button.
2. Press the OVERSPEED TC TEST OFF button to start the test.

3. The appearance of the button changes while this function is active.

Press the button again to deactivate the function.

Releasing the safety system This function makes it possible to test several functions of the safety system
with the engine at a standstill, as otherwise these functions could only be
tested with a specific filling or engine speed with the engine running. The
safety system can therefore be released manually when the engine is at a
standstill.
Safety system is not released for the test
operation.

Safety system is released for the test

operation.
It is deactivated automatically after 30
minutes.
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8.6 MISC
8.6.8 Parametrisation
The PARAMETERS SETTING menu is a screen that provides an overview of
all engine-specific parameters. Most of these parameters are preset and, in
contrast to the speed governor parameters, cannot be modified by the user.

Data loss may cause engine problems!

Once a defective module has been replaced, it may not be possible to
restore the most recent parameters. If the parameters are set
incorrectly this can lead to problems with engine operation.
• Make a note of all parameters in the tables in the chapter
"Documentation of engine configuration".
• Each time a parameter is changed it is necessary to perform a backup
afterwards.

Displaying the menu Press the PARAMETERS SETTING button in the MISC menu.

Screen page 1/4 PARAMETERS shows the engine and system-specific

parameters in addition to preset parameters.

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Screen 2/4 PARAMETERS contains info parameters.

SaCoS_one GENSET, Operating Instructions, EN 111 (136)

 8 MAN Diesel & Turbo
8.6 MISC

Screen 3/4 Governor PARAMETERS provides an overview of all parameters

relevant to the speed governor.
The user can change these values.

The chapter "Adjusting the speed governor parameters" provides an exact

description of how to make and restore the standard parameter settings.
8 Functions of the touchscreen

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 MAN Diesel & Turbo 8

Screen 4/4 PLC PARAMETERS provides an overview of all parameters for

the communication protocol and static pressures. These parameters can be

8.6 MISC
modified by the user.
For details on the communication protocol setup, refer to the chapter "Con-
figuration of the modbus interface"

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SaCoS_one GENSET, Operating Instructions, EN 113 (136)

 8 MAN Diesel & Turbo
8.6 MISC

8.6.9 Starting blocks and errors (optional)

Access Press the START- / BLOCKINGS & FAILURES button in the ENGINE START/
STOP SEQUENCE menu.

Example The START- / BLOCKINGS & FAILURES menu appears. This overview con-
tains all active starting blocks (i.e. criteria that prevent an engine start) and
starting errors (i.e. criteria that lead to the starting process being aborted).
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 MAN Diesel & Turbo 8

8.6 MISC
8.6.10 PLC diagnosis
Access Press the PLC DIAGNOSTIC button in the MISC menu.

or:
Press the PLC DIAGNOSTIC button in the navigation bar of the PROJECT
INFO menu.

Example The PLC DIAGNOSTIC menu is displayed.

8 Functions of the touchscreen

Functions of the buttons A range of information on the modules and their features (firmware and soft-
ware) can be displayed in this menu.
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SaCoS_one GENSET, Operating Instructions, EN 115 (136)

 8 MAN Diesel & Turbo

Press this the button to display the over-

8.6 MISC

view:
PLC-DIAG.: ENGINE CONTROL (-CM-).
Press this the button to display the over-
view:
PLC-DIAG.: DISPLAY MODULE (-DM-).
Press this the button to display the over-
view:
PLC-DIAG.: GATEWAY MODULE (-
GM-).

PLC diagnosis: engine The example shows the overview PLC-DIAG.: ENGINE CONTROL (-CM-).
control (example)

The following information is displayed here:

▪ Type of engine installation (marine/stationary/GenSet)
▪ Relative load of PLC program
▪ CPU temperatures
8 Functions of the touchscreen

▪ Emission Identifier (only Control Module)

▪ Firmware version
▪ Serial number of module
▪ Version of PLC software
▪ Date of parametrisation
▪ Engine type
▪ Engine number
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Note:
The information in the PLC-DIAG.: Display Module (-DM-) overview in
virtually identical, apart from the Emission Identifier!

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 MAN Diesel & Turbo 8

PLC diagnosis: The example screenshot shows the PLC-DIAG.: ENGINE CONTROL (-GM-)
overview. The PLC-DIAG. Display Module (-DM-) overview contains virtually

8.6 MISC
Gateway Module (example)
the same information.

The following information is displayed:

▪ Type of engine installation (marine/stationary/GenSet)
▪ Relative load of PLC program
▪ CPU temperatures
▪ Ethernet addresses and subnet masks
▪ Firmware version
▪ Serial number of module
▪ Version of PLC software
▪ Date of parametrisation

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SaCoS_one GENSET, Operating Instructions, EN 117 (136)

 8 MAN Diesel & Turbo
8.6 MISC

8.6.11 Service screens

Access Press the SERVICE PAGES button in the MISC menu.

Example The SERVICE PAGES menu consists of four pages and is displayed
Service page 1 of 4 Page 1 contains an overview of all measured values

Service page 2 of 4 The current status of the digital inputs is shown on page 2.
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8.6 MISC
Service page 3 of 4 The current status of the digital outputs is shown on page 3.

8 Functions of the touchscreen

Service page 4 of 4 The current status of the analogue outputs is shown on page 4.
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SaCoS_one GENSET, Operating Instructions, EN 119 (136)

 8 MAN Diesel & Turbo
8.6 MISC
8 Functions of the touchscreen

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 MAN Diesel & Turbo 8

8.6 MISC
8.6.12 Language selection
The SELECT LANGUAGE menu has two functions:
▪ Language selection
▪ Adjusting units of measurement
Available languages The following languages are available.
(standard) ▪ English
▪ German
▪ Portuguese
▪ Spanish
Selecting the menu language 1. Press the SELECT LANGUAGE button in the MISC menu.

2. Tap the flag of the relevant country to select a language. The language
selected is displayed in the CURRENT LANGUAGE field and saved
automatically.
Example English has been selected in this example.

8 Functions of the touchscreen

Adjusting the units of The following engine data (temperatures and pressures) can be modified:
2013-04-17 - 1.9

measure ▪ Temperatures: °C, °F

▪ Pressure: bar, psi, kg/cm², Mpa
The required unit of measure can be selected via the various buttons. This is
saved automatically and the corresponding button for the unit selected fades
out.

SaCoS_one GENSET, Operating Instructions, EN 121 (136)

 8 MAN Diesel & Turbo
8.6 MISC
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9 Alarm handling

9.2 List of all alarms

9.1 Alarm line
The alarm line appears below the info panel on almost every screen page.
The most recent active alarm is always displayed in this line.

9.1.1 Display of alarms

Colours Once an alarm has been acknowledged, the text colour changes from white
to yellow. The alarms are also labelled using symbols.

Examples Grey, empty alarm line: No active alarm.

Alarm is active but has not yet been acknowledged: White alarm message in
red
alarm line

Alarm has been acknowledged but is still active: Yellow alarm message in
blue
alarm line.

9.1.2 Acknowledgement of alarms in the alarm line

The alarm currently displayed in the alarm line can be acknowledged as fol-
lows:
1. Tap the alarm line to highlight the alarm.
The alarm line turns blue.
2. Press the ACK button.
The alarm has now been acknowledged.
3. If additional alarms are active, the most recent alarm is now displayed in
the alarm line. Otherwise the most recent acknowledged alarm is dis-
played.

9.2 List of all alarms

9 Alarm handling
2013-04-17 - 1.9

9.2.1 Accessing the list

Press the ALL ALARMS button (appears at the bottom left of nearly every
screen page).

SaCoS_one GENSET, Operating Instructions, EN 123 (136)

 9 MAN Diesel & Turbo

or:
9.2 List of all alarms

Press the ALARM GROUPS button in the MAIN MENU.

or:
Press the ALL ALARMS button in the MISC menu.

The LIST OF ALL ALARMS is an overview of all alarms that are currently
active. Alarms can only be acknowledged in this menu.

The alarms are sorted according to status (active / inactive) and triggering
time. The most recently triggered alarm is right at the top of the list.
9 Alarm handling

Important!
Alarms can only be acknowledged in the LIST OF ALL ALARMS. To
2013-04-17 - 1.9

reset an alarm, the corresponding alarm group must first be selected

via the navigation on the right-hand side of the menu.

Colour of alarm lines Once an alarm has been acknowledged, the text colour changes from white
to yellow. The alarms are also labelled using symbols.

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The alarm which is currently selected is displayed as yellow text on a brown

background.

9.2 List of all alarms

Alarm is active but has not yet been acknowledged:
white alarm message in red alarm line:

Alarm has been acknowledged but is still active:

yellow alarm message in blue alarm line

Note:
Reset alarms are moved automatically to HISTORY.

Alarm groups The alarm list can only be sorted using the grey alarm group buttons (right).
Only alarms in the selected groups are displayed.
Button Alarm group Description of alarm group
A Automatic shutdowns -SafSys-

B Reducing –SafSys-

C System alarms –SafSys-

D System alarms -E.C.-

E Pre-alarm –AlSys-

F System alarms –AlSys-

All groups List of all alarms

9 Alarm handling

Note
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The description of the displayed alarm groups also appears in the title
line.
The alarm groups are also described in the TROUBLESHOOTING menu
(see chapter "Troubleshooting").

SaCoS_one GENSET, Operating Instructions, EN 125 (136)

 9 MAN Diesel & Turbo
9.2 List of all alarms

9.2.2 Resetting alarm messages

An alarm can only be reset once it has been acknowledged and its cause
has been eliminated.
Acknowledge The ACK button in the List of All Alarms/Alarm groups acknowledges all
alarms that are currently displayed.
ACKbutton in the navigation bar.

Reset Alarms can be reset in the alarm groups menu.

Notice!
The RESET button does not just reset one alarm! This button resets all
group alarms that are displayed. If the number of active alarms
exceeds one screen page, repeat the reset procedure until no more
alarms are active.

1. Eliminate the cause of the alarm.

2. Press the RESET button in the navigation bar.

All acknowledged alarms on the screen are now reset.

Reset shutsdown in case of Display Module failure

In case the Display Module does not work anymore, it is not possible
to reset shutdowns. If the engine is required urgently, the shutdown
can be reset by restarting the system (Switching off/on the power
supply.)

9.2.3 History
HISTORY contains additional information on the alarms. It contains the date
and time of the following events:
▪ Alarm triggered
9 Alarm handling

▪ Alarm acknowledged
▪
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Alarm reset
▪ Alarm removed from the alarm list
Press the HISTORY button in the navigation bar of the LIST OF ALL
ALARMS.

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 MAN Diesel & Turbo 9

9.2 List of all alarms

The history page structured in a similar manner to the alarm list. The time
stamps for the various events can be displayed by pressing the grey buttons
in the navigation bar on the right.
INTO button If you press the grey INTO button, the text changes and so does the time
stamp in the alarm line.
This means you can call up the following four time stamps consecutively by
pressing this button:
INTO = alarm trigger time (white on red background).
ACK = time the alarm was acknowledged (yellow on blue background)
OUTOF = time the alarm was deactivated (black on grey background)
RESET = time the alarm was reset (orange on grey background).

9.2.4 Troubleshooting
The Help button can be found on the bottom right of the LIST OF ALL
ALARMS and the ALARM GROUPS menu. In other menus this can be found
in the navigation bar.
Access Press the Help button.

Example The ALARM-TROUBLESHOOTING menu is displayed.

9 Alarm handling
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SaCoS_one GENSET, Operating Instructions, EN 127 (136)

 9 MAN Diesel & Turbo

Alarm abbreviation Press the ALARM ABBREVIATIONS button.

9.2 List of all alarms

Page 1 of 3 shows a list of all abbreviations that appear in the alarm mes-
sages.

The index of abbreviations is continued on page 2 of 3.

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 MAN Diesel & Turbo 9

9.3 Common Alarm

The alarm groups are described on page 3 of 3.

Press the ALARM GROUPS ABBREVIATIONS button in the ALARM-TROU-

BLESHOOTING menu to go directly to page 3 of 3.

9.3 Common Alarm

A common alarm is always output if a new system alarm of the safety system
(alarm group C), a new pre-alarm of the alarm system (alarm group E) or a
system alarm of the alarm system (alarm group F) occurs.
The higher-level control system detects a new alarm on the falling edge.
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SaCoS_one GENSET, Operating Instructions, EN 129 (136)

 9 MAN Diesel & Turbo
9.5 Abbreviations in the alarm messages

9.4 Alarm messages

The complete list of alarm messages can be found in the doucment
„SaCoS_one GENSET Systems Messages“. In this document all system
messages are described.

9.5 Abbreviations in the alarm messages

Abbreviation Meaning
ACO Automatic Change-over
Aft.; AFT. after
ALARM PREPROC. Alarm Pre-processing Unit
AlSys Alarm Pre-processing Unit
AP Alarm Pre-processing Unit
APU Alarm Pre-processing Unit
ATEX-UNIT Atmosphère Explosible Unit
bef.; BEF. before
C.A. charge-air
CM Control Module
CMS Control Module Small
COMM. communication
COMP. compartment
COMPS. compensation
CONNECT. connection
CR Common Rail
CW cooling water
CYL. cylinder
DEV.; DEVIAT. deviation
DF Dual Fuel
DIFF. difference, differential
DM Display Module
DSENG: disengage
EC-SYST. Engine Control System
EC, E.C. Engine Control
9 Alarm handling

EMERG. emergency
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EOP External Operating Panel

ERR. error
EXH. exhaust
FEEDB. ERR. feedback error
FL. flushing

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Abbreviation Meaning

9.5 Abbreviations in the alarm messages

FUNCT. function
FUNCT.ERR. function error
GENER. generator
GM Gateway Module
HP high pressure
HT high temperature
I/O Input/Output
IM Injection Module
LEAK leakage
LEAK:MON-UNIT Leakage Monitoring Unit
LOP Local Operating Panel
LP low pressure
LT low temperature
LUB.; LUBRIC. lubrication
MED. medium
MVD mean value deviation
OMD oil mist detector
OVRD DSENG override disengage
OVRD RED override reduction request

OVRD SD override shutdown

PGI Performance Gas Injection
PreAl. Pre-alarm
PREPROC. pre-processing
PRESS. pressure
QCO Quick Change-over
RED reduction request
ROP Remote Operating Panel
SAF.SYST. Safety System
SafSys Safety System
SD shutdown
SETP. setpoint
9 Alarm handling

SF sensor fault
TC turbocharger
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TEMP. temperature
WING bridge wing

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 10 MAN Diesel & Turbo

10 Repairs and cleaning

Electric shock due to damaged lines!

Vibrations and wear can damage the insulation of electrical lines. There
is a possibility of electric shocks occurring at the damaged points and
at exposed electrical contacts.
• Electric lines and connections must be regularly checked for damage
and exposed electrical contacts.
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11 Spare parts

11.1 Ordering spare parts

11.1 Ordering spare parts

11.1.1 Identification of spare parts

A spare part can be identified and assigned using the following information:
▪ Serial number of the control system
▪ Equipment ID
▪ The completed configuration table from chapter 6.3 "Tests" (only for
spare parts marked with * in the spare parts list).

Serial number of the The serial number of the control system is on the
control system type plate in the control cabinet. The following illustration shows an example
of a SaCoSone GENSET type plate.

The serial number of the system is right at the top of the type plate.

Equipment ID You can find the equipment IDs for spare parts in the following documents:
▪ Assembly plan
▪ Circuit diagram
The equipment ID also appears on a yellow label on the spare part.
11 Spare parts
2013-04-17 - 1.9

SaCoS_one GENSET, Operating Instructions, EN 133 (136)

 11 MAN Diesel & Turbo
11.2 Spare parts list for SaCoS_one_ GENSET V1.1.X

Equipment ID (red) in the assembly plan

11.1.2 Contact
All Service contacts are listed in the chapter "Contact".

11.2 Spare parts list for SaCoSone GENSET V1.1.X

This spare parts list is valid for:
▪ SaCoSone GENSET V1.1.X with the following engine types: L16 / 24,
11 Spare parts

L21 / 31, L27 / 38, L32 / 40.

2013-04-17 - 1.9

The list contains all important spare parts:

BMK Unit Description
1D1 CU SaCoSone Display Module 1.X, programmed
3D1 CU SaCoSone Display Module 1.X, programmed
10R1 CU/CB Metal foil resistor

134 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo 11

BMK Unit Description

11.2 Spare parts list for SaCoS_one_ GENSET V1.1.X

10R2 CU/CB Metal foil resistor
10R3 CU/CB Metal foil resistor
10R4 CU/CB Metal foil resistor
10S1 CU Emergency-stop button, complete
30D2 CU WAGO PLC / fieldbus coupler
CANopen with D-Sub
30D3 CU WAGO PLC / filter module
field and system supply

30D4 CU WAGO PLC / Analogue INPUT; 2 x AI / PT100 / RTD

30D5 CU WAGO PLC / Analogue INPUT; 2 x AI / PT100 / RTD
30D6 CU WAGO PLC / Analogue INPUT; 2 x AI / PT100 / RTD
30D7 CU PLC, end module
30R1 CU/CB Metal foil resistor
30R6 CU/CB Metal foil resistor
30R7 CU/CB Metal foil resistor
30R3 CU/CB Metal foil resistor
30R9 CU/CB Metal foil resistor
30R13 CU/CB Metal foil resistor
30R14 CU/CB Metal foil resistor
30R15 CU/CB Metal foil resistor
30R16 CU/CB Metal foil resistor
30R17 CU/CB Metal foil resistor
30S1 CU Emergency-stop button, complete
30S2 CU Selector switch
Local/remote
30S3 CU Rotary switch
lower/raise
70D1 VIT WAGO PLC / fieldbus coupler
CANopen with D-Sub
70D2 VIT WAGO PLC / filter module
field and system supply

70D3 VIT WAGO PLC / Analogue INPUT

11 Spare parts

4 x DI / 3.0 ms
2013-04-17 - 1.9

70D4 VIT WAGO PLC / Analogue INPUT

2 x AI / 0-10 V AC/DC
70D5 VIT WAGO PLC / Analogue INPUT
2 x AO / 0-10 V DC
70D6 VIT WAGO PLC / end module

SaCoS_one GENSET, Operating Instructions, EN 135 (136)

 11 MAN Diesel & Turbo

BMK Unit Description

11.2 Spare parts list for SaCoS_one_ GENSET V1.1.X

70F1 VIT Automatic Fuse K/10 A

70F2 VIT Automatic Fuse K/1 A
70H1 VIT Signal lamp: 24 V DC OK
70K1 VIT 24 V AC/DC Relay / 2 CO (230 V AC/DC / 2 A)
70K2 VIT 24 V AC/DC Relay, 1 Changeover Contact (250 V / 2 A)`
70K3 VIT 24 V power relay with 2 changeover contacts (250 V/10 A)
with socket
70K4 VIT 24 V power relay with 2 changeover contacts (250 V/10 A)
with socket
70K5 VIT 24 V power relay with 2 changeover contacts (250 V/10 A)
with socket
70S1 VIT Selector switch VIT Emergency Mode

500D1 GM SaCoSone Gateway Module 1.X, programmed

* = when requesting these spare parts, use of the engine configuration table in the
chapter "Documentation of engine configuration" is required.
11 Spare parts

2013-04-17 - 1.9

136 (136) SaCoS_one GENSET, Operating Instructions, EN

 MAN Diesel & Turbo

Operating Instructions

Operating Instructions
Hydraulic actuator MA 2.035-1

Material number ................................ 285.14301-0006

0_Deckblatt_en_V1-0.fm

Original instructions
 MAN Diesel & Turbo

MAN Diesel & Turbo

86224 Augsburg, Germany
Phone +49 821 322-0
Fax +49 821 322-3382
[email protected]
www.mandieselturbo.com
0_Deckblatt_en_V1-0.fm

Copyright © 2012 MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.

Revision Erstellung Datum Check Datum Freigabe Datum

1.0 Specht 06.03.2012 Koulouris 14.03.2012 Mulder 16.04.2012
 MAN Diesel & Turbo

Table of contents

Table of contents
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.1 Contact information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 Structure and use of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
2.1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Structure of instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Symbols and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5 Residual dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Personal protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.7 Requirements of the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.8 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
4 Safety considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
7 Filling with oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
8.2 Proportional solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
11 MAN servicing options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.1 Services in detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.1.1 Exchange service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.1.2 Reparation service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.2 Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2
11.3 Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 2

12 Material declaration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
11.14301-0006_ENIVZ.fm

1
2
Table of contents
MAN Diesel & Turbo

11.14301-0006_ENIVZ.fm
 MAN Diesel & Turbo

1 Preface

Contact information
1.1 Contact information
The MAN Diesel & Turbo Group offers worldwide round-the-clock service, 365
days a year. Apart from the MAN Diesel & Turbo service headquarters in Augs-
burg, Copenhagen, Stockport and St. Nazaire, service centres on all conti-
nents provide comprehensive and continuous support. A long service life
associated with MAN Diesel & Turbo engines dictates a spare parts pro-
gramme that ensures components are available for engines in operation for
decades. Based on high-capacity machines, MAN Diesel & Turbo service pro-
duction facilities are able to comply with special customer requests with the
utmost precision and flexibility.

24 hour hotline
Tel: +49 1801 15 15 15

Technical Service 24 hour hotline

Tel: +49 821 322-1499
Fax: +49 821 322-3838
Email: [email protected]

Spare Parts 24 hour hotline

Tel: +49 821 322-1799
Fax: +49 821 322-3574
Email: [email protected]

Turbocharger Service 24 hour hotline

Spare parts
Tel: +49 821 322-4030

Technical Service (radial)

Tel: +49 821 322-4020

Technical Service (axial)

Tel: +49 821 322-4010
1_Contact_en_V1-1.fm

Fax: +49 821 322-3998

Email:
[email protected]
Preface

[email protected]
[email protected]

1-1
 MAN Diesel & Turbo

1.2 Structure and use of the operating manual

Structure and use of the operating manual

The operating manual contains information which is intended to support the

user in his work, and information that needs to be observed in order to ensure
safe operation. This information is intended to complement the experience and
capabilities of the members of staff who are responsible for
• the system management,
• the operation, monitoring and checking as well as
• the maintenance and repair work
of the component.
The operating manual must be available to the members of staff at all times.
The members of staff delegated with the task of operating the component
must adequately familiarise themselves with the structure of the operating
instructions, so that they can find the information they need without an ex-
tended search.
Liability/Guarantee MAN Diesel & Turbo SE Augsburg accepts no liability for material damage or
personal injury and/or environmental damage caused by partial or complete
non-observance of the operating manual.
The guarantee becomes invalid in the event of intervention by unauthorised
persons.
In the event of personal injury or material damage, claims made on the basis
of liability and guarantee are excluded if the damage or injury can be traced to
one of the following causes:
• If damage and/or breakdowns can be traced to the use of other than
genuine spare parts.
• If the component is operated incorrectly, the maintenance or repairs are
inadequate.
• If the component is operated with incorrectly fitted, faulty or non-
functioning safety and protection equipment.
• If there is non-compliance with the operating instructions concerning
operating, maintenance and repair.
• If the component is modified without the explicit approval of MAN Diesel &
Turbo SE Augsburg. In particular, the fitting or removal of parts is prohibi-
ted.
• In the event of inadequate monitoring of components.
• In the event of damage caused by foreign bodies and force majeure. 1_Contact_en_V1-1.fm
Preface

1-2
 MAN Diesel & Turbo

Observe the operating A prerequisite for the protection of the members of staff from dangers, for the
manual prevention of faults and for the operation of the component in a fault-free and

Structure and use of the operating manual

safe manner is the knowledge of the content of the technical documentation
of the component.
• The operating manual must always be available (in the control room, for
example).
• All persons who are responsible for the transport, assembly, initial commis-
sioning, operating, maintaining or repair of the component must be
acquainted with the operating manual. We recommend that the user has
the operators confirm to him in writing that they are acquainted with the
operating manual.
• All requirements and instructions in this operating manual must be
complied with.
• The documentation of purchased items is a constituent part of this opera-
ting manual. All safety information in this operating manual and all other
information must be observed.
• All relevant national regulations, regulations concerning accident prevention
environmental protection as well as the confirmed technical regulations for
safe and proper working must be complied with.
1_Contact_en_V1-1.fm

Preface

1-3
1-4
Preface Structure and use of the operating manual
MAN Diesel & Turbo

1_Contact_en_V1-1.fm
 MAN Diesel & Turbo

2 Safety regulations

Intended use
2.1 Intended use
The component can only be used in accordance with the details given in the
contract. Any other use is considered to be non-intended. Unilateral modifica-
tions and changes to the component are strictly prohibited for safety reasons.
MAN Diesel & Turbo SE accepts no responsibility for damage caused thereby,
all associated risks are to be borne by the operator.

IMPORTANT!
The operating and installation conditions prescribed in this operating
manual must be strictly adhered to. No non-genuine parts may be
used on the component since, otherwise, the required level of safety
will not be ensured. Any method of operation that would have a
detrimental effect on the safety of the component must not be used.

2.2 Structure of instructions

Safety messages and symbols are quoted at the relevant positions in the
operating manual if there is a danger to life or the danger of personal injury or
material damage to the component or the danger of environmental damage.
These safety messages must be strictly adhered to.
Safety messages typically contain a coloured warning symbol indicating the
severety of the danger as well as text describing the type, source and conse-
quences of the danger and measures for avoiding the danger. In addition, they
can appear with other symbols. These symbols represent the type of danger
as well as measures for avoiding it.
2_Sicherheitsvorschriften_en_V1-1.fm

Safety regulations

2-1
 MAN Diesel & Turbo

2.3 Symbols and instructions

Symbols and instructions

The following table describes the levels of danger for safety messages in the
technical product information provided by MAN Diesel & Turbo SE:

Symbol Danger level Description

Danger level 1 Indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

Danger level 2 Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

Danger level 3 Indicates a hazardous situation which, if not

avoided, may result in minor or moderate injury.

Danger level 4 Indicates a property damage message.

No danger level Additional notes, information and tips.

Take care when handling The following must be observed when dealing with the operating manual and
the component:
• The safety and danger messages referring to the component must be ob-
served in order to ensure that neither the members of staff nor the com-
2_Sicherheitsvorschriften_en_V1-1.fm

ponent, nor the environment is endangered.

Safety regulations

• Do not remove the safety and danger symbols on the component; they
must remain legible and must be replaced if necessary.
Safety messages and safety symbols are placed all over the plant.
Examples:
• Prohibition
• Symbols for fire prevention
• Warning beams
• Alarm and signalling systems

2-2
 MAN Diesel & Turbo

2.4 Safety equipment

Safety equipment
Danger!
Danger of severe injury or of injuries resulting in death
• It is always the case that the component must only operate in normal
mode if all the safety equipment is present, is fitted properly and is fully
functional.
• In operating modes where there is a temporary removal of specific safety
equipment is required, the component must only be operated if the
members of staff are particularly careful and that it has been ensured
that all the safety equipment will be re-fitted properly and immediately
checked for functionality as soon as the work involved has been comple-
ted.
• The proper function of all safety equipment must, at all times, be ensured
in accordance with the instructions concerning inspection and repair in
the component documentation.
• All warning symbols must be visible and legible.
2_Sicherheitsvorschriften_en_V1-1.fm

Safety regulations

2-3
 MAN Diesel & Turbo

2.5 Residual dangers

Residual dangers

The component represents state of the art technology and current safety
standards.
Incorrect operation In the case of incorrect operation, alienated use and non-observance of the
instruction in the operating manual, there is a danger of severe personal or fatal
injury and the danger of damage to the component and other assets belonging
to the operator and the danger of environmental damage.
If the component is in operation, it is the responsibility of the operator to check
the safe and proper condition of the component, including the safety protec-
tion devices, at regular intervals, but at least after each repair.

Residual dangers
General residual dangers
• Danger from operational, maintenance and repair faults
• Danger from unstable components
• Danger caused by unexpected start-up
• Danger from the loss of power supply (electrical, hydraulic, pneumatic)
• Danger caused by faults and incorrect functioning
• Danger from the failure of, or faults in, the control system
• Danger from software errors

Safety regulations for operators, maintenance and inspection

personnel
Residual dangers for operators and protective measures
• All rotating and otherwise moving parts must be protected from inad-
vertent touching.
• The operation of the component without the protective equipment fitted
is not permitted.

Safety regulations for operators, maintenance and inspection

personnel
Use of solvents
• Danger of injury to the eyes or skin and possibly the respiratory tract if
2_Sicherheitsvorschriften_en_V1-1.fm

vapours are produced! When using solvents, comply with the instruc-
Safety regulations

tions for the use, dangers and disposal.

• Fire or explosion danger if these agents are used for cleaning! Petrol or
chlorinated hydrocarbons must not be used for cleaning purposes.

2-4
 MAN Diesel & Turbo

2.6 Personal protection

Personal protection
When working on and standing by the component, you must wear the follo-
wing protective clothing:
• Safety shoes
• Safety helmet
• Protective gloves for fitting and repair work
• Chemical-resistant clothing and protective gloves for cleaning work,
especially when handling solvents
• Safety goggles for cleaning work, especially when handling solvents and
when using compressed air for cleaning
• Hearing protection
Proper condition If the component is in operation, it is the responsibility of the operator to check
the safe and proper condition of the component, including the safety protec-
tion devices, at regular intervals, but at least after each repair.
Trained staff The component may only be operated, maintained or repaired by staff
members who have the required technical training and who have been
instructed properly in the handling of the component.
The local health and safety regulations must be observed.
It is the responsibility of the user to ensure that regular training of the operators
is carried out.
Smoking and the use of naked flames on the component is strictly prohibited!
Safety Equipment To prevent bodily injury in the form of burns, which in accordance with EN 809
arise at mean temperatures in excess of 60 ° C, adequate safety equipment
has to be used.

2.7 Requirements of the operating personnel

Qualifications The staff members performing the tasks of operating, maintaining, inspecting
and assembling must have the relevant qualifications for this work. If the staff
do not have the required knowledge, they must be trained and instructed
accordingly. Necessary trainings can be carried out at an MAN Diesel & Turbo
PrimeServ Academy. For training requests, please contact MAN Diesel & Tur-
bo Primeserv (see "1.1 Contact information").

Training During the project phase of the module at MAN Diesel & Turbo, special em-
phasis was placed on simplicity, reliability and safety. Nevertheless, a com-
ponent must always be operated carefully and all the safety and precautionary
measures must be complied with. It is therefore imperative that all operators
2_Sicherheitsvorschriften_en_V1-1.fm

have the requisite technical training and instruction in the operation of the com-
Safety regulations

ponent. All handbooks and operating instructions must be available and must
be worked through carefully.

2-5
 MAN Diesel & Turbo

2.8 Environmental protection

Environmental protection

When handling the component, it has to be ensured that materials which can
endanger the environment are disposed of properly. Service materials must
not be allowed to enter the sewerage system and the ground water system.
All relevant national regulations concerning environmental protection and the
technical regulations for safe and proper working must be complied with.

Safety regulations for operators, maintenance and inspection

personnel
General
• Non-observance of the safety instructions can endanger the en-
vironment.
• The safety instructions in this operating manual and in the operating ma-
nuals of the equipment must be complied with.
• All leaks from motors, pumps, pump units, tanks and piping must be
rectified immediately.

Safety regulations for operators, maintenance and inspection

personnel
Lube oils and combustible materials, solvents
• Lube oils and combustible materials as well as solvents must not be dis-
posed of into the environment, must not be included with the household
waste or burned in unsuitable facilities.
• Before draining the lube oil, combustible material, coolant, hot liquids or
cleaning agents, check the local environmental protection regulations
and comply with them.
• Deposits can contain compounds which are environmentally damaging
and dangerous to health. It is therefore particularly important to define
proper procedures for the safe and proper disposal of deposits.
• Lube oils and combustible materials, solvents and their containers must
not be included with household waste. They must also not enter the
sewerage system or permeate into the ground.
• The relevant regulations concerning disposal must be strictly adhered to!
• Lubricants must be returned for recycling. Socket brackets, rollers,
gearboxes, housings, shafts and sheet metal used for steelwork as well
as the beams and motor housings must be recycled.
2_Sicherheitsvorschriften_en_V1-1.fm

• Filters, cables and electrical components must be recycled in

Safety regulations

accordance with the regulations issued by the authorities.

2-6
 MAN Diesel & Turbo

3 General

This handbook is provided to assist users of the MAN Diesel & Turbo hydraulic
actuator MA 2.035-1. The information contained is believed to be accurate at
the time of publication but MAN Diesel & Turbo reserves the right to introduce
design alterations where appropriate. For further information, please contact
MAN Diesel & Turbo at one of the addresses given on page 1 - 1.

The hydraulic actuator MA 2.035-1 is a proportional actuator, in which the out-

put shaft position is proportional to the electric input signal. The actuator does
not contain a mechanical back-up facility. If the control signal to the actuator
is disconnected, the actuator output shaft will return to position 0, stopped po-
sition.
The essential part of the actuator is the solenoid to which the pilot valve, con-
trolling the flow of oil to and from the power piston, is attached. The power pis-
ton is connected by linkage to the output shaft.

The hydraulic actuator MA 2.035-1 is a self-contained device that only requires

a rotary drive input from the engine to drive the integral oil pump. The drive may
be in either direction. The casing of the actuator acts as an oil reservoir and the
integral pump and accumulator provide the pressure that is used to generate
the work output.
3_General.fm

General

3-1
 MAN Diesel & Turbo

3_General.fm
General

3-2
 MAN Diesel & Turbo

4 Safety considerations

Caution!
The hydraulic actuator MA 2.035-1 is part of a speed governing control
loop including the fuel pumps and linkage. Any failure of this control
may cause the engine to stop or overspeed.
• It is essential that an independent overspeed trip is fitted and tested to
see that the engine is protected.
• The overspeed trip must be able to stop the engine without operating
through the actuator.

Correct installation of the actuator is essential for safe operation. This

handbook provides general guidance, but for precise instruction please refer
to SaCoSone GENSET operating instruction and the respective drawings.

If working on, or disconnecting the actuator, please check that the necessary
safeguards are in place to ensure that the engine cannot be started locally,
remotely or via some automatic system.

Ensure that work is only undertaken by a skilled personal and that all normal
precautions are taken.

Safety considerations
4_Safety_considerations.fm

4-1
4-2
Safety considerations
MAN Diesel & Turbo

4_Safety_considerations.fm
 MAN Diesel & Turbo

5 Technical data

Nominal operating speed 300 - 2000 rpm.

Nominal work output 40.5 joules (30 ft.lbf.)

Torque (Increase fuel) 67 Nm. (49.5 lb.ft.)
Torque (decrease fuel) 52 Nm. (38.5 lb.ft.)

Output shaft angular travel 46.7 degrees.

28 degrees should normally be used for the travel between full speed no-load and
full speed full-load position.
The additional 9.35 degrees at each end of the travel allow for positive fuel shut off
and additional fuel for acceleration. The output scale is marked 0 to 10. Thus 2 to 8
would be the recommended working range.

Output shaft dimensions Standard 3/4 inch 48 SAE serration at both sides.
Optional 5/8 inch 36 SAE serrations at both sides.

Drive shaft type Serrated or keyed.

Drive shaft rotation Both directions.

Actuator installed location Vertical flange mounted. The actuator will function at an angle of 10 degrees to the
vertical and will cope with normal excursions from the vertical as would be associat-
ed with shipboard use.

Weight 28.5 kg (63 lb.)

Oil supply Self contained, 2.75 liters

Control signal 0 – 1000 mAmp. Nominal operating range.

250 mAmp for output position 2 – No Load.
750 mAmp for output position 8 – full Load.

Technical data
5_Technical_Data.fm

5-1
 MAN Diesel & Turbo

1 Oil Filler Plug 5 Output Position Indicator

(both side)

2 Cover Terminal Strip 6 Output Shaft (both side)

3 Cable Clip 7 Drain Plug

(both side, size 1/4 BSP)

4 Oil Sight Glass

Technical data

5_Technical_Data.fm

Connection Diagram

5-2
 MAN Diesel & Turbo

6 Installation

Ensure that the engine cannot be rotated or started while the installation is in
progress.

Take care when lifting the actuator into position.

The actuator should be located by a spigot and 4 holding down bolts. The
spigot is fitted with an O-ring seal.

If the actuator is driven by means of a bevel gear fitted in the driveshaft, ensure
that the drive shaft is not side loaded as this could cause the drive to break.
Refer to the SaCoSone GENSET operating instructions, particularly when set-
ting the tooth clearance on bevel gears. The recommended backlash is 0.003
/ 0.006 inches (0.08 / 0.15 mm) and the bevel gear should be retained by tigh-
tening the nut on the drive shaft with a torque of between 35-40 lbf.ft (48-
54 Nm)

When connecting the fuel control linkage, please refer to the SaCoSone
GENSET operating instructions. The following is a general guide:
• The linkage should be set so that:
The fuel pump is in position “0 mm“ and the index on the actuator must be
in position “0“.
The fuel pump must be in position for 100% engine load and the index on
the actuator must be in position “8“.
• It is essential that all fuel is shut-off somewhere between output position 2
and 0 (this ensures that the engine can be stopped by the actuator).
• Linearity of movement is important and this is achieved by having fuel rack
links and levers at right angles when in mid position (output 5).
• The linkage should move freely, be free of backlash and be designed to give
linearity. If there is a spring link this should not collapse during normal ope-
ration.
6_Installation.fm

Installation

6-1
6-2
Installation
MAN Diesel & Turbo

6_Installation.fm
 MAN Diesel & Turbo

7 Filling with oil

The actuator may be filled with oil through the top filler plug. The hydraulic actu-
ator MA 2.035-1 has precision parts and, therefore, oil cleanliness is essential.
Clean around the filler plug before removing it and fill using clean oil passing
through a 100-mesh filter.

The hydraulic actuator has been designed to work using an SAE 30 grade
mineral oil for most applications, but high or low temperatures may dictate a
higher or lower viscosity.

The guidelines are as follows:

• Do use good quality mineral oil with good oxidation stability and anti-foam-
ing properties.
• Do ensure that the correct oil level is maintained.
• Do not use hydraulic oils or those with a high alkaline value
(TBN less than 15).

Filling with oil

7_Filling_with_oil.fm

7-1
7-2
Filling with oil
MAN Diesel & Turbo

7_Filling_with_oil.fm
 MAN Diesel & Turbo

8 Operation

Hydraulic system
8.1 Hydraulic system
The drive shaft drives the gear oil pump. The oil is transferred to the accumu-
lator. The accumulator is spring loaded and will open the relief hole allowing
excessive oil to be drained to the sump if the oil pressure in the system is 18
bar. The pressurised oil is also transferred to top side of the power piston and
to the pilot valve. Trough an extra set of gear, the pilot valve sleeve is also dri-
ven in order to minimise static friction.
The power piston is of a differential type, that is that the surface at the bottom
side is bigger than the one at the top side. Therefore, applying oil to, or draining
oil from the bottom side of the power piston will make the power piston move
in either upwards or downwards direction.

8.2 Proportional solenoid

The control signal of the electronic governor is connected to the coil. This crea-
tes an electro-magnetic force in the coil assembly. The magnets are in centre
of the coil assembly when the pilot valve is in the lapped position. The bias
spring pushes the pilot valve assembly downwards.

Under steady state conditions the 3 forces in the system - the bias spring
8_Operation.fm

Operation

force, the electro-magnetic force and the force of the magnets themselves -
are in balance. If the current of the control signal is increased, the electro-
magnetic force increases, moving the pilot valve down and oil flows to the
power piston. This causes the power pistons to move up and the output shaft
to rotate to a higher position. Attached to power piston linkage is the feedback
lever which pushes the bias spring downwards.

8-1
 MAN Diesel & Turbo

If the output shaft moves to a higher position, the deflection of the bias spring
is reduced and with it the force it applies to the system. If the reduction of the
Proportional solenoid

bias spring force has compensated the initial increase of the electro-magnetic
force, the pilot valve has returned to lapped position again and the power pis-
ton remains stationary.
If the electro-magnetic force is decreased, the power piston and with it the out-
put shaft will move to a lower position, until the bias spring has compensated
for the electro-magnetic force reduction and the pilot valve is in lapped position
again.

8_Operation.fm
Operation

This figure shows a cross section of the actuator. The power piston is located
behind the pilot valve and coil assembly and is therefore not visible.

8-2
 MAN Diesel & Turbo

9 Settings

The relation between the control signal current and the actuator output posi-
tion is dependent on the strength of the magnets in the coil assembly and the
setpoint of the bias spring. The strength of the magnets can not be altered on
site as it needs a special charging tool. However the setpoint of the bias spring
can be changed by adjusting the bias spring setpoint screw.

Adjustment of the bias spring setpoint must only be done if the relation is found
not to be correct by measuring the control signal current and comparing this
with the actual output position.

The normal relation between the control signal and the actuator output position
is:
• 250 mAmp for output position 2
• 750 mAmp for output position 8
By adjusting the bias setpoint screw, this setting can be offset. If the set point
screw is turned clockwise, the actuator will run with a higher output position at
the same control signal.
9_Settings.fm

Settings

9-1
 MAN Diesel & Turbo

Caution!
If the setting of the bias setpoint screw is being changed while the
actuator is fitted to the engine, the following must be observed.

As the actuator, while it is in operation, is part of a closed loop system, there

will be no visible change of the output position of the actuator. This is because
if the engine load is not changed, the required amount of fuel and thus actuator
output shaft position will not change either.
Therefore, while in close loop, the effect of adjusting the bias setpoint screw is
that the initial change of the actuator position causes the engine speed to in-
or decrease. This is compensated for by the electronic governor in adjusting
the control signal to the actuator.
Because of this, never adjust the bias setpoint screw without measuring the
control signal and observing the load position of the electronic governor. Also
never adjust the actuator setting in order to match the load indication signal to
f.i. the pitch and load control system to the actual engine load.

Caution!
Failing to observe these guidelines may result in offsetting the actua-
tor setting to such extend that the electronic governor becomes out of
control and cannot stop the engine which may overspeed!

9_Settings.fm
Settings

9-2
 MAN Diesel & Turbo

10 Maintenance

The hydraulic actuator MA 2.035-1 contains precise specialist parts and requi-
res dedicated test and calibration equipment. If operated correctly, the actua-
tor will provide long service. It is recommended that oil is changed at least
every 6000 hours or when the engine oil is renewed.
If the actuator oil becomes dirty, this indicates the need to replace the drive
shaft oil seal.
In general, every 25,000 running hours an overhaul is required. This should be
undertaken by MAN Diesel & Turbo or an agent appointed and trained by
them. To provide a flexible solution, MAN Diesel & Turbo offers an exchange
program for completely overhauled actuators.
10_Maintenance.fm

Maintenance

10 - 1
 Maintenance

10 - 2
MAN Diesel & Turbo

10_Maintenance.fm
 MAN Diesel & Turbo

11 MAN servicing options

Services in detail
MAN PrimeServ provides prompt and reliable services to reduce production
downtimes to an absolute minimum. In cooperation with the MAN Service
Engineers and the additional assistance of our worldwide network of authori-
zed service providers we are able to offer local services.
Factory options for servicing this product provided by your local MAN service
provider are available as follows:

Exchange
• Urgent Exchange (24-hour service)
• Normal Replacement

Repair
• Flat Rate Repair

11.1 Services in detail

11.1.1 Exchange service

Urgent Exchange
Exchange is a premium program designed for customers with the need of
immediate service. It allows you to request and receive a replacement unit in
minimum time (usually within 48 hours of the request) assuming that a suitable
unit is in stock.
The flat-rate program includes a MAN product warranty of 1 year.

Normal Replacement
In case of either an expected or planned maintenance this option allows you
to call your Full-Service Distributor for requesting a replacement control unit. If
the unit is available at the time of the call, it can usually be shipped out within
14 days, including a warranty of 180 days.

In both cases we offer you the possibility to return your field control unit (which
is substituted with a like-new replacement) to the Full-Service Distributor within
50 days. Therefore you will get a credit advice. Charges for the Exchange/Re-
placement service are based on a flat rate plus variable shipping expenses.
MAN servicing options

11.1.2 Reparation service

All of our repair hubs offer free diagnosis unless you choose not to complete
11_Servicing_options.fm

the reparation. If the ratio of the reparation value and the replacement value is
not favorable, we will inform you. Depending on the severity of the damage we
will either repair or replace the damaged part.
The repair service fee does not cover replacements of missing or non repai-
rable accessory items, severely abused, corroded or water damaged equip-
ment.

11 - 1
 MAN Diesel & Turbo

Option: Flat Rate Reparation Service

Benefits

This program offers you reparation services for your products with the advan-
tage of a convenient standard reparation fee. The main advantage of this op-
tion is the knowledge of your reparation costs in advance. Repair parts are
covered by a 90 day replacement warranty if it is determined that the part failed
due to a manufacturing defect.

11.2 Benefits
Our factory repair services provide the following advantages:
• We only use genuine high quality replacement parts
• Return unit is thoroughly cleaned
• All components are evaluated using factory certified test equipment
• Units are upgraded to current state of the art /actual specifications.
• If necessary the latest software upgrade will be installed.
• Detailed reparation report
• All reparations are warranted
• Reparations are performed by MAN factory-trained technicians

11.3 Before you call...

Please have following information available:
• Model and spec number of the unit
• Article & serial number
• Failure information (fault and alarm codes, descriptions)
• Application which the product is used on
• Available time (Length of time in service)
MAN servicing options

11_Servicing_options.fm

11 - 2
 MAN Diesel & Turbo

12 Material declaration

Material declaration
12_Material_Declaration.fm

12 - 1
 Material declaration

12 - 2
MAN Diesel & Turbo

12_Material_Declaration.fm
 MAN Diesel & Turbo

Service bulletin
Hydraulic actuator MA 2.035-1

Material number ................................ 11.14301-0006 / 11.14301-0007

0_Deckblatt_en_V1-0.fm

Original instructions

-1
 MAN Diesel & Turbo

MAN Diesel & Turbo

86224 Augsburg, Germany
Phone +49 821 322-0
Fax +49 821 322-3382
[email protected]
www.mandieselturbo.com
0_Deckblatt_en_V1-0.fm

Copyright © 2011 MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.

Revision Erstellung Datum Check Datum

1.1 Specht, GMD3-AUG 06.05.2011 Knödler, GMD3-AUG 30.03.2011

-2
 MAN Diesel & Turbo

1 Introduction

There have been reports of oil leakage of the hydraulic actuators article no
11.14301-0006 and 11.14301-0007. To overcome this, the design has been
updated.
All actuators with serial number 1129493 and onwards have been supplied to
the latest standard.
For actuators which do suffer from this oil leakage, a service pack has been
made available. This leaflet shows how the parts involved are to be replaced
on site.
The picture below shows the location of the leakage. At the bottom part of the
actuator, there is a gap between the base plate and the front plate.
At this location, there is a pipe from within the base plate into the aluminum
front plate connecting two oil holes.

Introduction
1_Introduction.fm

1-1
 MAN Diesel & Turbo

This pipe is sealed within the front plate with Loctite grade 601.
It has been found that there are actuators whose Loctite sealing leaks.

Pipe and front plate have been modified to allow for sealing by means of an
O-ring.
Introduction

1_Introduction.fm

1-2
 MAN Diesel & Turbo

2 Contents

The service pack contains the following items:

• Front Plate 1 off.

• Oil transfer pipe long 1 off.
• Oil transfer pipe short 1 off.
• O-ring (fitted on oil pipe) 4 off.
• Gasket 1 off.
• Cap screw M5x25 2 off.
• Copper washer 14 off.
2_Contents.fm

Contents

2-1
 MAN Diesel & Turbo

2_Contents.fm
Contents

2-2
 MAN Diesel & Turbo

3 Procedure

Warning!
Carefully read the instructions below. Failing to do so may result in
personal injuries and / or severe damage!
• Changing the parts of the actuator must be done by qualified personnel
only.
• Before the work is started:
- The engine must be stationary.
- It must be impossible to start the engine, neither locally nor
remotely.
- The power supply to the engine control system must be switched
off.
• The work involved will take about 30 minutes. During this period, the
engine is out of operation and not available for f.i. emergency power
supply.

Please note that the actuator is part of the engine speed control system and is
a delicate instrument. Before working on the actuator, it must be cleaned from
the outside.
3_Procedure.fm

Procedure

3-1
 MAN Diesel & Turbo

3_Procedure.fm
Procedure

Cross section of the actuator indicating the parts to be replaced

3-2
 MAN Diesel & Turbo

Warning!
The engine is to be stopped and prevented from starting!
• Switch off the power supply to the Engine Control System!

Drain the oil from the actuator

Remove the cover of the connection box and disconnect both external and in-
ternal wiring. Remove the terminal block.
3_Procedure.fm

Procedure

3-3
 MAN Diesel & Turbo

Remove the capscrews from the front plate. Please note the difference in
length.
There are actuators in which the capscrews at position “A” are not present.
However the M5 threaded holes are always present in the casing and in the
gasket.
The new front plate can therefore be fitted with 4 + 10 cap screws.

Remove the front plate from the casing by pulling it off. It may be necessary to
use a screwdriver as illustrated.
3_Procedure.fm
Procedure

3-4
 MAN Diesel & Turbo

The front plate removed from the actuator

3_Procedure.fm

Procedure

3-5
 MAN Diesel & Turbo

Re-assemble the actuator using the parts from the Service Pack.
The oil pipes are to be fitted in the front plate as shown.
Fit the new gasket and next the front plate against the casing.
Use the supplied copper washers when fitting the capscrews.
For those actuators where the old front plate was secured with 12 cap screws
only ; 2 extra ones are in the Service Pack.
Fit the terminal block and re-connect the wiring. Fit the cover plate of the
connection box.
Re-fill the actuator with oil.
Finished!

3_Procedure.fm
Procedure

3-6
Crankshaft

510/610
 MAN Diesel
Description
Crankshaft and Main Bearings 510.01
Page 1 (1) Edition 05H

L27/38

Crankshaft and Main Bearings Vibration Damper

The crankshaft, which is a one-piece forging, is sus- A vibration damper is mounted on the crankshaft
pended in underslung bearings. The main bearings to limit torsional vibrations. The damper consists of
are of the rillenlager type, which are coated with a a primary and a secondary part. Between these,
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 the crankshaft
by means of two 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

02.17 - ES0
MAN Diesel & Turbo
Work Card 510-01.00
Page 1 (6) Checking of Main Bearings Alignment
Edition 14

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 412
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Checking of main bearings alignment (autolog).

Starting Position Hand Tools

Turning gear in engagement (if
mounted).
Cover for crankshaft has been
removed from frame.
All indicator valves open.

Related Procedure

Qualified Manpower Replacement and wearing parts

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

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

2005.06.27.
 MAN Diesel & Turbo
510-01.00 Work Card
Checking of Main Bearings Alignment Page 2 (6)
Edition 14

L27/38

Procedure
1) Remove the side covers from the crank casing.
2) Turn the crankshaft to bring the crank web for
cylinder no 1 to position X, see fig 8.
3) Place the dial gauge in the punch marks in the
counterweight, see fig 1.
4) Adjust the dial gauge to 0.
5) Turn the crankshaft to position P, T, S and Y
and read the dial gauge in each position and fill
in the form Checking of Main Bearing Alignment
(Autolog), page 6 and 7.
6) Repeat the procedure on the remaining crank
webs.
7) Compare the values to earlier values taken after
the sea trial.
8) Please contact us if the values exceed the val-
ues shown in this Working Card.

Figure 1: Placing of dial gauge

2005.06.27.
MAN Diesel & Turbo
Work Card 510-01.00
Page 3 (6) Checking of Main Bearings Alignment
Edition 14

L27/38

2005.06.27.
 MAN Diesel & Turbo
510-01.00 Work Card
Checking of Main Bearings Alignment Page 4 (6)
Edition 14

L27/38

Schedules
Measurement of crank throw deflections by means of dial indicator (autolog)
Crank throw deflection = Difference in dial indicator readings in two diametrically opposite
crank throw positions, i.e. two positions displaced 180o
Vertical deflection = Difference in top-bottom readings
Horizontal deflection = Difference in side-side readings
Horizontal deflections of crank throws
Unless otherwise stated the values refer to cold engine
For new or realigned aggregate Aim for + or − 3/100 mm
Acceptable + or − 5/100 mm
For aggregate in service realignment is recommended if deflections exceed + or − 8/100 mm
Vertical deflection of crank throw nearest flywheel
Unless otherwise stated the values refer to cold engine
Flexible coupling between diesel engine and driven machine
- New or recently overhauled engine, norminal + 8/100 - − 20/100 mm
- New or recently overhauled engine, max. + 15/100 - − 23/100 mm
- Operating engine, check alignment immediately + 22/100 - − 25/100 mm
Flexdisc between diesel engine and driven machine
- New or recently overhauled engine, max. + 0/100 - − 35/100 mm
Vertical deflection of crank throws remaining
Unless otherwise stated the values refer to cold engine
Flexible coupling between diesel engine and driven machine
- New or recently overhauled engine, norminal + or − 8/100 mm
- New or recently overhauled engine, max. + or − 15/100 mm
- Operating engine, check alignment immediately + or − 22/100 mm
Flexdisc between diesel engine and driven machine
- New or recently overhauled engine, norminal + or − 8/100 mm
- New or recently overhauled engine, max. + or − 15/100 mm
- Operating engine, check alignment immediately + or − 22/100 mm

2005.06.27.
MAN Diesel & Turbo
Work Card 510-01.00
Page 5 (6) Checking of Main Bearings Alignment
Edition 14

L27/38

2005.06.27.
 MAN Diesel & Turbo
510-01.00 Work Card
Checking of Main Bearings Alignment Page 6 (6)
Edition 14

L27/38

2005.06.27.
MAN Diesel & Turbo
Work Card 510-01.05
Page 1 (4) Inspection of Main and Guide Bearing Shells
Edition 10

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 035
52001 036 (extra tool)
Shut off cooling water
Shut off fuel oil and hydraulic tools according to working card
520-01.06
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Dismantling, inspection and/or replacement and
mounting of main and guide bearing shells.

Starting Position Hand Tools

Engine out of operation Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Copaslip/Molycote

Related Procedure
Criteria for replacement of bear- 506-01.16
ings
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2

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

2013.06.12
 MAN Diesel & Turbo
510-01.05 Work Card
Inspection of Main and Guide Bearing Shells Page 2 (4)
Edition 10

L27/38
6) Place a tackle above the handles of the two lift-
ing tools. Connect it to the handle and pull tight
to carry the weight of the main bearing cap an
screw the side stay bolts out.

Dismantling of main bearing

Warning!
Use protective gloves
1) Dismantle the crankcase covers on both sides
of the engine fore and aft of the main bearing in
question.

Warning!
Use protective gloves and safety glasses
2) Turn the engine until the crank is in a conven-
ient possition for carrying out the work.
3) Install the hydraulic tool on the side bolts for the
main bearing cap to be lowered. Loosen and
remove the nuts (1), see fig 1. Leave the rods in
to avoid that the main bearing cap drops down
when removing the nuts for the main bearing
cap. Figure 2: Installing lifting tool on main bearing cap

7) Slacken the tackle until the lifting tool is resting

against the engine frame.
8) Remove the lower bearing shell from the bear-
ing cap.
9) Press the tool for turning the upper bearing half
out into the lubricating oil bore in the crank jour-
nal, see fig 3.
10) Turn the upper bearing half out by turning the
crankshaft.

Figure 1: Hydraulic tools mounted on tie rods

4) Install the hydraulic tool on the tie rods for the

main bearing cap inside the crankcase. Loosen
and remove the nuts (2), see fig 1.
5) Install the tool for the main bearing cap, see fig
2.

2013.06.12
MAN Diesel & Turbo
Work Card 510-01.05
Page 3 (4) Inspection of Main and Guide Bearing Shells
Edition 10

L27/38
8) The lifting tool for the main bearing cap can now
be removed.
9) Mount the hydraulic jacks according to Working
Card 520-01.06.
10) Tighten the tie rods with a pressure of, see Data
for tightening torque description 500.40, step 1
and turn the nuts against the frame.
11) Tighten the side tie rods with a pressure of see
Data for tightening torque description 500.40,
step 1 and turn the nuts against the bearing
cap.
12) Tighten the tie rods with a pressure of, see Data
for tightening torque description 500.40, step 2
and turn the nuts against the frame.
13) Tighten the side tie rods with a pressure of see
Data for tightening torque description 500.40,
step 2 and turn the nuts against the bearing
Figure 3: Using turning-out tool cap.
14) Release the pressure completely and rise the
pressure once again on the tie rods to, see
Mounting of main bearing Data for tightening torque description 500.40,
step 2 and turn the nuts against the bearing
1) Carefully wash the new bearing in diesel fuel to cap.
remove the preservation.
15) Release the pressure and remove the hydraulic
2) Add oil to the bearing surface of the upper tools.
bearing shell and slide it by hand into position
as far as possible. Make sure that the bearing is 16) Release the pressure completely and rise the
placed in the middle of the longitudinal direction pressure once again on the side tie rods to, see
of the bearing bore. Data for tightening torque description 500.40,
step 2 and turn the nut against the engine
3) If the bearing cannot be brought into correct frame.
position by hand, the tool for turning out the
bearing can be used to turn in the bearing. 17) Release the pressure and remove the hydraulic
make sure the joint faces of the bearing shell tools.
and the frame are in line.
4) Add oil to the bearing surface of the lower bear- Dismantling of guide bearing
ing shell and place it in the main bearing cap. All 4 thrust ring halves are identical.
Make sure the joint faces of the bearing shell
Check or replacement of the thrust rings is carried
and the bearing cap are in line.
out, when checking or replacing the aft main bear-
5) Add molykote paste to the surface around the ing.
hole for the side tie rods on the main bearing
Before lowering the aft main bearing cap, as descri-
cap.
bed under "Dismantling of main bearing", the crank-
6) Lift the bearing cap into position by means of shaft must be moved a little axially to make sure
the tackle and screw the side studs in by hand. there is noe axial force on the fore or aft thrust
Add some liquid sealing compound to the nuts rings.
to seal against the frame and screw on the nuts
but do not tighten.
7) Fit the nuts on the tie rods for the main bearing
cap in the crankcase.

2013.06.12
 MAN Diesel & Turbo
510-01.05 Work Card
Inspection of Main and Guide Bearing Shells Page 4 (4)
Edition 10

L27/38

Dismantling of thrust rings

1) When lowering the main bearing cap, care must
be taken that the lower thrust rings do not drop
into the oil pan.
2) The fore and aft upper thrust rings have come
down a little at the same time as the main bear-
ing cap was lowered and can easily be turned
out while the main bearing cap is resting in the
lifting tools.

Installation of thrust rings

1) The upper fore and aft thrust rings can easily be
turned in if the crankshaft is in the right axial
position.
2) Leave the two halves hanging over the main
journal with the joint faces in horizontal position.
3) Add some grease to the back of the lower
thrust rings and place the thrust rings on the
main bearing cap. Make sure the guide flaps
are located in the grooves machined in the
bearing cap.
4) Lift the bearing cap and assemble as described
under "Mounting of main bearing".
5) For min./max. axial guide bearing clearance and
min./max. radial main bearing, see description
500.35.

Figure 4: Guide bearing

2013.06.12
 MAN Diesel

Plate
Page 1 (2) Crankshaft 51001-10H

L27/38

141 165
177
189
273
190

285
200

190

104

094
082
224
070
075
212

033
08028-0D/H5250/94.08.12

045
057
236 069

08.14 - ES0
 MAN Diesel

Plate
51001-10H Crankshaft Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

033 1/E Crankshaft, Krumtap,

6 cyl. engine 6 cyl. motor

045 1/E Crankshaft, Krumtap,

7 cyl. engine 7 cyl. motor

057 1/E Crankshaft, Krumtap,

8 cyl. engine 8 cyl. motor

069 1/E Crankshaft, Krumtap,

9 cyl. engine 9 cyl. motor

070 2/C Cylindrical pin, ø25 Cylindrisk stift, ø25

075 2/C Cylindrical pin, ø30 Cylindrisk stift, ø30

(optional) (option)

082 4/C Nut Møtrik

094 4/C Bolt Bolt

104 2/C Counterweight Kontravægt

141 16/E Screw Skrue

165 1/E Cylindrical pin Cylindrisk stift

177 1/E Cylindrical pin Cylindrisk stift

189 4/E Screw Skrue

190 1/E Gearwheel 2/2 Tandhjul 2/2

200 1/E Cylindrical pin Cylindrisk stift

212 2/C Spring pin Fjederstift

224 Plug screw Propskrue

6/E 6 cyl. engine 6 cyl. motor
7/E 7 cyl. engine 7 cyl. motor
8/E 8 cyl. engine 8 cyl. motor
9/E 9 cyl. engine 9 cyl. motor

236 1/E Screw Skrue

273 1/E Plug screw Propskrue

285 2/E Cylindrical pin Cylindrisk stift

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

08.14 - ES0
 MAN Diesel

Plate
Page 1 (2) Crankshaft 51001-11H

5L27/38

141 165
177
189
190

200 273

285

190

094
224 082
070
212
104

248
021
236
08028-0D/H5250/94.08.12

07.40 - ES0
 MAN Diesel

Plate
51001-11H Crankshaft Page 2 (2)

5L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

021 1/E Crankshaft Krumtap

070 2/C Cylindrical pin Cylindrisk stift

082 4/C Nut Møtrik

094 4/C Bolt Bolt

104 9/E Counterweight Kontravægt

141 16/E Screw Skrue

165 1/E Cylindrical pin Cylindrisk stift

177 1/E Cylindrical pin Cylindrisk stift

189 4/E Screw Skrue

190 1/E Gearwheel 2/2 Tandhjul 2/2

200 1/E Cylindrical pin Cylindrisk stift

212 2/C Spring pin Fjederstift

224 5/E Plug screw Propskrue

236 1/E Screw Skrue

248 1/E Counterweight Kontravægt

273 1/E Plug screw Propskrue

285 2/E Cylindrical pin Cylindrisk stift

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

07.40 - ES0
 MAN Diesel & Turbo

Plate
Page 1 (2) Crankshaft 51001-16

L27/38

141 165
177
189
273
190

285
200

190

104

094
082
224
070
075
212
08028-0D/H5250/94.08.12

033
045
057
236 069

11.37 - ES0
 MAN Diesel & Turbo

Plate
51001-16 Crankshaft Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

033 1/E Crankshaft, Krumtap,

6 cyl. engine 6 cyl. motor

045 1/E Crankshaft, Krumtap,

7 cyl. engine 7 cyl. motor

057 1/E Crankshaft, Krumtap,

8 cyl. engine 8 cyl. motor

069 1/E Crankshaft, Krumtap,

9 cyl. engine 9 cyl. motor

070 2/C Cylindrical pin, ø25 Cylindrisk stift, ø25

075 2/C Cylindrical pin, ø30 Cylindrisk stift, ø30

(optional) (option)

082 4/C Nut Møtrik

094 4/C Bolt Bolt

104 2/C Counterweight Kontravægt

141 16/E Screw Skrue

165 1/E Cylindrical pin Cylindrisk stift

177 1/E Cylindrical pin Cylindrisk stift

189 4/E Screw Skrue

190 1/E Gearwheel 2/2 Tandhjul 2/2

200 1/E Cylindrical pin Cylindrisk stift

212 2/C Spring pin Fjederstift

224 Plug screw Propskrue

6/E 6 cyl. engine 6 cyl. motor
7/E 7 cyl. engine 7 cyl. motor
8/E 8 cyl. engine 8 cyl. motor
9/E 9 cyl. engine 9 cyl. motor

236 1/E Screw Skrue

273 1/E Plug screw Propskrue

285 2/E Cylindrical pin Cylindrisk stift

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

11.37 - ES0
 MAN Diesel & Turbo

Plate
Page 1 (2) Crankshaft 51001-17

5L27/38

141 165
177
189
190

200 273

285

190

094
224 082
070
212
104

248
021
236
08028-0D/H5250/94.08.12

11.37 - ES0
 MAN Diesel & Turbo

Plate
51001-17 Crankshaft Page 2 (2)

5L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

021 1/E Crankshaft Krumtap

070 2/C Cylindrical pin Cylindrisk stift

082 4/C Nut Møtrik

094 4/C Bolt Bolt

104 9/E Counterweight Kontravægt

141 16/E Screw Skrue

165 1/E Cylindrical pin Cylindrisk stift

177 1/E Cylindrical pin Cylindrisk stift

189 4/E Screw Skrue

190 1/E Gearwheel 2/2 Tandhjul 2/2

200 1/E Cylindrical pin Cylindrisk stift

212 2/C Spring pin Fjederstift

224 5/E Plug screw Propskrue

236 1/E Screw Skrue

248 1/E Counterweight Kontravægt

273 1/E Plug screw Propskrue

285 2/E Cylindrical pin Cylindrisk stift

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

11.37 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Flywheel with Gear Rim 51003-14H

L27/38

010
022
034
046
058
105

071

083
130

142 095

Crankshaft see plate 51001

12.37 - ES0
 MAN Diesel & Turbo

Plate
51003-14H Flywheel with Gear Rim Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

010 1/E Flywheel, Svinghjul

5 cyl. engine 5 cyl. motor

022 1/E Flywheel, Svinghjul

6 cyl. engine 6 cyl. motor

034 1/E Flywheel, Svinghjul

7 cyl. engine 7 cyl. motor

046 1/E Flywheel, Svinghjul

8 cyl. engine 8 cyl. motor

058 1/E Flywheel, Svinghjul

9 cyl. engine 9 cyl. motor

071 16/E Bolt Bolt

083 1/E Gear rim Tandkrans

095 10/E Screw Skrue

105 32/E Nut Møtrik

130 1/E O-ring O-ring

142 1/E Nut Møtrik

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

12.37 - ES0
 MAN Diesel

Plate
Page 1 (2) Vibration Damper with Attachment 51004-23

L27/38

Crankshaft
016
see plate 51001

161

053

041

161
08028-0D/H5250/94.08.12

06.02 - ES0
 MAN Diesel

Plate
51004-23 Vibration Damper with Attachment Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

016 1/E Vibration damper Svingningsdæmper

041 1/E Spur gear Tandhjul

053 8/E Bolt Bolt

161 16/E Nut Møtrik

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

06.02 - ES0
 MAN Diesel

Plate
Page 1 (2) Vibration Damper with Attachment 51004-24

L27/38

Crankshaft
016
see plate 51001

161

053

041

161
08028-0D/H5250/94.08.12

06.02 - ES0
 MAN Diesel

Plate
51004-24 Vibration Damper with Attachment Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

016 1/E Vibration damper Svingningsdæmper

041 1/E Spur gear Tandhjul

053 8/E Bolt Bolt

161 16/E Nut Møtrik

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

06.02 - ES0
 MAN Diesel

Plate
Page 1 (2) Vibration Damper with Attachment 51004-25

L27/38

Crankshaft
016
see plate 51001

161

053

041

161
08028-0D/H5250/94.08.12

06.02 - ES0
 MAN Diesel

Plate
51004-25 Vibration Damper with Attachment Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

016 1/E Vibration damper Svingningsdæmper

041 1/E Spur gear Tandhjul

053 8/E Bolt Bolt

161 16/E Nut Møtrik

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

06.02 - ES0
ASSEMBLY & INSPECTION
INSTRUCTIONS

The Complete Solution

 DCB-GS COUPLING

CONTENTS

1) General Description and Operation ……………………………………… 2

2) Assembly ……………………………………………………………………… 3

3) Final Alignment ……………………………………………………………… 6

4) Removal of Rubber Elements ……………………………………………… 7

5) Periodic Inspection ……………………………………………………… 9

6) Storage of Spare Rubber Blocks ……………………………………… 10

7) Specification of Assembly Fluid ……………………………………… 11

8) Table of Tightening Torques ……………………………………………… 12

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-1-
DCB-GS COUPLING

SECTION 1
General Description & Operation

The flexible coupling assembly has two main metal parts, an Outer Member (1) with blades extending
radially inwards and an Inner Member (2) with similar blades extending radially outward. Between
these blades rubber Blocks (3) and Tubes (4) are inserted to cushion the drive, detune torsional
vibration conditions and accept misalignment in all directions. The Cover (5) and Keep-plate (where
fitted) provide a limit to the axial elongation of the blocks when under compression.

Under steady drive conditions only the blocks are under load, these being referred to as ‘driving
blocks’. The tubes are placed in the trailing cavities. These only come into operation under reverse
torque conditions.

No lubrication of the coupling is required and the coupling should operate for long periods of time
with no attention other than the Periodic Inspection described under Section 5.

Keep-plate may
be fitted here 1

1. Outer Member 3
2. Inner Member
3. Block
4. Tube 4
5. Cover (split)

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-2-
 DCB-GS COUPLING

SECTION 2
Assembly

Driving Machine Inner Member Driven Equipment

Outer Member

Determine direction
of rotation when
Keep-plate viewed from this face

Driven Shaft

Cover

It is assumed that assembly commences with the coupling as shown in the sketch above where:

1) Both driving and driven machines are in position and are correctly aligned to each other.
2) The driven shaft (or flange) is temporarily secured in the correct axial position.
3) Flywheel (or driving flange), keep-plate and outer member have been correctly correlated
and are securely bolted together.
4) Cover rests on shaft behind the inner member.

Note: Most DCB-GS couplings use split covers to facilitate insertion and removal of rubber blocks.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-3-
DCB-GS COUPLING

SECTION 2
Assembly (continued)

The assembly procedure for DCB-GS couplings is as follows:

1) Fasten keep plate to outer member flange where appropriate.

2) Lightly brush the walls of each cavity with silicone fluid as specified in Section 7, or
available from Renold Hi-Tec Couplings.
3) Lightly brush each block and the outer surfaces of each tube with silicone fluid.
4) Check the direction of rotation of the coupling to determine the driving and trailing cavities.
Direction of rotation is as viewed on flywheel face (refer to sketch on previous page).
For clockwise rotation the driving cavity will be on the right hand side of the outer member
blade. For anti-clockwise rotation the driving cavity will be on the left hand side of the outer
member blade. Note that the driving cavity has the larger radius.
5) Insert the first block into any driving cavity. Ensure that it is pushed until it reaches the back
of the coupling.
6) Insert one block in each driving cavity around the coupling in the same manner as the first.
7) Take a tube; manually compress the walls so that it can be squeezed into the trailing
cavity. Ensure that the tube is pushed to the far end of the cavity. For larger tubes a G-
clamp may be required to compress the tube enough to insert it in the cavity.
8) Insert a row of tubes in the trailing cavities as described above.
9) For couplings containing two or more rows of rubber elements, repeat steps 4–7, inserting
first a row of blocks, then a row of tubes, until the coupling is fully assembled. Refer to
notes on following page.
10) Fasten the cover to the Outer Member using the Disk Lock self-locking washers.
11) Tighten the Cover screws to the torque tightening value as specified in Section 8.

Note: It is recommended that the keep plate be fastened to the outer member before the
rubber elements and cover are assembled.
Fastening the cover to the outer member before adding the blocks and assembling the
keep plate is not the recommended assembly method as the keep plate may not locate to
the outer member properly due to the deformation of the compressed rubber elements.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-4-
 DCB-GS COUPLING

1 2

3 4
Note: The coupling shown is designed to rotate in the anticlockwise direction.

For specially balanced applications the blocks and/or tubes may be numbered. In this event, the
elements should be assembled in numerical order around the coupling. For couplings with multiple
rows of blocks, the row designation will be labelled A, B, C etc. See diagram below.

6 1

5 2

3 A
4 B
C
RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-5-
DCB-GS COUPLING

SECTION 3
Final Alignment

The final alignment may be checked using two dial indicators rigidly attached to the driven shaft as
shown in the sketch.

As the coupling is rotated the indicators will provide values of parallel and angular misalignments.

An improved method is to use two additional dial indicators positioned diametrically opposite the first
two and to take readings simultaneously from all four indicators. This method eliminates error due to
such factors as gear influences axial float which can be readily observed and eliminated when the
two sets of readings are compared.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-6-
 DCB-GS COUPLING

SECTION 4
Removal of Rubber Elements

If the cover is a single piece it should be removed and placed as far back as possible along the shaft.
Split covers may be removed and stored until required.

Each cavity of the DCB-GS coupling may contain more than one element. The first stage of element
removal is to remove all blocks at the cover side of the coupling.

The use of a lever such as a bar or screwdriver is recommended to ease elements from their cavities.
This should be inserted at the corner of the cavity giving the widest point of access and using a lever
action against the cavity edge, the block should then become free. It may be necessary to repeat this
at opposite corners of the cavity.

When the complete circle of blocks has been removed the exposed cavity surfaces should be lightly
brushed with silicone fluid to aid the removal of the other rows of blocks.

After the first row of blocks has been removed the tubes should be removed from the trailing cavities.
The use of a lever is also recommended for this exercise.

With all tubes removed the remaining blocks should now be removed.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-7-
DCB-GS COUPLING

Renold Hi-Tec Couplings DCB-GS couplings are designated in the following manner
Example: DCB-GS 626.5

6 2 6.5 6.5” diameter driving element

2 rows of elements

6 driving elements spaced radially

around the coupling

DCB-GS 626.5 - 6 blocks, 2 rows per cavity, 6.5” diameter blocks.

DCB-GS 658.5 - 6 blocks, 5 rows per cavity, 8.5” diameter blocks.

Table of setting tolerances

Maximum Axial &
Renold Hi- Maximum
Axial & Radial Setting Tolerance ‘A’
Tec Angular Mis-
Radial Setting (Run out at ØG – TIR)
Couplings alignment
Movement Tolerance
DCB-GS mm mm Degree ØG mm mm
6 x 2.5 1.5 0.37 0.7 296 0.3
6 x 3.5 2.0 0.50 0.7 414 0.4
6 x 4.5 2.5 0.62 0.7 532 0.5
6 x 5.5 3.0 0.75 0.7 650 0.6
6 x 6.5 3.5 0.87 0.7 770 0.7
6 x 7.5 3.5 0.87 0.7 888 0.8
6 x 8.0 4.0 1.00 0.7 946 0.9
6 x 8.5 4.5 1.13 0.7 1005 1.0
6 x 9.5 5.0 1.25 0.7 1124 1.0
6 x 11.0 6.0 1.50 0.7 1300 1.2
6 x 13.0 8.0 2.00 0.7 1537 1.5
6 x 15.0 10.0 2.50 0.7 1774 1.6

Note: Setting Tolerance ‘A‘ refers to the position of the dial indicator as recommended in the
diagram on page 5.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-8-
 DCB-GS COUPLING

SECTION 5
Periodic Inspection

Inspection of the rubber blocks after the first 12 months of operation will provide a basis on which a
future inspection programme can be decided.

It will only be necessary to inspect the blocks at the cover end of the coupling. (Those which can be
seen after removal of the cover.)

Block hardness should be checked using a durometer to measure shore hardness. The maximum
allowable change in hardness is 10 degrees. If the change exceeds 5 degrees consideration should
be given to the timing of the next inspection to ensure that the 10-degree limit is not exceeded.

Visual inspection of the rubber blocks should be made to determine whether any obvious
abnormalities have occurred. This type of coupling is fitted with circular rubber elements that are
precompressed at rest position; hence some deformation can be expected and will not affect the
performance of the coupling. The diagram below shows acceptability criteria for deformation.

Certain types of damage may be confined to the surface with no appreciable effect on performance.
When in doubt one block and one tube should be removed from the coupling and hardness checked
at different points to assess the overall condition of the rubber.
% ALLOWABLE DEFORMATION (FROM NOMINAL)

RUBBER HARDNESS (SHORE A)

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
-9-
DCB-GS COUPLING

SECTION 6
Storage of Spare Rubber Blocks

The British Standards Institute recommend the following storage conditions for vulcanised elastomers
to avoid changes in properties which are indicated by softening, hardening, cracking or other surface
degradation.

Deteriation can be accelerated by the synergistic effect of the combined factors heat light, humidity,
oxygen and ozone.

These effects can be minimised by careful selection of storage conditions, i.e.: -

TEMPERATURE: The storage temperature should be less than 25°C. For long term
storage a maximum temperature of 15°C is recommended
HUMIDITY: Moist conditions should be avoided and no condensation should
occur.
LIGHT: All polymeric products should be protected against light, especially
sunlight or artificial light with high ultra violet content.
OXYGEN & OZONE: Where possible components should be protected from air circulation
by storage in containers. Ozone is particularly damaging and for this
reason, parts should not be stored near electrical equipment where
sparks or silent discharges are possible.
DEFORMATION: Mouldings should be stored in a strain free condition.
LIQUIDS: Mouldings should not be contaminated with liquids in storage.
CLEANING: If cleaning is required for storage, soap and water is relatively
harmless. The washed components should be allowed to dry at room
temperature.
STORAGE TIME: Where items have been stored for five years or more a Laboratory
check on quality must be carried out before use.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
- 10 -
 DCB-GS COUPLING

SECTION 7
Specification of Assembly Fluid

To ease assembly of the Renold Hi-Tec Coupling the rubber elements and coupling cavities can be
coated with silicone fluid available in 250ml containers from Renold Hi-Tec Couplings. Only a small
amount of fluid is required to lubricate the element and the cavities. The fluid is not essential to the
operation of the coupling it merely eases the assembly process. The specification below lists the
properties.

Manufacturer: Dow Corning 200 fluid

Viscosity: 1000 cs
Brussels No: 39018010
Boiling Point: 230°C
Specific Gravity: 0.97

Fire and Explosion Hazard Data

Flash Point Closed cup 93°C, Open cup 285°C
Extinguishing Media CO2 Foam, dry Powder or fine water spray
Special Procedures None

Health Hazard Data

Skin No significant effect
Eyes May cause temporary discomfort – flush with water
Inhalation No significant effect
Ingestion Mildly toxic estimated LD595000mg/kg

Spill or Leaks
Procedure Mop, wipe or soak up with absorbent material.

Waste Disposal
Can be land filled or burned in accordance with local regulations

Special Protection
Safety glasses to be worn.

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
- 11 -
DCB-GS COUPLING

SECTION 8
Table of tightening Torques

Cover Setscrew Grade 8.8

Renold Hi-Tec
Size Torque Tighten to
Couplings DCB-GS
Dia x Pitch Nm
6x2.5 M10 x 1.5 45
6x3.5 M14 x 2.0 120
6x4.5 M18 x 2.5 250
6x5.5 M20 x 2.5 360
6x6.5 M24 x 3.0 625
6x7.5 M30 x 3.5 1250
6x8.0 M30 x 3.5 1250
6x8.5 M36 x 4.0 2190
6x9.5 M36 x 4.0 2190
6x11.0 M42 x 4.5 3100
6x13.0 M48 x 5.0 4600
6x15.0 M56 x 5.5 7400

RENOLD Hi-Tec Couplings. Tel: +44 (0) 1422 255000 Fax: +44 (0) 1422 255100 E-Mail: [email protected]
- 12 -
RENOLD Power RENOLD Hi-Tec Couplings SA Brampton RENOLD RENOLD Australia Prop Ltd
Transmission Corporation Usatges No1 – Local 5 Z.I.A. Rue de la Pointe 508-520 Wellington Road
8750 Global Way 08850 – GAVA (Barcelona) B.P.359-59473 Mulgrave, Victoria 3170
West Chester, Ohio 45069 Spain SECLIN CEDEX Australia
USA Tel: +34 (93) 638 05 58 France Tel: +61 (0) 3 9262 33 33
Tel: +001 513 942 1000 Fax: +34 (93) 638 07 37 Tel: +33 (0) 3 20 16 2929 Fax: +61 (0) 3 9561 85 61
Fax: +001 513 942 8500 Fax: +33 (0) 3 20 16 2900
Toll Free: 800 850 8141

E4-05-134 Rev 101

DCB-GS A&M English/0902
Engine frame/Oil pan

511/611
MAN Diesel & Turbo

Description
Engine Frame and Base Frame 511.01
Page 1 (1) Edition 04H

L27/38

Engine Frame The main bearings for the underslung crankshaft are
carried in heavy supports by tierods from the interme-
The monobloc cast iron engine frame is designed diate frame floor, and are secured with the bearing
to be very rigid. All the components of the engine caps.These are provided with side guides and held in
frame are held under compression stress. The frame place by means of studs with hydraulically tightened
is designed for an ideal flow of forces from the cylin- nuts. The main bearing is equipped with replaceable
der head down to the crankshaft and gives the outer shells which are fitted without scraping.
shell low surface vibrations.
On the sides of the frame there are covers for ac-
Two camshafts are located in the engine frame. cess to the cam­shafts and crankcase. Some covers
The valve camshaft is located on the exhaust side are fitted with re­lief valves which will operate if oil
in a very high position and the injection camshaft is vapours in the crank­case are ig­nited (for in­stance in
located on the service side of the engine. the case of a hot bearing).

Base Frame

The engine and alternator are mounted on a rigid

base frame. The alternator is considered as an in-
tegral part during engine design. The base frame,
which is flexibly mounted, acts as a lubricating oil
reservoir for the engine.

Fig 1 Engine frame Fig 2 Main bearings

00.13 - ES0
MAN Diesel & Turbo
Work Card 511-01.00
Page 1 (2) Functional test of crankcase safety relief valves
Edition 08

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Functional test of crankcase safety relief valves

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1 51106 237 1/cover
51106 524 4/relief valve
51106 740 1/relief valve
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2006.11.20
 MAN Diesel & Turbo
511-01.00 Work Card
Functional test of crankcase safety relief valves Page 2 (2)
Edition 08

L27/38

Functional Testing
Functional testing of the crankcase safety relief
valves cannot be performed during operation of the
engine, but it must be checked during overhauls
that the valve flap is movable.

When Painting
When painting the engine, take care not to block up
the safety relief valves with paint.

Check of opening pressure

To check the proper opening pressure, proceed as
follows:
1 Cover 2 Relief valve
Warning!
Figure 1: Cover with safety relief valve
Use protective gloves
1) Remove the relief valve cover from the engine.
2) Place the cover on the floor with the pressure
area upwards.
3) Apply a weight at 20 kg on the pressure area.
The relief valve must open under this pressure.
4) Remount the relief valve cover of the engine. If
the safety relief valves are actuated, the engine
must be stopped immediately, and it must not
be restarted until the cause is detected and the
fault is fixed, see also description 503.04, Igni-
tion in Crankcase.

2006.11.20
MAN Diesel & Turbo
Plate
Page 1 (3) Frame P51101-27

L27/38

2013.05.14 - 5 cyl. engine

 MAN Diesel & Turbo
Plate
P51101-27 Frame Page 2 (3)

L27/38

2013.05.14 - 5 cyl. engine

MAN Diesel & Turbo
Plate
Page 3 (3) Frame P51101-27

L27/38
Item No. Qty Item designation Item No. Qty Item designation

049 2/E Cylindrical pin 456 2/E Tie rod

062 4/C Tie rod 887 /I Loctite 270
074 8/C O-ring 899 4/C Ring
086 34/E Nut 922 6/E Cu-gasket, M80
098 1/E Frame (without oil mist detector) 934 6/E Plug, M80
099 1/E Frame (with oil mist detector) 946 1/C Cylindrical pin
157 6/E Main bearing cap 958 44/E Spring pin
169 1/E Main bearing cap, axial 971 /I Glue
182 12/E Tie rod
194 12/E Crown nut
204 7/E Cylindrical pin
216 14/E Cross bolt
228 14/E Nut
265 12/E O-ring
277 4/C Nut
289 4/C Stud
290 6/E Sealing ring
300 6/E Plug
312 14/E Protecting cap
324 1/E O-ring
336 1/E Spray nozzle
348 4/E Spring lock
361 14/E Screw
373 1/E O-ring
385 1/E Cover
397 6/E Cu-gasket, M60
407 6/E Plug, M60
419 1/C Connecting piece
420 1/C O-ring
432 2/E Plug
444 2/E Washer

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder
Qty/E = Qty/Engine
Qty/I = Qty/Individual

2013.05.14 - 5 cyl. engine

MAN Diesel & Turbo
Plate
Page 1 (3) Frame P51101-28

L27/38

2013.05.14 - 6 cyl. engine

 MAN Diesel & Turbo
Plate
P51101-28 Frame Page 2 (3)

L27/38

2013.05.14 - 6 cyl. engine

MAN Diesel & Turbo
Plate
Page 3 (3) Frame P51101-28

L27/38
Item No. Qty Item designation Item No. Qty Item designation

049 2/E Cylindrical pin 456 2/E Tie rod

062 4/C Tie rod 887 /I Loctite 270
074 8/C O-ring 899 4/C Ring
086 40/E Nut 922 7/E Cu-gasket, m80
108 1/E Frame (without oil mist detector) 934 7/E Plug, m80
109 1/E Frame (with oil mist detector) 946 1/C Cylindrical pin
157 7/E Main bearing cap 958 52/E Spring pin
169 1/E Main bearing cap, axial 971 /I Glue
182 14/E Tie rod
194 14/E Crown nut
204 8/E Cylindrical pin
216 16/E Cross bolt
228 16/E Nut
265 14/E O-ring
277 4/C Nut
289 4/C Stud
290 7/E Sealing ring
300 7/E Plug
312 16/E Protecting cap
324 1/E O-ring
336 1/E Spray nozzle
348 4/E Spring lock
361 16/E Screw
373 1/E O-ring
385 1/E Cover
397 7/E Cu-gasket, m60
407 7/E Plug, m60
419 1/C Connecting piece
420 1/C O-ring
432 2/E Plug
444 2/E Washer

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder
Qty/E = Qty/Engine
Qty/I = Qty/Individual

2013.05.14 - 6 cyl. engine

MAN Diesel & Turbo
Plate
Page 1 (3) Frame P51101-29

L27/38

2013.05.14 - 7 cyl. engine

 MAN Diesel & Turbo
Plate
P51101-29 Frame Page 2 (3)

L27/38

2013.05.14 - 7 cyl. engine

MAN Diesel & Turbo
Plate
Page 3 (3) Frame P51101-29

L27/38
Item No. Qty Item designation Item No. Qty Item designation

049 2/E Cylindrical pin 456 2/E Tie rod

062 4/C Tie rod 887 /I Loctite 270
074 8/C O-ring 899 4/C Ring
086 46/E Nut 922 8/E Cu-gasket, m80
121 1/E Frame (without oil mist detector) 934 8/E Plug, m80
122 1/E Frame (with oil mist detector) 946 1/C Cylindrical pin
157 8/E Main bearing cap 958 60/E Spring pin
169 1/E Main bearing cap, axial 971 /I Glue
182 16/E Tie rod
194 16/E Crown nut
204 9/E Cylindrical pin
216 18/E Cross bolt
228 18/E Nut
265 16/E O-ring
277 4/C Nut
289 4/C Stud
290 8/E Sealing ring
300 8/E Plug
312 18/E Protecting cap
324 1/E O-ring
336 1/E Spray nozzle
348 4/E Spring lock
361 18/E Screw
373 1/E O-ring
385 1/E Cover
397 8/E Cu-gasket, m60
407 8/E Plug, m60
419 1/C Connecting piece
420 1/C O-ring
432 2/E Plug
444 2/E Washer

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder
Qty/E = Qty/Engine
Qty/I = Qty/Individual

2013.05.14 - 7 cyl. engine

MAN Diesel & Turbo
Plate
Page 1 (3) Frame P51101-30

L27/38

2013.05.14 - 8 cyl. engine

 MAN Diesel & Turbo
Plate
P51101-30 Frame Page 2 (3)

L27/38

2013.05.14 - 8 cyl. engine

MAN Diesel & Turbo
Plate
Page 3 (3) Frame P51101-30

L27/38
Item No. Qty Item designation Item No. Qty Item designation

049 2/E Cylindrical pin 456 2/E Tie rod

062 4/C Tie rod 887 /I Loctite 270
074 8/C O-ring 899 4/C Ring
086 52/E Nut 922 9/E Cu-gasket, m80
133 1/E Frame (without oil mist detector) 934 9/E Plug, m80
134 1/E Frame (with oil mist detector) 946 1/C Cylindrical pin
157 9/E Main bearing cap 958 68/E Spring pin
169 1/E Main bearing cap, axial 971 /I Glue
182 18/E Tie rod
194 18/E Crown nut
204 10/E Cylindrical pin
216 20/E Cross bolt
228 20/E Nut
265 18/E O-ring
277 4/C Nut
289 4/C Stud
290 9/E Sealing ring
300 9/E Plug
312 20/E Protecting cap
324 1/E O-ring
336 1/E Spray nozzle
348 4/E Spring lock
361 20/E Screw
373 1/E O-ring
385 1/E Cover
397 9/E Cu-gasket, m60
407 9/E Plug, m60
419 1/C Connecting piece
420 1/C O-ring
432 2/E Plug
444 2/E Washer

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder
Qty/E = Qty/Engine
Qty/I = Qty/Individual

2013.05.14 - 8 cyl. engine

MAN Diesel & Turbo
Plate
Page 1 (3) Frame P51101-31

L27/38

2013.05.14 - 9 cyl. engine

 MAN Diesel & Turbo
Plate
P51101-31 Frame Page 2 (3)

L27/38

2013.05.14 - 9 cyl. engine

MAN Diesel & Turbo
Plate
Page 3 (3) Frame P51101-31

L27/38
Item No. Qty Item designation Item No. Qty Item designation

049 2/E Cylindrical pin 456 2/E Tie rod

062 4/C Tie rod 887 /I Loctite 270
074 8/C O-ring 899 4/C Ring
086 58/E Nut 922 10/E Cu-gasket, m80
145 1/E Frame (without oil mist detector) 934 10/E Plug, m80
146 1/E Frame (with oil mist detector) 946 1/C Cylindrical pin
157 10/E Main bearing cap 958 76/E Spring pin
169 1/E Main bearing cap, axial 971 /I Glue
182 20/E Tie rod
194 20/E Crown nut
204 11/E Cylindrical pin
216 22/E Cross bolt
228 22/E Nut
265 20/E O-ring
277 4/C Nut
289 4/C Stud
290 10/E Sealing ring
300 10/E Plug
312 22/E Protecting cap
324 1/E O-ring
336 1/E Spray nozzle
348 4/E Spring lock
361 22/E Screw
373 1/E O-ring
385 1/E Cover
397 10/E Cu-gasket, m60
407 10/E Plug, m60
419 1/C Connecting piece
420 1/C O-ring
432 2/E Plug
444 2/E Washer

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/C = Qty/Cylinder
Qty/E = Qty/Engine
Qty/I = Qty/Individual

2013.05.14 - 9 cyl. engine

 MAN Diesel
Plate
Page 1 (2) Front-end Box 51103-19H

L27/38

Mounting of charge air

cooler, see plate 51235

Charge air pipes,

see plate 51230

Lubricating oil filter,

see plate 51502

840
852
864
099
038
051
146 205
876 183

985
997
349 171
986
099
099
888
038 911
08028-0D/H5250/94.08.12

109
099
038
923

06.41 - ES0
MAN Diesel

Plate
51103-19H Front-end Box Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

038 14/E Screw Skrue

051 4/E Washer Skive

099 18/E Spring washer Fjederskive

109 1/E Cover Dæksel

146 4/E Thermostatic Termostatelement

element for lub. oil for smøreolie

171 4/E Retaining ring Sikringsring

183 1/E Cover Dæksel

205 1/E Gasket Pakning

349 4/E Screw Skrue

840 1/E O-ring O-ring

852 1/E O-ring O-ring

864 1/E Closing piece Låsestykke

876 4/E Sleeve Bøsning

888 12/E Thrust washer Trykskive

911 12/E Screw Skrue

923 1/E Cover Dæksel

985 4/E Sleeve Bøsning

986 /I Loctite 243 Loctite 243

997 4/E O-ring O-ring

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

06.41 - ES0
 MAN Diesel & Turbo

Plate
Page 1 (2) Front-end Box 51103-08H

L27/38

Centrifugal by-pass filter, 445

see plate 51515
087+ 218 935
099 217+ 445
242+ 577 516
541 433 528
959 099 494
636 469 504
960 553 457
673
661
648 482
972 984 470
229 719 301
624 075 996 697
528 195 038 947
063 196
099

026 408
08028-0D/H5250/94.08.12

10.29 - ES0
 MAN Diesel & Turbo

Plate
51103-08H Front-end Box Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

026 1/E Cover Dæksel 624 4/E Screw Skrue

038 4/E Screw Skrue 636 1/E Thrust piece Trykstykke

063 4/E Nut Møtrik 648 1/E Covering plate Dækselplade

075 2/E Washer Skive 661 1/E Screw Skrue

087+ 4/E Screw Skrue 673 1/E Nut Møtrik

099 8/E Spring washer Fjederskive 697 1/E O-ring O-ring

195 4/E Stud Tap 719 1/E Spring Fjeder

196 /I Loctite 638 Loctite 638 935 1/E Intermediate piece Mellemstykke

217+ 1/E Flange Flange 947 1/E Intermediate piece Mellemstykke

218 /I Packing silicone Packing silicone 959 1/E O-ring O-ring

paste paste
960 1/E Cover Dæksel
229 1/E O-ring O-ring
972 1/E Casing Hus
242+ 4/E Nut Møtrik
984 1/E Piston Stempel
301 1/E O-ring O-ring
996 1/E Retaining ring Sikringsring
408 1/E O-ring O-ring
+ To be used if cen- + Anvendes hvis ikke
433 10/E Screw Skrue trifugal by-pass filter centrifugal by-pass
is not mounted filter er monteret
445 2/E O-ring O-ring

457 1/E Bracket for by-pass Konsol for centrifugal

centrifugal filter by-pass filter

469 4/E Screw Skrue

470 1/E Plug screw Propskrue

482 1/E Packing ring Pakningsring

494 1/E Cover Dæksel

504 1/E O-ring O-ring

516 4/E Screw Skrue

528 8/E Spring washer Fjederskive

08028-0D/H5250/94.08.12

541 1/E Spring Fjeder

553 1/E Piston Stempel

577 1/E O-ring O-ring

When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.

* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/E = Qty/Engine Qty/E = Qty/Motor

10.29 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Front-end Box 51103-29

L27/38

014 720
732

697
589
744 947
590
756 408

038
099 Mounting of charge air
cooler, see plate 51235

Charge air pipes,

134 see plate 51230
122
Lubricating oil filter,
see plate 51502

026
612
600
Charge air cooler,
see plate 51201 840
852
864

Cooling water pumps,

see plate 51610 099
732 051 038
099
827
720 349
815 986
839
Mounting of Lube oil
thermostatic elements,
see plate 51545
793 099
099 803 Lubricating oil pump,
see plate 51501 038
781
109
Lubricating oil cooler,
see plate 51506 099
038
923

11.35 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
51103-29 Front-end Box Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

014 1/E Front-end box Front-end box 923 1/E Cover Dæksel

026 1/E Cover Dæksel 947 1/E Intermediate piece Mellemstykke

038 18/E Cylindrical screw Cylindrisk skrue 986 /I Glue Lim

051 4/E Washer Skive

099 22/E Locking spring Låsefjederskive

washer

109 1/E Cover Dæksel

122 1/E Screw Skrue

134 1/E Sealing ring Tætningsring

349 4/E Screw Skrue

408 1/E O-ring O-ring

589 1/E Closing screw Låseskrue

590 1/E Seal Tætning

600 15/E Screw Skrue

612 4/E Screw Skrue

697 1/E O-ring O-ring

720 18/E Closing screw Skrue

732 18/E O-ring O-ring

744 1/E Plug screw Propskrue

756 1/E Seal ring Tætningsring

781 4/E Screw Skrue

793 1/E O-ring O-ring

803 1/E Cover Dæksel

815 12/E Stud screw Tapskrue

827 12/E Disc Skive

839 12/E Nut Møtrik

840 1/E O-ring O-ring

852 1/E O-ring O-ring

864 1/E Closing piece Låsestykke

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

11.35 - ES0 - Tier II

MAN Diesel & Turbo
Plate
Page 1 (2) Main bearing P51104-04

L27/38

2013.04.18 - MIBA AISn+

 MAN Diesel & Turbo
Plate
P51104-04 Main bearing Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

021 /I Main bearing shells 1)

033 4/E Thrust bearing ring

When ordering spare parts, see also page 500.50/600.50. Note 5 cyl. - 7/E, 6 cyl. - 8/E, 7 cyl. - 9/E, 8 cyl. - 10/E, 9
1)

cyl. - 11/E
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.04.18 - MIBA AISn+

MAN Diesel & Turbo
Plate
Page 1 (2) Main bearing P51104-05

L27/38

2013.04.18 - MIBA
 MAN Diesel & Turbo
Plate
P51104-05 Main bearing Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

021 /I Main bearing shells 1)

033 4/E Thrust bearing ring

When ordering spare parts, see also page 500.50/600.50. Note 5 cyl. - 7/E, 6 cyl. - 8/E, 7 cyl. - 9/E, 8 cyl. - 10/E, 9
1)

cyl. - 11/E
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.04.18 - MIBA
MAN Diesel & Turbo
Plate
Page 1 (2) Main bearing P51104-06

L27/38

2013.04.18 - DAIDO
 MAN Diesel & Turbo
Plate
P51104-06 Main bearing Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

021 /I Main bearing shells 1)

033 4/E Thrust bearing ring

When ordering spare parts, see also page 500.50/600.50. Note 5 cyl. - 7/E, 6 cyl. - 8/E, 7 cyl. - 9/E, 8 cyl. - 10/E, 9
1)

cyl. - 11/E
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.04.18 - DAIDO
MAN Diesel & Turbo

Plate
Page 1 (2) Cover on Frame 51106-38

L27/38

130 022 105

142 117

548
573
585
597
607

561
083
095
010

129

Crankshaft see plate 51001

12.38 - ES0
 MAN Diesel & Turbo

Plate
51106-38 Cover on Frame Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

010 1/E Cover Dæksel

022 22/E Screw Skrue

083 1/E Cover Dæksel

095 1/E O-ring O-ring

105 8/E Screw Skrue

117 8/E Lock washer Låseskive

129 1/E Sealing ring Tætningsring

130 1/E Cover Dæksel

142 4/E Screw Skrue

548 4/E Lock disc Låseskive

561 1/E O-ring O-ring

573 2/E Screw Skrue

585 2/E Thrust washer Trykskive

597 2/E Pin Stift

607 1/E Dead center pointer Dødpunktsviser

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

12.38 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Covers on Frame 51106-43

L27/38

009
010 For top covers,
003 see plate 50510

010
009

006
001

008
007

009
010
004
010
009

012
006 013

002
008
007 005

For covers on frame,

see plate 51106

12.50 - ES0
 MAN Diesel & Turbo

Plate
51106-43 Covers on Frame Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

001 5/E Covering Inddækning

002 1/E Covering Inddækning

003 5/E Covering Inddækning

004 1/E Covering Inddækning

005 1/E Covering Inddækning

006 6/E Screw Skrue

007 12/E Screw Skrue

008 12/E Washer Skive

009 24/E Screw Skrue

010 24/E Washer Skive

012 7/E Cylindrical screw Cylindrisk skrue

013 7/E 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

12.50 - ES0
MAN Diesel & Turbo

Plate
Page 1 (3) Covers on Frame 51106-40

L27/38

029
022
021

031

005
030
024 009

008 015

014
023 014
022
016 002

022
048
021
047
001
046

045 022
041
021 022 021

13.47 - ES0
 MAN Diesel & Turbo

Plate
51106-40 Covers on Frame Page 2 (3)

L27/38

002
001

014 006
022

021

016

007

022
022 021 009
021

022
021 010

13.47 - ES0
MAN Diesel & Turbo

Plate
Page 3 (3) Covers on Frame 51106-40

L27/38
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

001 2/C Cover Dæksel 045 1/D Safety valve Sikkerhedsventil

002 2/C O-ring O-ring 046 6/D Hexagon screw Sekskantskrue

005 2/E O-ring O-ring 047 6/D Disc Skive

006 1/E O-ring O-ring 048 1/D O-ring O-ring

007 1/E Cover Dæksel

008 1/E Cover Dæksel

009 2/E O-ring O-ring

010 1/E Cover Dæksel

014 2/C O-ring O-ring

015 Cover with safety Dæksel med sikker-

valves, complete hedsventil, komplet
incl. item 041, 045, 046, inkl. item 041, 045, 046,
047, 048 047, 048
4/E 5, 6, 7 cyl. engine 5, 6, 7 cyl. motor
5/E 8, 9 cyl. engine 8, 9 cyl. motor

016 Cover for crankcase Dæksel

6/E 5 cyl. engine 5 cyl. motor
8/E 6 cyl. engine 6 cyl. motor
10/E 7 cyl. engine 7 cyl. motor
11/E 8 cyl. engine 8 cyl. motor
13/E 9 cyl. engine 9 cyl. motor

021 Cylindrical screw Cylindrisk skrue

114/E 5 cyl. engine 5 cyl. motor
134/E 6 cyl. engine 6 cyl. motor
154/E 7 cyl. engine 7 cyl. motor
174/E 8 cyl. engine 8 cyl. motor
194/E 9 cyl. engine 9 cyl. motor

022 Disc Skive

120/E 5 cyl. engine 5 cyl. motor
140/E 6 cyl. engine 6 cyl. motor
160/E 7 cyl. engine 7 cyl. motor
180/E 8 cyl. engine 8 cyl. motor
200/E 9 cyl. engine 9 cyl. motor

023 6/E Cylindrical screw Cylindrisk skrue

024 2/E Cylindrical screw Cylindrisk skrue

029 1/E Cover Dæksel

030 1/E Cover Dæksel

031 6/E Hexagon screw Sekskantskrue

041 1/D Cover Dæksel

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
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

13.47 - ES0
MAN Diesel & Turbo

Plate
Page 1 (3) Covers on Frame 51106-42

L27/38

029
022
021

031

030 005
024
008 009

022 015
023
014
051 014 057
055, 061 013
058
056
**) **) Splash oil,
048 002
see plate 50962
059, 060 022
021
001

046 041
047 045 022
021 022
021

13.47 - ES0
 MAN Diesel & Turbo

Plate
51106-42 Covers on Frame Page 2 (3)

L27/38

002
001

014 006
022

021

016

007

022
022 021 009
021

022
021 010

13.47 - ES0
MAN Diesel & Turbo

Plate
Page 3 (3) Covers on Frame 51106-42

L27/38
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

001 2/C Cover Dæksel

031 6/E Hexagon screw Sekskantskrue
002 2/C O-ring O-ring
041 1/D Cover Dæksel
005 2/E O-ring O-ring
045 1/D Safety valve Sikkerhedsventil
006 1/E O-ring O-ring
046 6/D Hexagon screw Sekskantskrue
007 1/E Cover Dæksel
047 6/D Disc Skive
008 1/E Cover Dæksel
048 1/D O-ring O-ring
009 2/E O-ring O-ring
051 1/D Cover Dæksel
010 1/E Cover Dæksel
055 1/D Threaded bar Gevindstuds
013 Cover, splash oil, com- Dæksel, splash oil,
plete incl item 051, komplet inkl item 051, 056 1/D Protecting pipe beskyttelsesrør
055, 056, 057, 058, 059, 055, 056, 057, 058, 059,
060, 061 060, 061 057 2/D Cylindrical screw Cylindrisk skrue
1/E 5 cyl. engine 5 cyl. motor
2/E 6 cyl. engine 6 cyl. motor 058 1/D Plate Plade
3/E 7, 8 cyl. engine 7, 8 cyl. motor
4/E 9 cyl. engine 9 cyl. motor 059 1/D Screw Skrue

014 2/C O-ring O-ring 060 /I Glue Lim

015 Cover with safety Dæksel med sikker- 061 /I Packing-silicone Packing-silicone
valves, complete incl. hedsventil, komplet inkl. paste paste
item 041, 045, 046, item 041, 045, 046,
047, 048 047, 048
4/E 5, 6, 7 cyl. engine 5, 6, 7 cyl. motor
5/E 8, 9 cyl. engine 8, 9 cyl. motor

016 1/C Cover for crankcase Dæksel for krumtaphus

021 Cylindrical screw Cylindrisk skrue

114/E 5 cyl. engine 5 cyl. motor
134/E 6 cyl. engine 6 cyl. motor
154/E 7 cyl. engine 7 cyl. motor
174/E 8 cyl. engine 8 cyl. motor
194/E 9 cyl. engine 9 cyl. motor

022 Disc Skive

120/E 5 cyl. engine 5 cyl. motor
140/E 6 cyl. engine 6 cyl. motor
160/E 7 cyl. engine 7 cyl. motor
180/E 8 cyl. engine 8 cyl. motor
200/E 9 cyl. engine 9 cyl. motor

023 6/E Cylindrical screw Cylindrisk skrue

024 2/E Cylindrical screw Cylindrisk skrue

029 1/E Cover Dæksel

030 1/E Cover Dæksel

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
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

13.47 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-01

L27/38

113 162

150
005

091

101

149

137
125

12.39 - ES0 - 582 mm

 MAN Diesel & Turbo

Plate
51109-01 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

005 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 582 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-02

L27/38

113 162

150
017

091

101

149

137
125

12.39 - ES0 - 689 mm

 MAN Diesel & Turbo

Plate
51109-02 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

017 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 689 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-03

L27/38

113 162

150
029

091

101

149

137
125

12.39 - ES0 - 719 mm

 MAN Diesel & Turbo

Plate
51109-03 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

029 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 719 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-04

L27/38

113 162

150
030

091

101

149

137
125

12.39 - ES0 - 803 mm

 MAN Diesel & Turbo

Plate
51109-04 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

030 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 803 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-05

L27/38

113 162

150
042

091

101

149

137
125

12.39 - ES0 - 826 mm

 MAN Diesel & Turbo

Plate
51109-05 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

042 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 826 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-06

L27/38

113 162

150
054

091

101

149

137
125

12.39 - ES0 - 830 mm

 MAN Diesel & Turbo

Plate
51109-06 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

054 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 830 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-07

L27/38

113 162

150
066

091

101

149

137
125

12.39 - ES0 - 850 mm

 MAN Diesel & Turbo

Plate
51109-07 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

066 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 850 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Coupling guard 51109-08

L27/38

113 162

150
078

091

101

149

137
125

12.39 - ES0 - 869 mm

 MAN Diesel & Turbo

Plate
51109-08 Coupling guard Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

078 1/E Coupling guard Koblingsskærm

091 3/E Cover Dæksel

101 30/E Screw Skrue

113 17/E Screw Skrue

125 6/E Screw Skrue

137 6/E Washer Skive

149 6/E Nut Møtrik

150 17/E Screw Skrue

162 2/E Eye bolt Øjebolt

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

12.39 - ES0 - 869 mm

MAN Diesel & Turbo

Plate
Page 1 (2) Base Frame - One Bearing 51111-07H

L27/38

080

175

126
138
092

151
163

Level switch in oil sump,

018 see plate 50920

031
043
055
079 067

06.18 - ES0
 MAN Diesel & Turbo

Plate
51111-07H Base Frame - One Bearing Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

018 1/E Base frame, Bundramme,

5 cyl. engine 5 cyl. motor

031 1/E Base frame, Bundramme,

6 cyl. engine 6 cyl. motor

043 1/E Base frame, Bundramme,

7 cyl. engine 7 cyl. motor

055 1/E Base frame, Bundramme,

8 cyl. engine 8 cyl. motor

067 1/E Base frame, Bundramme,

9 cyl. engine 9 cyl. motor

079 7/E Screw Skrue

080 4/E Screw Skrue

092 4/E Nut Møtrik

126 Screw Skrue

32/E 5 cyl. engine 5 cyl. motor
36/E 6 cyl. engine 6 cyl. motor
40/E 7 cyl. engine 7 cyl. motor
44/E 8 cyl. engine 8 cyl. motor
48/E 9 cyl. engine 9 cyl. motor

138 Disc Skive

32/E 5 cyl. engine 5 cyl. motor
36/E 6 cyl. engine 6 cyl. motor
40/E 7 cyl. engine 7 cyl. motor
44/E 8 cyl. engine 8 cyl. motor
48/E 9 cyl. engine 9 cyl. motor

151 1/E Packing ring Pakningsring

163 1/E Plug screw Propskrue

175 13/E 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

06.18 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Base Frame - Two Bearings 51111-10

L27/38

080

175

126
138
092

151
163

Level switch in oil sump,

018 see plate 50920

031
043
055
079 067

12.33 - ES0
 MAN Diesel & Turbo

Plate
51111-10 Base Frame - Two Bearings Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

018 1/E Base frame, Bundramme,

5 cyl. engine 5 cyl. motor

031 1/E Base frame, Bundramme,

6 cyl. engine 6 cyl. motor

043 1/E Base frame, Bundramme,

7 cyl. engine 7 cyl. motor

055 1/E Base frame, Bundramme,

8 cyl. engine 8 cyl. motor

067 1/E Base frame, Bundramme,

9 cyl. engine 9 cyl. motor

079 7/E Screw Skrue

080 4/E Screw Skrue

092 4/E Nut Møtrik

126 Screw Skrue

32/E 5 cyl. engine 5 cyl. motor
36/E 6 cyl. engine 6 cyl. motor
40/E 7 cyl. engine 7 cyl. motor
44/E 8 cyl. engine 8 cyl. motor
48/E 9 cyl. engine 9 cyl. motor

138 Disc Skive

32/E 5 cyl. engine 5 cyl. motor
36/E 6 cyl. engine 6 cyl. motor
40/E 7 cyl. engine 7 cyl. motor
44/E 8 cyl. engine 8 cyl. motor
48/E 9 cyl. engine 9 cyl. motor

151 1/E Packing ring Pakningsring

163 1/E Plug screw Propskrue

175 13/E 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

12.33 - ES0
 MAN Diesel
Plate
Page 1 (2) Covering 51120-01H

L27/38

066
054 078 A

3 x M10 to be drilled in
cover when mounting

091
101 150

113

017
208 125
221 137
233

029 149
030

125
B
137
08028-0D/H5250/94.08.12

4 x M8 to be drilled in
base frame when mounting
162
B
042
8 x M6 to be drilled in
cooler when mounting 198
029 125 029
030 137 174 186
4 x M6 to be drilled in
base frame when mounting

06.40 - ES0
MAN Diesel
Plate
51120-01H Covering Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

017 1/E Guard for cooler Skærm for køler

8 cyl. engine 8 cyl. motor

029 12/E Screw Skrue

030 13/E Washer Skive

042 1/E Guard Skærm

054 1/E Guard Skærm

066 2/E Screw Skrue

078 2/E Washer Skive

091 3/E Screw Skrue

101 3/E Washer Skive

113 1/E Guard Skærm

125 17/E Screw Skrue

137 17/E Washer Skive

149 1/E Guard Skærm

150 2/E Bracket Holder

162 1/E Distance piece Afstandsstykke

174 1/E Guard Skærm

186 1/E Nut Møtrik

198 1/E Guard Skærm

208 1/E Guard for cooler Skærm for køler

5 cyl. engine 5 cyl. motor

221 1/E Guard for cooler Skærm for køler

6, 7 cyl. engine 6, 7 cyl. motor

233 1/E Guard for cooler Skærm for køler

9 cyl. engine 9 cyl. motor
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

06.40 - ES0
Turbocharger

512/612
MAN Diesel & Turbo

Description
Turbocharger System 512.01
Page 1 (1) Edition 14

L27/38

P8 M1 P2 P9

TE TE TE TE TE TE ZT
61 62 60 60 60 60 88

SE TE TE TE
(see compressed air diagram)

89 98-3 98-2 98-1

Exhaust gas to TC SI
89-90
Compressed air - inlet

SE
90-1
SE
Charging air from TC 90-2

PT TE
31 31
Alternator
Water mist
catcher
Condensed Lambda controller
water separator

Funnel delivered P6 Compressed air - inlet

by customer (see compressed air diagram) Optional

Fig. 1 Diagram for compressed air system

Turbocharger System through the cooler, the end cov­ers be­ing designed
with partitions which cause the coo­ling water to turn.
The turbocharger system of the engine, which is a
constant pressure system, consists of an exhaust The cooling water for the low temperature stages of
gas receiver, a turbocharger, a charging air cooler the charge air is controlled by the scavenging pres­
and a charging air receiver. sure to ensure sufficient scavenging temperature for
burning HFO. A water mist catcher can be adopted
The turbine wheel of the turbocharger is driven by after the air cooler as an option.
the engine exhaust gas, and the turbine wheel drives
the turbocharger compressor, which is mounted on From the exhaust valves, the exhaust gas is led
the common shaft. The compressor draws air from through to the exhaust gas receiver where the
the engine room through the air filters. pulsatory pressure from the indi­vidual cylinders is
equalized and passed on to the turbocharger as a
The turbo­charger forces the air through the char­ constant pressure, and further to the exhaust outlet
ging air cooler to the char­ging air receiver. From the and silencer ar­range­ment.
char­ging air re­ceiver the air flows to each cylinder
through the in­let valves. The exhaust gas receiver is made of pipe sections,
one for each cylinder, connected to each other by
The charging air cooler is a compact two-stage tube­ means of compensators to prevent excessive stress
-type coo­ler with a large cooling sur­face. The high in the pipes due to heat expansion.
temperature water is passed through the first stage
of the charging air cooler and the low temperature To avoid exces­sive thermal loss and to ensure a
water is passed through the second stage. At each reasonably low surface tem­pera­ture the exhaust gas
stage of the cooler the water is passed two times receiver is in­sulated.

11.45 - ES0 - Tier II

MAN Diesel & Turbo

Description
Turbocharger System 512.01
Page 1 (2) Edition 15

L27/38

P8 M1 P2 P9

TE TE TE TE TE TE ZT
62 60 60 60 60 88
(see compressed air diagram)

61

SE TE TE TE
89 98-3 98-2 98-1
Compressed air - inlet

Exhaust gas to TC SI
89-90

SE
90-1
SE
Charging air from TC 90-2

PT TE
31 31
Alternator
Water mist
catcher
Condensed Lambda controller
water separator

Funnel delivered P6 Compressed air - inlet

by customer (see compressed air diagram)

Fig. 1 Diagram for compressed air system

Turbocharger System The charging air cooler is a compact two-stage tube­-

type coo­ler with a large cooling sur­face. The high
The turbocharger system of the engine, which is a temperature water is passed through the first stage
constant pressure system, consists of an exhaust of the charging air cooler and the low temperature
gas receiver, a turbocharger, a charging air cooler water is passed through the second stage. At each
and a charging air receiver. stage of the cooler the water is passed two times
through the cooler, the end cov­ers be­ing designed with
The turbine wheel of the turbocharger is driven by partitions which cause the coo­ling water to turn.
the engine exhaust gas, and the turbine wheel drives
the turbocharger compressor, which is mounted on The cooling water for the low temperature stages of
the common shaft. The compressor draws air from the charge air is controlled by the scavenging pres­
the engine room through the air filters. sure to ensure sufficient scavenging temperature for
burning HFO. A water mist catcher can be adopted
The turbo­charger forces the air through the char­ after the air cooler as an option.
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.

13.20 - ES0 - shut-off valve

 MAN Diesel & Turbo

512.01 Turbocharger System Description

Edition 15 Page 2 (2)

L27/38
The exhaust gas receiver is made of pipe sections, Shut-off valve (Ricksaver)
one for each cylinder, connected to each other by
means of compensators to prevent excessive stress The valve is applicable for installations with risk of
in the pipes due to heat expansion. gas penetration such as some applications. Further,
the valve is applied on the dual fuel engines.
To avoid exces­sive thermal loss and to ensure a
reasonably low surface tem­pera­ture the exhaust gas The principle of the valve is to activate in case of
receiver is in­sulated. external gas leakage alarm in the safety system or
in case of overspeed. In both cases the safety sy­
stem will release the rig saver valve shortly after the
shutdown signal. The reason for the slight delay is to
get as much air out of the turbocharger as possible
before the valve blocks for the air passage between
the turbocharger and the engine.

13.20 - ES0 - shut-off valve

MAN Diesel

Description Cleaning the Turbocharger In Service 512.05

Page 1 (1)
Water Washing of Compressor Edition 01

General

Compressor Chemical cleaning will not improve the cleaning

process as this primarily is based on the mechanical
Fouling of the airways depends primarily on the pu- effect from the impact of the water droplets.
rity of the inlet air and thus, in turn, on the general
maintenance condition of the machinery, i.e. mainly Certain types of fluid solvents can give formation
of the gas and oil tightness of the engines and on the of deposits on the compressor wheel, and should
fresh air ventilation system of the engine room. under no circumstances be used.

Fouling of air filter, compressor or charging air cooler The intervals between cleaning by injection of water
may be observed as changes in performance para- should be adjusted after assessing the degree and
meters: rate of fouling in the particular plant, i.e. based on
observations and experience.
- Decreasing charging air pressure.
- Decreasing turbocharger rotor speed.
- Increasing exhaust gas temperature.
- Severe fouling of airways may even result in
compressor surge.

Regular cleaning during operation by injection of

water before the compressor wheel will reduce the
fouling rate considerably, and consequently prolong
the intervals between dismantling necessary for
mechanical cleaning.

94.26 - ES0U-G
MAN Diesel

Description Cleaning the Turbocharger in Service 512.10

Page 1 (3)
Dry Cleaning - Turbine Edition 02H

L21/31, L27/38
L23/30H, V28/32S
Description Cleaning System

The tendency to fouling on the gas side of turbo- The cleaning system consists of a cleaning agent
chargers depends on the combustion conditions, container (2) with a capacity of approx. 0.5 liters and
which are a result of the load and the maintenance a removable cover. Furthermore the system consists
condition of the engine as well as the quality of the of an air valve (3), a closing valve (1) and two snap
fuel oil used. on connectors.

Fouling of the gas ways will cause higher exhaust The position numbers (2) and (3) indicate the system's
gas temperatures and higher wall temperatures of "blow-gun". Only one "blow-gun" is used for each
the combustion chamber components and will also engine plant. The blow-gun is working according to
lead to a higher fuel consumption rate. the ejector principle with pressure air (working air)
at 5-7 bar as driven medium. Injection time approx.
Tests and practical experience have shown that radi- 2 min. Air consumption approx. 5 Nm3/2 min.
al-flow turbines can be successfully cleaned by the
dry cleaning method.

This cleaning method employs cleaning agents con-

sisting of dry solid bodies in the form of granules. A
certain amount of these granules, depending on the
turbocharger size, is, by means of compressed air,
blown into the exhaust gas line before the gas inlet
casing of the turbocharger.

The injection of granules is done by means of wor-

king air with a pressure of 5-7 bar.

On account of their hardness, particularly suited

blasting agents such as nut-shells, broken or artifi-
cially shaped activated charcoal with a grain size of
1.0 mm to max. 1.5 mm should be used as cleaning
agents.
1 Closing valve 2 Container
The solid bodies have a mechanical cleaning effect 3 Air valve 4 working air inlet
which removes any deposits on nozzle vanes and 5 Exhaust pipe 6 Snap coupling
turbine blades.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine
Dry cleaning can be executed at full engine load and
does not require any subsequent operating period of
the engine in order to dry out the exhaust system.

Experience has shown that regular cleaning intervals

are essential to successful cleaning, as excessive
fouling is thus avoided. Cleaning every second day
during operation is recommended.

The cleaning intervals can be shorter or longer based

on operational experience.

97.08 - ES2
 MAN Diesel

512.10 Cleaning the Turbocharger in Service Description

Page 2 (3)
Edition 02H Dry Cleaning - Turbine
L21/31, L27/38
L23/30H, V28/32S
Dry cleaning of turbochargers

Suppliers of cleaning agents:

1. "Solf Blast Grit, Grade 14/25"

TURCO Products B.V.

Verl. Blokkenweg 12, 617 AD EDE - Holland
Tel.:08380 - 31380, Fax.: 08380 - 37069

2. Designation unknown

Neptunes Vinke B.V.

Schuttevaerweg 24, 3044 BB Rotterdam
Potbus 11032, 3004 E.A. Rotterdam, Holland
Tel.: 010 - 4373166 Fax.: 4623466

3. "Grade 16/10"

FA. Poul Auer GmbH

Strahltechnik
D-6800 Mainheim 31, Germany

4. "Granulated Nut Shells"

Eisenwerke Würth GmbH + Co.

4107 Bad Friederichshall, Germany
Tel.: 0 71 36-60 01

5. "Soft Blasting Grade 12/3a"

H.S. Hansen Eftf. Kattegatvej 2

2100 Copenhagen Ø, Denmark
Tel.:(31) 29 97 00 Telex: 19038

6. "Crushed Nutshells"

Brigantine, Hong Kong

7. "Turbine Wash"

Ishikawajima-Harima Heavy Industries Co.

Ishiko Bldg., 2-9-7 Yassu, Chuo-Ku
Tokyo 104, Japan
Tel.: 03-2 77-42 91

97.08 - ES2
MAN Diesel

Description Cleaning the Turbocharger in Service 512.10

Page 3 (3)
Dry Cleaning - Turbine Edition 02H

L21/31, L27/38
L23/30H, V28/32S
8. "A-C Cleaner" (Activated Coal)

Mitsui Kozan Co. Ltd. (Fuel Dept.)

Yamaguchi Bldg., 2-1-1 Nihonbashi
Muromachi, Chuo-Ku
Tokyo 103, Japan

9. "OMT-701"

Marix KK
Kimura Bldg., 6-2-1 Shinbashi
Minato-Ku, Tokyo 105, Japan
Tel.: 03-4 36-63 71, Telex: 242-7232 MAIX J

10. "OMT-701"

OMT Incorporated
4F, Kiji Bldg., 2-8 Hatchobori,
4-chome, Chuo-Ku, Tokyo 104, Japan
Tel.: 03-5 53-50 77, Telex: 252-2747 OMTINC J

11. "Marine Grid No. 14" (Walnut)

Hikawa Marine
Kaigan-Dori 1-1-1, Kobe 650, Japan
Tel.: 0 78-3 21-66 56

12. "Marine Grid No. 14"

Mashin Shokai
Irie-Dori, 3-1-13, Hyogo-Ku
Kobe 652, Japan
Tel.: 0 78-6 51-15 81

13. Granulate

MAN Diesel
Teglholmsgade 41 2450 København SV, Danmark
Tel.: +45 33 851100 Fax.: +45 33 851030

The list is for guidance only and must not be considered complete. We
undertake no responsibility that might be caused by these or other pro-
ducts.

97.08 - ES2
MAN Diesel & Turbo

Description Cleaning the Turbocharger in Service 512.15

Page 1 (1)
Water Washing - Turbine Side Edition 03

L16/24, L21/31,
L27/38
Description fuel quality these intervals can be shorter or longer.
However, the turbine must be washed at the latest
The tendency to fouling on the gas side of turbo­ when the exhaust gas tempe­rature upstream of the
chargers depends on the combustion conditions, turbine has risen about 20° C above the normal
which are a result of the load on and the maintenance temperature.
condition of the engine as well as the quality of the
fuel oil used. Heavily contami­nated turbines, which where not
cleaned periodically from the very beginning or after
Fouling of the gas ways will cause higher exhaust an overhaul, cannot be cleaned by this method.
gas temperatures and higher surface temperatures
of the combustion chamber components and will If vibration in the turbocharger occur after water-
also lead to a lower performance. washing has been carried out, the washing should
be repeated. If unbalance still exists, this is pre­
Tests and practical experience have shown that sumably due to heavy fouling, and the engine must
radial-flow turbines can be successfully cleaned be stopped and the turbocharger dismantled and
by injection water into the inlet pipe of the turbine. manually cleaned.
The cleaning effect is based on the water solubility
of the deposits and on the mechanical action of the The washing water should be taken from the fresh
im­pinging water droplets and the water flow rate. water system and not from the fresh cooling water
system or salt water system. No cleaning agents and
The necessary water flow is depending on exhaust solvents need to be added to the water.
gas flow and temperature. E.g. the flow needed for
L16/24 is from 2.5 - 5 litres per minute for 5 and 9 To avoid corrosion during standstill, the engine must,
cylinder engines. The water flow must be so high upon completing of water washing run for at least 1
that all of the water do not evaporate. Also the wa­ hour before stop so that all parts are dry.
terflow must not be so high that the turbine wheel is
drowned and stops rotating. The washing sequence
should be in accordance with the turbocharger ma­ Water Washing System
nual. Engine load, exhaust gas temperature before
turbine and turbine speed must be according to The water washing system consists of a pipe system
turbocharger manual. Carry out sequential washing equipped with a regulating valve, a manoeuvring
so that exhaust gas temperature after turbine drops valve, a 3-way cock and a drain pipe with a drain
below 100°C and in the drying period increases to valve from the gas outlet, see illustration on working
more than 100°C. For preadjustment of the washing card 512-15.00.
tool, install the correct orifice for the actual engine
size, check that the water flow is in accordance with The water for washing the turbine, is supplied from
the table by adjusting the water pressure. Check in the external fresh water system through a flexible
a bucket that the water flow is in the correct range. hose with couplings. The flexible hose must be
disconnected after water washing.
Water flow Diameter orifice
l/min mm By activating the manoeuvring valve and the regu­
lating valve, water is led through the 3-way cock to
5-9L16/24 2-5 2.5
the exhaust pipe intermediate flange, equipped with
5-9L21/31 5-10 3.5
a channel to lead the water to the gas inlet of the
5-9L27/38 8-15 4.5 turbocharger.

Experience has shown, that washing at regular inter­ The water which is not evaporated, is led out through
vals is essential to successful cleaning, as excessive the drain pipe in the gas outlet.
fouling is thus avoided. Washing at inter­vals of 100
hours is therefore recommended. De­pending on the

12.16 - ES0
 MAN Diesel
Description
Control Air for Charge Air Blow off 512.38
Page 1 (1) Edition 01H

L27/38

Functionality of SCR Valves at Charge Air

Inlet Cooler Small valve Big valve Outlet

The valves for the SCR system is mounted to keep

the exhaust gas temperature after TC above 310°C, if
possible. This temperature is needed for the catalyst
to perform as intended.

The system exists of two different valves with a

opening area of 5 cm2 (small valve) and 10 cm2 (big
valve). The two valves openes and closed according
to the diagram shown below with the temperatures
written below.

The function is activated when engine is running and

deactivated when engine is stopped. Fig 1

Control of Valves for SCR Temperature

Small valve = Valve A

Big valve = Valve B
Valve pos.

B open

B close

A open

A close
08028-0D/H5250/94.08.12

t15L t15H t10L t10H t5L t5H Temp.

t15L = 309° C t15H = 312° C

t10L = 315° C t10H = 320° C
t 5L = 325° C t 5H = 330° C

Fig 2 Diagram of valve function

07.22 - ES0
MAN Diesel & Turbo
Work Card 512-01.00
Page 1 (5) Overhaul of Charging Air Cooler
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 012
52000 032
Shut off cooling water 52001 239
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Overhaul of charging air cooler.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 3-4 Plate No. Item No. Quantity
Number : 2 51201 030 1/k
51201 113 1/k
51201 150 1/k
Data 51103 408 8/E
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2001.07.23.
 MAN Diesel & Turbo
512-01.00 Work Card
Overhaul of Charging Air Cooler Page 2 (5)
Edition 03

L27/38

Description
The charging air cooler is normally cleaned and
overhauled at the intervals indicated in the "Planned
Maintenance Program", or if observations prove
that the cooler does not work satisfactory, see sec-
tion 502.

Dismounting of charging air cooler

Warning!
Use protective gloves
1) Turn off the cooling water inlet and outlet
valves.
2) Remove the charging air pipe, see fig 1.
3) Mount the lifting tool and tighten the four bolts, 1 Charging air pipe
see fig 4.
Figure 1: Charging air pipe
4) Attach a tackle hook to the lifting tool and
slightly tighten the wire.
5) Loosen and remove the bolts for the charging
air cooler, see fig 2.
6) Lift and pull the air cooler out of the cooler
housing and place it on a couple of wooden
planks on the floor.
7) Remove screws (1), end cover (2), reversing
cover (5) and side plate (6), see fig 3.

1 Bolts

Figure 2: Bolts for chargin air cooler

2001.07.23.
MAN Diesel & Turbo
Work Card 512-01.00
Page 3 (5) Overhaul of Charging Air Cooler
Edition 03

L27/38

1 Screw 2 End cover

3 Gasket 4 Gasket
5 Reversing cover 6 Side plate

Figure 3: Charging air cooler

2001.07.23.
 MAN Diesel & Turbo
512-01.00 Work Card
Overhaul of Charging Air Cooler Page 4 (5)
Edition 03

L27/38

Figure 4: Mounting of lifting tool

3) Fouling and deposition in the pipes can be
Cleaning and inspecting removed with a hand or machine operated cir-
cular steel brush.
1) Clean the cooler element of the water and air
sides.
After using cleaning agents the manufacturing
Mounting of charging air cooler
recommendation must be followed. 1) Renew gaskets (3) for end cover and gasket (4)
The greatest care must be exercised when dis- for reversing cover before assembling end cover
mantling cleaning and mounting the cooler ele- (2), reversing cover (5) and side plate (6). See fig
ment, as the thin fins of the tubes cannot stand 4.
impacts and pressure. Note: Before mounting the air cooler, the O-ring at
Nevertheless, the metal is bent, it should be the water connections must be replaced, see fig 5.
carefully straightened, as bent fins will increase
the pressure drop across the cooler considera-
bly.
Should one or more cooler tubes become leaky
it/they must immediately be made tight, either
by expanding the tube ends into the tube plates
or by blanking of the tube(s) concerned with
plugs.
It is important that the charging air cooler is not
leaky as any water that leaks in will be carried
together with the air into the cylinders where it
will damage valves, piston rings, and cylinder
liners.
2) Also clean the end cover and coat it on the
inside with an anti-corrosion agent.

2001.07.23.
MAN Diesel & Turbo
Work Card 512-01.00
Page 5 (5) Overhaul of Charging Air Cooler
Edition 03

L27/38

Figure 5: O-ring at water connections

2) Lift the air cooler by the lifting tool and carefully

push it into its housing.
3) Mount the bolts for the air cooler, see fig 3.
4) Mount the screws for the charge air pipe, see
fig 1.

Out of service periods

At longer periods out of service, recommendations
for the entire system is followed. Please see section
501.

2001.07.23.
MAN Diesel & Turbo
Work Card 512-01.10
Page 1 (2) Exhaust Pipe Compensator
Edition 02

V28/32S, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2003.01.27. - ES0
 MAN Diesel & Turbo
512-01.10 Work Card
Exhaust Pipe Compensator Page 2 (2)
Edition 02

V28/32S, L21/31, L27/38

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

Description
To minimize toxic gases in the engine room and to
keep the exhaust gas insulation in good condition, it
is necessary to keep the exhaust pipe compensa-
tors tight.
1) Start the engine.
2) Feel and look for any leak in the exhaust gas
pipe compensators.
Note:
If any leak is discovered, the compensator in ques-
tion must be renewed.

2003.01.27. - ES0
MAN Diesel & Turbo
Work Card 512-05.00
Page 1 (4) Water Washing of Compressor Side
Edition 01

L23/30H, V28/32S, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Water washing of compressor side. Turbocharger
cleaning with engine in service.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1 See the special
instructions for
turbocharger.
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2002.05.13. - ES0
 MAN Diesel & Turbo
512-05.00 Work Card
Water Washing of Compressor Side Page 2 (4)
Edition 01

L23/30H, V28/32S, L21/31, L27/38

Health Risk! 2) Discharge the excesspressure in the container

by drawing out the spindle in the safety valve
Warning! (see fIg. 1) before loosening the top cover.
The spindle returns automatically by means of a
Health Risk!
built-in spring
Due to vibrations during engine operation, espe-
3) Fill the container with 2 litres fresh water (see
cially in awkward positions!
the scale on the container).
Warning!
Before Cleaning
The cleaning process is only to be carried out when Do not use sea water or cooling water!
the engine is at operating temperature (see Operat-
4) Mount the top cover on the container.
ing Data 500.30 / 600.30) and when it is loaded as
close as possible to full load (see Main Particulars 5) Blow air into the container by means of a blow
500.00 / 600.00). gun, until an operation pressure of 3 bar is
reached (see fig 2).
See also "Cleaning the Turbocharger in Service, The safety valve will open at a pressure of 4 bar
Water Washing of Compressor", 512.05 / 612.05. Excesspressure will discharge through the
safety valve
Cleaning Procedure

1 Work air 2 Blow gun

3 Top cover 4 Container

Figure 2: .
1 Spindle 2 Safety valve

Figure 1: .
6) Connect the plug-in coupling of the lance to the
snap coupling on the pipe (see fig 3).
1) Run the engine with as high a load as possible.

2002.05.13. - ES0
MAN Diesel & Turbo
Work Card 512-05.00
Page 3 (4) Water Washing of Compressor Side
Edition 01

L23/30H, V28/32S, L21/31, L27/38

1 Injection tube 2 Pipe

3 Snap coupling 4 Plug-in coupling
5 Hand valve with handle 6 Container
7 Charge air line

Figure 3: .

7) Depress the handle on the hand valve until the

water is completely injected into the compres-
sor (approx. 30 seconds).
The water will enter the compressor in atomized
condition, impinge the vanes of the compressor
wheel with high velocity and thus wash off the
dirt deposited.
8) Release the plug-in coupling and vent the con-
tainer by drawing the spindle out of the safety
valve.

After cleaning
9) Run the engine for minimum 10 minutes at
unaltered high load.
10) Compare the measurements of the operating
data (see fig 4) before and after the cleaning
procedure (see Operating Data 500.30 /
600.30).

2002.05.13. - ES0
 MAN Diesel & Turbo
512-05.00 Work Card
Water Washing of Compressor Side Page 4 (4)
Edition 01

L23/30H, V28/32S, L21/31, L27/38

IF THEN
the comparison indicates success of the washing proce- the water washing of the compressor side is finished
dure
the comparison indicates lack of the washing procedure carry out the washing procedure from step 1 with 10
minutes interval from the initial washing
severe dirt is being deposited in the compressor dismantling of the compressor components for manual
cleaning is necessary (see special turbocharger manual in
section 512 / 612).

2002.05.13. - ES0
MAN Diesel & Turbo
Work Card 512-10.00
Page 1 (2) Cleaning the Turbine, dry cleaning
Edition 05

V28/32S, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 51210 136
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Cleaning and/or maintenance of air filter.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2003.01.27.
 MAN Diesel & Turbo
512-10.00 Work Card
Cleaning the Turbine, dry cleaning Page 2 (2)
Edition 05

V28/32S, L21/31, L27/38

Health Risk! 2) Fill the container (2) with granulate. The amount
depending on the type of turbocharger.
Warning!
NR12, NR14, NR15, NR17, 0.3 liters
Health Risk! NR20
Due to vibrations during engine operation, espe- NR24, NR26 0.4 liters
cially in awkward positions! NR29, NR34 0.5 liters

3) Connect to the working air system (4).

Dry cleaning
4) Connect the dry cleaning device to valve (1) and
open valve (3). Then open valve (1) slowly until a
hissing sound indicates that the granulate is
being injected. Injection period: Approx. 2 min
or until the container is empty.
Note: If vibrations occur after cleaning the turbine it
is necessary to repeat the cleaning process until no
vibrations are observed.

1 Stop valve 2 Container

3 Valve 4 Working air

Figure 1: Dry cleaning

The device is connected immediately before the TC

gas inlet.
Appropriate cleaning materials are granulates from
nut shells or activated charcoal of a grain size of 1
mm (max. 1.5 mm)

Cleaning sequence
Please also consult the instruction plate on the
engine.
The cleaning is to be carried out at high engine
load, min. 75 % MCR.
1) Before connecting the cleaning device, see fig
1, open the stop valve (1) and check that the
passage is not blocked. Close the valve again.

2003.01.27.
MAN Diesel & Turbo
Work Card 512-15.00
Page 1 (3) Water Washing of Turbine Side
Edition 03

L16/24, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Water washing of turbine side, cleaning with
engine in service.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/2 Plate No. Item No. Quantity
Number : 1 See the special
instruction for tur-
bocharger.
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2009.09.21.
 MAN Diesel & Turbo
512-15.00 Work Card
Water Washing of Turbine Side Page 2 (3)
Edition 03

L16/24, L21/31, L27/38

Cleaning Procedure
1) Adjust the engine load to approx. 20 % and let
the engine stabilize for 10 min.
2) Open the drain cock at the turbocharger outlet
and check for free passage, see fig 1.
3) Turn the 3-way cock to position 2 "Open", see
fig. 2 and check for free passage. If ok turn to
the water wash position 3 "Wash".
4) Connect the water supply to the water wash
system.
Figure 1: 3-way cock.
5) Activate the manoeuvring valve, see fig 1.
Then open the regulating valve and adjust the
water flow until the drain flow is approx. 0,25 l/
min.
6) Continue the water washing 5 - 10 min. or until
the drain water is free of particles.
7) Release the manoeuvring valve and disconnect
the water supply.
Turn the 3-way cock to position 1, "Closed"
and check that the water drain flow has stop-
ped.
8) Continue at this load at least 5 min. before
increasing the load to the normal condition.
9) After the water washing, the engine should run
for at least 1 hour before stop.
Note: The regulating valve has to be opened slowly.
The manoeuvring valve must not be locked in open
position.
The water injection time mentioned in item 6 must
be not exceeded.
For water washing of turbine side, see also descrip-
tion for water washing.

2009.09.21.
MAN Diesel & Turbo
Work Card 512-15.00
Page 3 (3) Water Washing of Turbine Side
Edition 03

L16/24, L21/31, L27/38

Figure 2: Arrangement for water washing.

2009.09.21.
MAN Diesel & Turbo
Work Card 512-15.00
Page 1 (2) Water Washing of Turbine Side
Edition 04

L16/24, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Water washing of turbine side, cleaning with
engine in service.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/2 Plate No. Item No. Quantity
Number : 1 See the special
instruction for tur-
bocharger.
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2012.04.16.
 MAN Diesel & Turbo
512-15.00 Work Card
Water Washing of Turbine Side Page 2 (2)
Edition 04

L16/24, L21/31, L27/38

Cleaning procedure Turn the 2-way cock to position 1, "Closed" and

check that the water drain flow has stopped.
1) Adjust the engine load to approx. 20 % and let
the engine stabilize for 10 min. 8) Continue at this load at least 5 min. before
increasing the load to the normal condition.
2) Open the drain cock at the turbocharger outlet
and check for free passage, see fig 1. 9) After the water washing, the engine should run
for at least 1 hour before stop.
Note: The regulating valve has to be opened slowly.
The water injection time mentioned in item 6 must
be not exceeded.
For water washing of turbine side, see also descrip-
tion for water washing.

Figure 1: Arrangement for water washing

3) Turn the 2-way cock to position 2 "Open", see Figure 2: .

fig. 2 and check for free passage. If ok connect
the washing tool to the quick coupling.
4) Connect the water supply to the water wash
system. Activate the 2-way cock on exhaust
pipe.
5) Activate the manoeuvring valve, see fig 1.
Check that exhaust gas temperature drops
below 100°C and that the turbine do not stop.
Activating tme according to TC-manual.
6) Repeat sequence according to TC-manual.
7) Release the manoeuvring valve and disconnect
the water supply.

2012.04.16.
 MAN Diesel
Plate
Page 1 (2) Charge Air Cooler 51201-19

L27/38

902

353
125
113
A-A

A
030

162
137

149

029
017

150 042
08028-0D/H5250/94.08.12

066 054 902 078

10.10 - ES0 - Tier II

 MAN Diesel

Plate
51201-19 Charge Air Cooler Page 2 (2)

L27/38
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

017 2/K Side plate Sideplade

029 8/K Screw Skrue

030 1/K O-ring O-ring

042 8/K Screw Skrue

054 4/K Plug screw Propskrue

066 4/K Cu-washer Cu-skive

078 4/K Screw Skrue

113 1/K Gasket end cover Pakning endedæksel

125 1/K End cover Endedæksel

137 1/K Cooler block Kølerblok

149 1/K Reversing cover Vendekammer

150 1/K Gasket Pakning

reversing cover vendekammer

162 1/E Charging air cooler, Charging air cooler,

complete komplet

353 22/K Screw Skrue

902 10/K Screw Skrue

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

10.10 - ES0 - Tier II

 MAN Diesel
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-20

L27/38

048 048 036

024

036

012

061 024 073

Turbocharger arrangement,
see plate 51203

097
107
119
168
181
08028-0D/H5250/94.08.12

061

09.46 - ES0
 MAN Diesel
Plate
51202-20 Exhaust Pipe Arrangement Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

012 1/E Cover Dæksel

024 Gasket Pakning

9/E 5 cyl. engine 5 cyl. motor
11/E 6 cyl. engine 6 cyl. motor
13/E 7 cyl. engine 7 cyl. motor
15/E 8 cyl. engine 8 cyl. motor
17/E 9 cyl. engine 9 cyl. motor

036 Screw Skrue

54/E 5 cyl. engine 5 cyl. motor
66/E 6 cyl. engine 6 cyl. motor
78/E 7 cyl. engine 7 cyl. motor
90/E 8 cyl. engine 8 cyl. motor
102/E 9 cyl. engine 9 cyl. motor

048 Nut Møtrik

54/E 5 cyl. engine 5 cyl. motor
66/E 6 cyl. engine 6 cyl. motor
78/E 7 cyl. engine 7 cyl. motor
90/E 8 cyl. engine 8 cyl. motor
102/E 9 cyl. engine 9 cyl. motor

061 1/C Exhaust manifold Udstødsmanifold

073 Compensator Kompensator

4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor
6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor
8/E 9 cyl. engine 9 cyl. motor

097 1/C Clamping strap 2/2 Holder 2/2

107 2/C Screw Skrue

119 2/C Nut Møtrik

168 2/C Spring pin Fjederstift

181 1/C Sealing ring Tætningsring 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

09.46 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Mounting of Turbocharger 51203-30

L27/38

See special
instruction book for TC

003

002

018
019
012
013

015
020 008
016
022
024
021

023 020

010
005
006

13.06 - ES0 - TCR18

 MAN Diesel & Turbo

Plate
51203-30 Mounting of Turbocharger Page 2 (2)

L27/38
Item no Item no
Qty Designation Benævnelse Qty Designation Benævnelse

002 1/E Support Støtte

003 1/E Support Støtte

005 8/E Hexagon screw Skrue

006 8/E Distance piece Afstandsstykke

008 2/E Hexagon bolt Bolt

010 1/E Cylindrical pin Cylindrisk passtift

012 6/E Hexagon screw Skrue

013 6/E Lock washer Låseskive

015 1/E Cylindrical screw Cylindrisk skrue

016 1/E Throttle screw Drøvleskrue

018 1/E Seal Tætning

019 1/E Screw plug Skrueprop

020 4/E Packing ring Pakningsring

021 1/E Sealing ring Tætningsring

022 1/E Sealing ring Tætningsring

023 1/E Sealing ring Tætningsring

024 1/E Sealing ring Tætningsring

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

13.06 - ES0 - TCR18

MAN Diesel & Turbo

Plate
Page 1 (2) Mounting of Turbocharger 51203-32

L27/38

See special
instruction book for TC

003

012
002
013

018
019

022 008

021
020
015 021
024

024
005
023
010
016 006

025

13.06 - ES0 - TCR20

 MAN Diesel & Turbo

Plate
51203-32 Mounting of Turbocharger Page 2 (2)

L27/38
Item no Item no
Qty Designation Benævnelse Qty Designation Benævnelse

002 1/E Support Støtte

003 1/E Support Støtte

005 8/E Hexagon screw Skrue

006 8/E Distance piece Afstandsstykke

008 2/E Hexagon screw Skrue

010 1/E Cylindrical pin Cylindrisk passtift

012 6/E Hexagon screw Skrue

013 6/E Lock washer Låseskive

015 1/E Cylindrical screw Cylindrisk skrue

016 1/E Throttle screw Drøvleskrue

018 1/E Seal Tætning

019 1/E Screw plug Skrueprop

020 2/E Packing ring Pakningsring

021 2/E O-ring O-ring

022 1/E O-ring O-ring

023 1/E Sealing ring Tætningsring

024 1/E Sealing ring Tætningsring

025 1/E Sealing ring Tætningsring

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

13.06 - ES0 - TCR20

MAN Diesel & Turbo
Plate
Page 1 (2) Exhaust pipe before turbocharger P51204-03

L27/38

2013.07.16 - TCR18
 MAN Diesel & Turbo
Plate
P51204-03 Exhaust pipe before turbocharger Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

157 1/E Pipe piece

169 10/E Nut
170 5/E Bolt
182 1/E Clamp
194 1/E Pipe bend
204 26/E Bolt
216 1/E Compensator
228 2/E Gasket
241 16/E Nut
253 1/E Socket
265 1/E Seal ring
277 1/E Screw plug
289 1/E Seal ring
361 1/E Gasket

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.07.16 - TCR18
MAN Diesel & Turbo
Plate
Page 1 (2) Exhaust pipe before turbocharger P51204-05

L27/38

2013.07.16 - TCR20
 MAN Diesel & Turbo
Plate
P51204-05 Exhaust pipe before turbocharger Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

157 1/E Pipe piece

169 5/E Nut
170 5/E Bolt
182 1/E Clamp
194 1/E Pipe bend
204 5/E Bolt
216 1/E Compensator
228 2/E Gasket
241 16/E Nut
253 1/E Socket
265 1/E Packing ring
277 1/E Screw plug
289 1/E Packing ring
290 5/E Nut
300 8/E Bolt
324 8/E Screw
336 1/E Seal ring
348 8/E Disc
361 1/E Gasket

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.07.16 - TCR20
MAN Diesel & Turbo

Plate
Page 1 (2) Water Washing of Compressor Side 51205-02

General

331

343

355

12.41 - ES0S-G
 MAN Diesel & Turbo

Plate
51205-02 Water Washing of Compressor Side Page 2 (2)

General
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

331 1/E Fitting Kobling

343 1/E Fitting Forskruning

355 1/E Container complete Beholder komplet

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

12.41 - ES0S-G
 MAN Diesel

Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 51210-01

L23/30H, L21/31,
L27/38, V28/32S

053
016 112 028 041 028 065 077

089 148

100

136
08028-0D/H5250/94.08.12

01.12 - ES0
 MAN Diesel

Plate
51210-01 Blowgun for Dry Cleaning of Turbocharger Page 2 (2)

L23/30H, L21/31,
L27/38, V28/32S
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

016 1/E Snap coupling Snapkobling

028 2/E Nipple Nippel

041 1/E Tee T-stykke

053 1/E Ball valve Kugleventil

065 1/E Snap coupling Snapkobling

077 1/E Snap coupling Snapkobling

089 1/E Packing ring Pakningsring

100 1/E Container, complete beholder, komplet

112 1/E Socket Muffe

136 1/E Blowgun, complete Rensepistol, complete

148 /I Granulate Granulat

08028-0D/H5250/94.08.12

When ordering spare parts, see also page 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

01.12 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Heat Insulation and Cover before Turbocharger 51211-09

L27/38

287

238
275
251 263
275 275 310

299 322
334 371
346
358
383

309

371

11.21 - ES0 - TCR20

 MAN Diesel & Turbo
Plate
51211-09 Heat Insulation and Cover before Turbocharger Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

238 1/E Heat insulation Varmeisolering

251 1/E Heat insulation Varmeisolering

263 1/E Heat insulation Varmeisolering

275 1/E Heat insulation Varmeisolering

287 1/E Connecting wire Samlingstråd

299 1/E Cover Inddækning

309 1/E Plate Plade

310 1/E Plate Plade

322 1/E Plate Plade

334 1/E Cover Inddækning

346 2/E Eye bolt Øjebolt

358 2/E Nut Møtrik

371 3/E Screw Skrue

383 27/E 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

11.21 - ES0 - TCR20

 MAN Diesel
Plate
Page 1 (2) Water Washing of Turbine Side 51215-02

L27/38

037

013

025
216
228
241 049

121
133
145
062
074
08028-0D/H5250/94.08.12

086
216
228
241
108
121
157 133
145
170

07.45 - ES0
 MAN Diesel
Plate
51215-02 Water Washing of Turbine Side Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

013 1/E 3-way cock 3-vejsventil

025 2/E Straight male stud Lige forskruning

037 1/E Pipe branch Rørforgrening

049 1/E Pipe Rør

062 1/E Straight female Lige kobling

coupling

074 1/E Adaptor, Mellemstykke

male/female

086 1/E Valve for water wash Ventil for vandvask

108 1/E Pipe Rør

121 2/E Plate Plade

133 2/E Pipe clamp Rørklemme

145 4/E Screw Skrue

157 1/E Regulating valve Reguleringsventil

170 1/E Pipe Rør

216 2/E Clamp Klemme

228 2/E Plate Plade

241 4/E Nut Møtrik

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

07.45 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Water washing of turbine side P51215-04

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

2014.01.09
 MAN Diesel & Turbo
Plate
P51215-04 Water washing of turbine side Page 2 (2)

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

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

290 1/E Snap coupling

300 1/E Coupling for manometer
312 1/E Pipe
324 1/E Restriction for lub. oil pipe
336 1/E Restriction for lub. oil pipe
348 1/E Restriction for lub. oil pipe
361 1/E Elbow coupling
385 1/E Tee
397 1/E Bushing
407 1/E Pressure gauge
419 2/E Straight male coupling
420 1/E Regulating valve
432 1/E Bushing
444 1/E Ball valve
456 1/E Snap coupling
468 1/E Snap coupling
481 1/E Water washing of turbine side,
complete

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

ace.
* = Only available as part of a spare parts kit/not availa-
ble separately
Qty/E = Qty/Engine

2014.01.09
MAN Diesel & Turbo

Plate
Page 1 (2) Charge Air Pipes 51230-14

L27/38

007
020

030

002

005

020 017
018 013
018 012
017 014
030
007
036
004
040
034
035
040

11.21 - ES0 - TCR20

 MAN Diesel & Turbo

Plate
51230-14 Charge Air Pipes Page 2 (2)

L27/38
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

002 1/E Air manifold Luftmanifold

004 11/E Cylindrical screw Cylindrisk skrue

005 2/E Cylindrical screw Cylindrisk skrue

007 1/E Intermediate flange Mellemflange

012 8/E Hexagon socket Skrue

head cap screw

013 8/E Hexagon nut Møtrik

014 8/E Disc Skive

017 16/E Hexagon screw Skrue

018 16/E Nut Møtrik

020 1/E Compensator, axial Kompensator, aksial

030 1/E Pipe piece Rørstykke

034 5/E Cylindrical screw Cylindrisk skrue

035 5/E Locking spring Låseskive

washer

036 2/E Cylindrical screw Skrue

040 /I Silicone oil Siliconeolie

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

11.21 - ES0 - TCR20

MAN Diesel & Turbo
Plate
Page 1 (2) Charge air pipes P51230-25

L27/38

2013.04.10
 MAN Diesel & Turbo
Plate
P51230-25 Charge air pipes Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

002 1/E Charge air manifold

004 13/E Hexagon socket screw
005 2/E Hexagon screw
007 1/E Intermediate flange
008 8/E Hexagon screw
009 8/E Hexagon nut
010 8/E Disc
018 1/E Pipe piece
019 1/E Compensator
020 2/E Gasket
021 1/E Intermediate flange
022 1/E Shut-off valve
023 2/E Gasket
025 6/E Hexagon screw
026 6/E Nut
027 6/E Hexagon screw
028 12/E Hexagon socket screw
029 12/E Cyindrical screw
030 5/E Hexagon socket screw
031 5/E Disc
040 /I Silicone oil

When ordering spare parts, see also page 500.50/600.50.

* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.04.10
Compressed air system

513/613
MAN Diesel & Turbo

Description 513.01
Page 1 (2) Compressed Air System Edition 28

L27/38

88

Start limitation valve

86

Fig. 1 Diagram for 10 bar compressed air system

General Starting System

The compressed air system on the engine consists of The engine is started by means of a built-on air
a starting system, starting control system and safety starter, which is a turbine motor with gear box, safety
system. Further, the system supplies air to the jet clutch and drive shaft with pinion. Further, there is a
system and the stop cylinders on each fuel injection main starting valve.
pump. On 8 and 9 cylinders engines air is supplied
to the oil mist detector through a reduction valve.
Control System
The compressed air is supplied from the starting
air receivers (30 bar) through a reduction station, The air starter is activated electrically with a pneu­matic
where from compressed air at 10 bar is supplied to 3/2-way solenoid valve. The valve can be activated
the engine. The reduction station should be located manually from the starting box on the engine, and
as near the starting air receiver as possible. it can be arranged for remote control, manual or
automatic.
Working pressure for the air starter:
min. 8 bar For remote activation the starting coil is connected
max. 10 bar so that every starting signal to the starting coil goes
through the safe start function which is connected to
To avoid dirt particles in the internal system, a dirt the safety system mounted on the engine.
strainer equipped with a drain valve is mounted in
the inlet line to the engine.

11.44 - ES0 - Tier II

 MAN Diesel & Turbo

513.01 Description
Edition 28 Compressed Air System Page 2 (2)

L27/38
Further, the starting valve also acts as an emergency Pneumatic Start Sequence
starting valve which makes it possible to activate the
air starter manually in case of power failure. When the starting valve is opened, air will be sup­plied
to the drive shaft housing of the air starter.

Safety System The air supply will - by activating a piston - bring the
drive pinion into engagement with the gear rim on
As standard the engine is equipped with an emer- the engine flywheel.
gency stop. It consists of one on-off valve, see
diagram, which activates the stop cylinder on each When the pinion is fully engaged, the pilot air will
fuel injection pump. flow to, and open the main starting valve, whereby
air will be led to the air starter, which will start to
Air supply must not be interrupted when the engine turn the engine.
is running.
When the RPM exceeds approx. 158, at which firing
has taken place, the starting valve is closed whereby
the air starter is disengaged.

11.44 - ES0 - Tier II

MAN Diesel & Turbo

Description 513.01
Page 1 (2) Compressed Air System Edition 29

L27/38

88

Start limitation valve

86

Fig. 1 Diagram for 30 bar compressed air system

General Starting System

The compressed air system on the engine consists of The engine is started by means of a built-on air
a starting system, starting control system and safety starter, which is a turbine motor with gear box, safety
system. Further, the system supplies air to the jet clutch and drive shaft with pinion. Further, there is a
system and the stop cylinders on each fuel injection main starting valve.
pump. On 8 and 9 cylinders engines air is supplied
to the oil mist detector through a reduction valve.
Control System
The compressed air is supplied from the starting air
receivers (30 bar). The air starter is activated electrically with a pneu­matic
3/2-way solenoid valve. The valve can be activated
Working pressure for the air starter: manually from the starting box on the engine, and
min. 16 bar it can be arranged for remote control, manual or
max. 30 bar automatic.

To avoid dirt particles in the internal system, a dirt For remote activation the starting coil is connected
strainer equipped with a drain valve is mounted in so that every starting signal to the starting coil goes
the inlet line to the engine. through the safe start function which is connected to
the safety system mounted on the engine.

11.44 - ES0 - Tier II

 MAN Diesel & Turbo

513.01 Description
Edition 29 Compressed Air System Page 2 (2)

L27/38
Further, the starting valve also acts as an emergency Pneumatic Start Sequence
starting valve which makes it possible to activate the
air starter manually in case of power failure. When the starting valve is opened, air will be sup­plied
to the drive shaft housing of the air starter.

Safety System The air supply will - by activating a piston - bring the
drive pinion into engagement with the gear rim on
As standard the engine is equipped with an emer- the engine flywheel.
gency stop. It consists of one on-off valve, see
diagram, which activates the stop cylinder on each When the pinion is fully engaged, the pilot air will
fuel injection pump. flow to, and open the main starting valve, whereby
air will be led to the air starter, which will start to
Air supply must not be interrupted when the engine turn the engine.
is running.
When the RPM exceeds approx. 158, at which firing
has taken place, the starting valve is closed whereby
the air starter is disengaged.

11.44 - ES0 - Tier II

MAN Diesel & Turbo
Work Card 513-01.21
Page 1 (2) Air Filter
Edition 02

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

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Cleaning and/or maintenance of air filter.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : -

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

2012.08.27. - ES0
 MAN Diesel & Turbo
513-01.21 Work Card
Air Filter Page 2 (2)
Edition 02

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

Cleaning Air Filter

1) Depressurize unit.
2) Remove bowl and bowl guard assembly by
turning counter-clockwise.
3) Inspect bowl for damage seals and replace, if
nessesary.

Warning!
Use original tool!

4) If bowl becomes dirty clean it by wiping the

bowl with a soft dry cloth or mild detergent.
5) 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
place.
Align arrow on bowl guard with arrow on filter
body.

Warning!
Figure 1: Air filter
The area around the engine must be clean
and tidy!

To replace filter element

1) Depressurize unit
2) Remove bowl and bowl assembly by turning
counter-clockwise.
3) Unscrew baffle by turning counter-clockwise.
4) Remove fi lter element and discard.
5) Install new fi lter element and reassemble in
reverse order.
6) Before returning to service, insure that all seals
have been reinstalled or replaced.
7) Reinstall bowl and bowl guard assembly and
rotate bowl guard clockwise to securely lock in
place. Align arrow on bowl guard with arrow on
filter body.

2012.08.27. - ES0
MAN Diesel & Turbo
Work Card 513-01.30
Page 1 (10) Overhaul, Test and Inspection of Air Starter
Edition 04

L23/30H, V28/32S, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of air starter. Disassembly, overhaul and
assembly of the air starter.

Starting Position Hand Tools

All connections to the air starter
have been removed and air starter
is removed.

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : - 51309 161

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

2006.02.20. - TDI
 MAN Diesel & Turbo
513-01.30 Work Card
Overhaul, Test and Inspection of Air Starter Page 2 (10)
Edition 04

L23/30H, V28/32S, L27/38

gearbox housing. The spur gear (45) is installed on
the carrier shaft and secured by the bearing locknut
(47).
Drive assembly
The drive assembly, please see Fig 3, consists of a
piston (53), helical shaft spline (56), dental clutch
(58) and drive pinion shaft (61). The clutch assembly
(56 thru 64) is installed into the spur gear (65). The
Description spur gear (65) is supported by the aft bearing (66),
As with all TDI air starter products, there are no rub- which is secured by the retaining ring (67).
bing parts so there is no lubrication required. This The roller bearing (69) is installed into spur gear (65)
eliminates failures due to lubricator problems, the and secured by retaining ring (70). The forward
expense of installing and maintaining the system, bearing (66) is pressed into the drive housing. The
and the messy and hazardous oil film around the lip seal (75) is pressed into the forward side of drive
starter exhaust. The starter is factory grease housing (72).
packed for the life of the starter so it requires no The pinion collar (76) is installed on pinion shaft (61)
maintenance. behind pinion (77), which is secured by washer (78)
and screw (79).
Operation
The starters are powered by a pair of axial flow tur-
bines coupled to a simple planetary gear reduction
set. The starters incorporate an inertia bendix drive
coupled to the starter gearbox drive train to provide
a means of disengaging the pinion from the
engine’s ring gear.
It is important to properly install and operate the
starters to receive the full benefits of the turbine
drive advantages.

General
Turbine housing assembly
The Turbine housing assembly, please see Fig 1,
consists of a stage one (13) and a stage two (5) tur-
bine wheel mounted on sungear shaft (30). The
front bearing (8) is secured by a retainer plate (29).
The aft bearing (8) is preloaded by a wavy spring
(10). The ring gear (27) is installed between the tur-
bine assembly (23) and the gearbox housing and
secured by four screws (25).
Gearbox housing assembly
The gearbox housing assembly, please see Fig 2,
consist of a planet gear carrier shaft (32), three
planet gears (34), needle bearings (35), spacers
(33), and bearing pins (36).
The carrier shaft is mounted on two ball bearings
(38) in the gearbox housing (48). The aft bearing is
preloaded by use of spring washers (39). The for-
ward bearing is installed into the bearing housing
(43), which is secured by four screws (44) to the

2006.02.20. - TDI
MAN Diesel & Turbo
Work Card 513-01.30
Page 3 (10) Overhaul, Test and Inspection of Air Starter
Edition 04

L23/30H, V28/32S, L27/38

Figure 1: Turbine housing assembly

Tool description No
General Spanner wrench 52-20134
Always mark adjacent parts on the starter housing; Spanner wrench 52-21345
Nozzle 2/ Containment Ring (11), Turbine Housing
(23), Gearbox Housing (48), and Drive Housing (72) Shaft Removal Tool 2-26945
so these parts can be located in the same relative Stage 2 Rotor Puller Tool 52-20076
position when the starter is reassembled.
Carrier Shaft Holding Tool 52-20202
Do not disassemble the starter any further than
Tool, Bearing Pressing 52-20143
necessary to replace a worn or damaged part.
Tool, Bearing/Seal 2-26943
Always have a complete set of seals and o-rings on
hand before starting any overall of a the starter. Table 1: service tools
Never use old seals or o-rings.
The tools listed in Table 1 are suggested for use by
technicians servicing the starters.
The best results can be expected when these tools
are used, however the use of other tools are
acceptable.

2006.02.20. - TDI
 MAN Diesel & Turbo
513-01.30 Work Card
Overhaul, Test and Inspection of Air Starter Page 4 (10)
Edition 04

L23/30H, V28/32S, L27/38

Figure 2: Gearbox housing assembly

Note:
Drive housing Use only a soft tooth vise to secure the pinion to
avoid damaging pinion.
Removal of drive housing
This screw is torqued to 60 lb ft during assembly
Mark position of drive assembly (72) relative to
therefore a large wrench may be required when
gearbox housing (48) for reference during reassem-
removing screw.
bly.
Remove washer (78), pinion (77) and spacer (76)
Remove the eight screws (73), please see Fig 3,
from pinion shaft (61). If pinion is too tight, place a
and pull drive assembly from gearbox housing. If
screwdriver underneath pinion and lift up on pinion
drive housing is too tight, tap it with a mallet to
to remove from shaft.
loosen.
Remove helical spline shaft assembly (54-64) from
Remove o-ring (71) from aft end of drive hous-
spur gear shaft (65). Remove spring (64) from shaft.
ing(72).
Use press tool and arbor press to remove spur gear
Note:
shaft (65) from drive housing (72).
Before removing the eight screws (73), install a
spacer between pinion (77) and drive housing (72) Use a screwdriver to remove lip seal (75) from for-
to allow for easy installation during reassembly. ward end of drive housing (72).
Pre-engaged Drive Disassembly Remove retainer ring (70) and bearing (69) from for-
Secure pinion (77) in a soft tooth vise while support- ward end of spur gear shaft (65).
ing aft end of the air starter. Rotate pinion screw Remove retainer ring (67) and press bearing (66)
(79) counterclockwise to remove using a 3/4" from spur gear shaft (65).
socket and wrench.

2006.02.20. - TDI
MAN Diesel & Turbo
Work Card 513-01.30
Page 5 (10) Overhaul, Test and Inspection of Air Starter
Edition 04

L23/30H, V28/32S, L27/38

Remove retainer ring (54) and bearing (55) from heli-
cal spline shaft (56).

Figure 3: Drive assembly

Use an arbor press to remove carrier shaft (32) from
Gearbox housing bearing housing (43). The bearing housing must be
elevated and supported to remove carrier shaft.
Removal of gearbox housing
Note:
Remove the screws (25) securing the gearbox (48)
Do not support the bearing housing on the four lips
to the turbine assembly (23).
as they could break while pressing on carrier shaft.
Remove ring gear (27) from turbine (23) or gearbox
Remove spring washer (39), spring retaining plates
assembly (48). The ring gear could remain on either
(40), and bearing spacer (42) from carrier shaft.
assembly when separation occurs.
Remove aft bearing (38) from shaft by pressing
Gearbox disassembly shaft while supporting bearing.
Place gearbox assembly (48), please see Fig 2 on
Planet gear disassembly
flat surface with aft end facing up.
Remove retainer ring (31) from planet shaft (36) and
Remove four screws (44) and lift carrier shaft push planet shaft through assembly.
assembly (32) from gearbox housing.
Slide the planet gear (34) from carrier shaft and
Place carrier shaft assembly on carrier shaft holding remove two spacers (33).
tool (52-20202) and use a screwdriver to remove
Use press tool to remove needle bearing (35) from
tang of lock washer (46) from slot of retainer nut
planet gear (34).
(47).
Place tool No 52-20134 (Spanner Wrench) over
shaft and into slots of retainer nut (47). Hold carrier
shaft assembly down and turn spanner wrench
counter clockwise to remove retainer nut, lock
washer (46), spur gear (45), and woodruff key (37)
from carrier shaft (32).

2006.02.20. - TDI
 MAN Diesel & Turbo
513-01.30 Work Card
Overhaul, Test and Inspection of Air Starter Page 6 (10)
Edition 04

L23/30H, V28/32S, L27/38

Remove o-ring (19) from aft end of turbine housing.
Turbine Housing Remove the seal spacer (15) from the forward side
of nozzle 2 (11). Place the stage 2 nozzle on the
Stage 2 rotor removal
exhaust end. Press through the forward lip seal
Place the turbine assembly (23), please see Fig 1,
onto the bearing until it, including the aft lip seal and
with ring gear (27) on a flat surface with (exhaust)
seal spacer disengages from the nozzle. Turn the
end up and remove the six screws (1), and the
nozzle over and press on the forward lip seal to
screen (2).
remove.
Secure the stage 2 rotor (5) and remove the turbine
screw (3) and washer (4).
Cleaning
Install the rotor puller tool No 52-20076 and remove
the stage 2 rotor. Degrease all metal parts, except bearings, using a
commercially approved solvent.
Remove the woodruff key (6) from the turbine shaft
(30). Clean aluminum parts. Remove parts, rinse in hot
water, and dry thoroughly.
Turbine Shaft Removal
Place the turbine housing on a flat surface with the Clean corroded steel parts with a commercially
sun gear end facing up. approved stripper.

Remove four screws (16) and bearing retainer plate Clean corroded aluminum parts and rinse in hot
(29) from turbine housing. water and dry thoroughly.

Using the shaft removal tool No 2-26945, press on

the aft end of the turbine shaft (30) while supporting Inspection
the turbine housing (23). Use Table 2 as a guide to check for acceptable
Press the turbine shaft (30) through the aft bearing condition of the parts listed.
(8) until the shaft is completely out of the housing Check all threaded parts for galled, crossed strip-
(23). ped, or broken threads.
Remove the woodruff key (14), seal spacer (7), Check all parts for cracks, corrosion, distortion,
bearing spacer (28), and bearing (8) from turbine scoring, or general damage.
shaft (30).
Check all bearing bores for wear and scoring. Bear-
The bearing can be removed from the shaft by
ing bores shall be free of scoring lines, not to
pressing the shaft through the bearing while sup-
exceed 0.005" width and 0.005" depth.
porting bearing.
Check gear teeth and turbine housing ring gear for
Separate the stage 2 nozzle assembly (11) from the
wear. In general, visually check for spalling, fretting,
turbine assembly (23) by firmly holding the turbine
surface flaking, chipping, splitting, and corrosion.
assembly, while tapping nozzle 2 with a mallet. If
nozzle 2 is too tight, it can be removed by installing If wear is apparent, check the gear teeth dimen-
two threaded screws into nozzle 2 and using them sions in accordance with Table 3. Nicks and dents
as jacks to separate nozzle 2 from the turbine that cannot be felt with a .020 inch radius scribe are
assembly. acceptable.
Note:
Rotate the stage 1 rotor if necessary to allow the
jacks to travel through the large holes in the rotor.
The jacks will damage the stage 1 rotor if pressure
is applied to the rotor while removing nozzle 2.
Remove stage 1 rotor (13) and o-ring (12) from noz-
zle 2.
Remove the four screws (16) and nozzle 1 (17) from
the turbine assembly. It may be necessary to tap
the screws with a hammer and chisel to loosen.

2006.02.20. - TDI
MAN Diesel & Turbo
Work Card 513-01.30
Page 7 (10) Overhaul, Test and Inspection of Air Starter
Edition 04

L23/30H, V28/32S, L27/38

Part Description Check For Requirements

(Defective Parts Must Be Replaced)
Pinion Chipped Teeth, Cracks Defective unit to be replaced. Use Fig. 3 as a guideline for
acceptable pinion wear.
Drive Housing Cracks and breakage Cracks are not acceptable
Planet Gear Cracked, chipped, or galled teeth. Wear must not exceed limits per Table 3.
Wear must not exceed limits per There shall be no evidence of excessive wear.
Table 4.
Carrier Shaft Cracks, scoring or raised metal in Deformation or metal smearing in planet pin holes and
planet shaft holes and keyways. keyways are not acceptable. Scoring on bearing diameter
Integrity of knurl connection. not to exceed .005" depth.
Wear must not exceed limits per Table 3.
Planet Pins Wear grooves or flat spots Wear grooves in flat spots not permitted.
Wear must not exceed limits per Table 3.
Washers Wear created grooves Wear must not exceed limits per Table 3.
Gearbox Housing Cracks and Breakage Cracks and breakage not acceptable.
Sungear / Turbine Shaft Cracks, scoring, wear created Wear must not exceed limits per Table 3.
grooves, chipped or broken gear-
teeth, galling or scoring on bearing
surface of shaft. Raised metal on
the keyway.
Spacers Parallelism of end surfaces Ends must be parallel within 0.0005".
Turbine Housing Cracks and breakage Cracks and breakage are not acceptable. Minor surface
Ring Gear Cracks, wear, chipped, or broken damage is permitted if function is not impaired.
gear teeth. Wear must not exceed limits per Table 3.
Seal Assembly Wear grooves or scratched surfa- Wear is not permitted.
ces on carbon ring.
Seal Spacer Wear Grooves No wear permitted.
Needle Bearings Freedom of needle rollers Replace bearings
Ball bearings Freedom of rotation without exces- Replace bearings
sive play between races
Containment Corrosion, erosion, cracks and bro- Cracks and breakage are not acceptable.
Ring/ Nozzle ken nozzle edges. Minor surface damage is permitted if function is not
impaired.
Turbine Rotors Corrosion, erosion, cracks and bro- Minor tip rub is permitted if function is not impaired.
ken edges. Wear is not permitted.
Tip wear; bore and key way wear

Table 2: Parts Inspection Check Requirements

2006.02.20. - TDI
 MAN Diesel & Turbo
513-01.30 Work Card
Overhaul, Test and Inspection of Air Starter Page 8 (10)
Edition 04

L23/30H, V28/32S, L27/38

Part description Limit, Inches Turbine housing

Ring gear / Turbine Hous- Turbine shaft installation
ing 5.0890 max. Press the bearing (8), please see Fig 1, onto the
Internal measurement shaft (30) until seated.
between two .084" diameter
pins. Support the shaft and press on the inner race only
with press tool No 2-26943 as shown in Table 1.
Sun Gear / Turbine Shaft
Bearing diameter 0.6690 min Press the bearing/shaft assembly (8, 30), keyway
External measurement over end first, into bearing housing of the turbine housing
two .096 diameter pins. 0.952 min (23). Use press tool No 2-26943 if required. Do not
7.5:1 0.808 min press on the end of the shaft because the load
9:1 0.670 min could damage the balls of the bearing.
11.4:1
Install bearing retainer plate (29) and secure with
Planet Gear four screws (16). Torque screws to 40 in-lbs.
External measurement over
two .0864" diameter pins. 2.3067 min Place turbine housing with sun gear end down on a
7.5:1 2.3699 min flat surface, while using ring gear to support turbine
9:1 2.4359 min housing. Install long bearing space (28) and seal
11.4:1 spacer (7) over shaft.
Carrier Shaft Install the O-ring (19) into the aft face of the turbine
Bearing Diameter 1.1800 min housing (23).
Planet Pin Bore 0.8750 max
Nozzle 1 installation
Planet Pins Press the aft seal (15) into nozzle 1 (19) using press
Bearing Diameter 0.873 min tool No 2-26943 per Table 1, with the lips facing
Thrust Washer up.
Thickness .055 min Install nozzle 1 onto the turbine housing (23). Orient
Table 3: Parts Wear Limits the nozzles facing the air inlet (21) and install four
screws (16) to secure the nozzle. Do not tighten the
screws at this time.
General
Note:
The tools listed in Table 1 are suggested for use by
The rotation of the turbine assembly is opposite
technicians servicing the starters. The best results
from the pinion rotation, therefore this nozzle must
can be expected when the proper tools are used,
be configured for LH (CCW) if the pinion rotation is
however, use of other tools is acceptable.
RH (CCW), or configured for RH (CW) if pinion rota-
Caution: tion is LH (CCW).
Replace all screws , O-rings, lip seals, and bearings
Rotor 1 installation
when the starter is reassembled.
Install the large woodruff key (14) for stage 1 rotor
Note: into the turbine shaft (30).
Always press the inner race of a ball bearing when
Install the stage 1 rotor (13), while supporting sun
installing a bearing on a shaft. Always press the
gear end of shaft, onto the turbine shaft by aligning
outer race of a ball bearing when installing into a
the slot in the rotor with the woodruff key and hand
housing.
press the rotor until firmly seated. Use press tool No
The list of kits and components, which are available 2-26943 if required.
to aid in rebuilding the starters. Lubricate all O-rings
Visually inspect that the key was not pushed out
with petroleum jelly or Parker-O-Ring Lube before
during assembly. Note that the direction of rotation
assembly.
was oriented properly. This turbine rotor can be
Caution: installed backwards.
The screws that secure the Containment Ring/
Install spacer (7) onto sun gear (30).
Stage 2. Nozzle must have a drop of Loctite RC290
applied to the threads before being used.

2006.02.20. - TDI
MAN Diesel & Turbo
Work Card 513-01.30
Page 9 (10) Overhaul, Test and Inspection of Air Starter
Edition 04

L23/30H, V28/32S, L27/38

To center nozzle 1, temporarily install Nozzle 2 (11) Gearbox Housing
on the turbine housing and tighten the four screws
that secure nozzle 1 (17) to 30 in-lb. The four Planetary gear carrier reassembly
screws can be accessed via the holes in nozzle 2 Press needle bearing (35) into planet gears (34). The
and the first stage turbine rotor. Remove Nozzle 2 planet gears are not identified by part number,
when the four screws are tight. therefore, dimensionally check if correct gears are
being used. Use Table 3 for over the wire measure-
Nozzle 2 installation ments.
Install the O-ring (9) into the bearing bore of nozzle
2 (11). Do not lubricate this O-ring. With a thrust washer (33), please see Fig 2 , on each
side of gear, slide gear into carrier shaft slots (32),
Install O-ring (12) onto the outer diameter of nozzle and align with pin holes.
2 and install nozzle 2 (11) onto the turbine housing
(23). Lightly slide plant shafts into aligned holes, making
sure retainer ring groove on end of pins goes in first.
Note:
The rotation of the turbine assembly is opposite Note:
from the pinion rotation, therefore this nozzle must Make sure that anti-rotation pins on shafts are
be configured for LH (CCW) rotation if the pinion properly located in retaining slots of carrier shaft
rotation is RH (CW), or configured for RH (CW) if (32).
pinion rotation is LH (CCW). Install retainer ring (31) onto planet shaft (36) using
Install the seal spacer (7) onto the shaft and the a retainer ring tool.
wavy spring washer (10) into the bearing bore of the Gearbox reassembly
stage 2 nozzle. Install bearing (38) into the bearing housing (43) and
While supporting the sun gear end of the shaft, secure with retaining ring (41).
press the aft bearing (8) onto the shaft by pressing Press aft bearing (38) onto carrier shaft (32) using
onto the inner and outer race simultaneously. Use Tool No 52-20143 per Table 1. Pressing force
press tool No 2-26943 per Table 1. Press until should be on the inner race of bearing.
bearing is seated. Install spring washer (39), spring retaining plate (40)
Install the stage 2 woodruff key (6) into the shaft and bearing spacer (42) onto shaft and locate
(30). against bearing.
Stage 2 rotor installation Position bearing housing assembly (38,41,43) over
Install the stage 2 rotor (5) onto the shaft. Use press carrier shaft (32) and press until firmly seated.
tool No 2-26943 if required. Visually inspect that the
key was not pushed out during assembly. Note that Install woodruff key (37) into slot on carrier shaft (32)
the direction of rotation was oriented properly. This and install spur gear (45) on carrier shaft aligning
turbine can be installed backwards. slot on gear with woodruff key.
Install the rotor washer (4) and secure with screws Place bearing housing assembly on carrier shaft
(3). Tighten screw to 100 in-lb. holding tool No 2-20202 per Table 1. Install lock-
washer (46) and retainer nut (47). Torque to 90-100
Install the exhaust screen (2) and secure with six ft.lb. After the slotted round nut (47) has been tight-
screws (1). Tighten the screws to 80 in-lb. ened, the tab of the washer (46) is driven into one of
Air inlet installation the slots.
Place the O-ring (22) into the groove on the air inlet Place O-ring (12) onto outer diameter of gearbox
(21). housing (48).
Install the 2" NPT air inlet flange (21) and secure Install carrier shaft assembly into aft side of gearbox
with six screws (20). Tighten the six screws to 170 housing (48) and secure with four screws (44). Tor-
in-lb. que to 113 in-lbs.

2006.02.20. - TDI
 MAN Diesel & Turbo
513-01.30 Work Card
Overhaul, Test and Inspection of Air Starter Page 10 (10)
Edition 04

L23/30H, V28/32S, L27/38

Install drive assembly (72) onto gearbox assembly
Drive Housing (48) and secure with eight screws (73). Torque to
113 in.lbs.
Drive reassembly
Install bearing (69), please see Fig 3, into forward
end of spur gear shaft (65) and secure with retaining
ring (70).
Press bearing (66) onto spur gear shaft (65) and
secure with retaining ring (67).
Press bearing (68) into drive housing (72) until
seated firmly into housing.
Press lip seal (75) into forward end of drive housing
(72) and install O-ring into O-ring groove on drive
housing.
Install spur gear assembly (65-67) into gearbox
drive housing (72) until firmly seated.
Install bearing (55) onto aft end of drive shaft
assembly (56-61) and secure with retaining ring
(54). Lubricate drive shaft assembly using grease
No 9-94121-002.
Lubricate inner diameter of spur gear assembly (65)
using grease No 9-94121-002.
Install spacer (62), spring (64), and pinion spacer
(76) onto pinion drive shaft assembly (56-61) then
install into aft end of spur gear (65). The gears on
helical shaft (56) must be aligned into the aft end of
the spur gear shaft (65).
Press the helical shaft assembly into the spur gear
shaft (65) until end of shaft protrudes from forward
end of drive housing.
Maintain pressing force and install pinion onto drive
shaft (61). Secure with screw (79). Torque to 60 ft.
lb.
Install spacer between pinion (79) and drive housing
(72) before releasing pressure from helical shaft.
Final assembly
Place turbine assembly (23) with aft end on a flat
surface and install ring gear. Ensure notches on ring
gear are aligned with screw positions on turbine
housing.
Thoroughly grease planet gears (34), ring gear (27),
sun gear (30), spur gears (45, 65) using grease No
9-94121-002.
Rotate carrier shaft (35) slightly, and at the same
time, align gearbox into the front of turbine housing
(26).
Install six gearbox to turbine assembly screws (25)
and torque 113 in-lbs.

2006.02.20. - TDI
MAN Diesel & Turbo
Work Card 513-01.30
Page 1 (2) Overhaul, Test and Inspection of Air Starter
Edition 05

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of air starter. Disassembly, overhaul and
assembly of the air starter.

Starting Position Hand Tools

All connections to the air starter
have been removed and air starter
is removed.

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 1 51309 133 1 (repair kit,
main valve)
51309 172 1 (set of
Data seals)
Data for pressure and tolerance (Page 500.35) 51309 173 1 (repair kit,
Data for tightening torque (Page 500.40) rotor)
Declaration of weight (Page 500.45)

2002.09.09. - Gali
 MAN Diesel & Turbo
513-01.30 Work Card
Overhaul, Test and Inspection of Air Starter Page 2 (2)
Edition 05

L27/38

Operation

Before putting into operation

▪ Check if the installation has been accomplished

in accordance with our instructions
▪ Check the adjustment of the auto-start device (if
installed), to ensure:
– the speed of the starter shaft never exceeds
the value of 2.500 rpm.
– the starter stops working, once the engine
hasattained a speed 1 to 1.5 times is igni-
tion speed.
▪ Check that the air receiver is charged and that
the flow valve is opened.
▪ Test for leaks and check that the control circuit
is not chocked.
▪ Check for correct meshing of the driving pinion
with the flywheel gear ring by means of several
short starter impulses.

On putting into operation

In case of manual start, operate the push-button
valve for very short periods only.

Complete Overhaul
▪ Strip the starter and clean all lines and pipe-
work.
▪ Check rotors and advance mechanism; clean
same and replace worn or rusted parts.
▪ Check the driving pinion for wear and replace it
if necessary.
▪ Revice all valves and replace joints.

Storage
When leaving our works, the starters contain anti-
rust oil to protect their inner parts. In spite o this, we
must recommended storage in a dry place.

2002.09.09. - Gali
MAN Diesel & Turbo
Work Card 513-01.40
Page 1 (2) Emergency Starting Valve
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Lubricating, disassembly and reassembly of emer-
gency starting valve in starting system.

Starting Position Hand Tools

Small screwdriver

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2000.10.23.
 MAN Diesel & Turbo
513-01.40 Work Card
Emergency Starting Valve Page 2 (2)
Edition 03

L27/38

Emergency starting valve

The emergency starting valve is placed on the tur-
bine starter and should be tested according to the
planned maintenance programme.
1) Switch the engine to "local" on the operating
box panel.
2) Push the emergency start button with a screw-
driver, as shown in fig 1, until the engine ignites.
3) Release the button. The button is springloaded
and will automatically return to the start posi-
tion.

Figure 1: Emergency starting valve

2000.10.23.
MAN Diesel & Turbo
Work Card 513-01.90
Page 1 (2) Check of Compressed Air Piping System
Edition 03

L16/24, V28/32S, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of compressed air piping system.

Starting Position Hand Tools

Compressed air connected to the engine. Screwdriver.

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2002.05.13. - ES0
 MAN Diesel & Turbo
513-01.90 Work Card
Check of Compressed Air Piping System Page 2 (2)
Edition 03

L16/24, V28/32S, L21/31, L27/38

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

With Air Connected

1) Examine the piping system for leaks.
2) Retighten all bolts and nuts in the piping sys-
tem.
3) Drain the system for condensed water. This
should be based on observations.
4) Check flexible connections for leaks and dam-
ages.
It is important that the flexible connections are
free from paint and grease and in healthy condi-
tion.
5) Check manometers.

With Air Disconnected and Stopped

Engine
1) Move all valves and cocks in the piping system.
Lubricate valve spindles with graphite or similar.
2) Connect the air supply and make a function test
of the emergency valve. See Description
513.01.

2002.05.13. - ES0
MAN Diesel & Turbo
Work Card 513-25.00
Page 1 (2) Turning Gear
Edition 03

V28/32S, L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Manual turning of engine.

Starting Position Hand Tools

Indicator valve in cylinder head has to be open Standard spanner with a long shaft
Plate 50501

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1/4 Plate No. Item No. Quantity
Number : 1

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

2013.09.02. - Manual
 MAN Diesel & Turbo
513-25.00 Work Card
Turning Gear Page 2 (2)
Edition 03

V28/32S, L21/31, L27/38

Manual Turning Gear Figure 3: Position 3 - Engine turning position

Warning: The diesel engine can be started locally

on the emergency start arrangement eventhough 3) Engine turning position.
the turning gear is engaged. Pull out the handle knob (1) and push the turn-
ing gear into engagement. When microswitch is
Note: Inform all staff working on the engine that the activated the engine is in blocking position.
turning gear is engaged. When the turning device is fully engaged the
handle knob will lock the turning device.
Adjustment of the turning gear Note: The turning gear must be fully engaged dur-
1) Engine running position. ing the entire turning of engine.
This is the stand-by position of the turning gear The engine can now be turned by spanner by
when the engine is running. means og the SW22 hexagon. (As option el-motor
or pneumatic can be supplied).
When turning the engine has been completed the
turning gear is disengaged by pulling out the handle
knob and afterwards pull back the turning gear.

Trouble tracing
Turning gear shaft can not be moved easily:

Figure 1: Position 1 - Engine running position ▪ Dismantle the shaft and clean for rust. New
lubrication to avoid rust.
2) Engine blocking position. Engine is not starting:
Engine is in blocking position when the turning ▪ Check the microswitch ZS 75 mounted on the
gear is engaged. turning gear.

Figure 2: Position 2 - Engine blocking position

Pull out the handle knob (1) and push the turning
gear into engagement. When the microswitch is
activated the engine is in blocking position.

2013.09.02. - Manual
MAN Diesel & Turbo
Plate
Page 1 (2) Air starter P51309-09

V28/32S, L27/38

2013.07.16 - TDI
 MAN Diesel & Turbo
Plate
P51309-09 Air starter Page 2 (2)

V28/32S, L27/38
Item No. Qty Item designation Item No. Qty Item designation

1 6/S Screw* 63 2/S Thrust washer*

3 1/S Screw* 64 1/S Retaining ring*
7 1/S Bearing spacer* 67 1/S Ball bearing*
8 2/S Bearing* 69 1/S Ball bearing*
9 1/S O-ring* 70 1/S Bearing, needle roller*
10 1/S Spring washer* 72 1/S O-ring*
13 2/S O-ring* 74 1/S Screw*
14 2/S Seal spacer* 76 1/S Lip seal*
15 2/S Lip seal* 78 1/S Pinion
18 8/S Screw*
78a 1/S Pinion incl. item 79 and 80
21 1/S O-ring*
79 1/S Washer, pinion*
22 6/S Screw*
80 1/S Screw*
23 1/S Inlet flange*
160 1/E Air starter complete, output gear
24 1/S O-ring* ratio 11.7:1
25 1/S Turbine housing* 161 1/S Spare parts kit (item
1,3,7,8,9,10,13,14,15,18,21,22,2
26 1/S Pipe plug* 4,27,36,39,45,50,56,61,63,64,67,
27 1/S O-ring* 69,70,72,74,76
28 1/S Ring gear* 162 1/S Spare parts kit (item
23,24,25,26,27,28,29,30,31,32)
29 1/S Bearing spacer*
30 1/S Clamping plate*
31 1/S Turbine shaft*
32 3/S Retainer ring*
35 3/S Planet gear
36 3/S Needle bearing*
39 2/S Bearing*
45 4/S Screw*
50 6/S Screw*
56 1/S Bearing*
61 1/S Bearing, needle roller*
62a 1/S Shaft (lh)
62b 1/S Shaft (rh)

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine
Qty/S = Qty/Starting Air Motor

2013.07.16 - TDI
 MAN Diesel
Plate
Page 1 (2) Air Starter 51309-11H

L27/38
08028-0D/H5250/94.08.12

02.34 - ES0 - b/c

MAN Diesel
Plate
51309-11H Air Starter Page 2 (2)

L27/38
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

140 1/S Pinion Tandhjul

141 1/S Air starter, complete Startemotor, komplet

142 1/S Solenoid valve Magnetventil

143 1/S Strainer Filter

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./S = Qty./Starter Qty./S = Qty./Starter

02.34 - ES0 - b/c

 MAN Diesel
Plate
Page 1 (3) Air Starter (supplement for plate 51309-11H) 51309-12H

Serial no. > 01-0026 L27/38

08028-0D/H5250/94.08.12

02.34 - ES0 - b
MAN Diesel
Plate
51309-12H Air Starter (supplement for plate 51309-11H) Page 2 (3)

L27/38 Serial no. > 01-0026

Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

1 1/S Special circlip Clips 31 4/S Flat washer Skive

2* 1/S Retaining ring Sikringsring 32 4/S Stud Tap

3 1/S Needle bearing Nåleleje 34 1/S Servo-limiter unit Servo-limiter unit

4 4/S Allen screw Skrue 35 1/S Servo supplement Servo supplement

5 4/S Special washer Skive 36 2/S Allen screw Skrue

6 1/S Front cover Fordæksel 37* 8/S Washer Skive

7* 1/S Special joint Speciel samling 38 4/S Special bolt Bolt

8 1/S Bearing extrac. ring Lejering 39 2/S Flexible pipe Flexibelt rør

9 23/S Cylinder roller Cylinderrulle 40 1/S Silencer Lyddæmper

10 1/S Bearing disc Lejeskive 41 4/S Stud Tap

12 1/S Special nut Møtrik 42 4/S Flat washer Skive

13 1/S Special washer Skive 43 4/S Nut Møtrik

14* 1/S Ring Ring 44* 1/S Secondary rotor Secondary rotor

15 1/S Hauling crown ccw Rotordæksel 45 1/S Check valve Checkventil

16 1/S Spring Fjeder 46 1/S Elastic pin Elastisk tap

17 1/S Splined shaft ccw Fjedrende aksel 47* 1/S Membrana Membran

18 1/S Guide cylinder Styrecyllinder 48 1/S Plug Prop

19* 1/S O-ring O-ring 49* 1/S Special nut Møtrik

20 1/S Follower Medfølger 50* 1/S Lip seal Tætningsring

21 2/S Allen screw Skrue 51* 1/S Main valve Hovedventil

22 2/S Special washer Skive 52* 1/S O-ring O-ring

23 1/S Motor body ccw Motorhus 53* 1/S Distributor Fordeler

24* 1/S Primary rotor Primary rotor 54* 1/S Bushing Bøsning

25 1/S Valve body ccw Ventilhus 55* 1/S O-ring O-ring

26 1/S Silencer Lyddæmper 56* 1/S O-ring O-ring

27 1/S Bend Bøjning 57* 1/S Seal shell Dæksel

08028-0D/H5250/94.08.12

28 1/S Flat washer Skive 58* 1/S Special washer Skive

29 1/S Special nut Møtrik 59* 1/S Special nut Møtrik

30 4/S Special nut Møtrik 60 1/S Spring Fjeder

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./Starter Qty./S = Qty./Starter

02.34 - ES0 - b
 MAN Diesel
Plate
Page 3 (3) Air Starter (supplement for plate 51309-11H) 51309-12H

Serial no. > 01-0026 L27/38

Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

61 4/S Stud Tap

64 1/S Plug joint Tætningsprop

66* 1/S O-ring O-ring

67 1/S Inlet nozzle Indstrømningsdyse

68* 1/S O-ring O-ring

69 4/S Special washer Skive

70 4/S Allen screw Skrue

71 1/S Special pipe 6x4 Rør 6x4

72 1/S Elastic pin Elastisk tap

74* 1/S O-ring O-ring

75 1/S Front labyrinth seals Tætning

76* 1/S Ball bearing Kugleleje

77* 1/S O-ring O-ring

78 1/S Front labyrinth seals Tætning

79 1/S Front labyrinth seals Tætning

80 1/S Front labyrinth seals Tætning

81 2/S Rod Stang

82* 1/S O-ring O-ring

83* 1/S Ball bearing Kugleleje

133 1/S Repair kit for main Reservedelssæt for

valve, comprising item hovedventil indehold-
49, 50, 51, 52, 53, 54, 55, ende item 49, 50, 51,
56, 57, 58, 59 52, 53, 54, 55, 56, 57,
58, 59

172 1/S Set of seals, compri- Tætningssæt, indehold-

sing item 2, 7, 14, 19, ende item 2, 7, 14, 19,
37, 47, 50, 52, 55, 56, 37, 47, 50, 52, 55, 56,
66, 68, 74, 77, 82 66, 68, 74, 77, 82

173 1/S Repair kit, compris- Reservdelssæt, inde-

ing item 172, 24, 44, holdende item 172, 24,
08028-0D/H5250/94.08.12

76, 83 44, 76, 83

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./Starter Qty./S = Qty./Starter

02.34 - ES0 - b
MAN Diesel & Turbo
Plate
Page 1 (3) Air Starter (supplement for plate 51309-11H) P51309-13

Serial no. > 02-0101 L27/38

Serial no > 02-0101

1 2 3 4* 5 6 7* 8 9
10 12 13 14* 15 * 16* 17*

11*

26 27 28 30

32
All valves and fittings 36 35
has to be approved by
classification society. 34* 72

34*
39 37*
38
39 40
38 39
37*
37*
71 38
23* 79* 82* 80* 25*
75* 77* 78* 24*
46
18 19* 74*

76* 83*
47* 48 71
21 22 20

81 41 42 43 44* 45*

39
61 66*
38

37*
64
49* 50* 51* 52* 53* 54* 55* 56* 57* 58* 59* 60
67
69 70
68*

2014.02.14 - Gali
 MAN Diesel & Turbo
Plate
P51309-13 Air Starter (supplement for plate 51309-11H) Page 2 (3)

L27/38 Serial no. > 02-0101

Item No Item No
Qty Designation Benævnelse Qty Designation Benævnelse

1 4/S Allen screw Skrue 32 4/S Stud Tap

2 4/S Special washer Skive 34 1/S Servo-limiter unit Servo-limiter unit

3 1/S Front cover Fordæksel 35 1/S Servo supplement Servo supplement

4* 1/S Retaining ring Sikringsring 36 2/S Allen screw Skrue

5 1/S Needle bearing Nåleleje 37* 8/S Washer Skive

6 1/S Special circlip Clips 38 4/S Special bolt Bolt

7* 1/S Special joint Speciel samling 39 2/S Flexible pipe Flexibelt rør

8 1/S Bearing extrac. ring Lejering 40 1/S Silencer Lyddæmper

9 23/S Cylinder roller Cylinderrulle 41 4/S Stud Tap

10 1/S Bearing disc Lejeskive 42 4/S Flat washer Skive

11* 1/S Labyrinth sealing Labyrinttætning 43 4/S Nut Møtrik

12 1/S Special nut Møtrik 44* 1/S Secondary rotor Secondary rotor

13 1/S Special washer Skive 45 1/S Check valve Checkventil

14* 1/S Ring Ring 46 1/S Elastic pin Elastisk tap

15 1/S Hauling crown ccw Rotordæksel 47* 1/S Membrana Membran

16 1/S Spring Fjeder 48 1/S Plug Prop

17 1/S Splined shaft ccw Fjedrende aksel 49* 1/S Special nut Møtrik

18 1/S Guide cylinder Styrecylinder 50* 1/S Lip seal Tætningsring

19* 1/S O-ring O-ring 51* 1/S Main valve Hovedventil

20 1/S Follower Medfølger 52* 1/S O-ring O-ring

21 2/S Allen screw Skrue 53* 1/S Distributor Fordeler

22 2/S Special washer Skive 54* 1/S Bushing Bøsning

23 1/S Motor body ccw Motorhus 55* 1/S O-ring O-ring

24* 1/S Primary rotor Primary rotor 56* 1/S O-ring O-ring

25 1/S Valve body ccw Ventilhus 57* 1/S Seal shell Dæksel

26 1/S Silencer Lyddæmper 58* 1/S Special washer Skive

27 1/S Bend Bøjning 59* 1/S Special nut Møtrik

28 1/S Special nut Møtrik 60 1/S Spring Fjeder

30 4/S Special nut Møtrik 61 4/S Stud Tap

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./Starter Qty./S = Qty./Starter

2014.02.14 - Gali
MAN Diesel & Turbo
Plate
Page 3 (3) Air Starter (supplement for plate 51309-11H) P51309-13

Serial no. > 02-0101 L27/38

Item No Item No
Qty Designation Benævnelse Qty Designation Benævnelse

64 1/S Plug joint Tætningsprop

66* 1/S O-ring O-ring

67 1/S Inlet nozzle Indstrømningsdyse

68* 1/S O-ring O-ring

69 4/S Special washer Skive

70 4/S Allen screw Skrue

71 1/S Special pipe 6x4 Rør 6x4

72 1/S Elastic pin Elastisk tap

74* 1/S O-ring O-ring

75 1/S Front labyrinth seals Tætning

76* 1/S Ball bearing Kugleleje

77* 1/S O-ring O-ring

78 1/S Front labyrinth seals Tætning

79 1/S Front labyrinth seals Tætning

80 1/S Front labyrinth seals Tætning

81 2/S Rod Stang

82* 1/S O-ring O-ring

83* 1/S Ball bearing Kugleleje

133 1/S Repair kit for main valve, Reservedelssæt for

comprising item 49, 50, 51, hovedventil indehold-
52, 53, 54, 55, 56, 57, 58, 59 ende item 49, 50, 51,
52, 53, 54, 55, 56, 57,
58, 59

172 1/S Set of seals, compri-sing Tætningssæt, indehold-

item 4, 7, 11, 14, 19, 37, ende item 4, 7, 11, 14,
47, 50, 52, 55, 56, 66, 68, 19, 37, 47, 50, 52, 55,
74, 77, 82 56, 66, 68, 74, 77, 82

173 1/S Repair kit, comprising item Reservdelssæt, inde-

24, 44, 172 holdende item 24, 44,
172

174 1/S Repair kit, comprising item Reservedelssæt, inde-

76 and 83 holdende item 76 og 83

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./Starter Qty./S = Qty./Starter

2014.02.14 - Gali
MAN Diesel & Turbo
Plate
Page 1 (2) Main starting valve P51310-06

L23/30H, V28/32S, L21/31, L27/38

2013.10.10 - TDI - L23/30H Mk2

 MAN Diesel & Turbo
Plate
P51310-06 Main starting valve Page 2 (2)

L23/30H, V28/32S, L21/31, L27/38

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

116 1/V Housing

177 1/V Retainer
189 1/V Screen
190 1/V O-ring*
200 1/V O-ring*
212 1/V Piston
224 1/V Dampener, shock*
236 1/V O-ring, cap
238 1/V Spring*
261 1/V O-ring*
273 1/V End cap
285 1/V O-ring*
297 1/V Retainer
307 1/V O-ring
319 1/V Part of item 230
320 1/V Solenoid valve
332 2/V Screw
344 1/S Main starting valve, complete
356 1/V Spare parts kit
(190,200,224,248,261,285)

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/S = Qty/Starting Air Motor
Qty/V = Qty/Valve

2013.10.10 - TDI - L23/30H Mk2

 MAN Diesel

Plate
Page 1 (2) Main Stop Valve 51315-03

L21/31,
L23/30H, L27/38
08028-0D/H5250/94.08.12

00.41 - EO0
 MAN Diesel

Plate
51315-03 Main Stop Valve Page 2 (2)

L21/31,
L23/30H, L27/38
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

042 1/E Stop valve, Stopventil,

complete komplet

066 1/V Gasket Pakning

078 1/V Gasket Pakning

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./V = Qty./Valve Antal/V = Antal/Ventil

00.41 - EO0
 MAN Diesel
Plate
Page 1 (2) Solenoid Valve, 3/2 51318-01H

Generel
08028-0D/H5250/94.08.12

05.33 - EO0
MAN Diesel
Plate
51318-01H Solenoid Valve, 3/2 Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

001 1/E Solenoid valve, Magnetventil,

complete komplet

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

05.33 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Solenoid valve, 3/2 P51318-02

L16/24, L23/30H, V28/32S, L21/31, L27/38, L18/28

2013.09.03
 MAN Diesel & Turbo
Plate
P51318-02 Solenoid valve, 3/2 Page 2 (2)

L16/24, L23/30H, V28/32S, L21/31, L27/38, L18/28

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

013 1/E Solenoid valve, complete

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2013.09.03
MAN Diesel & Turbo
Plate
Page 1 (2) Solenoid valve, 3/2 P51318-03

L16/24, L23/30H, V28/32S, L21/31, L27/38, L18/28, L16/24S, L21/31S, L23/30S,

L27/38S

2014.03.31
 MAN Diesel & Turbo
Plate
P51318-03 Solenoid valve, 3/2 Page 2 (2)

L16/24, L23/30H, V28/32S, L21/31, L27/38, L18/28, L16/24S, L21/31S, L23/30S,

L27/38S
Item No. Qty Item Designation Item No. Qty Item Designation

025 1/E Solenoid valve, complete

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2014.03.31
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

190 1/E Filter complete Filter komplet

200 1/F Repair kit Reparationssæt

(filter and O-ring) (filter og O-ring)

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 51322-06H

L27/38

052

027

015 003

039
08028-0D/H5250/94.08.12

07.51 - ES0
MAN Diesel
Plate
51322-06H Pressure Reduction Valve Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

003 1/E Pressure reduction Magnetventil,

valve, complete komplet

015 1/E Filter Filter

027 1/E Manometer and pres- Manometer og magnet-

sure reduction valve ventil

039 1/E Safety valve Sikkerhedsventil

040 1/E Repair kit Reparationssæt

(filter and O-ring) (filter og O-ring)

052 1/E Manometer Manometer

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

07.51 - ES0
 MAN Diesel

Plate
Page 1 (2) Pressure Reduction Valve 51322-04H

General
08028-0D/H5250/94.08.12

03.22 - ES0
MAN Diesel

Plate
51322-04H Pressure Reduction Valve Page 2 (2)

General
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse

015 1/V Cover Dæksel

027 10/V Screw Skrue

039* 2/V Filter Filter

040 1/V Tube incl. o-ring Rør, inkl. o-ring

052* 1/V O-ring O-ring

064* 1/V Diaphragh Membran

076* 1/V O-ring O-ring

088* 1/V O-ring O-ring

111 1/V Valve, complete Ventil, komplet

123* 1/V O-ring O-ring

135* 1/V Valve spring Ventilfjeder

147* 1/V O-ring O-ring

159* 1/V O-ring O-ring

160 1/V Bottom plug, incl. Bundprop, inkl.

o-ring o-ring

172 2/V Pipe plug Rørprop

184* 2/V O-ring O-ring

196 1/V Repair kit, incl. item Reparationssæt, inkl.

039, 052, 064, 076, 088, item 039, 052, 064, 076,
123, 135, 147, 159, 088, 123, 135, 147, 159,
and 184 and 184

206 1/E Reduction valve, Reduktionsventil,

complete komplet

218 1/E Pilot valve, complete Styreventil, komplet

231 1/V Repair kit for Reparationssæt for

item 218 item 218

243 2/V Screw Skrue

255 1/V Manometer Manometer

0-25 bar - PI 70 0-25 bar - PI 70
08028-0D/H5250/94.08.12

267 1/E Pressure reduction Trykreduktionsventil,

valve, complete as komplet som plate
plate 61322 61322

279 1/V Repair kit for Reparationssæt for

item 206 item 206

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/V = Qty/Valve Antal/V = Antal/Ventil

03.22 - ES0
 MAN Diesel

Plate
Page 1 (2) Cover for Turning Gear 51325-12

L21/31, L27/38,
V28/32S

226

214
238

180
251
263

192
202

For turning gear, see plate 51325

08028-0D/H5250/94.08.12

08.17 - ES0
 MAN Diesel

Plate
51325-12 Cover for Turning Gear Page 2 (2)

L21/31, L27/38,
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

180 1/E Cover Dæksel

192 3/E Stud Tap

202 3/E Nut Møtrik

214 1/E Plate Plade

226 1/E Limit switch Afbryder

238 2/E Screw Skrue

251 2/E Screw Skrue

263 2/E Washer Skive

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

08.17 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Manual Turning Gear 51325-20

L21/31, L27/38,
V28/32S

645

789
981
777
765 885

777 574

873
550

728 669 633 657

944

956
968
586
549 S4
S5
537 716

562
753
598 907
670 836 848 861
608 S4
S5

S5-S5 S4-S4
897

694 621
682

11.29 - ES0
 MAN Diesel & Turbo

Plate
51325-20 Manual Turning Gear Page 2 (2)

L21/31, L27/38,
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

537 1/E Counter nuts for Møtrik, sekskantet 907 /I Glue Lim
pull rods
944 1/E Shaft Aksel
549 1/E Washer Skive
956 1/E Spindle Spindel
550 1/E Gear wheel Tandhjul
968 1/E Key Not
562 1/E Shaft Aksel
981 1/E Turning gear, Tørnegear, komplet
574 1/E Flange Flange complete

586 4/E Cyl. screw Cylinderskrue

598 1/E Retaining ring Seeger-sikring

for shaft

608 1/E Ball bearing Kugleleje

621 1/E Key Not

633 1/E Worm gear Snekkegear

645 4/E Cyl. screw Cylinderskrue

657 1/E Flange Flange

669 4/E Cyl. screw Cylinderskrue

670 1/E Shaft Aksel

682 1/E Handle knob with pin Håndtag med stift

694 1/E Pipe Rør

716 1/E Cylindrical pin Cylinderstift

728 1/E Handle Håndtag

753 1/E Cyl. screw Cylinderskrue

765 1/E Limit switch Limit switch

777 4/E Cyl. screw Cylinderskrue

789 1/E Plate Plade

836 1/E Disc Skive

848 1/E Compression spring Trykfjeder

861 1/E Disc Skive

873 1/E Cover plate Dækplade

885 2/E Washer Skive

897 1/E Circlip Låsering

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

11.29 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Pneumatic Turning Gear 51325-21

L21/31, L27/38,
V28/32S

993

645
932

789

777
765 885

777 574

873 550

728 669 633 657

586
549 S4
S5
537 716

562
753
598 907
670 836 848 861
608 S4
S5

S5-S5 S4-S4
897

694 621
682

12.02 - EO0
 MAN Diesel & Turbo

Plate
51325-21 Pneumatic Turning Gear Page 2 (2)

L21/31, L27/38,
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

537 1/E Counter nuts for Møtrik, sekskantet 907 /I Glue Lim
pull rods
932 1/E Compressed-air motor Trykluftsmotor
549 1/E Washer Skive
993 1/E Turning gear, Tørnegear, komplet
550 1/E Gear wheel Tandhjul complete

562 1/E Shaft Aksel

574 1/E Flange Flange

586 4/E Cyl. screw Cylinderskrue

598 1/E Retaining ring Seeger-sikring

for shaft

608 1/E Ball bearing Kugleleje

621 1/E Key Not

633 1/E Worm gear Snekkegear

645 4/E Cyl. screw Cylinderskrue

657 1/E Flange Flange

669 4/E Cyl. screw Cylinderskrue

670 1/E Shaft Aksel

682 1/E Handle knob with pin Håndtag med stift

694 1/E Pipe Rør

716 1/E Cylindrical pin Cylinderstift

728 1/E Handle Håndtag

753 1/E Cyl. screw Cylinderskrue

765 1/E Limit switch Limit switch

777 4/E Cyl. screw Cylinderskrue

789 1/E Plate Plade

836 1/E Disc Skive

848 1/E Compression spring Trykfjeder

861 1/E Disc Skive

873 1/E Cover plate Dækplade

885 2/E Washer Skive

897 1/E Circlip Låsering

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

12.02 - EO0
 MAN Diesel

Plate
Page 1 (2) Electric Turning Gear (3 x 400V) 51325-22

L21/31, L27/38,
V28/32S

970

645
513
789

777
765 885

777 574

873 550

728 669 633 657

586
549 S4
S5
537 716

562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12

S5-S5 S4-S4
897

694 621
682

09.34 - EO0
MAN Diesel

Plate
51325-22 Electric Turning Gear (3 x 400V) Page 2 (2)

L21/31, L27/38,
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

513 1/E El motor El-motor 897 1/E Circlip Låsering

537 1/E Counter nuts for Møtrik, sekskantet 907 /I Glue Lim
pull rods
970 1/E Turning gear, Tørnegear, komplet
549 1/E Washer Skive complete

550 1/E Gear wheel Tandhjul

562 1/E Shaft Aksel

574 1/E Flange Flange

586 4/E Cyl. screw Cylinderskrue

598 1/E Retaining ring Seeger-sikring

for shaft

608 1/E Ball bearing Kugleleje

621 1/E Key Not

633 1/E Worm gear Snekkegear

645 4/E Cyl. screw Cylinderskrue

657 1/E Flange Flange

669 4/E Cyl. screw Cylinderskrue

670 1/E Shaft Aksel

682 1/E Handle knob with pin Håndtag med stift

694 1/E Pipe Rør

716 1/E Cylindrical pin Cylinderstift

728 1/E Handle Håndtag

753 1/E Cyl. screw Cylinderskrue

765 1/E Limit switch Limit switch

777 4/E Cyl. screw Cylinderskrue

789 1/E Plate Plade

836 1/E Disc Skive

848
08028-0D/H5250/94.08.12

1/E Compression spring Trykfjeder

861 1/E Disc Skive

873 1/E Cover plate Dækplade

885 2/E 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

09.34 - EO0
 MAN Diesel

Plate
Page 1 (2) Electric Turning Gear (3 x 440V) 51325-23

L21/31, L27/38,
V28/32S

275

645
287
789

777
765 885

777 574

873 550

728 669 633 657

586
549 S4
S5
537 716

562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12

S5-S5 S4-S4
897

694 621
682

09.34 - EO0
MAN Diesel

Plate
51325-23 Electric Turning Gear (3 x 440V) Page 2 (2)

L21/31, L27/38,
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

275 1/E Turning gear, Tørnegear, komplet

complete 885 2/E Washer Skive

287 1/E El motor El-motor 897 1/E Circlip Låsering

537 1/E Counter nuts for Møtrik, sekskantet 907 /I Glue Lim
pull rods

549 1/E Washer Skive

550 1/E Gear wheel Tandhjul

562 1/E Shaft Aksel

574 1/E Flange Flange

586 4/E Cyl. screw Cylinderskrue

598 1/E Retaining ring Seeger-sikring

for shaft

608 1/E Ball bearing Kugleleje

621 1/E Key Not

633 1/E Worm gear Snekkegear

645 4/E Cyl. screw Cylinderskrue

657 1/E Flange Flange

669 4/E Cyl. screw Cylinderskrue

670 1/E Shaft Aksel

682 1/E Handle knob with pin Håndtag med stift

694 1/E Pipe Rør

716 1/E Cylindrical pin Cylinderstift

728 1/E Handle Håndtag

753 1/E Cyl. screw Cylinderskrue

765 1/E Limit switch Limit switch

777 4/E Cyl. screw Cylinderskrue

789 1/E Plate Plade

08028-0D/H5250/94.08.12

836 1/E Disc Skive

848 1/E Compression spring Trykfjeder

861 1/E Disc Skive

873 1/E Cover plate Dækplade

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

09.34 - EO0
 MAN Diesel

Plate
Page 1 (2) Electric Turning Gear (3 x 480V) 51325-24

L21/31, L27/38,
V28/32S

299

645
309
789

777
765 885

777 574

873 550

728 669 633 657

586
549 S4
S5
537 716

562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12

S5-S5 S4-S4
897

694 621
682

09.34 - EO0
MAN Diesel

Plate
51325-24 Electric Turning Gear (3 x 480V) Page 2 (2)

L21/31, L27/38,
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

299 1/E Turning gear, Tørnegear, komplet 885 2/E Washer Skive
complete
897 1/E Circlip Låsering
309 1/E El motor El-motor
907 /I Glue Lim
537 1/E Counter nuts for Møtrik, sekskantet
pull rods

549 1/E Washer Skive

550 1/E Gear wheel Tandhjul

562 1/E Shaft Aksel

574 1/E Flange Flange

586 4/E Cyl. screw Cylinderskrue

598 1/E Retaining ring Seeger-sikring

for shaft

608 1/E Ball bearing Kugleleje

621 1/E Key Not

633 1/E Worm gear Snekkegear

645 4/E Cyl. screw Cylinderskrue

657 1/E Flange Flange

669 4/E Cyl. screw Cylinderskrue

670 1/E Shaft Aksel

682 1/E Handle knob with pin Håndtag med stift

694 1/E Pipe Rør

716 1/E Cylindrical pin Cylinderstift

728 1/E Handle Håndtag

753 1/E Cyl. screw Cylinderskrue

765 1/E Limit switch Limit switch

777 4/E Cyl. screw Cylinderskrue

789 1/E Plate Plade

08028-0D/H5250/94.08.12

836 1/E Disc Skive

848 1/E Compression spring Trykfjeder

861 1/E Disc Skive

873 1/E Cover plate Dækplade

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

09.34 - EO0
Fuel oil system

514/614
MAN Diesel & Turbo
Description 514.01
Page 1 (2) Internal fuel oil system
Edition 16

L27/38
Internal fuel oil system

Figure 1: Diagram for fuel oil system

Fuel injection equipment
General Each cylinder unit has its own set of injection equip-
The internal built-on fuel oil system as shown in fig. ment comprising injection pump unit, high-pressure
1 consists of the following parts: pipe and injection valve.
▪ the running-in filter The injection equipment and the distribution supply
pipes are housed in a fully enclosed compartment
▪ the high-pressure injection equipment
thus minimizing heat losses from the preheated fuel.
▪ the waste oil system This arrangement reduces external surface temper-
atures and the risk of fire caused by fuel leakage.
Running-in filter The injection pump units are with integrated roller
The running-in filter has a fineness of 50 microns guide directly above the camshaft.
(sphere passing mesh) and is placed in the fuel inlet The fuel quantity injected into each cylinder unit is
pipe. Its function is to remove impurities in the fuel adjusted by means of the governor, which main-
pipe between safety filter and the engine in the run- tains the engine speed at the preset value by a con-
ning-in period. tinuous positioning of the fuel pump racks, via a
Note: The filter must be removed before ship deliv- common regulating shaft and spring-loaded link-
ery or before handling over to the customer. ages for each pump.

It is adviced to install the filter every time the extern The injection valve is for "deep" building-in to the
fuel pipe system has been dismantled, but it is centre of the cylinder head.
important to remove the filter again when the extern The injection oil is supplied from the injection pump
fuel oil system is considered to be clean for any to the injection valve via a double-walled pressure
impurities. pipe installed in a bore in the cylinder head.

2011.11.28
 MAN Diesel & Turbo
514.01 Description
Internal fuel oil system Page 2 (2)
Edition 16

L27/38
This bore has an external connection to lead the
leak oil from the injection valve and high-pressure
pipe to the waste oil system, through the double
walled pressure pipe.
A bore in the cylinder head vents the space below
the bottom rubber sealing ring on the injection
valve, thus preventing any pressure build-up due to
gas leakage, but also unveiling any malfunction of
the bottom rubber sealing ring due to leak oil.

Waste oil system

Waste and leak oil from the hot box, fuel injection
valves, fuel injection pumps and high-pressure
pipes, is led to the fuel leakage alarm unit, from
which it is drained into the sludge tank.
The leakage alarm unit consists of a box, with a
float switch for level monitoring. In case of a leak-
age, larger than normal, the float switch will initiate
an alarm. The supply fuel oil to the engine is led
through the leakage alarm unit in order to keep this
heated up, thereby ensuring free drainage passage
even for high-viscous waste/leak oil.

Sludge tank
In normal operation no fuel should leak out from the
components of the fuel system. In connection with
maintenance, or due to unforeseen leaks, fuel or
water may spill in the hot box of the engine. The
spilled liquids are collected and drained by gravity
from the engine through the dirty fuel connection.
Waste and leak oil from the hot box is drained into
the sludge tank.
The tank and the pipes must be heated and insula-
ted, unless the installation is designed for operation
exclusively on MDO/MGO.

2011.11.28
MAN Diesel & Turbo
Description 514.01
Page 1 (2) Internal fuel oil system
Edition 19

L27/38
Internal fuel oil system

Figure 1: Diagram for fuel oil system

Fuel injection equipment
General Each cylinder unit has its own set of injection equip-
The internal built-on fuel oil system as shown in fig. ment comprising injection pump unit, high-pressure
1 consists of the following parts: pipe and injection valve.
▪ the running-in filter The injection equipment and the distribution supply
pipes are housed in a fully enclosed compartment
▪ the high-pressure injection equipment
thus minimizing heat losses from the preheated fuel.
▪ the waste oil system This arrangement reduces external surface temper-
atures and the risk of fire caused by fuel leakage.
Running-in filter The injection pump unit are with integrated roller
The running-in filter has a fineness of 50 microns guide directly above the camshaft.
and is placed in the fuel inlet pipe. Its function is to The fuel quantity injected into each cylinder unit is
remove impurities in the fuel pipe between safety fil- adjusted by means of the governor, which main-
ter and the engine in the running-in period. tains the engine speed at the preset value by a con-
Note: The filter must be removed before ship deliv- tinuous positioning of the fuel pump racks, via a
ery or before handling over to the customer. common regulating shaft and spring-loaded link-
ages for each pump.
It is adviced to install the filter every time the extern
fuel pipe system has been dismantled, but it is The injection valve is for "deep" building-in to the
important to remove the filter again when the extern centre of the cylinder head.
fuel oil system is considered to be clean for any The injection oil is supplied from the injection pump
impurities. to the injection valve via a double-walled pressure
pipe installed in a bore in the cylinder head.

2011.09.26 - ES0
 MAN Diesel & Turbo
514.01 Description
Internal fuel oil system Page 2 (2)
Edition 19

L27/38
This bore has an external connection to lead the The tank and the pipes must be heated and insula-
leak oil from the injection valve and high-pressure ted, unless the installation is designed for operation
pipe to the waste oil system, through the double exclusively on MDO/MGO.
walled pressure pipe.
A bore in the cylinder head vents the space below
the bottom rubber sealing ring on the injection
valve, thus preventing any pressure build-up due to
gas leakage, but also unveiling any malfunction of
the bottom rubber sealing ring due to leak oil.

Waste oil system

Clean leak oil from the fuel injection valves, fuel
injection pumps and high-pressure pipes, is led to
the fuel leakage alarm unit, from which it is drained
into the clean leak fuel oil tank.
The leakage alarm unit consists of a box, with a
float switch for level monitoring. In case of a leak-
age, larger than normal, the float switch will initiate
an alarm. The supply fuel oil to the engine is led
through the leakage alarm unit in order to keep this
heated up, thereby ensuring free drainage passage
even for high-viscous waste/leak oil.
Waste and leak oil from the hot box is drained into
the sludge tank.

Clean leak fuel tank

Clean leak fuel is drained by gravity from the engine.
The fuel should be collected in a separate clean
leak fuel tank, from where it can be pumped to the
service tank and reused without separation. The
pipes from the engine to the clean leak fuel tank
should be arranged continuously sloping. The tank
and the pipes must be heated and insulated, unless
the installation is designed for operation exclusively
on MDO/MGO.
The leak fuel piping should be fully closed to pre-
vent dirt from entering the system.

Sludge tank
In normal operation no fuel should leak out from the
components of the fuel system. In connection with
maintenance, or due to unforeseen leaks, fuel or
water may spill in the hot box of the engine. The
spilled liquids are collected and drained by gravity
from the engine through the dirty fuel connection.
Waste and leak oil from the hot box is drained into
the sludge tank.

2011.09.26 - ES0
MAN Diesel & Turbo

Description
Fuel Injection Pump 514.02
Page 1 (1) Edition 01

General

Fuel Injection Pump

The fuel pump and the roller guide are one unit, To injection valve
placed over the fuel cam. A pipe supplies lubricat-
ing oil from the camshaft bearing to the roller guide.
Delivery valve
Delivery valve housing
The barrel is installed with seals on the outer circum-
ference at various levels to avoid leakages and to
give the possibility to drain fuel from the lower part
of the barrel bore.
Barrel
At the same time it also gives the possibility to add
sealing oil to minimize fuel contamination of the
lubricating oil.

The injection amount of the pump is regulated by

transversal displacement of a toothed rack in the
side of the pump housing. By means of a gear ring,
the pump plunger with the two helical millings, the Fuel
cutting-off edges, is turned whereby the length of
Fuel rack
the pump stroke is reckoned from when the plunger
closes the inlet holes until the cutting-off edges again
uncover the holes.

A delivery valve is installed on top of the barrel. In the

delivery valve housing a second valve is installed.This
valve will open for oscillating high pressure waves
between the needle in the fuel injection valve and
the delivery valve on the pump, causing the needle
in the fuel valve to stay closed after the injection is
Lub oil
finished. This will reduce formation of carbon around
the nozzle tip and save fuel.

The amount of fuel injected into each cylinder unit

is adjusted by means of the governor, which main­
tains the engine speed at the preset value by a
con­tinuous positioning of the fuel pump racks, via a
common regulating shaft and spring-loaded link­ages
for each pump.

The rack for fuel control is shaped as a piston at one

end. The piston works inside a cylinder. When the Roller
cylinder is pressurized, the fuel rack will go to zero
and the engine will stop.

Fig 1 Fuel injection pump

12.04 - ES1
MAN Diesel & Turbo

Description
Fuel Injection Valve 514.06
Page 1 (1) Edition 01

General

Fuel Injection Valve

The fuel valve is uncooled and placed in a sleeve in

the centre of the cylinder head.

O-rings around the fuel valve body prevent fuel and

lubricating oil from mixing. From the side of the cyl-
inder head, a lance for fuel supply is screwed into
the fuel valve (L16/24 is mounted by means of 3 leaf Sleeve
springs). The lance is sealed with a bushing and two
o-rings where the lance goes into the cylinder head.
A double-walled high pressure pipe connects the fuel
pump with the lance.
Lance
Leak oil from the fuel valve or from a possible defec-
tive high pressure pipe is led to the bore for the lance
in the cylinder head. From here a pipe will drain the
fuel to the leakage alarm and further to the leak oil Fuel inlet
connection. From here the HFO can be led to leak
oil tank and MDO/MGO to the day tank.

Needle

Nozzle complete

Fig 1 Fuel injection valve

12.04 - ES1
MAN Diesel & Turbo

Description 514.25
Page 1 (2) HFO/MDO Changing Valves (V1 and V2) Edition 02H

L21/31, L27/38
V28/32S
Description To maintain recirculation in the HFO flow line when
the GenSet is operated on MDO a by-pass valve
The fuel changing system consist for GenSet of two must be installed between the inlet changing valve
three-way valves (V1 and V2) with a electric/pneu- (V1) and the outlet valve (V2) at each GenSet as
matically operated actuator of the simplex type with shown in fig. 1.
spring return and a common valve control box for
the total GenSet plant.
Valve Control Box
The system facilitates a flexible selection of MDO and
HFO-operating at any load condition. This system Electrical power supply to the valve control box is
gives the advantage of individually choosing MDO 380 Volt - 50 Hz, or 440 Volt - 60 Hz, depending on
or HFO mode of operation of the GenSets. the plant specification, and is established in form of
a single cable connection from the switchboard.

Filter PI

Air pressure: 6 bar

Water trap Reduction Air consumption

valve per stroke : 1.1 litre

ø6 ø6

Valve con-
trol box
*
MDO MDO

* *
Valve V1 Valve V2

HFO HFO

A1 A2
Inlet engine Outlet engine

* MAN Diesel & Turbo supply

Fig. 1 Pneumatic diagram for 3-way changing valves V1 & V2.

The three-way valves should be placed as near as Due to a built-in transformer, the power supply voltage
possible to the engines.The control box can be placed will be converted to a 24 Volt DC pilot voltage for ser-
in the engine room or in the engine control room. ving the relays, contactors, and indication lamps.

05.35 - EO0
 MAN Diesel & Turbo

514.25 HFO/MDO Changing Valves (V1 and V2)

Description
Edition 02H Page 2 (2)

L21/31, L27/38,
V28/32S
Furthermore the 24 V DC pilot voltage is used for In case of black-out and other situations resulting in
operating the fuel changing valves with a pneumati- dead voltage potential, the fuel changing valves will
cally and electrically operated actuator of the simplex be de-energized and automatically take MDO-posi­
type with return springs. tion due to the built-in return spring.

The mode of valve operation is:

HFO-position: Energized
MDO-position: De-energized

Fig 1 Ball valve with actuator.

05.35 - EO0
MAN Diesel & Turbo
Work Card 514-01.01
Page 1 (4) Removal and fitting of fuel injection valve
Edition 01

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 013
52000 050
Shut off cooling water 52000 074
Shut off fuel oil 52000 407
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description

Starting Position Hand Tools

Ring and open end spanner, 12 mm
Operating media systems closed/
depressurised Ring and open end spanner, 24 mm
Engine shut down Socket spanner, 24 mm

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2010.01.11.
 MAN Diesel & Turbo
514-01.01 Work Card
Removal and fitting of fuel injection valve Page 2 (4)
Edition 01

L27/38

Short description 11) Clean complete injection valve outside with fuel,
remove adhering with wire brush. Scratch injec-
Execute work on time according to the mainte- tion nozzle only with wooden spatulas, in order
nance schedule, enable/support economic opera- not to damage nozzle bore. Clean cylindrical set
tion, prevent operating problems damages. Fuel of nozzle bodies.
injection valves affect the loading of the injection
system and the operating values of the engine. Caution: Cleaning should be done on the side
They are to be checked if there are deviations in the away of the workbench.
operating values, to be overhauled if necessary or
changed.

Dismantling of a fuel inction valve

Notice: An engine that runs usually on heavy oil,
should be operated for a short while on Diesel oil
before disassembling the fuel injection valves.
Initial state: Stop valves on fuel pipes closed. Oil
pump (Reserve) shut off, Cylinder head cover
removed, indicator valve opened.
Caution: Injection valve should be disassembled
only with opened indicator valve.
1) Remove the side cover over the fuel pump and
the top cover over the rocker arms for the cylin-
der head.
2) Dismantle the delivery pipe between the fuel
pump and the lance (5) fig 1.
3) Remove the nuts (1) and the thrust piece (2).
4) Unscrew the screw (3) and remove the locking
device (4).
5) Unscrew the lance (5) and remove it from the
cylinder head. Figure 1: Fuel injection valve assembly

6) Install the extractor tool, see fig. 2 and pull out

the fuel valve.
7) Extract injector valve by turning the spindle nut
until it is loose.
Notice: Injection valve may be dismantled only with
disassembly and assembly fixture.
8) Thread off spindle nut and remove the extractor
tool.
9) Cover opening in the cylinder head.
10) Place injection valve on workbench.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.01
Page 3 (4) Removal and fitting of fuel injection valve
Edition 01

L27/38

Figure 3: Fuel injection valve complete

4) Assemble injection valve in bore, taking care of

Figure 2: Extractor tool mounted on fuel injection valve correct positioning of the bore for threaded
piece. Fit new round ring seals (8), lubricated
with clean lubricating oil, in the ring groove,
ensuring that this is tensioned equally on the
Assembling of fuel injection valve entire periphery and not twisted.
Initial state: Injection valve, especially cylindrical 5) Ad lubricant pasta to the thread of the lance (5)
seat of nozzle bodies cleaned carefully. Opening and screw it into the fuel valve.
pressure, tightness and nozzle bores checked.
6) Place the thrust collar (item 2 figure 1) on the
Notice: Injection valve from reserve stock or spares fuel injection valve and apply lubricant type GN
delivery cleaned and check from outside. or similar on screw thread, contact surface and
Working steps hexagon nuts (1). Then tighten with hand and
after installation of the lance (5) the hexagon
1) Fit new round ring seals (8), lubricated with
nuts (1) can be tightened to the specified torque
clean lubricating oil, in the ring groove, ensuring
of 115 Nm. Prior to the tightening It might be
that this is tensioned equally on the entire
necessary to turn the fuel valve a little to make
periphery and not twisted.
the thread catch. Tightening torque for the
2) Fill the inside space (spring room) of the injec- lance is 75 Nm.
tion valve through leakage fuel draining hole,
Notice: If the injection valve is installed in an operat-
with clean fuel.
ing hot cylinder head, tighten the hexagonal nuts (7)
3) Remove cover for bore in the cylinder head and only after temperature equalisation, with specified
clean the bore and seat face in the cylinder torque.
head carefully.
7) Place the locking device on the hexagon of the
Caution: When cleaning, see that no external lance and secure it with the screw (4) lubricated
objects fall into the combustion chamber! with oil. Tightening torque 115 Nm.

2010.01.11.
 MAN Diesel & Turbo
514-01.01 Work Card
Removal and fitting of fuel injection valve Page 4 (4)
Edition 01

L27/38
8) Ad lubricant type GN or similar to the lance (5)
and the fuel pump top and install the high pres-
sure pipe. Tightening torque: 50 Nm.
9) Close indicator valve.
10) Open stop valves on fuel pipes.
11) Attach cylinder head cover.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.02
Page 1 (5) Fuel injection valve to be checked
Edition 01

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 013
52000 050
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description

Starting Position Hand Tools

Related Procedure
Assembly of the fuel injection 514-01.04
valve

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 1 51701 015 1/V
51702 010 1/V
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2010.01.11.
 MAN Diesel & Turbo
514-01.02 Work Card
Fuel injection valve to be checked Page 2 (5)
Edition 01

L27/38

Short description Structure and pattern of the nozzle test

Check components for quality/wear condition stand
ensure/restore operating reliability. Fuel injection
valve affect the loading of the fuel injection system
and the operating values of the engine. They are to
be checked if there are deviations in the operating
values, to be overhauled if necessary or changed.
The work extends: Checking of parts/components.

Preliminary observations
Functioning capability and setting of the injection
valve affect the combustion course, the operating
values and the loading of the injection system. If the
operating values are changed (ignition pressure,
exhaust temperature) the opening pressure and
tightness of the concerned valves should be
checked. The nozzle test stand allows to pressure-
test and adjust the injection valve, using a hydraulic
hand pump. The fixture ensure comfortable working
under reproducible conditions.
In the testing of injection valves of modern 4-stroke 4 Test pressure pump for 5 Clamping for injection
engines the atomisation is no longer a test criterion, fuel nozzle valve complete
because the behaviour of the injection nozzle in 6 Adapter for fuel injection 7 High pressure pipe
engine operation cannot be verified. valve
An inferior spray pattern does not say anything
Figure 1: Nozzle test stand
about the functioning of the injection nozzles in the
engine. It is fully functional if the criteria for opening
pressure, tightness and free nozzle bores are fulfil-
led.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.02
Page 3 (5) Fuel injection valve to be checked
Edition 01

L27/38
ble then it is important to carry out the described
test at once after injection valves are removed from
engine. Otherwise the injection valve has to be sep-
arated and cleaned before testing.
Initial state: Injection valve is dismantled and
cleaned on the outside.
Notice: Use anti-corrosion oil for checking the
injection valves, so that they also given the conser-
vation treatment. Only absolutely clean anti-corro-
sion oil should be filled in the nozzle test stand oth-
erwise there could be malfunctioning in the pump or
in the injection valve to be tested. The fill level of the
oil container (12) should be checked.
1) Insert injection valve in the adapter head and
tighten uniformly with holder.
2) Thread in connection piece on pressure hose
connection of the injection valve and screw in
high pressure hose on connecting piece.
3) Set nozzle jet collector vessel under the injec-
tion nozzle and push it up until the expected
jets meet on the outer walls of the nozzle jets
collector vessel.
Caution: Never allow injection nozzle to spray into
open air but only in the collector! Do not touch fuel
1 Fixation for mounting 2 Lever for pump jets, as they penetrate the skin structure and cause
device painful inflammation! Do not use any open flames at
3 Partition of test rig in tab- 4 Lever with locking mech-
workplace! Smoking is absolutely prohibited! Use
letop (GXO-G011a) anism for rotating of suction on oil mist wherever possible!
mounting device
The checking and setting of the injection valves
5 Device to move show- 6 Pockets for e.g. mounting extends to the following steps:
case up and downwards device or tools
▪ Check opening pressure
7 Oil collecting tank 8 Fan to evacuate oil
vapour ▪ Check nozzle bores
9 Showcase to watch spray 10 Connection for high pres- ▪ Set target pressure
pattern sure pipe
▪ Check tightness
11 Lever to switch from 12 Relief valve lever (to
opening pressure to release pressure in high
boost test pressure pipe) Check opening pressure
13 Pressure gauge (with bar 1) Close pressure relief valve (12) if it exist on the
and PSI scaling)
test equipment used.
Figure 2: Nozzle test stand 2) Actuate hand pump (26) uniformly and raise
pressure until the injection nozzle opens. Note
opening pressure and compare with reference
value 420 bar. Actuate hand pump for min. 20
Preparation for inspection
strokes and rinse injection valve.
Notice: Heavy oil residues in the injection valves Notice: Opening pressure
can adversely affect test result and make cleaning
more difficult. It is therefore recommended that the The hydraulic pressure must be taken slowly past
engine run on Diesel oil for about 1 hour before dis- the opening pressure, as otherwise there are errors
assembling the injection valves. If that is not possi- while reading off the opening pressure. The test

2010.01.11.
 MAN Diesel & Turbo
514-01.02 Work Card
Fuel injection valve to be checked Page 4 (5)
Edition 01

L27/38
pressure must not exceed 430 bar! In case of new
nozzles elements, the nozzle needle can be stuck at
the first spray test and must be released by strong
rinsing. In case of already run-in nozzles, collect the
anti corrosion oil contaminated with fuel and do not
fill it again in the pressing device.
In case of new nozzles, there can be a drop in the
opening pressure up to 90 bar after a few operating Figure 3: Assessment of the nozzle hols. Left - open, right -
hours. partly clogged
This pressure drop does not mean any functional
deficiency and is characteristic of all fuel injection
nozzles. Adjust opening pressure to reference
It cannot be expected that the nozzle will spray or
value
make a sound, only opening pressure can be
checked. 1) Actuate hand pump uniformly and thus raise the
Decision: Opening pressure drop less /greater than hydraulic pressure, at the same time tension the
90 bar. compression spring (6) a little by using adjusting
screw (2). Repeat the process until the refer-
Opening press. drop less than 90 bar: ence value of 420 bar is reached.
▪ Continue with the next step Notice: Compression spring
Opening press. drop greater than 90 bar: Do not set a higher pressure than indicated, other-
wise the compression spring will be deformed.
▪ Separate injection valve as mentioned in work-
Adjust to the indicated higher spray pressure value
card 514-01.03
only after assembling a new compression spring to
▪ Carry out visual inspection (spring breakage) compensate for the initial setting of the compres-
▪ If component is in order, continue with the next sion springs.
step 2) If the reference value is set reproducibly, lock
the adjusting screw (2) with the hexagonal nut
Check nozzle bores (1) and check the opening pressure again.
1) Loosen the hexagonal nut (1) and turn back
adjusting screw (2) until compression spring (6) Check leak proofing
is released. 1) Stop the pumping of the tester and open the
2) Close pressure relief valve (if it exist or retighten pressure relief valve (12) if it exist on the test
the high pressure pipe). Actuate hand pump equipment reducing the pressure to 0 bar. Or
uniformly and adjust opening pressure with release pressure by loosening high pressure
adjusting screw (2) to 30 bar. pipe until pressure has dropped to 0 bar. This
ensures, that the nozzle is closed completely.
Decision: All nozzle holes open? Please refer to fig-
ure 3. 2) Close pressure relief valve and pressurize pipe
again.
▪ Yes, continue with the next step
3) To check the leak proofing, actuate hand pump
▪ No, Separate the injection valve as mentioned in
evenly until 250 bar are reached on the pres-
work card 514-01.03.
sure gauge (13). The injection valve is consid-
ered tight if no drops fall within 5 seconds.
Notice: Make sure, that no oil drop off from the
nozzle leakage bore (9) (Fig. 5 working cards
514-01.03). This may causes a misinterpretation of
the tight nozzle. Avoid this by wrapping a cleaning
rag around the injection nozzle.
Decision: Tightness OK? Please refer to figure 4.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.02
Page 5 (5) Fuel injection valve to be checked
Edition 01

L27/38
▪ Yes, The injection valve can be made available
for use!
▪ No, The injection valve should be replaced with
new unit.

Figure 4: Judgement on the tightness. Left - tight, right - drops

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.03
Page 1 (3) Fuel injection valve to be separated
Edition 01

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 050
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description

Starting Position Hand Tools

Torque wrench
Ring and open end spanner, 41 mm
Hexagonal screw driver (set)
Wire brush
Spatula (wood)
Depth gauge
Container with fuel
Polishing medium (wool)
Paper towels
Related Procedure
Lubricant (containing molybdenum disulphide)
Separation of components
Checking of parts/components

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2010.01.11.
 MAN Diesel & Turbo
514-01.03 Work Card
Fuel injection valve to be separated Page 2 (3)
Edition 01

L27/38

Short description 2) Place the fuel valve in a vice with soft jaws.
Check components for quality/wear condition, pre- 3) Loosen hexagonal nut (1) and turn back adjust-
vent operating problems/damages. Fuel injection ing screw (2) until compression spring (6) is
valves affect the loading of the fuel injection system released.
and the operating values of the engine. They are to 4) Turn the fuel valve 180° so the hexagon nut (1)
be checked if there are deviations in the operating is turned down.
values, to be overhauled if necessary or changed.
5) Loosen nozzle tensioning nut (4) carefully.

Prelimenary observation
Releasing the nozzle tensioning nut
Notice: Separate injection valve if, during the test
Notice: If there is heavy resistance when releasing,
according to work card 514-01.02, errors are
try to make the threads free again by softening
detected and if the nozzle element should be
them in fuel and turning to and fro. Do not release
changed due to the operation time. The separation
nozzle tensioning nut with force, as otherwise
is done by placing the valve in a vice with soft jaws.
threads can wear out and parts can become use-
less.
6) When threading out the nozzle tensioning nut
(4) use the following method: Unscrew released
nozzle tensioning nuts and at the same time
prevent them from lifting axially from holder by
continuously lightly hitting with rubber hammer
on nozzle bodies.
Notice: This method should prevent shaving or
scratching of the parallel pin of the sealing face
between nozzle body and holder during the thread-
ing off of the nozzle tensioning nut.
7) Thread off nozzle tensioning nut and remove
nozzle body. See that nozzle needle does not
fall out.
8) Extract nozzle needle from nozzle body and
place it in fuel for cleaning.

Nozzle needle
Notice: Never interchange nozzle needles from
nozzle body to nozzle body. They are manufactured
in pairs.
9) Remove the injection valve from the vice with
Figure 1: Fuel injection valve
soft jaws and place it on the workbench.
10) Thread off adjusting screw (2).
Separating of a fuel injection valve
11) Disassemble threaded pin (3) if existing.
1) Wash injection valve in fuel and remove adher-
ing coke with a wire brush.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.03
Page 3 (3) Fuel injection valve to be separated
Edition 01

L27/38
12) If all internal parts are not loose, screw in suita-
ble eye bolt in thrust piece (5) and extract thrust
piece. Then disassemble compression spring
(6) and thrust piece (7).
13) Place all parts for cleaning in Diesel oil and
wash them off. Then blow with compressed air.

Check components
The inspection of the components extends to:
▪ the nozzle holes
▪ the quality of fitting faces
▪ the mobility of the needle
▪ traces of corrosion on the nozzle tensioning nut
and the nozzle body 9 Nozzle needle 10 Nozzle body

▪ the nozzle specifications Figure 3: Checking the mobility of the nozzle needle
1) Clamp a suitable cleaning wire, please see plate
52000, item No 013 for cleaning the nozzles 5) Read off nozzle specifications on the collar of
holes. the nozzle body.
Original specification - see acceptance record of
the motor.

Figure 2: Cleaning the nozzle holes

2) Examine all components and especially sealing

faces for damage / traces of wear.

No rework on the seat and fitting faces Figure 4: Nozzle element with specification and IMO number

Notice: Seat and fitting faces should not be

machined manually nor mechanically, as the requi- 6) Change damaged parts. Replace nozzle needle
site accuracies cannot be achieved. and nozzle body together.
3) Check if nozzle needle can be moved in the
nozzle body easily and without perceivable
resistance, see Fig. 3.
4) Examine nozzle bodies for traces of corrosion.
Examine nozzle bodies for traces of corrosion.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.04
Page 1 (2) Assembly of the fuel injection valve
Edition 01

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 050
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description

Starting Position Hand Tools

Torque wrench
Ring and open end spanner
Hexagonal screw driver (set)
Lubricant (copaslip, containing molybdenum disul-
phide)

Related Procedure
Assembly of components

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1

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

2010.01.11.
 MAN Diesel & Turbo
514-01.04 Work Card
Assembly of the fuel injection valve Page 2 (2)
Edition 01

L27/38

Short description 8) Rub sealing face dry with sealing paper towel.
Insert nozzle body with nozzle needle on holder,
Impart necessary knowledge, ensure correct execu- paying attention to the position of pins.
tion of work. Fuel injection valves affect the loading
of the fuel injection system and the operating values 9) Paint pressure shoulder (11) on nozzle body
of the engine. They are to be checked if there are (10) with lubricant “Optimol Paste White T”.
deviations in the operating values, to be overhauled Please see Fig. 1.
if necessary or changed. 10) Paint screw threads of holder and nozzle ten-
sioning nut (4) as well as pressure shoulder (4)
Specification of the injection nozzle on nozzle tensioning nut with lubricant “Optimol
Paste White T”. Please see Fig. 1.
Notice: Check before the assembly whether speci-
fication of the injection nozzle matches with the ref- 11) Screw on by hand nozzle tensioning nut on
erence specification. The original specification can holder and in the second step tighten with
be referred from the acceptance record (number, specified torque (see work card). Rotate take-
number of nozzle bores, bore diameter, spraying up head by 180° and fix it.
angle). 12) Screw on hexagonal nut (1) loosely on adjusting
Initial situation: Injection valve separated, all indi- screw and tighten only after adjusting the open-
vidual parts carefully cleaned, damaged parts ing pressure, please see description 500.35.
changed.
1) Clean threaded pin (3) and bore carefully as
given in Loctite-specifications.
2) Hold holder body at an angle (with sealing face
facing up) and guide in thrust piece (5) including
compression spring (6) and spring plate (7). Pay
attention to the position of the groove for the
threaded pin (3) (see fig.1).
3) Paint screw thread of the threaded pin (3) with
securing compound Loctite 243 on a length of
5mm and thread in into holder until threaded
pin no longer projects. Check that the thrust
piece can still move in axial direction.
4) Screw in adjusting screw (2), do not yet tighten
compression spring.
5) Insert holder complete fuel valve in the nozzle
tester such that the sealing surface for nozzle
body (10) faces up and tighten evenly. Rotate
take-up head by 180° and fix it.
6) Dip nozzle needle (10) in clean fuel and guide
into the nozzle body, check easy movement.
7) Check nozzle needle stroke between top edge
of nozzle body and offset on nozzle needle. For Figure 1: Assembly of the nozzle
reference value see section “technical data” in
instruction book.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.05
Page 1 (4) Dismounting/mounting of fuel injection pump
Edition 08

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52001 203
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Fuel injection pumps to be removed to permit nec-
essary check.This also involves disassembly to a
certain extent. It may also be necessary to remove
pumps if components are to be replaced.
Hand Tools
Starting Position Reversing ratchet
Covering on exhaust gas counterside removed. Torque wrench 20-200 Nm
Fuel injection pipe dismounted. Injection pump Cross handle
cleaned / checked, fuel rack completely pushed in Annular extension, size 24
as precautionary measure of protection (full load Hexagon key wrench with ball head, 6 A/F
position). Set of open-end/ring spanners
Set of hexagon bolt drivers
Lifting tackle with rope
Copaslip or similar
Acid-free grease
Related Procedure
Adjustment of camshaft for valve 507-01.20
and injection timing
Disassembly and assembly and 514-01.06
repair of fuel injection pump

Replacement and wearing parts

Qualified Manpower
Plate No. Item No. Quantity
Duration in h : 2 51401 685 1/C
Number : 1 51401 457 1/C
51435 070 *8/C
51435 344 *4/C
Data 51435 356 4/C
*see plate 51435
Data for pressure and tolerance (Page 500.35)
for max amount
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2002.09.02.
 MAN Diesel & Turbo
514-01.05 Work Card
Dismounting/mounting of fuel injection pump Page 2 (4)
Edition 08

L27/38

Operating sequence 1 - Dismounting of bled and/or changing the length as adjusted is only
fuel injection pump allowed for zero position balancing the injection
pump and the governor.
Warning! 6) As a protective precaution for the fuel rack,
push it completely in (full load position).
Use protective gloves!
7) Screw off the hexagon nuts, (2) fig 1.
1) Turn the engine so that the follower of the injec-
tion pump is at cam base circle position (spring 8) Screw the holder, see fig 2, onto the injection
largely unloaded). pump.

2) Close all the necessary shut-off valves (such as

for the fuel oil pipes, air ducts etc.).
3) Disconnect the air duct, leaked fuel oil pipe, lub.
oil pipe and sealing oil pipe (if fitted) from the
injection pump.
4) Remove the screw, (3) fig 1,on the two pumps
beside and press the fuel oil pipe away from the
actual fuel pump.

1 Lever 2 Holder

Figure 2: Removing of fuel injection pump

Figure 1: Fuel injection pump as mounted 9) Insert the lever into the holder and connect it
with the bolt. Secure the bolt by means of the
5) Unscrew the hexagon head bolt, (1) fig 1, spring plug.
between the fuel rack and the articulated head. 10) Attach the rope to the lever by means of
Caution shackle and suspend it from the lifting tackle.
The position of the articulated head between the 11) Lift rope until the lever approximately has the
knuckle lever and the rack has been adjusted and position, see fig 2.
secured by the manufacturer. It is expressly pointed
out that the articulated head must not be disassem- 12) Depress the lever to lift the injection pump far
enough to come clear of the bore hole.

2002.09.02.
MAN Diesel & Turbo
Work Card 514-01.05
Page 3 (4) Dismounting/mounting of fuel injection pump
Edition 08

L27/38
Caution 2) Treat new o-ring seals, (1) fig 4, with acid-free
During removal, take care that stud bolts are not grease and fit them in the ring grooves on the
damaged. fuel oil orifice flanges, making sure not to twist
13) Keep the injection pump in this position and them.
remove it sideways. 3) Screw the holder onto the injection pump.
14) Cover the resultant opening in the crankcase. 4) Insert the lever in the holder and connect by
15) To transport the pump away, let the lever loose, means of the bolt. Secure the bolt by means of
see fig. 3. To transport the pump away, let the spring plug.
lever loose, see fig. 3. 5) Attach the rope to the lever by means of a
shackle and suspend from lifting tackle. Lift the
injection pump.
6) Treat a new o-ring seal, (1) fig 3, with acid-free
grease and fit it in the ring groove. Take care
that it is evenly tensioned over the circumfer-
ence and not twisted.
7) Press the lever down to lift the injection pump.
8) Push the injection pump under the change-air
pipe and over the bore hole.
Caution
Take care that the injection pump does not hit any
parts while being installed.
9) Release the pressure exerted on the lever, low-
ering the injection pump into the bore.
Caution
In introducing the injection pump, take care that
stud bolts do not suffer damage.
10) Remove the tool completely.
11) Treat new o-ring seals (2) fig 4 and (4) fig 1, with
acid-free grease and fit them in the ring grooves
on the flange, taking care that they are not twis-
ted.
Figure 3: Transporting of dismounted fuel injection pump

16) Put the injection pump down on a clean place.

17) Remove the tool completely.

Operating sequence 2 - Installing of fuel

injection pump
Warning!
Use protective gloves! Figure 4: Press the fuel pipes back into the pump

1) Clean the contact faces on the injection pump 12) Press the fuel pipes back into the pump, fig 4,
and the crankcase. and fit the plug screw, (3) fig 1.

2002.09.02.
 MAN Diesel & Turbo
514-01.05 Work Card
Dismounting/mounting of fuel injection pump Page 4 (4)
Edition 08

L27/38
13) Treat the thread and contact face of the hexa-
gon nut with coperslip or the like and screw it
hand-tight onto the stud bolts (do not drive
them home).
14) Turn the engine (follower of the injection pump
aligns on cams).
15) Tighten the hexagon nut with specified torque,
please see description 500.40.
16) Connect the air pipe, the leaked fuel oil pipe,
the lub. oil pipe and the sealing oil pipe (if appli-
cable) to the injection pump.
17) Mount the fuel inection pipe.
18) Check and adjustment of injection timing,
please see working card 507-01.20.
19) Attach the articulated head to the fuel rack.
Caution
The correct length of the articulated head between
the knuckle lever and the fuel rack has been adjus-
ted and secured by the manufacturer. It is expressly
pointed out that changes to the length so adjusted
are only allowed to be made for a balancing of the
zero position between the injection pump and gov-
ernor.
20) Open all the shut-off valves that have been
closed in operating sequence 1.
21) Verify that the fuel rack is in the "zero position"
end position when the complete fuel admission
linkage is at "zero position" (compare fuel rack
position with that on the other injection pumps).
22) After putting into operation, determine the igni-
tion pressure by taking indicator diagrams.
Note:
Precise settings are very essential for the output,
combustion properties and trouble-free operation of
the engine.

2002.09.02.
MAN Diesel & Turbo
Work Card Disassembly/assembly and repair of fuel injection 514-01.06
Page 1 (7)
pump Edition 19

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52002 031
52002 043
Shut off cooling water 52002 055
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Injection pumps to be disassembled individually/
jointly at intervals specified in the maintenance
schedule. Dubious,worn,damaged parts to be
replaced to ensure operational reliability/efficiency.
Hand Tools
Starting Position Reversing ratchet
Injection pump detached and cleaned on the exte- Torque wrench 20-200 Nm
rior. All the parts cleaned and checked for dam- Cross handle
age, and replaced if necessary. Tappet and valve Screw driver insert, size 12 x 12.5
support assembled. Screw driver insert, size 10 x 12.5
Thickness gauge 0.05 - 1.0 mm
Set of open-end/ring spanners
Set of hexagon bolt drivers
MoS2 lubricant
Loctite 243 bonding agent
Related Procedure Acid-free grease
Dismounting/mounting of fuel 514-01.05
injection pump

Replacement and wearing parts

Qualified Manpower
Plate No. Item No. Quantity
Duration in h : 2 51401 720 1/C
Number : 1 51401 744 1/C
51401 504 1/C
51401 482 2/C
Data 51401 697 2/C
51401 707 1/C
Data for pressure and tolerance (Page 500.35)
51401 110 1/C
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2012.05.21.
 MAN Diesel & Turbo
514-01.06 Disassembly/assembly and repair of fuel injection Work Card
Page 2 (7)
Edition 19 pump

L27/38

Disassembly/assembly and Repair of Fuel Disassembly of fuel pump

Injection Pump
If damages occur at the injection pump during the
warranty period the service of the manufacturer or
of a contracted workshop shall be utilized, other-
wise you lose your rights under the guarantee.
Note! It must be cared during the disassembly of
the injection pump that the workplace is free of
chips and contaminations. It is recommended to
clean all parts with diesel fuel oil, and to place them
on a non-fuzzing cloth.
The complete injection pump must not be placed
on hard or metallic surfaces by the roller. Do not
use the extractable control rack as a handle!

The Following Guidelines shall be

considered
▪ Do not mix up parts of the pump element and
of the constant-pressure release valve.
▪ High-pressure surfaces must be protected
against damage, and cleaned with clean Diesel
fuel and a non-fuzzing cloth or paper when they
are installed again.
▪ O-rings on demounted parts shall generally be
replaced by new O-rings before parts are instal-
led again.
▪ Only original O-rings of MAN shall be used.
Apply paste for lip-type sealings to the O-rings
before installation.
▪ Cylindrical screws must be coated by graphite
paste on the bearing surface and on the thread;
tighten them crosswise and step by step (in
three steps of equal torque) to the required Figure 1: Unloading of the compression spring in the fuel injec-
tion pump
tightening torque.
▪ The cylindrical screws shall be loosened cross- 1) Screw out the hexagon socket bolts (1), take off
wise and step by step (in three steps of equal the valve support and put down on clean place,
torque), too. see fig 2.
2) See fig 1/I. Screw the spindle back, place the
bridge diagonally onto the casing and attach it
by means of hexagon nuts.

2012.05.21.
MAN Diesel & Turbo
Work Card Disassembly/assembly and repair of fuel injection 514-01.06
Page 3 (7)
pump Edition 19

L27/38
3) Turn the spindle until the thrust pad contacts
the tappet, see fig 1/II.
4) Turn the spindle to depress the tappet far
enough to unload the screw plug so the latter
can be removed, see fig 1/III.

Figure 2: Fuel injection pump

5) Turn the spindle back to unload the compres- 9) Screw off the hexagon socket bolts (3) and take
sion spring, see fig 1/IV. the tappet (16) off.
6) Remove the complete tool. 10) Take the thrust plate out and pull the plunger
7) Disassemble the tappet together with the pump base plate (14) off the plunger.
plunger and put down on clean place. 11) Take the compression spring out of the casing,
Caution! disassemble the spring cup (4) and the regulat-
Do not touch the pump plunger with your bare ing sleeve (5).
hands. Protect the control edges on the pump 12) Unscrew the cylinder and remove the regulator
plunger from damage. rod, see fig 4.
8) Measure the clearance (A), fig 2, of the pump 13) Screw out both baffle screws (6).
plunger between the thrust plate (2) and the 14) Unscrew the hexagon socket screws (7) and
plunger base plate, note down and compare take the thrust ring (19) off.
with specified value, see description 500.35. In
case of exceeding values, please replace wear- 15) Put the thrust plate onto the monobloc cylinder
ing parts. and fasten it in place, see fig 3.

2012.05.21.
 MAN Diesel & Turbo
514-01.06 Disassembly/assembly and repair of fuel injection Work Card
Page 4 (7)
Edition 19 pump

L27/38
16) Screw two hexagon head bolts into the thrust Note: The replacement of rollers should be entrus-
plate down to contact with the casing. ted to a service base on MAN personnel as a mat-
17) Attach the monobloc cylinder to the casing by ter of principle because the roller bolt has been fit-
turning the hexagon head bolts. ted in the tappet by freezing.

Note: Take care to avoid tilting of the monobloc cyl- 20) Check the complete valve support, (20) fig 2, for
inder as it is being pulled out. tightness and verify that the individual parts
move easily. Disassemble the valve support if
18) Remove the monobloc cylinder from the casing necessary.
and put it down on a clean support.
21) Clean all the parts with clean diesel oil and
check them for wear or damage.
Note: A pump element consists of the plunger and
monobloc cylinder. Plunger and monobloc cylinder
can only be replaced together because they fit
together.

Assembly of fuel pump

1 Regulating rod 2 Plunger packing

1 Hexagon head bolt 2 Thrust plate 3 Cylinder 4 Regulating sleeve

3 Bolt 4 Casing
Figure 4: Fuel injection pump - top view
5 Monobloc cylinder
1) Prior to assembly, slightly oil all the parts with
Figure 3: Removing the monobloc cylinder thin-bodied mineral oil.
Note:Metallic sealing and contact faces must be
19) Measure the axial and radial clearance of roller
absolutely dry when assembled.
(8), fig 2, note down and compare with the
specified clearances, see description 500.35. In 2) Fit a new plunger packing in the ring groove,
case of exceeding values, please replace wear- see fig 4.
ing parts.

2012.05.21.
MAN Diesel & Turbo
Work Card Disassembly/assembly and repair of fuel injection 514-01.06
Page 5 (7)
pump Edition 19

L27/38
Note:Alignment of the marks M/M is of great impor- - Remove item (2) and (3).
tance. - Calibrate the sealing ring with the bushing
3) Fit the fuel rack in the casing. shell (4).

4) Apply loctite 243 to the thread of the cylinder 7) Introduce the monobloc cylinder into casing,
over length of 6 mm and screw home into the taking note of the position of the cylindrical pin,
casing with a new gasket fitted. refer to fig 5.

5) Treat new sealing rings (9) and o-ring seals (10

and 11) with acid-free grease and fit them in
ring groove, taking care that the o-ring seals are
evenly tensioned aver the circumference, and
not twisted, see fig 2.

a Sealing ring b Sealing ring

X Pressure side

Figure 6: Assembly of sealing rings

8) Place the thrust plate, see fig 5, onto the mono-

bloc cylinder, mount the bridge over the thrust
plate on the casing, and screw the hexagon nut
1 Bridge 2 Thrust plate down to contact with the thrust plate, see fig 5.
3 Locating pin Screw the hexagon head bolt into the bridge.
9) Force the monobloc cylinder into the casing by
Figure 5: Installaling a new barrel turning the hexagon head bolt, making sure that
the locating pin is between the cylindrical pins,
6) Assembly of sealing rings, according to fig. 6. see fig 5.
Following require that extra tool are supplied by Note: When forcing the monobloc cylinder into the
MAN Diesel & Turbo, please see plate 52002. casing, prevent it from tilting.
- Mount the long sleeve (1) fig 6.
- Heat the sealing ring (a) to approximately 10) Removel the tool.
90°C. 11) Put the thrust ring (2), fig 2, onto the monobloc
- The sealing ring (a) on the expanding sleeve cylinder.
(2) and fit into groove. 12) Apply copaslip or the like to the threads and
- Remove item (1) and (2). contact faces of the hexagon socket bolts,
- Calibrate the sealing ring with the bushing screw home hand-tight and tighten to the
shell (4). specified torque, please see description 500.40.
- Mount the short sleeve (3), and press the For order of tightening, see fig 7.
heated sealing ring (b) on expending sleeve (3)
and fit into groove.

2012.05.21.
 MAN Diesel & Turbo
514-01.06 Disassembly/assembly and repair of fuel injection Work Card
Page 6 (7)
Edition 19 pump

L27/38
21) Carefully push the plunger and tappet into the
monobloc cylinder and/or casing, taking note of
the position of the longitudinal groove in the
tappet for the screw plug (17).
22) Screw the spindle back and place the bridge
diagonally onto the casing and fasten it by hex-
agon nuts, see fig 1/I.
23) Turn the spindle until the thrust pad contacts
1 Hexagon socket bolt 2 Valve support the tappet see fig 1/II.
3 Thrust ring 4 Hexagon socket bolt 24) Turn the spindle to depress the tappet far
enough to allow the screw plug equipped with a
1- Order of bolt tightening 9- Order of tightening
8 19 new gasket to be fitted, see fig 1/III.
25) Insert a masuring mandrel in cavitation holes.
Figure 7: Order of tightening the fixing bolts for the monobloc Depress the tappet spring until plunger just
cylinder (left) and valve support (right)
have contact with measuring mandrel area of
6.5h6, see fig 2. Check that the clearance (B)
13) Place the valve support onto the monobloc cyl- from roller to mounting surface comply the
inder, taking note of the bore/cylindrical pin (12) dimension, see fig 2 and description 500.35. In
position. case of exceeding values please exchange the
14) Apply copaslip or the like to the threads and trust plate (2).
contact faces of the hexagon socket bolts, 26) Remove the complete tool.
screw home hand-tight and tighten to the
specified torque in three steps. 27) Screw the baffle screws (6) complete with new
Please see description 500.40. For ordering of gaskets (18) into the casing specified.
tightening, see fig 7.
15) Fit the regulating sleeve so that the markings Preservation
(M), see fig 4, on the fuel rack and regulating The main functional components of each injection
sleeve coincide. pump supplied by the manufacturer has been pre-
16) Install the spring plate through the regulating served during its check-up in the test stand.
sleeve into the casing. P3 gero cut S 102 having a viscosity of 3.5 mm2/
Note: Prior to installing the spring plate, verify once sec at 20°C according to DIN 53015 is used as
again that the markings of the regulating sleeve and preserving agent.
fuel rack match. All external surfaces are primed.
17) Fit the compression spring (13) in the casing. The processed external surfaces are coated with
18) Put the plunger base plate (14) onto the pump anti-rust grease or preserved with preserving oil
plunger (15). Insert the thrust plate (2) in the Castrol Rustilo DWX31 having a specific gravity of
plunger base plate. 820 kg/m3 at 15°C according to DIN 51757.
Causion This preservation is effective for 2 years.
Do not touch pump plungers with your bare hands.
Protect control edges on plungers against damage. Re-preservation
19) Put the tappet (16) over the plunger base plate If the injection pump has not been put into opera-
and fasten it by four hexagon socket bolts (3). tion within 2 years after its delivery a re-preservation
20) Measure the clearance (A), fig 2, of the pump has to be carried out.
plunger between the thrust plate (2) and the For that purpose, a protective cap must be
plunger base plate, note down and compare removed from the fuel discharge (upper connection)
with specified value, see description 500.35. In at the injection pump.
case of exceeding values, please replace wear-
ing parts.

2012.05.21.
MAN Diesel & Turbo
Work Card Disassembly/assembly and repair of fuel injection 514-01.06
Page 7 (7)
pump Edition 19

L27/38
The suction chamber of the injection pump is filled
with preserving agent through the fuel discharge
boring, and closed.
By moving the plunger, the hollows are filled with
preserving agent.
All external surfaces coated with anti-rust agent
must be preserved once more.
The control rack has to be moved in regular inter-
vals of approx. 3 months to avoid a sticking of the
plunger.

2012.05.21.
MAN Diesel & Turbo
Work Card 514-01.07
Page 1 (2) Grinding of fuel injection valve seat face
Edition 01

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 050
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description

Starting Position Hand Tools

Related Procedure
Creatin of correct contact pattern

Qualified Manpower Replacement and wearing parts

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

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

2010.01.11.
 MAN Diesel & Turbo
514-01.07 Work Card
Grinding of fuel injection valve seat face Page 2 (2)
Edition 01

L27/38

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

Short description
Ensure correct execution of work, assess contact
pattern/wear status, restore contact pattern again.
The injection valve seat face in the cylinder head
should be checked on every disassembly of the fuel
injection valve by means of touching up sampling
and reworked if necessary.

Grinding the seat area

Initial state: Fuel injection valve dismantled.
1) Before mounting the fuel valve, clean and
inspect the valve sleeve in the cylinder head.
2) If necessary, grind the seating face with the
grinding tool see Fig. 1. 1 Pressure piece 2 Guide piece
3) Place grinding tool in cylinder head, paying 3 Pin
attention to guide piece (2) is in correct position
inside cylinder head. Figure 1: Grinding tools complete
4) Rotate grinding tool to and fro, raise in-between
and blow off grinding dust with compressed air.
5) Remove grinding tool see Fig. 1 after the grind-
ing process is complete and clean valve seat
carefully.

2010.01.11.
MAN Diesel & Turbo
Work Card 514-01.90
Page 1 (2) Check of fuel oil piping system
Edition 05

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of fuel oil piping system.

Starting Position Hand Tools

Engine is running.

Related Procedure

Qualified Manpower Replacement and wearing parts

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

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

2008.02.04.
 MAN Diesel & Turbo
514-01.90 Work Card
Check of fuel oil piping system Page 2 (2)
Edition 05

L21/31, L27/38

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

Fuel oil system

1) Dismount the covers to the injection pumps.
Blow through drain pipes from the pump bed.
2) Examine the piping system for leaks.
3) Retighten all bolts and nuts in the piping sys-
tem.
4) Move all valves in the piping system. Lubricate
valve spindles with graphite or similar.
5) Check flexible connections for leaks and dam-
ages.
It is important that the flexible connections are free
from paint and grease and in healthy condition.
6) Check for any leak of the O-ring for the fuel
injection pipe.
Concerning fuel oil condition, see section 504.

2008.02.04.
 MAN Diesel & Turbo

Plate
Page 1 (3) Fuel Injection Pump 51401-23H

L27/38

421
457
230*
589* 577* 697
590* 612* 707
122 313* 110 482
301* 719 242
146* 229
482 398
600 242
636* 624 494 374
099* 349

504
648* 325
087
648* 661* 254
661* 720 685
109* 732
744 266

278

531 291
183a
063* 183b
183c
08028-0D/H5250/94.08.12

014 051* 217 183d

183e
205 183f
183g
183h
038* 183i
183j
673* 183k
026* 183l
183m

09.08
 MAN Diesel & Turbo

Plate
51401-23H Fuel Injection Pump Page 2 (3)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

014 1/P Roller guide, com­­plete Rullestyr, komplet inkl. 278 1/P Spring plate Fjederplade
incl. item 026, 038, 051, item 026, 038, 051,
063, 673 063, 673 291 1/P Pump spring Pumpefjeder

026* 1/P Roller Rulle 301* 1/P Pressure valve Fjeder for
spring trykventil
038* 1/P Roller pin Rulletap
313* 1/P Spring plate Fjederplade
051* 1/P Roller guide Rullestyr
325 1/P Plug screw Propskrue
063* 1/P Threaded pin Gevindtap
349 1/P Plug screw Propskrue
087 1/P Pump element, com­ Pumpeelement, kom-
plete incl. item 099, 109, plet inkl. item 099, 109, 374 1/P Stop plate Stopplade
636, 648, 661 636, 648, 661
398 2/P Screw Skrue
099* 1/P Barrel Cylinder
421 6/P Cylindrical screw Cylindrisk skrue
109* 1/P Plunger Stempel
457 1/P O-ring O-ring
110 1/P O-ring O-ring
482 2/P Packing ring Pakningsring
122 1/P Pressure valve, com­ Trykventil, komplet inkl.
plete incl. item 146, item 146, 230, 301, 494 1/P Seal ring Tætningsring
230, 301, 313, 577, 589, 313, 577, 589, 590,
590, 612 612 504 1/P Seal ring Tætningsring

146* 1/P Distance sleeve Afstandsbøsning 531 /I Loctite 243 Loctite 620

183a 1/P Shim, 11.40 mm Skive, 11.40 mm 565 1/C Fuel Injection Pump, Brændselspumpe,
183b 1/P Shim, 11.25 mm Skive, 11.25 mm complete as shown on komplet som vist på
183c 1/P Shim, 11.20 mm Skive, 11.20 mm front page forsiden
183d 1/P Shim, 11.15 mm Skive, 11.15 mm
183e 1/P Shim, 11.10 mm Skive, 11.10 mm 577* 1/P Cylindrical pin Cylindrisk stift
183f 1/P Shim, 11.05 mm Skive, 11.05 mm
183g 1/P Shim, 11.00 mm Skive, 11.00 mm 589* 1/P Spring Fjeder
183h 1/P Shim, 10.95 mm Skive, 10.95 mm
183i 1/P Shim, 10.90 mm Skive, 10.90 mm 590* 1/P Pressure valve Trykventil
183j 1/P Shim, 10.85 mm Skive, 10.85 mm
183k 1/P Shim, 10.80 mm Skive, 10.80 mm 600 8/P Cylindrical screw Cylindrisk skrue
183l 1/P Shim, 10.75 mm Skive, 10.75 mm
183m 1/P Shim, 10.60 mm Skive, 10.60 mm 612* 1/P Ball Kugle

205 1/P Thrust piece Trykstykke 624 1/P Thrust ring Trykring

217 4/P Screw Skrue 636* 1/P Cylindrical pin Cylindrisk stift

229 1/P Pump casing, Pumpehus, 648* 2/P Ball Kugle

incl. item 719 inkl. item 719
661* 2/P Threaded pin Genvingtap
230* 1/P Connecting piece Forbindelsesstykke
08028-0D/H5250/94.08.12

673* 1/P Bush Bøsning

242 2/P Screw Skrue
685 1/P O-ring O-ring
254 1/P Control rack Reguleringsstang
697 2/P Sealing ring Tætningsring
266 1/P Control sleeve Kontrolbøsning

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
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

09.08
 MAN Diesel & Turbo

Plate
Page 3 (3) Fuel Injection Pump 51401-23H

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

707 1/P O-ring O-ring

719 2/P Cylindrical pin Cylindrisk stift

720 1/P Seal ring Tætningsring

732 1/P Cylinder Cylinder

744 1/P Seal ring Tætningsring

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/P = Qty/Pump Qty/P = Qty/Pumpe
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

09.08
 MAN Diesel & Turbo

Plate
Page 1 (3) Fuel Injection Pump 51401-24H

L27/38

421
457
230*
589* 577* 697
590* 612* 707
122 313* 110 482
301* 719 242
146* 229
482 398
600 242
636* 624 494 374
099* 349

504
648* 325
087
648* 661* 254
661* 720 685
109* 732
744 266

278

531 291
183a
063* 183b
183c
08028-0D/H5250/94.08.12

014 051* 217 183d

183e
205 183f
183g
183h
038* 183i
183j
673* 183k
026* 183l
183m

10.49 - ES0, MAN

 MAN Diesel & Turbo

Plate
51401-24H Fuel Injection Pump Page 2 (3)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

014 1/P Roller guide, com­­plete Rullestyr, komplet inkl. 266 1/P Control sleeve Kontrolbøsning
incl. item 026, 038, 051, item 026, 038, 051,
063, 673 063, 673 278 1/P Spring plate Fjederplade

026* 1/P Roller Rulle 291 1/P Pump spring Pumpefjeder

038* 1/P Roller pin Rulletap 301* 1/P Pressure valve Fjeder for
spring trykventil
051* 1/P Roller guide Rullestyr
313* 1/P Spring plate Fjederplade
063* 1/P Threaded pin Gevindtap
325 1/P Plug screw Propskrue
087 1/P Pump element, com­ Pumpeelement, kom-
plete for biofuel incl. plet for biofuel inkl. item 349 1/P Plug screw Propskrue
item 099, 109, 636, 099, 109, 636, 648, 661
648, 661 374 1/P Stop plate Stopplade

099* 1/P Barrel Cylinder 398 2/P Screw Skrue

109* 1/P Plunger Stempel 421 6/P Cylindrical screw Cylindrisk skrue

110 1/P O-ring O-ring 457 1/P O-ring O-ring

122 1/P Pressure valve, com­ Trykventil, komplet inkl. 482 2/P Packing ring Pakningsring
plete incl. item 146, item 146, 230, 301,
230, 301, 313, 577, 589, 313, 577, 589, 590, 494 1/P Seal ring Tætningsring
590, 612 612
504 1/P Seal ring Tætningsring
146* 1/P Distance sleeve Afstandsbøsning
531 /I Loctite 243 Loctite 620
183a 1/P Shim, 11.40 mm Skive, 11.40 mm
183b 1/P Shim, 11.25 mm Skive, 11.25 mm 565 1/C Fuel Injection Pump, Brændselspumpe,
183c 1/P Shim, 11.20 mm Skive, 11.20 mm complete for biofuel komplet for biofuel
183d 1/P Shim, 11.15 mm Skive, 11.15 mm
183e 1/P Shim, 11.10 mm Skive, 11.10 mm 577* 1/P Cylindrical pin Cylindrisk stift
183f 1/P Shim, 11.05 mm Skive, 11.05 mm
183g 1/P Shim, 11.00 mm Skive, 11.00 mm 589* 1/P Spring Fjeder
183h 1/P Shim, 10.95 mm Skive, 10.95 mm
183i 1/P Shim, 10.90 mm Skive, 10.90 mm 590* 1/P Pressure valve Trykventil
183j 1/P Shim, 10.85 mm Skive, 10.85 mm
183k 1/P Shim, 10.80 mm Skive, 10.80 mm 600 8/P Cylindrical screw Cylindrisk skrue
183l 1/P Shim, 10.75 mm Skive, 10.75 mm
183m 1/P Shim, 10.60 mm Skive, 10.60 mm 612* 1/P Ball Kugle

205 1/P Thrust piece Trykstykke 624 1/P Thrust ring Trykring

217 4/P Screw Skrue 636* 1/P Cylindrical pin Cylindrisk stift

229 1/P Pump casing, Pumpehus, 648* 2/P Ball Kugle

incl. item 719 inkl. item 719
661* 2/P Threaded pin Genvingtap
08028-0D/H5250/94.08.12

230* 1/P Connecting piece Forbindelsesstykke

673* 1/P Bush Bøsning
242 2/P Screw Skrue
685 1/P O-ring O-ring
254 1/P Control rack Reguleringsstang
697 2/P Sealing ring Tætningsring

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
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

10.49 - ES0, MAN

 MAN Diesel & Turbo

Plate
Page 3 (3) Fuel Injection Pump 51401-24H

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

707 1/P O-ring O-ring

719 2/P Cylindrical pin Cylindrisk stift

720 1/P Seal ring Tætningsring

732 1/P Cylinder Cylinder

744 1/P Seal ring Tætningsring

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/P = Qty/Pump Qty/P = Qty/Pumpe
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

10.49 - ES0, MAN

MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Injection Valve 51402-27H

L27/38

153

082 141

069 177

190

104
070 033
057 189

224*
116 236*

212 128*

248*

094
021

045

10.13, Tier II
 MAN Diesel & Turbo

Plate
51402-27H Fuel Injection Valve Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

021 1/V Injection nozzle Dyse

033 1/V O-ring O-ring

045 1/V Nozzle nut Dysemøtrik

057 1/V Pressure bolt Bolt

069 1/V Adjusting spindle Justebar spindel

070 1/V Pressure spring Trykfjeder

082 1/V Nut Møtrik

094 2/V Cylindrical pin Cylindrisk stift

104 1/V O-ring O-ring

116 1/C Fuel injection valve, Brændselsventil, kom­

complete incl. item 021, plet inkl. item 021, 045,
045, 057, 069, 070, 082, 057, 069, 070, 082, 094,
094, 104, 190, 212 104, 190, 212

128* 1/V Nozzle holder Dyseholder

141 1/V Bracket Spændestykke

153 2/V Nut Møtrik

177 2/V Bolt Bolt

189 1/V O-ring O-ring

190 1/V Guide for spring Fjederstyr

212 1/V Nozzle holder, Dyseholder,

complete komplet

224* 1/V Bush Bøsning

236* 1/V Cylindrical pin Cylindrisk stift

248* 1/V Bush Bøsning

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

10.13, Tier II
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Injection Pipe 51404-14H

L27/38

022
129 130
010 046
286 333
298

034
308
321 298
142 333
095 308
154 321
286

117

09.35
 MAN Diesel & Turbo

Plate
51404-14H Fuel Injection Pipe Page 2 (2)

L27/38

Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

010 1/C High pressure lance Højtrykslanse

022 1/C O-ring O-ring

034** 1/C High pressure pipe Højtryksrør bestående

consist of item 286, af item 286, 298, 308,
298, 308, 321, 333 321, 333

046 1/C O-ring O-ring

095 1/C Bolt Bolt

117** 1/C Fuel injection pipe, Højtryksrør,

complete, consist of komplet, bestående af
item 010, 022, 034, 046, item 010, 022, 034, 046,
095, 129, 142, 154 095, 129, 142, 154

129 1/C Ring Ring

130 1/C Locking washer Låseskive

142 1/C Disk Mellemstykke

154 1/C Sleeve Bøsning

286 2/C O-ring O-ring

298* 2/C O-ring O-ring

308* 2/C Sleeve Bøsning

321* 2/C Circlip Sikringsring

333* 2/C Nut Møtrik

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.
** = When ordering item 034 and 117 please order ** = Ved bestilling af item 034 og 117 venligst bestil
item 286 in addition ekstra af item 286
Qty/E = Qty./Engine Qty/E = Qty./Motor
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder

09.35
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Oil Filter Duplex 51415-11

General

070
072
073 028
014 012
015 019
013
024
025
026 020
027 021
029 022
030 036 023
031 037
032 038
033 075 039
040
034 076 041
035 077 043 042
078 044
079 045
018

002
003

004
005

010
011
016
017

006
007

13.07 - ES0, 25 my
 MAN Diesel & Turbo

Plate
51415-11 Fuel Oil Filter Duplex Page 2 (2)

General
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse

002 2/F Screw plug Propskrue 030 2/F Gasket, DN 40, DN 50, Pakning, DN 40, DN 50,
DN 65 DN 65
003 2/F Gasket Pakning
031 2/F Filter element, DN 25 Filterelement, DN 25
004 2/F Screw plug Propskrue
032 2/F Filter element, DN 32 Filterelement, DN 32
005 2/F Gasket Pakning
033 2/F Filter element, DN 40 Filterelement, DN 40
006 2/F Screw plug Propskrue
034 2/F Filter element, DN 50 Filterelement, DN 50
007 2/F Gasket Pakning
035 2/F Filter element, DN 65 Filterelement, DN 65
010 6/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32
036 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32
011 6/F Bolt, DN 40, DN 50, Bolt, DN 40, DN 50,
DN 65 DN 65 037 2/F Gasket, DN 40 Pakning, DN 40

012 2/F Cover, DN 25, DN 32 Dæksel, DN 25, DN 32 038 2/F Gasket, DN 50 Pakning, DN 50

013 2/F Cover, DN 40, DN 50, Dæksel, DN 40, DN 50, 039 2/F Gasket, DN 65 Pakning, DN 65
DN 65 DN 65
040 8/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32
014 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32
041 8/F Bolt, DN 40, DN 50 Bolt, DN 40, DN 50
015 2/F O-ring, DN 40, DN 50, O-ring, DN 40, DN 50,
DN 65 DN 65 042 8/F Bolt, DN 65 Bolt, DN 65

016 6/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32 043 8/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32

017 6/F Nut, DN 40, DN 50, Møtrik, DN 40, DN 50, 044 8/F Nut, DN 40, DN 50 Møtrik, DN 40, DN 50
DN 65 DN 65
045 8/F Nut, DN 65 Møtrik, DN 65
018 1/F Ball valve Kugleventil
070 2/F Screw Skrue
019 1/F Cock Hane
072 2/F Nut Møtrik
020 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32
073 2/F Spring washer Fjederskive
021 2/F O-ring, DN 40 O-ring, DN 40
075 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
022 2/F O-ring, DN 50 O-ring, DN 50 DN 25, complete ter, DN 25, Komplet

023 2/F O-ring, DN 65 O-ring, DN 65 076 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 32, complete ter, DN 32, Komplet
024 1/F Circlip ring, DN 25, Sikringsring, DN 25,
DN 32 DN 32 077 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 40, complete ter, DN 40, Komplet
025 1/F Circlip ring, DN 40 Sikringsring, DN 40
078 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
026 1/F Circlip ring, DN 50 Sikringsring, DN 50 DN 50, complete ter, DN 50, Komplet

027 1/F Circlip ring, DN 65 Sikringsring, DN 65 079 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 65, complete ter, DN 65, Komplet
028 1/F Plug key Prop

029 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32

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

13.07 - ES0, 25 my
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Oil Filter Duplex 51415-12

General

070 009
072
073 028
014 012
015 019
013
024
025
026 020
027 021
029 022
030 036 023
031 037
032 038
033 075 039
040
034 076 041
035 077 043 042
078 044
079 045
018

002
003

004
005

010
011
016
017

006
007

13.07 - ES0, 25 my
 MAN Diesel & Turbo

Plate
51415-12 Fuel Oil Filter Duplex Page 2 (2)

General
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse

002 2/F Screw plug Propskrue 029 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32

003 2/F Gasket Pakning 030 2/F Gasket, DN 40, DN 50, Pakning, DN 40, DN 50,
DN 65 DN 65
004 2/F Screw plug Propskrue
031 2/F Filter element, DN 25 Filterelement, DN 25
005 2/F Gasket Pakning
032 2/F Filter element, DN 32 Filterelement, DN 32
006 2/F Screw plug Propskrue
033 2/F Filter element, DN 40 Filterelement, DN 40
007 2/F Gasket Pakning
034 2/F Filter element, DN 50 Filterelement, DN 50
009 1/F Differential pressure Differential trykindikator
indicator 035 2/F Filter element, DN 65 Filterelement, DN 65

010 6/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32 036 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32

011 6/F Bolt, DN 40, DN 50, Bolt, DN 40, DN 50, 037 2/F Gasket, DN 40 Pakning, DN 40
DN 65 DN 65
038 2/F Gasket, DN 50 Pakning, DN 50
012 2/F Cover, DN 25, DN 32 Dæksel, DN 25, DN 32
039 2/F Gasket, DN 65 Pakning, DN 65
013 2/F Cover, DN 40, DN 50, Dæksel, DN 40, DN 50,
DN 65 DN 65 040 8/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32

014 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32 041 8/F Bolt, DN 40, DN 50 Bolt, DN 40, DN 50

015 2/F O-ring, DN 40, DN 50, O-ring, DN 40, DN 50, 042 8/F Bolt, DN 65 Bolt, DN 65
DN 65 DN 65
043 8/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32
016 6/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32
044 8/F Nut, DN 40, DN 50 Møtrik, DN 40, DN 50
017 6/F Nut, DN 40, DN 50, Møtrik, DN 40, DN 50,
DN 65 DN 65 045 8/F Nut, DN 65 Møtrik, DN 65

018 1/F Ball valve Kugleventil 070 2/F Screw Skrue

019 1/F Cock Hane 072 2/F Nut Møtrik

020 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32 073 2/F Spring washer Fjederskive

021 2/F O-ring, DN 40 O-ring, DN 40 075 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 25, complete ter, DN 25, Komplet
022 2/F O-ring, DN 50 O-ring, DN 50
076 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
023 2/F O-ring, DN 65 O-ring, DN 65 DN 32, complete ter, DN 32, Komplet

024 1/F Circlip ring, DN 25, Sikringsring, DN 25, 077 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 32 DN 32 DN 40, complete ter, DN 40, Komplet

025 1/F Circlip ring, DN 40 Sikringsring, DN 40 078 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 50, complete ter, DN 50, Komplet
026 1/F Circlip ring, DN 50 Sikringsring, DN 50
079 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
027 1/F Circlip ring, DN 65 Sikringsring, DN 65 DN 65, complete ter, DN 65, Komplet

028 1/F Plug key Prop

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

13.07 - ES0, 25 my
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Oil Filter Duplex 51415-13

General

070
072
073 028
014 012
015 019
013
024
025
026 020
027 021
029 022
030 036 023
031 037
032 038
033 075 039
040
034 076 041
035 077 043 042
078 044
079 045
018

002
003
008

004
005

010
011
016
017

006
007

13.07 - ES0, 25 my
 MAN Diesel & Turbo

Plate
51415-13 Fuel Oil Filter Duplex Page 2 (2)

General
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse

002 2/F Screw plug Propskrue 029 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32

003 2/F Gasket Pakning 030 2/F Gasket, DN 40, DN 50, Pakning, DN 40, DN 50,
DN 65 DN 65
004 2/F Screw plug Propskrue
031 2/F Filter element, DN 25 Filterelement, DN 25
005 2/F Gasket Pakning
032 2/F Filter element, DN 32 Filterelement, DN 32
006 2/F Screw plug Propskrue
033 2/F Filter element, DN 40 Filterelement, DN 40
007 2/F Gasket Pakning
034 2/F Filter element, DN 50 Filterelement, DN 50
008 1/F Oil Pan Bundkar
035 2/F Filter element, DN 65 Filterelement, DN 65
010 6/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32
036 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32
011 6/F Bolt, DN 40, DN 50, Bolt, DN 40, DN 50,
DN 65 DN 65 037 2/F Gasket, DN 40 Pakning, DN 40

012 2/F Cover, DN 25, DN 32 Dæksel, DN 25, DN 32 038 2/F Gasket, DN 50 Pakning, DN 50

013 2/F Cover, DN 40, DN 50, Dæksel, DN 40, DN 50, 039 2/F Gasket, DN 65 Pakning, DN 65
DN 65 DN 65
040 8/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32
014 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32
041 8/F Bolt, DN 40, DN 50 Bolt, DN 40, DN 50
015 2/F O-ring, DN 40, DN 50, O-ring, DN 40, DN 50,
DN 65 DN 65 042 8/F Bolt, DN 65 Bolt, DN 65

016 6/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32 043 8/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32

017 6/F Nut, DN 40, DN 50, Møtrik, DN 40, DN 50, 044 8/F Nut, DN 40, DN 50 Møtrik, DN 40, DN 50
DN 65 DN 65
045 8/F Nut, DN 65 Møtrik, DN 65
018 1/F Ball valve Kugleventil
070 2/F Screw Skrue
019 1/F Cock Hane
072 2/F Nut Møtrik
020 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32
073 2/F Spring washer Fjederskive
021 2/F O-ring, DN 40 O-ring, DN 40
075 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
022 2/F O-ring, DN 50 O-ring, DN 50 DN 25, complete ter, DN 25, Komplet

023 2/F O-ring, DN 65 O-ring, DN 65 076 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 32, complete ter, DN 32, Komplet
024 1/F Circlip ring, DN 25, Sikringsring, DN 25,
DN 32 DN 32 077 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 40, complete ter, DN 40, Komplet
025 1/F Circlip ring, DN 40 Sikringsring, DN 40
078 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
026 1/F Circlip ring, DN 50 Sikringsring, DN 50 DN 50, complete ter, DN 50, Komplet

027 1/F Circlip ring, DN 65 Sikringsring, DN 65 079 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 65, complete ter, DN 65, Komplet
028 1/F Plug key Prop

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

13.07 - ES0, 25 my
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Oil Filter Duplex 51415-14

General

070 009
072
073 028
014 012
015 019
013
024
025
026 020
027 021
029 022
030 036 023
031 037
032 038
033 075 039
040
034 076 041
035 077 043 042
078 044
079 045
018

002
003
008

004
005

010
011
016
017

006
007

13.07 - ES0, 25 my
 MAN Diesel & Turbo

Plate
51415-14 Fuel Oil Filter Duplex Page 2 (2)

General
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse

002 2/F Screw plug Propskrue 028 1/F Plug key Prop

003 2/F Gasket Pakning 029 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32

004 2/F Screw plug Propskrue 030 2/F Gasket, DN 40, DN 50, Pakning, DN 40, DN 50,
DN 65 DN 65
005 2/F Gasket Pakning
031 2/F Filter element, DN 25 Filterelement, DN 25
006 2/F Screw plug Propskrue
032 2/F Filter element, DN 32 Filterelement, DN 32
007 2/F Gasket Pakning
033 2/F Filter element, DN 40 Filterelement, DN 40
008 1/F Oilpan Bundkar
034 2/F Filter element, DN 50 Filterelement, DN 50
009 1/F Differential pressure ifferential trykindikator
indicator 035 2/F Filter element, DN 65 Filterelement, DN 65

010 6/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32 036 2/F Gasket, DN 25, DN 32 Pakning, DN 25, DN 32

011 6/F Bolt, DN 40, DN 50, Bolt, DN 40, DN 50, 037 2/F Gasket, DN 40 Pakning, DN 40
DN 65 DN 65
038 2/F Gasket, DN 50 Pakning, DN 50
012 2/F Cover, DN 25, DN 32 Dæksel, DN 25, DN 32
039 2/F Gasket, DN 65 Pakning, DN 65
013 2/F Cover, DN 40, DN 50, Dæksel, DN 40, DN 50,
DN 65 DN 65 040 8/F Bolt, DN 25, DN 32 Bolt, DN 25, DN 32

014 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32 041 8/F Bolt, DN 40, DN 50 Bolt, DN 40, DN 50

015 2/F O-ring, DN 40, DN 50, O-ring, DN 40, DN 50, 042 8/F Bolt, DN 65 Bolt, DN 65
DN 65 DN 65
043 8/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32
016 6/F Nut, DN 25, DN 32 Møtrik, DN 25, DN 32
044 8/F Nut, DN 40, DN 50 Møtrik, DN 40, DN 50
017 6/F Nut, DN 40, DN 50, Møtrik, DN 40, DN 50,
DN 65 DN 65 045 8/F Nut, DN 65 Møtrik, DN 65

018 1/F Ball valve Kugleventil 070 2/F Screw Skrue

019 1/F Cock Hane 072 2/F Nut Møtrik

020 2/F O-ring, DN 25, DN 32 O-ring, DN 25, DN 32 073 2/F Spring washer Fjederskive

021 2/F O-ring, DN 40 O-ring, DN 40 075 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 25, complete ter, DN 25, Komplet
022 2/F O-ring, DN 50 O-ring, DN 50
076 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
023 2/F O-ring, DN 65 O-ring, DN 65 DN 32, complete ter, DN 32, Komplet

024 1/F Circlip ring, DN 25, Sikringsring, DN 25, 077 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 32 DN 32 DN 40, complete ter, DN 40, Komplet

025 1/F Circlip ring, DN 40 Sikringsring, DN 40 078 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
DN 50, complete ter, DN 50, Komplet
026 1/F Circlip ring, DN 50 Sikringsring, DN 50
079 1/E Fuel oil filter duplex, Brændselsoliespaltefil-
027 1/F Circlip ring, DN 65 Sikringsring, DN 65 DN 65, complete ter, DN 65, Komplet

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

13.07 - ES0, 25 my
 MAN Diesel

Plate
Page 1 (2) Ball Valve with Actuator 51425-01

General

015

027 039

Seen from A
08028-0D/H5250/94.08.12

040

07.17 - ES0
MAN Diesel

Plate
51425-01 Ball Valve with Actuator Page 2 (2)

General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

015 1/Q Solenoid valve Magnetventil

027 1/Q Actuator Actuator

039 1/Q Limit switch Grænseafbryder

040 2/Q Ball valve Kugleventil

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

07.17 - ES0
 MAN Diesel

Plate
Page 1 (2) Butterfly Valve with Actuator 51425-03H

General

088

052

064
08028-0D/H5250/94.08.12

07.17 - ES0
MAN Diesel

Plate
51425-03H Butterfly Valve with Actuator Page 2 (2)

General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

052 1/Q Actuator Actuator

064 1/Q Butterfly valve Kugleventil

076 1/Q Spare parts kit Reservedelssæt

088 1/Q Butterfly valve with Kugleventil med actua-

actuator complete tor komplet

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/Q = Qty/Plant Qty/Q = Qty/Anlæg

07.17 - ES0
MAN Diesel
Plate
Page 1 (2) Butterfly Valve with Actuator 51425-06H

General

088

052

064

08028-0D/H5250/94.08.12

07.18
MAN Diesel
Plate
51425-06H Butterfly Valve with Actuator Page 2 (2)

General
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

052 1/Q Actuator Actuator

064 1/Q Butterfly valve Kugleventil

076 1/Q Spare parts kit Reservedelssæt

088 1/Q Butterfly valve with Kugleventil med actua-

actuator complete tor komplet

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/Q = Qty/Plant Qty/Q = Qty/Anlæg

07.18
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Oil Arrangement 51430-24

L27/38

240
252
492
335
264
323
276
406
384 240 418 372
264 252
276 347 215
360 288 431 227
012 502 239
514
036 396 443 359
024 240 455 480
048 252 097
264
467 107
276
479
168
181
144 119
156
120 061
132 085
Fuel oil leakage alarm,
see plate 50925 073

11.11 - ES0
 MAN Diesel & Turbo

Plate
51430-24 Fuel Oil Arrangement Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

012 1/E Screw Skrue 323 2/E Welding coupling Svejseforskruning

024 2/E Washer Skive 335 1/E Reducing standpipe Reduceringsstandrør

036 1/E Screw Skrue 347 1/E Pipe, Rør,

fuel oil outlet afgang brændolie
048 2/E Spring lock Fjederlås
359 1/E Non-return valve Kontraventil
061 1/E Pipe, Rør,
fuel oil inlet tilgang brændolie 360 1/E Pipe, Rør,
fuel oil outlet afgang brændolie
073 1/E Pipe, Rør,
fuel oil outlet afgang brændolie 372 1/E Pipe, drain Rør, dræn

085 1/E Pipe, drain Rør, dræn 384 1/E Adjustable tee Justerbar
coupling T-forskruning
097 3/E Packing Pakning
396 1/E Drain pipe Rør, dræn
107 12/E Screw Skrue
406 1/E Adjustable elbow Justerbar
119 1/E Bracket Konsol coupling vinkelforskruning

120 2/E Pipe clamp Rørholder 418 1/E Packing ring Pakningsring

132 4/E Screw Skrue 431 1/E Pipe Rør

144 1/E Pipe clamp Rørholder 443 1/E Straight male stud Ligeforskruning
coupling
156 2/E Screw Skrue
455 1/E Pipe Rør
168 1/E Adjustable elbow Justebar
coupling vinkelforskruning 467 6/E Pipe holder Rørholder

181 1/E Packing ring Pakningsring 479 6/E Slotted cheese head Kærvskrue
screw
193 2/E Straight male stud Ligeforskruning
coupling 480 1/E Welding coupling Svejseforskruning

203 2/E Packing ring Pakningsring 492 1/E Flat steel bar Fladstål

215 2/E Bracket Konsol 502 1/E Straight coupling Ligeforskruning

227 4/E Screw Skrue 514 1/E Pipe, fuel oil inlet Rør, tilgang brændolie

239 4/E Spring lock Fjederlås

240 3/E Pipe clamp Rørholder

252 6/E Screw Skrue

264 5/E Pipe clamp Rørholder

276 10/E Screw Skrue

288 1/E Pipe, Rør,

fuel oil inlet tilgang brændolie

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

11.11 - ES0
 MAN Diesel
Plate
Page 1 (2) Pipes on Cylinder Section 51434-02H

L27/38

Connection on
Main pipe for Seen from A - A cylinder head
overspeed
Main pipe for drain
and leakage oil

502 551 526 514

742
754
766
778
Connection on
cylinder head
622 599 609 526
538 610 538 587 575 538 646 634 671 683
08028-0D/H5250/94.08.12

A A
56

56

56

563, 705, 717, 729, 730 538 658 695

07.05 - ES0
 MAN Diesel

Plate
51434-02H Pipes on Cylinder Section Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

502 1/E Main pipe for over- Hovedrør for over- 634 1/C Equal tee coupling T-forskruning
speed, 5 cyl. engine speed, 5 cyl. motor
646 1/C Branch pipe, Stikrør,
514 Pipe clamp Rørholder cylinder section cylindersektion
4/E 5 cyl. engine 5 cyl. motor
5/E 6 cyl. engine 6 cyl. motor 658 1/C Branch pipe, Stikrør,
6/E 7 cyl. engine 7 cyl. motor cylinder section cylindersektion
7/E 8 cyl. engine 8 cyl. motor
8/E 9 cyl. engine 9 cyl. motor 671 1/E Adjustable elbow Justebar
coupling vinkelforskruning
526 Screw Skrue
16/E 5 cyl. engine 5 cyl. motor 683 1/E Branch pipe, Stikrør,
20/E 6 cyl. engine 6 cyl. motor cylinder section cylindersektion
24/E 7 cyl. engine 7 cyl. motor
28/E 8 cyl. engine 8 cyl. motor 695 1/E Straight male stud Ligeforskruning
32/E 9 cyl. engine 9 cyl. motor coupling

538 4/C Banjo coupling Banjoforskruning 705 1/E Main pipe for drain Hovedrør for dræn
and leakage oil og lækageolie
551 1/C Branch pipe, Stikrør, 6 cyl. engine 6 cyl. motor
cylinder section cylindersektion
717 1/E Main pipe for drain Hovedrør for dræn
563 1/E Main pipe for drain Hovedrør for dræn and leakage oil og lækageolie
and leakage oil og lækageolie 7 cyl. engine 7 cyl. motor
5 cyl. engine 5 cyl. motor
729 1/E Main pipe for drain Hovedrør for dræn
575 Pipe clamp Rørholder and leakage oil og lækageolie
4/E 5 cyl. engine 5 cyl. motor 8 cyl. engine 8 cyl. motor
5/E 6 cyl. engine 6 cyl. motor
6/E 7 cyl. engine 7 cyl. motor 730 1/E Main pipe for drain Hovedrør for dræn
7/E 8 cyl. engine 8 cyl. motor and leakage oil og lækageolie
8/E 9 cyl. engine 9 cyl. motor 9 cyl. engine 9 cyl. motor

587 1/C Adjustable elbow Justerbar 742 1/E Main pipe for over- Hovedrør for over-
coupling vinkelforskruning speed, 6 cyl. engine speed, 6 cyl. motor

599 1/C Branch pipe, Stikrør, 754 1/E Main pipe for over- Hovedrør for over-
cylinder section cylindersektion speed, 7 cyl. engine speed, 7 cyl. motor

609 1/C Branch pipe, Stikrør, 766 1/E Main pipe for over- Hovedrør for over-
cylinder section cylindersektion speed, 8 cyl. engine speed, 8 cyl. motor

610 Banjo coupling Banjo forskruning 778 1/E Main pipe for over- Hovedrør for over-
4/E 5 cyl. engine 5 cyl. motor speed, 9 cyl. engine speed, 9 cyl. motor
5/E 6 cyl. engine 6 cyl. motor
6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor
8/E 9 cyl. engine 9 cyl. motor

622 Branch pipe, Stikrør,

cylinder section cylindersektion
08028-0D/H5250/94.08.12

4/E 5 cyl. engine 5 cyl. motor

5/E 6 cyl. engine 6 cyl. motor
6/E 7 cyl. engine 7 cyl. motor
7/E 8 cyl. engine 8 cyl. motor
8/E 9 cyl. engine 9 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

07.05 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Fuel Injection Pump Connections 51435-07H

L27/38

273
285 248 153
297 476 332 070 427 070
488 344 307 415 307
069
070
415
427

177 356 177

320 439
440 320

153
332
344
261 319 069 319
261

248 307 307 248

177
285
297

06.26 - ES0
 MAN Diesel & Turbo

Plate
51435-07H Fuel Injection Pump Connections Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

069 Insert pipe Rør 332 Lock screw Låseskrue

8/E 5 cyl. engine 5 cyl. motor 10/E 5 cyl. engine 5 cyl. motor
10/E 6 cyl. engine 6 cyl. motor 12/E 6 cyl. engine 6 cyl. motor
12/E 7 cyl. engine 7 cyl. motor 14/E 7 cyl. engine 7 cyl. motor
14/E 8 cyl. engine 8 cyl. motor 16/E 8 cyl. engine 8 cyl. motor
16/E 9 cyl. engine 9 cyl. motor 18/E 9 cyl. engine 9 cyl. motor

070 O-ring O-ring 344 Packing ring Pakningsring

20/E 5 cyl. engine 5 cyl. motor 10/E 5 cyl. engine 5 cyl. motor
24/E 6 cyl. engine 6 cyl. motor 12/E 6 cyl. engine 6 cyl. motor
28/E 7 cyl. engine 7 cyl. motor 14/E 7 cyl. engine 7 cyl. motor
32/E 8 cyl. engine 8 cyl. motor 16/E 8 cyl. engine 8 cyl. motor
36/E 9 cyl. engine 9 cyl. motor 18/E 9 cyl. engine 9 cyl. motor

153 2/E Cover Dæksel 356 O-ring O-ring

20/E 5 cyl. engine 5 cyl. motor
177 Screw Skrue 24/E 6 cyl. engine 6 cyl. motor
40/E 5 cyl. engine 5 cyl. motor 28/E 7 cyl. engine 7 cyl. motor
48/E 6 cyl. engine 6 cyl. motor 32/E 8 cyl. engine 8 cyl. motor
56/E 7 cyl. engine 7 cyl. motor 36/E 9 cyl. engine 9 cyl. motor
64/E 8 cyl. engine 8 cyl. motor
72/E 9 cyl. engine 9 cyl. motor 415 Clamping holder Rørholder
8/E 5 cyl. engine 5 cyl. motor
248 2/E Intermediate piece Forbindelsesstykke 10/E 6 cyl. engine 6 cyl. motor
12/E 7 cyl. engine 7 cyl. motor
261 2/E Intermediate piece Forbindelsesstykke 14/E 8 cyl. engine 8 cyl. motor
16/E 9 cyl. engine 9 cyl. motor
273 2/E Flange Flange
427 Screw Skrue
285 16/E Screw Skrue 8/E 5 cyl. engine 5 cyl. motor
10/E 6 cyl. engine 6 cyl. motor
297 16/E Lock disc Låseskive 12/E 7 cyl. engine 7 cyl. motor
14/E 8 cyl. engine 8 cyl. motor
307 Intermediate piece Forbindelsesstykke 16/E 9 cyl. engine 9 cyl. motor
3/E 5 cyl. engine 5 cyl. motor
4/E 6 cyl. engine 6 cyl. motor 439 Screw Skrue
5/E 7 cyl. engine 7 cyl. motor 16/E 5 cyl. engine 5 cyl. motor
6/E 8 cyl. engine 8 cyl. motor 20/E 6 cyl. engine 6 cyl. motor
7/E 9 cyl. engine 9 cyl. motor 24/E 7 cyl. engine 7 cyl. motor
28/E 8 cyl. engine 8 cyl. motor
319 Intermediate piece Forbindelsesstykke 32/E 9 cyl. engine 9 cyl. motor
3/E 5 cyl. engine 5 cyl. motor
4/E 6 cyl. engine 6 cyl. motor 440 Lock disc låse plade
5/E 7 cyl. engine 7 cyl. motor 16/E 5 cyl. engine 5 cyl. motor
6/E 8 cyl. engine 8 cyl. motor 20/E 6 cyl. engine 6 cyl. motor
7/E 9 cyl. engine 9 cyl. motor 24/E 7 cyl. engine 7 cyl. motor
28/E 8 cyl. engine 8 cyl. motor
320 Plate Plade 32/E 9 cyl. engine 9 cyl. motor
10/E 5 cyl. engine 5 cyl. motor
12/E 6 cyl. engine 6 cyl. motor 452 1/E Seamless steel pipe Sømløs stålrør
14/E 7 cyl. engine 7 cyl. motor
16/E 8 cyl. engine 8 cyl. motor 464 2/E Straight male stud Ligeforskruning
18/E 9 cyl. engine 9 cyl. motor coupling

476 2/E Screw plug Propskrue

488 2/E Seal ring Tætningsring

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

06.26 - ES0
Lubricating oil system

515/615
MAN Diesel & Turbo

Description 515.01
Page 1 (3) Internal Lubricating Oil System Edition 12

L27/38

PT
C13 C4 C15 C3

D
23

PT PI PT PSL
21 22 22 22
To main bearing.

15µ 2 bar
60µ ALTERNATOR.
To gear wheel drive

Filter
To cylinder Valve cam.
TE
21 60µ Lub. oil cooler. bearing
15µ
2 bar
TE
70/75° 27
A C
CYL. 1
B To
To damper
piston
Governor
drive
Engine driven High
lub. oil pump press.
pump Fuel cam shaft bearing.
Lub. oil
pressure Opening
regulation pressure Monitoring
valve 6.5 bar system

El driven pre. LAH LAL PAL PDAH

Centrifugalfilter lub. oil pump 28 28 25 21-22
Front-end Box
Oil mist LAH ZX LSH
detector 92 92 92
Oil mist detector is only standard for 8-9L27/38 GenSet

Fig 1 Diagram for internal lubricating oil system.

General Oil Quantities

As standard the lubricating oil system is based on The approximate quantities of oil necessary for a
wet sump lubrication. new engine, before starting up are given in the ta-
ble, see "B 12 01 1 Lubricating Oil in Base Frame"
All moving parts of the engine are lubricated with oil (max. litre H3)
circulating under pressure in a closed built-on system.
When engine or pre-lubricating oil pump is running
The lubricating oil is also used for the pur­pose of approx. 275 litres of lubricating oil is accumulated
cooling the pistons and turbocharger. in the front-end box and the lubricating oil system
of the engine.
The standard engine is equipped with built-on:
This oil will return to the oil sump when the engine
– Engine driven lubricating oil pump. and the pre-lubricating oil pump are stopped.
– Lubricating oil cooler.
– Lubricating oil thermostatic valve. This oil return may cause level alarm HIGH.
– Duplex full-flow depth filter.
– Pre-lubricating oil pump. The level alarm will disappear when the pre-lubrica-
ting oil pump is started again.

11.39 - ES0 - Tier I + II - Schaller

 MAN Diesel & Turbo

515.01 Description
Edition 12 Internal Lubricating Oil System Page 2 (3)

L27/38

Lubricating Oil Consumption ad 2) Lubricating oil for the main bearings is

sup-plied through holes in the engine frame. From
The lubricating oil consumption, see "Specific Lubri- the main bearings it passes through bores in the
cating Oil Consumption - SLOC, B 12 15 0 / 504.07" crankshaft to the connecting rod big-end bea­rings.

It should, however, be observed that during the The connecting rods have bored channels for sup-
running-in period the lubricating oil consumption ply of oil from the big-end bearings to the small-end
may exceed the values stated. bearings, which has an inner circumferential groove,
and a bore for distribution of oil to the piston.

Quality of Oil From the front main bearings channels are bored in
the crankshaft for lubricating of the damper.
Only HD lubricating oil (Detergent Lubricating Oil)
should be used, characteristics are stated in "Lubri­ ad 3) The lubricating oil pipes for the camshaft
cating Oil Specification B 12 15 0". drive gear wheels are equipped with nozzles which
are adjusted to apply the oil at the points where the
gear-wheels are in mesh.
System Flow
ad 4) The lubricating oil pipe for the gear wheels
The lubricating oil pump draws oil from the oil sump for the governor drive are adjusted to apply the oil
and presses the oil through the cooler and filter to at the points where the gear wheels are in mesh.
the main lubricating oil bore, from where the oil is
distri­buted to the various lubricating points. From the ad 5) The lubricating oil to the rocker arms is led
lubricating points the oil returns by gravity to the oil through bores in the engine frame to each cylinder
sump.The oil pressure is controlled by an adjustable head. The oil continuous through bores in the cylin-
spring-loaded relief valve built in the system. der head and rocker arm to the movable parts to be
lubricated at the rocker arm and valve bridge.
The main groups of components to be lubricated are:
ad 6) Through a bores in the frame lubricating oil is
1 – Turbocharger led to camshafts bearings.
2 – Main bearings, big-end bearing etc.
3 – Camshaft drive
4 – Governor drive Lubricating Oil Pump
5 – Rocker arms
6 – Camshaft The lubricating oil pump, which is of the gear wheel
type, is mounted on the front-end box of the engine
ad 1) The turbocharger is an integrated part of the and is driven by the crankshaft.
lubricating oil system, thus allowing continuous
priming and lubrication when engine is running. For
priming and during operation the tur­bo­char­ger is Lubricating Oil Cooler
connected to the lubricating oil circuit of the engine.
The oil serves for bearing lubrication and also for As standard the lubricating oil cooler is of the plate
dissipation of heat. type. The cooler is mounted on the front-end box.

The inlet line to the turbocharger is equipped with

an orifice in order to adjust the oil flow. Thermostatic Valve

The thermostatic valve is a fully automatic 3-way valve

with thermostatic elements set at fixed tem­pera­ture.

11.39 - ES0 - Tier I + II - Schaller

MAN Diesel & Turbo

Description 515.01
Page 3 (3) Internal Lubricating Oil System Edition 12

L27/38

Built-on Full-flow Depth Filter Draining of the Oil Sump

The lubricating oil filter is of the duplex paper car­­ It is recommended to use the separator suction pipe
tridge type. It is a depth filter with a nominel fineness for draining of the lubricating oil sump.
of 10-15 microns, and a safety filter with a fineness
of 60 microns.
External Pipe Connection

Pre-lubricating Please see "Crankcase Ventilation, B 12 00 0 /

515.31"
As standard the engine is equipped with an electric-
driven pre-lubricating pump mounted parallel to the
main pump. The pump is arranged for automatic
operation, ensuring stand-still of the pre-lubricating
pump when the engine is running, and running during
engine stand-still in stand-by position by the engine
control system.

11.39 - ES0 - Tier I + II - Schaller

MAN Diesel & Turbo

Description
Internal Lubricating Oil System 515.01
Page 1 (3) Edition 15

L27/38

C13 C4 C15 C3
PT
23

ZX
92
PT Oil mist LAH
21 detector 92 PT PSL To main bearing.
LSH 22 22
92
15µ 2 bar
60µ ALTERNATOR.
To gear wheel drive

Filter
To cylinder Valve cam.
TE
21 60µ Lub. oil cooler. bearing
15µ
2 bar
TE
70/75° 27
A C
CYL. 1
B To
To damper
piston
Governor
drive
Engine driven High
lub. oil pump press.
pump Fuel cam shaft bearing.
Lub. oil
pressure Opening
regulation pressure Monitoring
valve 6.5 bar system

El driven pre. LAH LAL PAL PDAH

Centrifugalfilter lub. oil pump 28 28 25 21-22
Front End Box Oil mist detector is only standard for enigne with output ≥ 2250 kW

Fig 1 Diagram for internal lubricating oil system.

General Oil Quantities

As standard the lubricating oil system is based on The approximate quantities of oil necessary for a
wet sump lubrication. new engine, before starting up are given in the ta-
ble, see "B 12 01 1 Lubricating Oil in Base Frame"
All moving parts of the engine are lubricated with oil (max. litre H3)
circulating under pressure in a closed built-on system.
When engine or pre-lubricating oil pump is running
The lubricating oil is also used for the pur­pose of approx. 275 litres of lubricating oil is accumulated
cooling the pistons and turbocharger. in the front-end box and the lubricating oil system
of the engine.
The standard engine is equipped with built-on:
This oil will return to the oil sump when the engine
– Engine driven lubricating oil pump. and the pre-lubricating oil pump are stopped.
– Lubricating oil cooler.
– Lubricating oil thermostatic valve. This oil return may cause level alarm HIGH.
– Duplex full-flow depth filter.
– Pre-lubricating oil pump. The level alarm will disappear when the pre-lubrica-
ting oil pump is started again.

12.16 - ES0 - Tier I + II - Dr Horn

 MAN Diesel & Turbo

515.01 Internal Lubricating Oil System Description

Edition 15 Page 2 (3)

L27/38

Lubricating Oil Consumption ad 2) Lubricating oil for the main bearings is sup-
plied through holes in the engine frame. From the main
The lubricating oil consumption, see "Specific Lubri- bearings it passes through bores in the crankshaft
cating Oil Consumption - SLOC, B 12 15 0 / 504.07" to the connecting rod big-end bea­rings.

It should, however, be observed that during the The connecting rods have bored channels for sup-
running-in period the lubricating oil consumption ply of oil from the big-end bearings to the small-end
may exceed the values stated. bearings, which has an inner circumferential groove,
and a bore for distribution of oil to the piston.

Quality of Oil From the front main bearings channels are bored in
the crankshaft for lubricating of the damper.
Only HD lubricating oil (Detergent Lubricating Oil)
should be used, characteristics are stated in "Lubri­ ad 3) The lubricating oil pipes for the camshaft
cating Oil Specification B 12 15 0". drive gear wheels are equipped with nozzles which
are adjusted to apply the oil at the points where the
gear-wheels are in mesh.
System Flow
ad 4) The lubricating oil pipe for the gear wheels
The lubricating oil pump draws oil from the oil sump for the governor drive are adjusted to apply the oil
and presses the oil through the cooler and filter to at the points where the gear wheels are in mesh.
the main lubricating oil bore, from where the oil is
distri­buted to the various lubricating points. From the ad 5) The lubricating oil to the rocker arms is led
lubricating points the oil returns by gravity to the oil through bores in the engine frame to each cylinder
sump.The oil pressure is controlled by an adjustable head. The oil continuous through bores in the cylin-
spring-loaded relief valve built in the system. der head and rocker arm to the movable parts to be
lubricated at the rocker arm and valve bridge.
The main groups of components to be lubricated are:
ad 6) Through a bores in the frame lubricating oil
1 – Turbocharger is led to camshafts bearings.
2 – Main bearings, big-end bearing etc.
3 – Camshaft drive
4 – Governor drive Lubricating Oil Pump
5 – Rocker arms
6 – Camshaft The lubricating oil pump, which is of the gear wheel
type, is mounted on the front-end box of the engine
ad 1) The turbocharger is an integrated part of and is driven by the crankshaft.
the lubricating oil system, thus allowing continuous
priming and lubrication when engine is running. For
priming and during operation the tur­bo­char­ger is Lubricating Oil Cooler
connected to the lubricating oil circuit of the engine.
The oil serves for bearing lubrication and also for As standard the lubricating oil cooler is of the plate
dissipation of heat. type. The cooler is mounted on the front-end box.

The inlet line to the turbocharger is equipped with

an orifice in order to adjust the oil flow. Thermostatic Valve

The thermostatic valve is a fully automatic 3-way valve

with thermostatic elements set at fixed tem­pera­ture.

12.16 - ES0 - Tier I + II - Dr Horn

MAN Diesel & Turbo

Description
Internal Lubricating Oil System 515.01
Page 3 (3) Edition 15

L27/38

Built-on Full-flow Depth Filter Draining of the Oil Sump

The lubricating oil filter is of the duplex paper car­­ It is recommended to use the separator suction pipe
tridge type. It is a depth filter with a nominel fineness for draining of the lubricating oil sump.
of 10-15 microns, and a safety filter with a fineness
of 60 microns.
External Pipe Connection

Pre-lubricating Please see "Crankcase Ventilation, B 12 00 0 /

515.31"
As standard the engine is equipped with an electric-
driven pre-lubricating pump mounted parallel to the
main pump. The pump is arranged for automatic
operation, ensuring stand-still of the pre-lubricating
pump when the engine is running, and running during
engine stand-still in stand-by position by the engine
control system.

12.16 - ES0 - Tier I + II - Dr Horn

MAN Diesel & Turbo
Description 515.31
Page 1 (2) Crankcase ventilation
Edition 03

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

Crankcase ventilation 1) The vent pipe from each engine is to run inde-
pendently to the manifold and be fitted with cor-
The crankcase ventilation is not to be directly con- rosion resistant flame screen within the mani-
nected with any other piping system. It is preferable fold.
that the crankcase ventilation pipe from each
engine is led independently to the open air. The out- 2) The manifold is to be located as high as practi-
let is to be fitted with corrosion resistant flame cable so as to allow a substantial length of pip-
screen separately for each engine. ing, which separates the crankcase on the indi-
vidual engines.
3) The manifold is to be vented to the open air, so
that the vent outlet is fitted with corrosion resist-
ant flame screen, and the clear open area of the
vent outlet is not less than the aggregate area
of the individual crankcase vent pipes entering
the manifold.
4) The manifold is to be provided with drainage
arrangement.
The ventilation pipe must be designed to eliminate
the risk of water condensation in the pipe flowing
back into the engine and should end in the open air:
▪ The connection between engine (C13 / C30)
and the ventilation pipe must be flexible.
▪ The ventilation pipe must be made with continu-
ous upward slope of minimum 5°, even when
the ship heel or trim (static inclination).
▪ A continuous drain must be installed near the
engine. The drain must be led back to the
sludge tank.
Engine Nominal diameter ND (mm)
A B C
L16/24 50 65
L21/31 65 40 80
L23/30H 50 - 65
L27/38 100 - 100
L28/32H 50 - 65
V28/32H 100 - 125
L32/40 125 50 125
V28/32S 100 - 125
Table 1: Pipe diameters for crankcase ventilation
▪ Dimension of the flexible connection, see pipe
Figure 1: Crankcase ventilation diameters Fig 2.
▪ Dimension of the ventilation pipe after the flexi-
However, if a manifold arrangement is used, its ble connection, see pipe diameters Fig 2.
arrangements are to be as follows:

2012.01.16 - ES1
 MAN Diesel & Turbo
515.31 Description
Crankcase ventilation Page 2 (2)
Edition 03

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

The crankcase ventilation flow rate varies over time,
from the engine is new/major overhauled, until it is
time to overhaul the engine again.
The crankcase ventilation flow rate is in the range of
3.5 – 5.0 ‰ of the combustion air flow rate [m³/h]
at 100 % engine load.
If the combustion air flow rate at 100 % engine load
is stated in [kg/h] this can be converted to [m³/h]
with the following formula (Tropic Reference Condi-
tion) :

Example :
Engine with a mechanical output of 880 kW and
combustion air consumption of 6000 [kg/h] corre-
sponds to :

The crankcase ventilation flow rate will then be in

the range of 19.2 – 27.4 [m³/h]
The maximum crankcase backpressure measured
right after the engine at 100 % engine load must not
exceed 3.0 [mbar] = 30 [mmWC].

2012.01.16 - ES1
MAN Diesel & Turbo
Work Card 515-01.00
Page 1 (3) Lubricating oil pump
Edition 04

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Disassembly, overhaul and assembly of lubricating
oil pump.

Starting Position Hand Tools

Feeler gauge 0.1 mm, min length 40-50 cm
Lubricating oil cooler 515-06.00
Feeler gauge 0.3 mm, min length 40-50 cm
Feeler gauge 0.35 mm, min length 40-50 cm

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1 51501 018 2/P
51501 102 4/P
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

1999.04.05
 MAN Diesel & Turbo
515-01.00 Work Card
Lubricating oil pump Page 2 (3)
Edition 04

L27/38

Preparing before dismounting 9) Mount the pump by the bolts and tighten these
according to description 500.40.
For access to the lubricating oil pump it is neces-
sary to remove the lubricating oil cooler. Please see 10) Re-new the O-rings for oil and water connec-
worcking card 515-06.00. tions to the lub. oil cooler.
11) Mount the lub. oil cooler to the frame plate.
Dismounting
1) Remove the bolts which are holding the lub. oil
pump.
2) Use the spring bolts to push out the pump.

Overhaul
3) Remove the bolt (1) and the spur gear (2), see
fig 1.
4) Remove the bolt (3) and the cover (4), see fig 1.
Take out the pinion spindles (5) and clean all parts
in gas oil and with a hard bush, (never use a steel
bush). The parts are blown clean with working air.
5) Check the wear of the bearing bush.
6) If the bearing bush is to be removed the existing 1 Bolt 2 Spur wheel
bearing bush is plugged out by means of a
3 Bolt 4 Cover
mandrel, the bores are cleaned, see fig 2, and
new bearing bush is mounted. 5 Gear wheel shaft 6 Guide pin
The bush is cooled down to -130°C, the hous-
ing or cover has room temperature. Figure 1: Lubricating oil pump

Note!
Criteria for replacement of bearing bush, see
A, fig 3.

7) Mount the pinion spindels (5) the cover (4) and

the bolt (3), the spur gear (2) and the bolt (1),
see fig 1.

Note!
Be aware that axle for spur gear is placed cor-
rectly in relation to guide pin on pump hous- Figure 2: Bores to be cleaned
ing.
Tighten the bolts according to page 500.40.

Note!
Check that the oil pump can run easily when the
pump is assembled.

Mounting
8) Change the O-rings on the pump.

1999.04.05
MAN Diesel & Turbo
Work Card 515-01.00
Page 3 (3) Lubricating oil pump
Edition 04

L27/38

Figure 3: Check of bearing bush

1999.04.05
MAN Diesel & Turbo
Work Card 515-01.05
Page 1 (3) Prelubricating Pump
Edition 08

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

Safety precautions Special tools

Engine stopped Plate No. Item No. Note

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

Short Description
Dismounting, replacement of the rotary shaft seal
and assembly of prelubricating pump.

Hand Tools
Starting Position
Bench vice.
Spanner.
Torque spanner.
Plier for lock ring.
Soft hammer.

Related Procedure

Replacement and wearing parts

Qualified Manpower
Duration in h : 2-3 Plate No. Item No. Quantity
Number : 1 See plate -
51504

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

2014.02.04
 MAN Diesel & Turbo
515-01.05 Work Card
Prelubricating Pump Page 2 (3)
Edition 08

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

8) Remove the gear wheels from the cover (014).
Dismounting is only possible by disturbing the
rotor shaft seal and by breaking the bearing
bush.
9) Remove the security ring (099) and take off the
rotary shaft seal (122).
10) Press out the driving gear shaft bearing bush,
Overhauls pull out the running bearing bush with the inner
wheel puller.
Overhauls for the purpose of avoiding functional
11) Gear box (026). Dismounting is only possible
trouble are not normally necessary for the prelubri-
by damaging the shaft bush. Press out the
cating pumps, when properly used, there is very lit-
shaft bushes.
tle wear on the pump gear shaft.
12) Pressure control valve (038). The pressure con-
trol valve can be dismounted also without dis-
Spare Parts
mounting the pump.
Before any overhaul is done, please note the follow-
ing:
Mounting
If a pump gets unusable by wear, it must be
1) The mounting process follows in reverse order,
replaced. Installation of spare parts cannot bring it
it is stressed that an exact cleaning works is
back to normal condition.
necessary.
It pays to keep extra pumps in stock or to have
Especially the sealing faces must be clean.
repairs (overhauls) carried out at our repair shop.
Tightening of screw pos. (075):
The shaft seal needs only to be replaced in case of
leakage or after dismounting of drive shaft. The R25 10 Nm
marks from the seal do not necessarily mean that R35 50 Nm
the sealing is defective, but there is a risk of leakage
after replacement of sealing. In connection with the bearing bush, attention must
be paid to the placement of the butt joint and the
We advise not to change the bearing bushes. In mounting depth.
connection with damages on the bearings it is nor-
mal that also the shafts and the parts in the gear The new shaft seal cannot be pressed into the pro-
box will be damaged. tection cover before exact mounting of the pump.

When ordering spare parts, do not forget to state O-ring must be changed.
the factory no. of the pump.

Replacement of mechanical seal

1) Disconnect the cable and pipe connection to
the pump.
2) Remove the pump from the engine base frame.
3) Separate the pump and the el-motor.
4) Remove the coupling part and key (109), see
fig. 1, from the driving gear shaft (051).
5) Loosen screws (075) and take off the pressure
control valve (038).
6) Tighten the pump to the flange. Pressure con-
trol valve (038) upwards.
7) Take off the gear box (026), if necessary use a
soft hammer for separation.

2014.02.04
MAN Diesel & Turbo
Work Card 515-01.05
Page 3 (3) Prelubricating Pump
Edition 08

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

Figure 1: Prelubricating pump

2014.02.04
MAN Diesel & Turbo
Work Card 515-01.10
Page 1 (3) Lubricating oil filter
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Replacement of paper filter element(s). Cleaning of
safety filter and filter housing.

Starting Position Hand Tools

Open-end ring spanner, 19".
Allen key, 6 mm.
Allen key, 10 mm.

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1 51502 013 2/Engine
51502 971 2/Engine
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2008.06.16
 MAN Diesel & Turbo
515-01.10 Work Card
Lubricating oil filter Page 2 (3)
Edition 03

L27/38

Lubricating Oil Filter 7) Dismantle the filter housing cap.

Please note: Never open the filter while it is in use. 8) Remove the inner safety element. Clean the ele-
The filter to be cleaned must be out of operation. ment with detergent. Check that it is intact.
9) Remove the outer elements.
Normal running
Note!
1) the valve is in position 2 or 4, see fig 2, and the
element not in use is vented and ready to use Our filter elements are of the disposable type.
(standby). Always change to new original filter.

10) Clean the filter housing and the cap.

Changing the filter
Note!
Warning!
Be sure that sealing ring in bottom of frontend
Use protective gloves box is removed/replaced before installing new
filter cartridge.
2) Switch to position 3, fig 2, and wait 5 minutes.
Then continue to position 1 or 5, fig 2. 11) Check the seal in the cap. Change if needed.
3) Wait 2 minutes. 12) Assemble the filter in reverse order.
4) Open the vent screw on the filter out of service. 13) Switch to position 2 or 4 and vent the
5) Wait 20 minutes. exchanged element by means of the vent
screw.

Figure 1: Vent screws

6) Dismantle the cover.

2008.06.16
MAN Diesel & Turbo
Work Card 515-01.10
Page 3 (3) Lubricating oil filter
Edition 03

L27/38

Figure 2: Name plate for lubricating oil filter

2008.06.16
MAN Diesel & Turbo
Work Card 515-01.20
Page 1 (3) Lubricating oil, thermostatic valve
Edition 04

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Inspection of thermostatic valve and replacement
of elements.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1 51103 146 2/Engine

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

2001.07.23
 MAN Diesel & Turbo
515-01.20 Work Card
Lubricating oil, thermostatic valve Page 2 (3)
Edition 04

L27/38

Adjustment and maintenance 6) Remount the element (4) by wriggling it some-

what over side.
The thermostatic valve cannot be adjusted, and
under normal working conditions maintenance is 7) Mount the sleeve (5).
not required. However, in some cases it is neces- 8) Mount the lock ring (1).
sary to replace the element.
9) Renew the gasket and mount the cover (2).
Tighten the bolt (1) according to page 500.40.

Check the element

10) Place the element in a bucket of water -12° C
below the nominal rating and stir the water vigo-
rously with the element for 5 minutes (the sliding
valve should not be off its seat).
11) Next, place the element in water 10° C above
the nominal rating and stir vigorously for 5
minutes. The element should not be fully
stroked.
This is determined by immediately placing the ele-
ment back in the valve housing, and pushing the
element spider fully into its counterbore. If the
resistance of the sliding valve overtravel spring can
be felt, the element is fully stroked. Perform the last
step quickly before the element has cooled.
1 Bolt 2 Cover Note!
3 Lock ring 4 Element
Do not use oil as the test bath.
5 Sleeve
On every high temperature elements, water and gly-
Figure 1: Lubricating oil thermostatic valve col may be used.

Replacement of the element

Warning!
Use protective gloves
1) Unscrew the bolts (1) and remove the cover (2),
see fig 1.
2) Remove the lock ring (3)
3) Remove the sleeve and element (4 and 5).
4) Thoroughly clean the sleeve (5).
5) Replace it or check, see "check the element".

2001.07.23
MAN Diesel & Turbo
Work Card 515-01.20
Page 3 (3) Lubricating oil, thermostatic valve
Edition 04

L27/38

Figure 2: Placing of lubricating oil thermostatic valve

2001.07.23
MAN Diesel & Turbo
Work Card 515-01.90
Page 1 (2) Check of lubricating oil piping system
Edition 03

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

Safety precautions Special tools

Engine stopped Plate No. Item No. Note

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

Short Description
Check and examination of the lubricating oil piping
system.

Hand Tools
Starting Position
Engine running.

Related Procedure

Replacement and wearing parts

Qualified Manpower
Duration in h : 1/2 Plate No. Item No. Quantity
Number : 1

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

2014.02.20
 MAN Diesel & Turbo
515-01.90 Work Card
Check of lubricating oil piping system Page 2 (2)
Edition 03

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

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

Checks to be carried out

1) Examine the external connections for leaks.
2) Retighten all bolts and nuts in the external sys-
tem.
3) Check flexible oil vapour discharge hose con-
nections for leaks and damages.

Note!
It is important that the flexible connections are
free from paint and grease and in healthy con-
dition.

Concerning lubricating oil condition, see section

504.

2014.02.20
MAN Diesel & Turbo
Work Card 515-06.00
Page 1 (5) Lubricating oil cooler
Edition 09

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air 52000 032
52002 508
Shut off cooling water 52002 521
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Separation, cleaning and assembling. Replace-
ment of plates and gaskets.

Starting Position Hand Tools

Cooling water and lube oil have been drained from Ring and open end spanner, 10 mm
cooler/engine. All external pipes are disconnected. Ring and open end spanner, 55 mm
Ring and open end spanner, 30 mm
Adjustable spanner

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 4 Plate No. Item No. Quantity
Number : 1

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

2013.01.18
 MAN Diesel & Turbo
515-06.00 Work Card
Lubricating oil cooler Page 2 (5)
Edition 09

L27/38

Introduction

Figure 1: Mounting of oil cooler in front-end box

Cleaning of the cooler must take place, when the Note!
pressure drop on the oil and water side exceeds an
allowable value and/or if oil cannot be sufficiently If these norms are exceeded, the guarantee will
cooled. cease to be valid.

Note!
Separation of edge-clamped frame
To prevent oil from dripping / flowing on the prelu-
bricating pump it is recommended to screen the Upon completion of the procedure “Cooling and
pump before the lubricating oil cooler is separated. Pressure Relief”, separate the frame by retaining
two or four diagonally placed bolts.

Separation Note!
Take care that the pressure plate does not tilt!
Cooling and pressure relief Loosen the bolts uniformly and diagonally (max. 10
Before opening the plate heat exchanger, it must be mm at a time), then push the pressure plate
cooled down to below 40° C and be without pres- towards the end support. When the pressure plate
sure! is not tight anymore, the plates can be removed.
The cooling must not exceed 10° C per minute. Note!
The pressure drop must not exceed 10 bar per
minute. When using plate heat exchangers on board ships,
the pressure plate have to be secured in order to
avoid danger during the movements of the ship.

2013.01.18
MAN Diesel & Turbo
Work Card 515-06.00
Page 3 (5) Lubricating oil cooler
Edition 09

L27/38

Note!
Cleaning The nitric acid has an important constructive effect
The capacity and corrosion resistance of the plate on the protective film of stainless steel.
heat exchangers depend on the cleanness of the
plates. Any coating on the plates can be removed
manually. Control of cleaning fluid concentrations
Sodium hydroxide (NaOH) solution is tritrated with
Manual cleaning 0.1 n hydro-chloric acid (HCI) with methyl orange or
methyl red as indicator.
Clean the plates with a soft brush and a suitable
detergent. In case of dense coating of scale or Nitric acid (HNO3) solution is titrated with 0.1 n
organic materials, the plates must be put in a bath sodium hydroxide (NaOH) with phenolphtalin as an
with detergent. indicator.
The concentration of the cleaning fluid in % can be
Note! calculated from the titration result using the follow-
Never use a steel brush, metal scraper or the like. ing formula:

A high-pressure cleaner can be used with care,

however, never with sand or other abrasives added.

Detergents a : ml cleaning fluid taken out for titration

A detergent is suitable, if it will removes any coating b : ml titration fluid used as cover
on the plates without causing any damage to plates
and gaskets. n : the molecular concentration of titration fluid
m : The molecular weight of the cleaning fluid
Note! (NaOH) molecular weight 40, HNO3 molecular
It is of great importance that decomposition of the weight 63)
protective film on the stainless steel does not take
place - the film preserves the corrosion resistance Replacement of plates and gaskets
of steel.
Do not use chlorine-containing agents such as
Marking
hydrochloricacid (HCI)!
The plates are marked with material codes and ref-
Oil and fats are removed by using a water emulsify- erence numbers at each end, plus codes for non-
ing oil solvent, e.g. BP-system cleaner. glued gaskets, if any, and stamped with the letter V
Organic and greasy coatings are removed by using and H at either end (Fig 1).
sodium hydroxide (NaOH): When facing the gasket, the plate is designated as
▪ max. concentration 1.5% a left plate, when letter V turns upwards - and as a
(1.5% concentration corresponds to 3.75 l 30% right plate when letter H turns upwards. Inlets and
NaOH per 100 l water). outlets of the V-plates are taking place through the
▪ max. temperature 85° C. corner holes Nos 1 and 4. Inlets and outlets of the
H-plates take place through corner holes Nos 2 and
Stone and lime/calcareous deposits are removed 3.
by using nitric acid (HNO3):
▪ max. concentration 1.5% Replacement of plates
(1.5% concentration corresponds to 1.75 l 62%
HNO3 per 100 l water). Before mounting a spare plate in the plate stack,
please make sure that the spare plate is identical
▪ max. temperature 65° C. with the faulty one.

2013.01.18
 MAN Diesel & Turbo
515-06.00 Work Card
Lubricating oil cooler Page 4 (5)
Edition 09

L27/38

Note! The insertion of the gaskets starts at both ends of

the plate - and continues with the straight sections
The same corner holes must be opened and letters along the edges.
V and H must be placed properly.
The gluing process is most easily performed by
placing the gaskets and the plates on a table. After
Replacement of glued gaskets pressing the gaskets into the grooves of the plate, it
is stacked.
On Plate 51506 stated are gasket and glue quan-
tity. The plates with the gaskets are mounted in the
frame which is lightly clamped. In the case of using
Please use a degreasing agent on the new gaskets.
rubber grooves, they are assembled to the mini-
The first plate after the end cover and the connector mum measure stated on the engine sign plus 0.2
grid must have gaskets in all grooves. The gaskets mm per plate.
must be cut according to the existing gaskets.
Heat up the plate heat exchanger to 90-100° C by
Loosen the glued gaskets by heating the plate in means of water or steam.
water at 100° C. Clean the plates and remove the
coatings, if any.
Please note
▪ The temperature must be kept for 1½-2 hours.
Cleaning of new gaskets and plates
▪ The liquid pressure must be kept as low as pos-
New gaskets and gasket grooves of the plates are
sible.
cleaned with a cloth moistened with degreasing
agent. The glue surfaces must be absolutely clean - If there is no possibility of heating the plate heat
without finger prints etc. exchanger, it must be placed in a place as warm as
possible with connections dismounted.
Please use our cleaning fluid, which conforms to
suppliers recommendations. At 20° C the drying time will be approx. 48 hours.
At 40° C, the drying time is approx. 24 hours.
Alternatively, please use:
▪ Trichloroethylene
Assembling
▪ Chlorothene VG
If the plates are dismounted, they must be properly
▪ Acetone assembled according to plate item numbers.
▪ Methyl ethyl ketone The fixed cover has number 1 and serial numbers
▪ Ethylacetat for the subsequent plates, and intermediate frames,
if any, are numbered 2, 3, 4, 5 etc.
It is important that all degreasing agent has evapo-
rated, before the glue is applied. This will normally
take approx. 15 min. at 20° C.
Clean the new gaskets on the glued surfaces with
fine-grained sandpaper instead of the degreasing
agent supplied.

Gluing
Pliobond 25, which is a solvent-based nitrile rubber
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.
Apply a thin layer of glue on the gasket grooves of
the plates and press the gaskets down into the gas-
ket grooves.

2013.01.18
MAN Diesel & Turbo
Work Card 515-06.00
Page 5 (5) Lubricating oil cooler
Edition 09

L27/38

Cyl. x min (mm) x max (mm)

7 66 69
8 85 88
9 97 101

Figure 2: .

Serial numbers are stamped in the right top corner

of the plates. Further, please note that the gasket
side must face the fixed cover.

Figure 3: Measuring x

Fastening
Fasten the nuts crosswise until the movable cover
to the measure x at each nut.
Cyl. x min (mm) x max (mm)
5 66 69
6 66 69

2013.01.18
MAN Diesel & Turbo
Work Card 515-15.00
Page 1 (3) Centrifugal bypass filter
Edition 09

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Cleaning procedure, cleaning intervals. Mainte-
nance intervals and procedures.

Starting Position Hand Tools

Big adjustable spanner
With the engine stopped or filter
isolated by means of a valve Tools for cleaning

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1 51515 301 1/Filter
51515 313 1/Filter
51515 325 1/Filter
Data
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2013.01.22
 MAN Diesel & Turbo
515-15.00 Work Card
Centrifugal bypass filter Page 2 (3)
Edition 09

L21/31, L27/38

Cleaning procedure 5) Remove sludge from inside the rotor by means

of a spatula and wipe clean. Ensure that all
1) Isolate the filter by closing the valve for lubricat- rotor components are throughly cleaned and
ing oil inlet to the filter. free from deposits of dirt before reassembling
Note! the rotor.

Ensure the centrifuge has come to a complete Note!

stop before proleading Failure to do so could cause an out-of-bal-
ance condition which will accelerate bearing
Warning! and spindle wear.
Use protective gloves
6) Remove stand tube (075) and clean.
2) Slacken cover clamp ring (266). Unscrew cover 7) Clean nozzle with brass wire. Examine top and
fixing nut and lift off cover (038). bottom bearings in tube assembly. If damaged
3) Lift off rotor assembly having allowed oil to drain or worn - replace tube assembly complete.
from nozzles. The rotor should be removed and Examine O-ring and renew if damaged.
replaced on the spindle with extreme care in 8) Place standtube, totaing it to ensure that it is
order to ensure that the bearings are not dam- properly located in the recess in the rotorbase.
aged. If the standtube shows any sign of damage then
it should be replaced.
9) Reassemble rotor complete and tighten top nut.

Note!
Ensure that rotor cover and rotor body are
always matched by balance number and pin
location. Do not interchange rotor cover.
10) Examine spindle journals. If damaged or worn -
replace with body assembly complete.
11) Reassemble rotor complete checking that rotor
revolves freely.
Tighten cover fixing nut and secure safety
clamp. The clamp ring should be securely fitted
at all times and the filter should not be run with-
out the clamp ring fitted.

Note!
A Rotor fixing nut 026 Rotor top nut
038 Cover 075 Stand tube
Check cover o-ring, - if damaged it must be
replaced.
266 Cover clamp ring
12) Open for lubricating oil.
Figure 1: Centrifugal bypass filter
13) With filter running, check all joints for leakage.
Check for excessive vibration.
4) Unscrew rotor top nut (026) and separate rotor.

2013.01.22
MAN Diesel & Turbo
Work Card 515-15.00
Page 3 (3) Centrifugal bypass filter
Edition 09

L21/31, L27/38

Maintenance - Bearings and spindles

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.
Dependent on the conditions, wear will eventually
take place on the spindle and bearings and these
should be replaced with factory fitted assemblies
only.

To check bearing clearances

This is most easily done by applying a dial gauge to
the outside of the rotor opposite each bearing in
turn and measuring the total play, thus:
14) Apply dial gauge and measure play.
15) Turn rotor 90° and repeat measurement.
16) Re-apply dial gauge at 90° to previous position
and repeat.
17) Turn rotor 90° and repeat.
The highest reading is the play in the bearing.
The maximum clearances when new are 0.10 mm
at top and 0.13 mm at bottom bearing. If the clear-
ance exceeds 0.30 mm top or 0.33 mm bottom
then replace with new bearing tube assembly.
The spindle and body assembly and the rotor bear-
ing tube assembly are factory assembled items and
should only be replaced with complete assemblies.

2013.01.22
MAN Diesel & Turbo
Plate
Page 1 (2) Lubricating oil pump P51501-07

L27/38, L27/38S

2014.03.13
 MAN Diesel & Turbo
Plate
P51501-07 Lubricating oil pump Page 2 (2)

L27/38, L27/38S
Item No. Qty Item Designation Item No. Qty Item Designation

018 2/P O-ring

031 1/E Lubricating oil pump complete,
5-6 cyl.engine 1)
043 1/E Lubricating oil pump complete,
7-9 cyl. engine 2)
055 3/P Cylindrical pin
067 5/P Screw
079 1/P Pump housing, 5-6 cyl. engine
080 1/P Pump housing, 7-9 cyl. engine
092 1/P Cover
102 4/P Bush
114 5/P Screw
126 1/P Gear wheel, 5-6 cyl. engine
138 1/P Gear wheel, 7-9 cyl. engine
151 1/P Gear wheel, 5-6 cyl. engine
163 1/P Gear wheel, 7-9 cyl. engine
175 1/P Cylindrical gear wheel
187 1/P Washer
199 1/P Screw
209 5/P Thrust washer

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

Incl. item 055, 067, 079, 092, 102, 114, 126, 151, 175,
ace. 187, 199, 209
2)
Incl. item 055, 067, 080, 092, 102, 114, 138, 163, 175,
* = Only available as part of a spare parts kit/not 187, 199, 209
available separately
Qty/E = Qty/Engine
Qty/P = Qty/Pump

2014.03.13
MAN Diesel & Turbo

Plate
Page 1 (2) Lubricating Oil Filter 51502-19H

L27/38
684
696
539 814 971
672 564
552
540
909

910
922
934
Front end box 946
see plate 51103
958

527

062
755 731 743

013
LEFT VALVE RIGHT
FILTER POSITION FILTER

DRAIN
IN USE EXCHANGE

802
FILTER
FILL, VENT
NORMAL AND
USE STANDBY

IN USE IN USE

FILL, VENT
AND NORMAL
STANDBY USE

DRAIN
EXCHANGE IN USE
FILTER
Lift fixation bolt before turning valve

503

863
887
755
659 731
826 743
588 755
647 875
576 838 899
635 312 851
169 025
623 037
194
253 049
204
050
055
086
10.06 - ES0
 MAN Diesel & Turbo

Plate
51502-19H Lubricating Oil Filter Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

013 2/E Filter cartridge Filterindsats 731 12/E Washer Skive

025 4/E Lock disc Låseskive 743 12/E Stud Tapskrue

037 4/E Screw Skrue 755 12/E Nut Møtrik

049 1/E Oil collector tray Oliebakke 802 1/E Plate Skilt

050 1/E Packing ring Pakningsring 814 1/E Gasket Pakning

055 1/E Sleeve Bøsning 826 1/E O-ring O-ring

062 2/E Safety filter Sikkerhedsfilter 838 1/E Covering plate Dæksel

086 1/E Plug screw Propskrue 851 1/E Covering plate Dæksel

169 1/E Cylindrical pin Cylindrisk stift 863 2/E Closing screw Låseskrue

194 1/E Cover Dæksel 875 2/E Screw Skrue

204 3/E Screw Skrue 887 2/E Retaining ring for Spændring for aksel
shafts
253 3/E Locking spring Låsefjederskiver
washer 899 6/E Screw Skrue

312 1/E Latch pin Låsestift 909 2/F Flange Flange

503 2/E Cover Dæksel 910 2/F Flange Flange

527 2/E Centering cover Centreret bøsning 922 2/F Spring Fjeder

539 2/E Ventilating insert Ventileringsindsats 934 2/F Screw Skrue

540 2/E Valve body Ventilhus 946 2/F Spring Fjeder

552 2/E Piston insert Stempelindsats 958 4/F O-ring O-ring

564 2/E Spring Fjeder 971 2/F O-ring O-ring

576 1/E Cylindrical pin Cylindrisk stift

588 1/E Cylindrical pin Cylindrisk stift

623 2/E O-ring Pakning

635 1/E Switch element Omskifterelement

647 1/E Connecting shaft Transmissionsaksel

659 1/E Switch element Omskifterelement

672 1/E Plate Plade

684 19/E Screw Skrue

696 19/E Locking spring Låsefjederskiver

washer

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

10.06 - ES0
 MAN Diesel

Plate
Page 1 (2) Prelubricating Pump with El-Motor 51504-05

General

349 337 362 254 325 301 291 266 374 350 278 313

421

470
445
470
408
494, 541 482
553, 565 433

386
504
398
08028-0D/H5250/94.08.12

457

469

528
516

09.37 - ES0
MAN Diesel
Plate
51504-05 Prelubricating Pump with El-Motor Page 2 (2)

General
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse

254 1/P Driving cover Medbringerdæksel 516 1/E Ball bearing, rear Kugleleje, bagside

266 1/P Gear casing Gearhus 528 1/E Ball bearing, front Kugleleje, forside

278 1/P End cover, complete, Endedæksel, komplet 541 1/E El-motor, 3x480 volt, El-motor, 3x480 volt, komplet
incl. item 386, 398, 408, inkl. item 386, 398, 408, complete
421, 433, 445, 457, 469 421, 433, 445, 457, 469
and 470 og 470 553 1/E El-motor, 220-240/380- El-motor, 220-240/380-420 volt,
420 volt, complete komplet
291 1/P Driving gear shaft Drivende gearaksel
565 1/E El-motor, 400/690 volt, El-motor, 400/690 volt, komplet
301 1/P Gear shaft Gearaksel complete

313 4/P Screw Skrue

325 2/P Parallel pin Styrestift

337 1/P Retaining ring Sikringsring

349 1/P Parallel key Not

350 2/P O-ring O-ring

362 1/P Rotary shaft seal Roterende akseltæt­

ning

374 1/E Pump, complete Pumpe, komplet uden

without el-motor el-motor

386 1/P End cover Endedæksel

398 1/P Piston Stempel

408 1/P Spindle Spindel

421 1/P Dome nut Lukkemøtrik

433 1/P Spring Fjeder

445 1/P Pipe nut Rørmøtrik

457 2/P Screwed plug Propskrue

469 2/P Sealing ring Tætningsring

470 2/P Sealing ring Tætningsring

482 1/P Coupling, complete Kobling, komplet

494 1/E El-motor, 3x400/3x440 El-motor, 3x400/3x440

volt, complete volt, komplet

504 1/E Pre.lub oil pump, Forsmørepumpe,

08028-0D/H5250/94.08.12

complete with el- komplet med el-motor

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 Antal/E = Antal/Motor
Qty./P = Qty./Pump Antal/P = Antal/Pumpe

09.37 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Lubricating oil cooler P51506-18

L27/38

2013-01-11 - en Tier II
 MAN Diesel & Turbo
Plate
P51506-18 Lubricating oil cooler Page 2 (2)

L27/38
Item No. Qty Item designation Item No. Qty Item designation

015 1/K Plate

027 8/K O-ring
039 17/K Screw
052 12/K Screw
064 2/K Plug screw
076 2/K Packing ring
088 1/K Plate
111 1/K Plate
123 12/K Self locking nut
135 12/K Washer
147 12/K Tierod, 5, 6, 7 cyl.
159 12/K Tierod, 8, 9 cyl.
184 1/E Lubricating oil cooler,5,6.7 cyl.
engine, complete
206 1/E Lubricating oil cooler, 8 cyl.
engine, complete
218 1/E Lubricating oil cooler, 9 cyl.
engine, complete
231 /I Glue
243 /I Cleaning fluid
375 17/K Spring washer
409 /I Cooling plate
410 /I Oil cooler plate
446 /I Gasket
458 /I Gasket

When ordering spare parts, see also page 500.50.

* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine
Qty/I = Qty/Individual
Qty/K = Qty/Cooler

2013-01-11 - en Tier II
 MAN Diesel

Plate
Page 1 (2) Centrifugal By-pass Filter 51515-03

L27/38
L21/31

266 171
470
110 134

122
470
158
482
278 146

229

242 183

230

109
195 051
038

063
205 026 087

217
08028-0D/H5250/94.08.12

014

469 099
254
457

445
433

09.10 - ES0
 MAN Diesel

Plate
51515-03 Centrifugal By-pass Filter Page 2 (2)

L27/38
L21/31
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse

014 1/F Body , complete incl. Sokkel, komplet inkl. 313 1/F Valve kit, consisting Ventilkit, indeholdende
item 099, 109, 433, 445, item 099, 109, 433, 445, of item 433, 445, 457, item 433, 445, 457,
457, 469 457, 469 469 469

026 1/F Valve body Ventilsokkel 325 1/F Seals kit, consisting Tætningskit, indehold-
of item 087, 099, 109, ende item 087, 099,
038 1/F Valve handle Ventilhåndtag 158, 242 109, 158, 242

051 1/F Nyloc nut Møtrik 337 1/E Centrifugal by-pass Centrifugal by-pass
filter, complete as filter, komplet som vist
063 1/F Valve adapter Ventiladapter shown on front på forsiden
page
087 1/F Valve seal Ventiltætning
433 1/F Plug Prop
099 1/F Flange gasket Flangepakning
445 1/F Washer Skive
109 1/F Filter body O-ring Filtersokkel O-ring
457 1/F Spring Fjeder
110 1/F Cover, complete incl. Dæksel, komplet inkl.
item 122, 134, 146, item 122, 134, 146, 469 1/F Shuttle Spole
158, 171 158, 171
470 2/F Washer Skive
122 1/F Cover Dæksel
482 1/F Circlip Låsering
134 1/F Cover nut pin Stift for dækselmøtrik
494 1/F Valve kit, consisting Ventilkit, indeholdende
146 1/F Cover fixing nut Dækselmøtrik of item 026, 038, item 026, 038, 051,
051, 063, 087 063, 087
158 1/F Cover nut O-ring Dækselmøtrik O-ring

171 1/F Cover nut collar Dækselmøtrik muffe

183 1/F Band clamp Spændering

195 1/F Rotor, complete incl. Rotor, komplet inkl. item

item 205, 217, 229, 205, 217, 229, 230, 242,
230, 242, 254, 266, 254, 266, 482, 470
482, 470

205 2/F Nozzle Dyse

217 1/F Bearing tube Lejerør

229 1/F Stand tube Standrør

230 1/F Circlip Låsering

242 1/F Rotor O-ring Rotor O-ring

254 1/F Pin Stift

08028-0D/H5250/94.08.12

266 1/F Rotor cover nut Rotordækselmøtrik

278 1/F Paper insert Papirindsats

301 1/F Cover nut fixing kit, Dækselmøtrikskit, inde-

consisting of item 134, holdende item 134, 146,
146, 158, 171 158, 171

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

09.10 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Cover / automatic filter P51517-03

L27/38

2013.12.16
 MAN Diesel & Turbo
Plate
P51517-03 Cover / automatic filter Page 2 (2)

L27/38
Item No. Qty Item Designation Item No. Qty Item Designation

001 1/E Oil filter

002 1/F Plate
003 1/F Gasket
004 1/F Round seal ring
005 1/F Round seal ring
006 4/F Threaded piece
007 12/F Stud screw
008 12/F Nut
009 12/E Washer
010 /I Glue

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine
Qty/F = Qty/Filter
Qty/I = Qty/Individual

2013.12.16
 MAN Diesel
Plate
Page 1 (2) Crankcase Venting 51531-08H

L27/38

202
214 383
226 395

238
179
131
180
192
202

155
167
143 023
047
251
263
08028-0D/H5250/94.08.12

275
287

08.24 - ES0
 MAN Diesel
Plate
51531-08H Crankcase Venting Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

023 4/E Screw Skrue

047 1/E Packing, square Pakning, firkantet

131 1/E Oil vapour discharge Ånderør

pipe

143 1/E Bracket Beslag

155 1/E Clamps Klemme

167 2/E Nut Møtrik

179 1/E Oil vapour dischage Ånderør

pipe

180 /I Glue Lim

192 4/E Screw Skrue

202 2/E Packing, square Pakning, firkantet

214 4/E Screw Skrue

226 4/E Nut Møtrik

238 1/E Oil vapour discharge Ånderør

pipe

251 1/E Hexagon nipple Nippel

263 1/E Ball valve Kugleventil

275 1/E Packing ring Pakningsring

287 1/E Plug screw Propskrue

383 1/E Packing, oval Pakning, oval

395 2/E Screw Skrue

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

08.24 - ES0
 MAN Diesel
Plate
Page 1 (2) Crankcase Venting 51531-09H

L27/38

202
214 383
226 395

405

429
214 238
226
192
202
155 179
430 180
442
454

131
Oil mist detector,
251 see plate 50960

263
023
047
08028-0D/H5250/94.08.12

275
287

08.27 - ES0
 MAN Diesel
Plate
51531-09H Crankcase Venting Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

023 4/E Screw Skrue

047 1/E Packing, square Pakning, firkantet

131 1/E Oil vapour discharge Ånderør

pipe

155 1/E Clamps Klemme

179 1/E Oil vapour dischage Ånderør

pipe

180 /I Glue Lim

192 4/E Screw Skrue

202 2/E Packing, square Pakning, firkantet

214 12/E Screw Skrue

226 12/E Nut Møtrik

238 1/E Oil vapour discharge Ånderør

pipe

251 1/E Hexagon nipple Nippel

263 1/E Ball valve Kugleventil

275 1/E Packing ring Pakningsring

287 1/E Plug screw Propskrue

383 1/E Packing, oval Pakning, oval

395 2/E Screw Skrue

405 1/E Oil vapour discharge Ånderør

pipe

429 2/E Packing, square Pakning, firkantet

430 2/E Self-locking nut Selvlåsende møtrik

442 1/E Flat steel bar Fladstål

454 1/E Angle profile Vinkel profil

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

08.27 - ES0
 MAN Diesel

Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-08H

L27/38
08028-0D/H5250/94.08.12

062 086

06.13- ES0
MAN Diesel

Plate
51535-08H Prelubricating Oil Arrangement Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

050 1/E Ball valve Kugleventil

062 1/E Straight male Ligeforskruning

stud coupling

086 1/E Pipe Rør

098 1/E Adjustable elbow Justerbar vinkel

121 1/E Reducing adapter Reduktionsadapter

133 1/E Non-return valve Kontaventil

170 1/E Pipe Rør

182 1/E Pipe Rør

241 4/E Screw Skrue

253 4/E Sleeve Bøsning

265 1/E Straight male Ligeforskruning

stud coupling

277 1/E Adjustable elbow Justerbar vinkel

289 1/E Pipe Rør

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

06.13 - ES0
MAN Diesel & Turbo
Plate
Page 1 (2) Lub. oil thermostatic elements P51545-03

L27/38

2014.02.28
 MAN Diesel & Turbo
Plate
P51545-03 Lub. oil thermostatic elements Page 2 (2)

L27/38
Item No. Qty Item Designation Item No. Qty Item Designation

018 4/E Thermostatic element for lub. oil

031 4/E Sleeve
043 4/E Retaining ring
055 1/E Cover
067 12/E Screw
079 1/E Gasket
092 12/E Locking spring washer
102 4/E Supporting ring
114 4/E O-ring

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

ace.
* = Only available as part of a spare parts kit/not
available separately
Qty/E = Qty/Engine

2014.02.28
Cooling water system

516/616
MAN Diesel & Turbo

Description
Cooling Water System 516.01
Page 1 (1) Edition 12

L27/38

Cooling Water System

The cooling water system consists of a low tempe­

rature system and a high temperature system.

Both the low and the high temperature systems are

cooled by fresh water.

The water in the low temperature system passes

through the low temperature circulating pump which
drives the water through the second stage of the
charge air cooler and then through the lubricating
oil cooler before it leaves the engine together with
the high temperature water.

The high temperature cooling water system

passes through the high temperature circulating
Charge air cooler
pump and then through the first stage of the charge
air cooler before it enters the cooling water jacket Lub. oil
and the cylinder head. Then the water leaves the cooler
engine with the low temperature water. HT Circuit LT Circuit

Both the low and high temperature water leaves the 79°C 35°C

engine through separate three-way thermostatic

valves which control the water temperature.

Fig. 1 Cooling water system

11.44 - ES0 - Tier II

MAN Diesel & Turbo

Description 516.01
Page 1 (1) Cooling Water System (two string) Edition 13

L27/38

Non-return valve with

restriction (ø3 mm)
TSH TE TI Two stage charge
12 12 12
F3/F4 air cooler
Thermostat housing
Normally
closed
F1 F2
79˚C
C A
B
TI
10
PI
Engine 10
driven PT
HT pump 10
Alternator

Pocket for TE14

Engine driven LT venting (external piping)
LT pump

Lub. oil cooler Option

TI Water cooled
B 04 alternator
C A
TI
35˚C 05

G1 G2
Front end box Optional
PT TE
01 01 Pre-heating valve

Fig 1 Diagram for internal cooling water system.

Cooling water system The engine on the cooling water side only requires
fresh water between 10 and 40°C.
The system is designed as a two string circuit with
four flange connections to the external centralized
coo­ling water system. High Temperature Circuit

The engine is equipped with a self-controlling tem- The built-on engine-driven HT-circulating pump of
perature water circuit. This is a simple solution with the centrifugal type pumps water through the first
low installation costs, which also can be interesting stage of the charge air cooler and then through the
in case of repowering. distri­buting bore to the bottom of the cooling water
guide jacket. The water is led out through bores at
the top of the cooling water guide jacket to the bore
Low Temperature Circuit cooled cylinder head for cooling of this, the exhaust
valve seats and the injector valve.
The components for circulation and temperature
regulation are placed in the internal system. From the cylinder heads the water is led through an
integrated collector to the thermostatic valve, and
The charge air cooler and the lubricating oil cooler depending on the engine load, a smaller or larger
are situated in serial order. After the LT water has amount of the water will be led to the external system
passed the lubricating oil cooler, it is let to the ther- or will be re-circulated.
mostatic valve and depending on the water tempe-
rature, the water will either be re-circulated or led to
the external system.

11.44 - ES0 - Tier II

MAN Diesel & Turbo
Work Card 516-01.90
Page 1 (2) Check of Cooling Water System
Edition 03

L21/31, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Check of cooling water system.

Starting Position Hand Tools

Engine is running

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : ½ Plate No. Item No. Quantity
Number : 1

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

2002.05.13.
 MAN Diesel & Turbo
516-01.90 Work Card
Check of Cooling Water System Page 2 (2)
Edition 03

L21/31, L27/38

Health Risk!
Warning!
Health Risk!
Due to vibrations during engine operation, espe-
cially in awkward positions!

Checks to be carried out

1) Examine the cooling water connetions for leaks.
2) Check flexible connections for leaks.
It is important that the flexible connections are
free from paint and grease and in healthy condi-
tion.
3) Check O-rings in water connections between
cylinder covers and also between cylinder cov-
ers and front-end box
4) Check the condition of the outmost of the two
O-rings (which makes up the tightening
between the water jacket and the combustion
space) by means of the inspection holes in the
cylinder cover.
Concerning check of the fresh water condition, see
section 504.

2002.05.13.
MAN Diesel & Turbo
Work Card 516-04.00
Page 1 (2) Cooling Water, Thermostatic Valve
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Inspection of thermostatic valve and replacement
of elements.

Starting Position Hand Tools

Top / Extension / Ratchet 14 mm
Cooling water drained from engine
(if necessary) Pliers for lock ring
Sealing paste

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2

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

2011.03.14.
 MAN Diesel & Turbo
516-04.00 Work Card
Cooling Water, Thermostatic Valve Page 2 (2)
Edition 03

L27/38

General
The thermostatic valves cannot be adjusted, and
under normal conditions maintenance is not
required. However, in some cases it is necessary to
clean or replace elements

Replacement of elements

Warning!
Use protective gloves!
1) Remove the casing by unscrewing bolts (A), see
fig 2.
2) Remove lock ring (2).
3) Remove element (4) from the casing.
Figure 2: Seen from front end of the engine
4) Thoroughly clean sleeve (3).

1 Bolt 2 Retaining ring

3 Sleeve 4 Element

Figure 1: Cooling water thermostatic valve

5) Remount a new element (4) by wriggling it

somewhat over side.
6) Mount lock ring (2) in the recess.
7) Clean the sealing surface of the casing. Tighten
bolts according to page 500.40.

2011.03.14.
MAN Diesel & Turbo
Work Card 516-10.00
Page 1 (3) HT and LT Water Pumps
Edition 02

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Disassembly, overhaul and assembly of HT and LT
pumps.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : 1 Plate No. Item No. Quantity
Number : 1 51610 010 4/E
51610 022 2/E
51610 095 2/E
Data 51610 250 1/E
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

1999.05.03.
 MAN Diesel & Turbo
516-10.00 Work Card
HT and LT Water Pumps Page 2 (3)
Edition 02

L27/38

HT and LT water pumps Disassembly of the pump

After the cooling water thermostat casing is 1) Remove the screw (2), see fig 1 and pull off the
removed, the cooling water pumps can be dis- washer (3) and spur gear (4).
mounted. 2) Remove the screw (5) and the cover (6).
Warning! 3) Remove the nut (7) with disc (8), then remove
impeller (9) and the slide ring joint (10).
Use protective gloves!
4) Take out the retaining ring (11), then pull out the
1) Remove the screws and pull out the pump by shaft (12) with bearings (13) and (16) and the
means of the spring bolts. shaft seal (14).

Inspection of the pump

1) Inspect the shaft for seizures after removing the
shaft seal and bearings, also inspect the impel-
ler for pittings and caviations. Clean all parts
carefully.

Assembling of the pump

1) Fit new bearings (13) and (16) together with a
new shaft seal (14).
2) Mount the shaft in the housing and lock it with
the retaining ring (11).
3) Fit the spur gear (4) and washer (3) with the
screw (2) and tight it according to page 500.40.
4) Carefully fit the slide ring joint (10), then fit the
disc (8) and the impeller (9) and tight the nut (7)
according to page 500.40.

1 Casing 2 Screw
5) Mount the cover (6) with the screw (5) and tight
them according to page 500.40.
3 Washer 4 Spur gear
6) Fit new O-rings on the pump housing and
5 Screw 6 Cover
pump cover, then mount the pump in the front
7 Self locking nut 8 Disc end box with the screws, and tighten them
9 Impeller 10 Slide ring joint according to page 500.40.
11 Retaining ring 12 Shaft
13 Deep groove ball bearing 14 Shaft seal
15 Lock washer 16 Ball bearing
17 O-ring 18 Disc spring

Figure 1: HT and LT water pumps

1999.05.03.
MAN Diesel & Turbo
Work Card 516-10.00
Page 3 (3) HT and LT Water Pumps
Edition 02

L27/38

Figure 2: HT and LT water pumps

1999.05.03.
MAN Diesel & Turbo

Plate
Page 1 (2) Mounting of Cooling Water Thermostatic Elements 51605-14

L27/38

037
074
013
336 121
049 037
086
098 145 133
133
145
108 216

121
074
324
098
133

062 108
468 025 241
481 253 145

11.34 - ES0 - Tier II

 MAN Diesel & Turbo

Plate
51605-14 Mounting of Cooling Water Thermostatic Elements Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

013 2/E Intermediate piece Mellemstykke

025 14/E Screw Skrue

037 4/E O-ring O-ring

049 2/E O-ring O-ring

062 1/E Thermostat housing, Termostathus, 1-streng

1-string

074 8/E Sleeve Bøsning

086 8/E Sleeve Bøsning

098 8/E O-ring O-ring

108 8/E Washer Skive

121 8/E Retaining ring Sikringsring

133 24/E Screw Skrue

145 28/E Spring washer Fjederskive

216 2/E Cover Dæksel

241 2/E Cover Dæksel

253 16/E Screw Skrue

324 4/E Thermostatic element Termostatelement for

for LT cooling water LT kølevand

336 4/E Thermostatic element Termostatelement for

for HT cooling water HT kølevand

468 1/E Thermostat housing, Termostathus, 2-streng

2-string

481 2/E Gasket Pakning

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

11.34 - ES0 - Tier II

 MAN Diesel

Plate
Page 1 (2) High- and Low Temperature Freshwater Pumps 51610-10H

L27/38
08028-0D/H5250/94.08.12

04.14 - ES0
 MAN Diesel

Plate
51610-10H High- and Low Temperature Freshwater Pumps Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

010 1/P O-ring O-ring

022 1/P O-ring O-ring

034 1/P Depp groove ball Radialkugleleje

bearing

046 1/P Ball bearing Kugleleje

071 1/P Retaining ring Sikringsring

083 1/P Shaft seal Pakdåse

095 1/P Slide ring joint Roterende pakning

105 2/E Freshwater pump, Ferskvandspumpe,

complete as shown komplet som vist
on front page på forside

117 4/P Screw Skrue

129 1/P Pump housing Pumpehus

130* 1/P Impeller Løbehjul

142 1/P Cover Dæksel

154 3/P Screw Skrue

166 3/P Lock washer Låseskive

178* 1/P Shaft Aksel

191* 1/P Screw Skrue

201* 1/P Disc Skive

213 1/P Spur gear Cylindrisk tandhjul

225* 1/P Washer Skive

237* 1/P Screw Skrue

250 1/P O-ring O-ring

453 1/P Kit for upgrading Opgraderingskit

incl. items no 130, inkl. item nr. 130,
178, 191, 201, 225 178, 191, 201, 225
and 237 og 237
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/P = Qty/Pump Qty/P = Qty/Pumpe
Qty/I = Qty/Individual Qty/I = Qty/Individuelt

04.14 - ES0
MAN Diesel

Plate
Page 1 (2) Cooling Water Connections 51630-07H

L27/38

224 212 212

021

045
069

021
212
116
128

021 200

212 189

190 212
045
069

045
069
021

13.04 - ES0
 MAN Diesel

Plate
51630-07H Cooling Water Connections Page 2 (2)

L27/38
Item no Item no
Qty Designation Benævnelse Qty Designation Benævnelse

021 2/E Flange Flange

045 4/E Screw Skrue

069 4/E Locking spring washer Låsefjederskive

116 1/E Elbow Vinkel

128 6/E Screw Skrue

189 10/E Intermediate piece Mellemstykke

190 10/E Intermediate piece Mellemstykke

200 10/E V-Profile clamp V-profil klemme

212 Seal ring Tætningsring

33/E 5 cyl. engine 5 cyl. motor
39/E 6 cyl. engine 6 cyl. motor
45/E 7 cyl. engine 7 cyl. motor
51/E 8 cyl. engine 8 cyl. motor
57/E 9 cyl. engine 9 cyl. motor

224 1/E Orifice plate Måleblænde

236 /I Packing-silicone paste Pakningssilicone

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

13.04 - ES0
 MAN Diesel
Plate
Page 1 (2) Preheater Unit 51635-02H

L27/38
08028-0D/H5250/94.08.12

00.44 - ES0
 MAN Diesel
Plate
51635-02H Preheater Unit Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

030 4/E Heater element Varmepartron

042 4/E Packiong ring Pakningsring

054 4/E HT pipe HT rør

066 4/E Packing, square Pakning, firkantet

078 16/E Screw Skrue

101 5/E Packing ring Pakningsring

113 12/E Screw Skrue

125 16/E Nut Møtrik

149 1/E HT pipe HT rør

150 1/E Foundation frame Fundamentsramme

162 1/E Freshwater pump Ferskvandspumpe

174 4/E Screw Skrue

186 4/E Nut Møtrik

208 2/E Washer Skive

221 2/E Split pin Split

233 1/E Packing ring Pakningsring

245 1/E Bleeding screw Afluftningsskrue

257 1/E Safety valve Sikkerhedsventil

269 4/E Screw Skrue

270 1/E Screw Skrue

282 1/E Nut Møtrik

294 1/E Non-return valve Kontraventil

316 2/E Ball valve Kugleventil

328 4/E Screw Skrue

341 1/E Plug screw Propskrue

353 1/E Packing ring Pakningsring

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

00.44 - ES0
 MAN Diesel
Plate
Page 1 (3) Preheater Unit 51635-07H

L27/38

005

017

042
054 091
101
113
125

137

149
162

150
174

017
186

198
08028-0D/H5250/94.08.12

208

221, 233
257
245

09.11 - ES0
 MAN Diesel
Plate
51635-07H Preheater Unit Page 2 (3)

L27/38

304
269 316
328
270 341
353
282

365

294
377

389
390

400
412

424
08028-0D/H5250/94.08.12

09.11 - ES0
 MAN Diesel
Plate
Page 3 (3) Preheater Unit 51635-07H

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

005 1/E Sleeve Bøsning 328 8/E Nut Møtrik

017 3/E Pipe clamp Rør 341 1/E Steel pipe Stålrør

042 2/E Screw Skrue 353 6/E Screw Skrue

054 2/E Pipe clamp Rør bøjle 365 1/E Cooling water pipe Kølevandsrør

091 1/E Bracket Beslag 377 1/E Cooling water pipe Kølevandsrør

101 8/E Screw Skrue 389 1/E Sleeve Bøsning

113 2/E Screw Skrue 390 1/E Adjustable elbow Kobling

coupling
125 1/E Cooling water pipe Kølevandsrør
400 1/E Screwed connection ??
137 1/E Packing Pakning
412 1/E Ball valve Kugleventil
149 2/E Straight male stud Lige forskruning
coupling 424 1/E Straight male stud, Ligeforskruning,
complete komplet
150 1/E Bracket Beslag

162 1/E Solenoid valve Elektromagnetisk

ventil

174 1/E Cooling water pipe Kølevandsrør

186 1/E Straight coupling, Kobling, komplet

complete

198 1/E Preheater unit Forvarmer

208 2/E Bracket Beslag

221 8/E Screw Skrue

233 16/E Washer Skive

245 1/E H.T. intermediate H.T. rør

pipe

257 2/E Adjustable elbow Justerbar vinkel

coupling, complete kobling, komplet

269 1/E Packing ring Pakningsring

270 4/E Weld-on flange Flange

282 1/E Reducers, concentric Reducers, concentric

08028-0D/H5250/94.08.12

294 1/E Male stud elbow Kobling

coupling

304 4/E Screw Skrue

316 1/E Non return valve Kontraventil

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

09.11 - ES0
Special equipment

517/617
MAN Diesel & Turbo

Plate
Page 1 (2) Kit for Inspection of Fuel Valve 51701-09

L27/38

015

See working card 514-01.10

104
033
189

022

046
286
298

094
298

286

286

13.04 - ES0, Tier II

 MAN Diesel & Turbo

Plate
51701-09 Kit for Inspection of Fuel Valve Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

015 Kit for fuel valve, complete

consisting of:

1 O-ring Plate 51402 Item 033

2 Cylindrcal pin Plate 51402 Item 094

1 O-ring Plate 51402 Item 104

1 O-ring Plate 51402 Item 189

1 O-ring Plate 51404 Item 022

1 O-ring Plate 51404 Item 046

2 O-ring Plate 51404 Item 286

2 O-ring Plate 51404 ITem 298

Please Note that this is a kit supply, and that

any exceeding number of o-rings and gaskets
are not accepted as return goods.

13.04 - ES0, Tier II

MAN Diesel & Turbo

Plate
Page 1 (2) Kit for Overhaul of Fuel Valve 51702-11

L27/38

010

See working card 514-01.10

104
033
189

022

046
286
298

094
298
021

286

286

13.04 - ES0, Tier II

 MAN Diesel & Turbo

Plate
51702-11 Kit for Overhaul of Fuel Valve Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

010 Kit for fuel valve, complete

consisting of:

1 Injection nozzle Plate 51402 Item 021

1 O-ring Plate 51402 Item 033

2 Cylindrcal pin Plate 51402 Item 094

1 O-ring Plate 51402 Item 104

1 O-ring Plate 51402 Item 189

1 O-ring Plate 51404 Item 022

1 O-ring Plate 51404 Item 046

2 O-ring Plate 51404 Item 286

2 O-ring Plate 51404 Item 298

Please Note that this is a kit supply, and that

any exceeding number of o-rings and gaskets
are not accepted as return goods.

13.04 - ES0, Tier II

MAN Diesel & Turbo

Plate
Page 1 (2) Kit for Complete Cylinder Unit Exchange 51703-09

L27/38

045

022 298
457
298
286
046

189
033

014
200 043

212

007

080
080

043

2014.02.24 - ES0
 MAN Diesel & Turbo

Plate
51703-09 Kit for Complete Cylinder Unit Exchange Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

045 Kit for cylinder unit, complete consisting of:

1 Gasket Plate 50507 Item 043

2 O-ring Plate 50507 Item 080

1 O-ring Plate 50510 Item 014

1 O-ring Plate 50610 Item 043

3 O-ring Plate 51234 Item 007

1 O-ring Plate 51401 Item 457

1 O-ring Plate 51402 Item 033

1 O-ring Plate 51402 Item 189

1 O-ring Plate 51404 Item 022

1 O-ring Plate 51404 Item 046

2 O-ring Plate 51404 Item 286

2 O-ring Plate 51404 Item 298

1 V-Profile clamp Plate 51630 Item 200

8 Seal ring Plate 51630 Item 212

Please Note that this is a kit supply, and that any exceeding number of o-rings and
gaskets are not accepted as return goods.

2014.02.24 - ES0
MAN Diesel & Turbo

Plate
Page 1 (2) Kit for Cylinder Unit 51704-21

L27/38

021

022 298
457
298
286
046

095
104
178 031
189 055
033

644

040 237
014 064
200 250
043

212
121
111

007
090 172

196
243

135

080
080

043

2014.02.24 - ES0
 MAN Diesel & Turbo

Plate
51704-21 Kit for Cylinder Unit Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

021 Kit per cylinder unit, complete consisting of:

1 O-ring Plate 50501 Item 040

2 O-ring Plate 50501 Item 064

1 O-ring Plate 50501 Item 111

1 Gasket Plate 50501 Item 135

2 O-ring Plate 50501 Item 172

1 O-ring Plate 50501 Item 196

1 O-ring Plate 50501 Item 243

2 Circlip Plate 50502 Item 095

4 Conical ring 2/2 Plate 50502 Item 178

1 O-ring Plate 50502 Item 237

1 O-ring Plate 50502 Item 250

4 O-ring Plate 50502 Item 644

1 Gasket Plate 50507 Item 043

2 O-ring Plate 50507 Item 080

1 Gasket Plate 50508 Item 121

1 O-ring Plate 50510 Item 014

1 Seal ring Plate 50610 Item 031

1 O-ring Plate 50610 Item 043

1 O-ring Plate 50610 Item 055

1 O-ring Plate 50801 Item 090

3 O-ring Plate 51234 Item 007

1 O-ring Plate 51401 Item 457

1 O-ring Plate 51402 Item 033

1 O-ring Plate 51402 Item 189

1 O-ring Plate 51402 Item 104

1 O-ring Plate 51404 Item 022

1 O-ring Plate 51404 Item 046

2 O-ring Plate 51404 Item 286

2 O-ring Plate 51404 Item 298

1 V-Profile clamp Plate 51630 Item 200

8 Seal ring Plate 51630 Item 212

Please Note that this is a kit supply, and that any exceeding number of o-rings and
gaskets are not accepted as return goods.

2014.02.24 - ES0
MAN Diesel & Turbo

Kit
Page 1 (2) Kit for renewal of Piston Rings 51706-10

L27/38

414*

296* 306
414* 127*
296*

127*

*Please order item 306

See Working Card 506-01.05

11.20 - EO0 - Tier II

 MAN Diesel & Turbo

Kit
51706-10 Kit for renewal of Piston Rings Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

306 Kit per renewal of piston rings for one piston, complete consisting of:

1 Piston ring Plate 50601 Item 414

1 Piston ring Plate 50601 Item 296

1 Oil scraper ring Plate 50601 Item 127

11.20 - EO0 - Tier II

MAN Diesel & Turbo

Kit
Page 1 (2) Kit for High- and Low Temperature Freshwater Pumps 51710-06

L27/38

See Working Card 516-10.00

697*

022*
010*

095*

250*

071*
046*

034* *Please order item 291

083*

13.21
 MAN Diesel & Turbo

Kit
51710-06 Kit for High- and Low Temperature Freshwater Pumps Page 2 (2)

L27/38
Item
No Qty Designation Where to find in the engine instruction book

291 Kit per one freshwater pump, complete consisting of:

1 O-ring Plate 51610 Item 010

1 O-ring Plate 51610 Item 022

1 Depp groove ball bearing Plate 51610 Item 034

1 Ball bearing Plate 51610 Item 046

1 Retaining ring Plate 51610 Item 071

1 Shaft seal Plate 51610 Item 083

1 Slide ring joint Plate 51610 Item 095

1 O-ring Plate 51610 Item 250

4 O-ring Plate 51103 Item 697

Please Note that this is a kit supply, and that
any exceeding number of o-rings and gaskets
are not accepted as return goods.

13.21
 MAN Diesel

Kit
Page 1 (2) Kit for Lubricating Oil Filter 51725-01

L27/38
971*
983*

See Working Card 515-01.10

909*

910*
922*
934*

946*

958*

LEFT VALVE RIGHT

FILTER POSITION FILTER

DRAIN
IN USE EXCHANGE
FILTER
FILL, VENT
NORMAL AND
USE STANDBY

IN USE IN USE

FILL, VENT
AND NORMAL
STANDBY USE

DRAIN
EXCHANGE IN USE
FILTER
Lift fixation bolt before turning valve
08028-0D/H5250/94.08.12

503*

* Please order item 503

08.02
MAN Diesel

Kit
51725-01 Kit for Lubricating Oil Filter Page 2 (2)

L27/38
Item
No Qty Designation Where to find in the engine instruction book

503 1/E Cover,

incl item 909, 910, 922, 934, 946, 958, 971, 983 Plate 51502

2/F Flange Plate 51502 Item 909

2/F Flange Plate 51502 Item 910

2/F Spring Plate 51502 Item 922

2/F Screw Plate 51502 Item 934

2/F Spring Plate 51502 Item 946

4/F O-ring Plate 51502 Item 958

2/F O-ring Plate 51502 Item 971

8/F Seal Plate 51502 Item 983

Please Note that this is a kit supply, and that
any exceeding number of o-rings and gaskets
are not accepted as return goods.

08028-0D/H5250/94.08.12

Qty/E = Qty/Engine
Qty/F = Qty/Filer

08.02
MAN Diesel & Turbo

Plate
Page 1 (2) Kit for Fuel Injection Pump Connections 51732-03

L27/38

494

070 070
344
070

356

457

685

Please see working card 514-01.05

14.08 - ES0
 MAN Diesel & Turbo

Plate
51732-03 Kit for Fuel Injection Pump Connections Page 2 (2)

L27/38
Item
no Qty Designation Where to find in the engine instruction book

494 Kit for fuel injection pump connections complete consisting of:

1 O-ring Plate 51401 Item 457

1 O-ring Plate 51401 Item 685

8 O-ring Plate 51435 item 070

4 Packing ring Plate 51435 item 344

4 O-ring Plate 51435 item 356

Please Note that this is a kit supply, and that

any exceeding number of o-rings and gaskets are
not accepted as return goods.

14.08 - ES0
MAN Diesel & Turbo

Kit
Page 1 (2) Kit for Vibration Damper P51735-04

L27/38

12.49 - EO0
MAN Diesel & Turbo

Kit
P51735-04 Kit for Vibration Damper Page 2 (2)

L27/38
Item
No Qty Designation Where to find in the engine instruction book

009 1/E Spare part kit for vibration damper, type D85/2/1
16/E Spring Pack
16/E Intermediate piece
1/E Clamping ring
1/E Flange
1/E Side plate
1/E Inner star
16/E Spring shims
a.r Expansion shim
16/E Bolt
16/E Disc spring
2/E O-ring
2/E O-ring

010 1/E Spare part kit for vibration damper, type D94/1/1
24/E Spring Pack
24/E Intermediate piece
1/E Clamping ring
1/E Flange
1/E Side plate
1/E Inner star
24/E Spacer
a.r Expansion shim
24/E Bolt
24/E Disc spring
2/E O-ring
2/E O-ring

022 1/E Spare part kit for vibration damper, type D94/2/1
24/E Spring Pack
24/E Intermediate piece
1/E Clamping ring
1/E Flange
1/E Side plate
1/E Inner star
24/E Spacer
a.r Expansion shim
24/E Bolt
24/E Disc spring
2/E O-ring
2/E O-ring

034 1/E Spare part kit for inspection of vibration damper, D85/2/1
16/E Disc spring
2/E O-ring
2/E O-ring

046 1/E Spare part kit for inspection of vibration damper, D94/1/1
16/E Disc spring
2/E O-ring
2/E O-ring

058 1/E Spare part kit for inspection of vibration damper, D94/2/1
16/E Disc spring
2/E O-ring
2/E O-ring

Please Note that this is a kit supply, and that

any exceeding number of o-rings and gaskets
are not accepted as return goods.

Qty/E = Qty/Engine
Qty/a.r = Qty/As required

12.49 - EO0
Specific plant
information

519/619
MAN Diesel & Turbo
Description 519.03
Page 1 (2) Resilient mounting of generating sets
Edition 08

L27/38
Resilient Mounting of Generating Sets 2) The support can also be made by means of two
steel shims, at the top a loose shim of at least
On resiliently mounted generating sets, the diesel 40 mm and below a shim of at least 10 mm
engine and the alternator are placed on a common which are adjusted for each conical mounting
rigid base frame mounted on the ship's/machine and then welded to the foundation.
house's foundation by means of resilient supports,
Conical type.
All connections from the generating set to the exter-
nal systems should be equipped with flexible con-
nections and pipes. Gangway etc. must not be wel-
ded to the external part of the installation.

Resilient support
A resilient mounting of the generating set is made
with a number of conical mountings. The number
and the distance between them depend on the size
of the plant. These conical mountings are bolted to
the brackets on the base frame (see fig 1).
The setting from unloaded to loaded condition is
normally between 5-11 mm for the conical mount-
ing.
The support of the individual conical mounting can
be made in one of the following three ways:

Figure 1: Resilient mounting of generating sets

1) The support between the bottom flange of the Figure 2: Support of conicals
conical mounting and the foundation is made
with a loose steel shim. This steel shim is adjus- 3) Finally, the support can be made by means of
ted to an exact measurement (min. 40 mm) for chockfast. It is necessary to use two steel
each conical mounting. shims, the top shim should be loose and have a
minimum thickness of 40 mm, the bottom shim
should be cast in chockfast with a thickness of
at least 10 mm.

2010.08.16 - ES1
 MAN Diesel & Turbo
519.03 Description
Resilient mounting of generating sets Page 2 (2)
Edition 08

L27/38
Irrespective of the method of support, the 40 mm
steel shim is necessary to facilitate a possible future
replacement of the conical mountings, which are
always replaced in pairs.

Check of Crankshaft Deflection

The resiliently mounted generating set is normally
delivered from the factory with engine and alternator
mounted on the common base frame.
Eventhough engine and alternator have been adjus-
ted by the engine builder, with the alternator rotor
placed correctly in the stator and the crankshaft
deflection of the engine (autolog) within the prescri-
bed tolerances, it is recommended to check the
crankshaft deflection (autolog) before starting up the
GenSet.

2010.08.16 - ES1
MAN Diesel & Turbo
Work Card 519-03.00
Page 1 (4) Fitting instructions for resilient mounting of GenSets
Edition 27

L23/30H, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Mounting and adjustment instruction for new Gen-
Set and adjustment instruction for existing plants.

Starting Position Hand Tools

The foundation should be welded and milled off on Ring and open-end spanner, 22 mm
shim surfaces. Ring and open-end spanner, 30 mm
Allen key, 6 mm
Feeler gauge, 1-2 mm
Measuring tool
Hydraulic jack (if necessary)

Related Procedure
Check of main bearings alignment 510-01.00
(autolog)
Replacement of conicals 519-03.05

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2 51903 013 1/conical
mounting
51903 025 4/conical
Data mounting
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2003.12.08 - Method 1
 MAN Diesel & Turbo
519-03.00 Work Card
Fitting instructions for resilient mounting of GenSets Page 2 (4)
Edition 27

L23/30H, L27/38
5) Lower the generating set until it rests com-
pletely on the foundation.
6) Check that all jacking bolts have full contact
with the foundation.
7) Turn all the internal buffers (2), see fig 1, to
check that they can move freely.

Mounting and adjustment instructions for

If all internal buffers Then
new generating sets (Method 1)
Can move freely Let conical elements settle
for 48 hours.
Make ready for adjustment of conical
Cannot be moved Turn the four jacking bolts
elements in the base casting clock-
wise or anticlock- wise to
If the conical elements have not been mounted by
release the internal buffer.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been
mounted by the factory, please start with item num- Adjustment of conical elements after 48
ber 2. hours settling
1) Fit the conical elements to the bracket on the
After the conical elements have been deflected
base frame by means of four bolts screwed into
under static load for 48 hours, the laden height (H1)
the tapped holes on the top casting (5), see fig
see fig 2, should be measured and compared to the
1.
recommended laden height.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.
3) Position the four jacking bolts in the tapped
holes (9) see fig 1, in the base casting (1).
4) Position the jacking bolts with a through-going
of minimum 40 mm, see fig 2.

1 Base casting 2 Internal buffer

3 Synthetic bush 4 Rubber element
5 Top casting 6 Top lock ring
7 Fixing bolt 8 Spring washer
9 Tapped hole 10 Protective cap
Figure 2: Conical mounting
Figure 1: Conical element

2003.12.08 - Method 1
MAN Diesel & Turbo
Work Card 519-03.00
Page 3 (4) Fitting instructions for resilient mounting of GenSets
Edition 27

L23/30H, L27/38
8) Care must be taken, during levelling of the 13) Remove all the jacking bolts.
installation, to ensure that individual mountings 14) Position each completed steel shim.
are not overloaded. The variation in laden height
should not exceed 2 mm and should ideally be 15) Lower the generating set until it rests com-
less. The laden height can be measured pletely in itself.
between top and base casting at H, on two 16) Number each steel shim together with each
sides (see fig 1). conical element.

Adjustment of internal buffer

17) Turn the internal buffer clockwise (downwards)
until it makes contact with the steel shim or
foundation.
18) Turn the internal buffer anticlockwise (upwards)
until it obtains contact with the base casting.

This must be four full turns.

If Then
Difference exceeds 2 mm Level the conical element 19) Turn the internal buffer two full turns clockwise
by adjusting the jacking (downwards) and check with a feeler gauge
bolts - commencing with between the base casting of the conical ele-
the conical element with ment and the steel shim that the internal buffer
the largest deviation (2), see fig 1, does not touch the steel shim or
Difference does not exceed The height of the steel shim foundation.
2 mm can be measured 20) Lock the internal buffer by remounting the top
lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
The difference between the two sides of a conical washer (8), see fig 1.
mounting should not be more than 0.6 mm.
Mounting of conical elements on the
Measuring of steel shim
foundation
9) Measure the steel shim on several points to
21) Drill four mounting holes in the foundation for
obtain the highest possible accuracy during
each conical element, either
preparation.
⇨ Mark the positions of the mounting holes on
the foundation through the conical element
Fabricating steel shim
and the steel shim.
10) Make sure that the minimum height of the steel (Re)move the set completely so that the
shim is 40 mm to secure a future replacement markings can be reached by drilling with
of the conical element. conventional tools.
Drill the mounting holes in the steel shim according Place the set on its former position by align-
to the conical base casting dimensions. ing it with the drilled holes.

or
Mounting of the completed steel shim
⇨ Drill the mounting holes in the foundation by
11) Turn the internal buffer anticlockwise until it means of the drilling pattern from the instal-
contacts the base casting to secure the laden lation drawing.
height of each conical element. The drilling has to be done on beforehand
12) Lift the generating set with crane or hydraulic
jack.

2003.12.08 - Method 1
 MAN Diesel & Turbo
519-03.00 Work Card
Fitting instructions for resilient mounting of GenSets Page 4 (4)
Edition 27

L23/30H, L27/38
and the set must be aligned with the foun-
dation holes before the work starts to avoid
further removal of the set.
22) Fix all the conical elements and the steel shims
to the foundation with four bolts per conical.

Note!
After completion of all works the buffer clearance
must be checked, see points 17, 18, 19 and 20.

2003.12.08 - Method 1
MAN Diesel & Turbo
Work Card 519-03.00
Page 1 (4) Fitting instructions for resilient mounting of GenSets
Edition 28

L23/30H, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Mounting and adjustment instruction for new Gen-
Set and adjustment instruction for existing plants.

Starting Position Hand Tools

The foundation should be welded and milled off on Ring and open-end spanner, 22 mm
shim surfaces. Ring and open-end spanner, 30 mm
Allen key, 6 mm
Feeler gauge, 1-2 mm
Measuring tool
Hydraulic jack (if necessary)

Related Procedure
Check of main bearings alignment 510-01.00
(autolog)
Replacement of conicals 519-03.05

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2 51903 013 1/conical
mounting
51903 025 4/conical
Data mounting
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2003.12.08 - Method 2
 MAN Diesel & Turbo
519-03.00 Work Card
Fitting instructions for resilient mounting of GenSets Page 2 (4)
Edition 28

L23/30H, L27/38
3) Position the supporting steel shim as per fig 2
and locate the conical element by means of
dowel pins.
4) Position the three jacking bolts in the tapped
holes in the supporting steel shim as per fig 2.
5) Position the jacking bolts with a through-going
of minimum 40 mm, see fig 2.
Mounting and adjustment instructions for 6) Lower the generating set until it rests com-
pletely on the foundation.
new generating sets (Method 2)
7) Check that all jacking bolts have full contact
with the foundation.
Make ready for adjustment of conical
8) Turn the internal buffer (2), see fig 1 to check
elements
that it can be moved freely.
If the conical elements have not been mounted by
the factory, they must be mounted on the prepared
brackets of the base frame. In case they have been
mounted by the factory, please start with item num-
ber 2.
1) Fit the conical elements to the bracket on the
base frame by means of four bolts screwed into
the tapped holes on the top casting (5), see fig
1.
A supporting steel shim with a minimum height of
40 mm, to secure a future replacement of the coni-
cal element, complete with tapped holes for three
jacking bolts and mounting holes drilled according
to conical base casting dimensions, is required.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.

Figure 2: Conical mounting

1 Base casting 2 Internal buffer
3 Synthetic bush 4 Rubber element
5 Top casting 6 Top lock ring
7 Fixing bolt 8 Spring washer
9 Tapped hole 10 Protective cap

Figure 1: Conical element

2003.12.08 - Method 2
MAN Diesel & Turbo
Work Card 519-03.00
Page 3 (4) Fitting instructions for resilient mounting of GenSets
Edition 28

L23/30H, L27/38

If all internal buffers Then Fabricating steel shim

Can move freely Let conical elements settle 11) Make sure that the minimum height of the steel
for 48 hours. shim is 10 mm.
Cannot be moved Turn the four jacking bolts Drill the mounting holes in the steel shim according
in the base casting clock- to the mounting holes in the conical base casting
wise or anticlock- wise to and the mounting holes in the supporting steel
release the internal buffer. shim.

Adjustment of conical elements after 48 Mounting of the completed steel shim

hours settling 12) Lift the generating set 1 mm totally be means of
After the conical elements have been deflected the three jacking bolts.
under static load for 48 hours, the laden height (H1) 13) Position each completed steel shim.
see fig 2, should be measured and compared to the
14) Re-lower the generating set by means of the
recommended laden height.
three jacking bolts until it rests completely in
9) Care must be taken, during levelling of the itself.
installation, to ensure that individual mountings
are not overloaded. The variation in laden height
should not exceed 2 mm and should ideally be
Adjustment of internal buffer
less. The laden height can be measured 15) Turn the internal buffer clockwise (downwards)
between top and base casting at H, on two until it makes contact with the steel shim or
sides (see fig 1). foundation.
16) Turn the internal buffer anticlockwise (upwards)
until it obtains contact with the base casting.

This must be four full turns.

17) Turn the internal buffer two full turns clockwise

(downwards) and check with a feeler gauge
between the base casting of the conical ele-
ment and the steel shim that the internal buffer
(2), see fig 1, does not touch the steel shim or
If Then foundation.
Difference exceeds 2 mm Level the conical element 18) Lock the internal buffer by remounting the top
by adjusting the jacking lock ring (6) and turn it to the nearest thread
bolts - commencing with
hole - then secure with fixing bolt (7) and spring
the conical element with
the largest deviation washer (8), see fig 1.

Difference does not exceed The height of the steel shim

2 mm can be measured Mounting of conical elements on the
foundation
19) Remove the dowel pins.
The difference between the two sides of a conical
mounting should not be more than 0.6 mm. 20) Drill four mounting holes in the foundation for
each conical element, either
Measuring of steel shim ⇨ Mark the positions of the mounting holes on
the foundation through the conical element
10) Measure the steel shim on several points to and the steel shims.
obtain the highest possible accuracy during (Re)move the set completely so that the
preparation. markings can be reached by drilling with

2003.12.08 - Method 2
 MAN Diesel & Turbo
519-03.00 Work Card
Fitting instructions for resilient mounting of GenSets Page 4 (4)
Edition 28

L23/30H, L27/38
conventional tools.
Place the set on its former position by align-
ing it with the drilled holes.

or
⇨ Drill the mounting holes in the foundation by
means of the drilling pattern from the instal-
lation drawing.
The drilling has to be done on beforehand
and the set must be aligned with the foun-
dation holes before the work starts to avoid
further removal of the set.
21) Fix all the conical elements and the supporting
steel shims/steel shims to the foundation with
four bolts per conical.
22) Weld the lowest steel shim of approx. 10 mm
height to the foundation.

Note!
After completion of all works, the buffer clearance
must be checked, see points 15, 16, 17 and 18.

2003.12.08 - Method 2
MAN Diesel & Turbo
Work Card 519-03.00
Page 1 (4) Fitting instructions for resilient mounting of GenSets
Edition 29

L23/30H, L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Mounting and adjustment instruction for new Gen-
Set and adjustment instruction for existing plants.

Starting Position Hand Tools

The foundation should be welded and milled off on Ring and open-end spanner, 22 mm
shim surfaces. Ring and open-end spanner, 30 mm
Allen key, 6 mm
Feeler gauge, 1-2 mm
Measuring tool
Hydraulic jack (if necessary)

Related Procedure
Check of main bearings alignment 510-01.00
(autolog)
Replacement of conicals 519-03.05

Qualified Manpower Replacement and wearing parts

Duration in h : 2 Plate No. Item No. Quantity
Number : 2 51903 013 1/conical
mounting
51903 025 4/conical
Data mounting
Data for pressure and tolerance (Page 500.35)
Data for tightening torque (Page 500.40)
Declaration of weight (Page 500.45)

2003.12.08 - Method 3
 MAN Diesel & Turbo
519-03.00 Work Card
Fitting instructions for resilient mounting of GenSets Page 2 (4)
Edition 29

L23/30H, L27/38
3) Position the supporting steel shim as per fig 2
and locate the conical element by means of four
hold-down bolts.
4) Position the three jacking bolts in the tapped
holes in the supporting steel shim as per fig 2.
5) Position the jacking bolts with a through-going
of minimum 10 mm plus permitted thickness,
as specified from the chockfast supplier, see fig
Mounting and adjustment instructions for 2.
new generating sets (Method 3)
6) Lowed the generating set until it rests com-
pletely on the foundation.
Make ready for adjustment of conical 7) Check that all jacking bolts have full contact
elements with the foundation.
If the conical elements have not been mounted by 8) Turn the internal buffer (2), see fig 1, to check
the factory, they must be mounted on the prepared that it can be moved freely.
brackets on the base frame. In case they have been
mounted by the factory, please start with item num-
ber 2.
1) Fit the conical elements to the bracket of the
base frame by means of four bolts screwed into
the tapped holes on the top casting (5) see fig
1.
A supporting steel shim with a minimum height of
40 mm, complete with tapped holes for three jack-
ing bolts, four mounting holes and four tapped
holes, drilled according to the conical base casting
dimension, is required see fig 2.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.

Figure 2: Conical mounting

1 Base casting 2 Internal buffer

3 Synthetic bush 4 Rubber element
5 Top casting 6 Top lock ring
7 Fixing bolt 8 Spring washer
9 Tapped hole 10 Protective cap

Figure 1: Conical element

2003.12.08 - Method 3
MAN Diesel & Turbo
Work Card 519-03.00
Page 3 (4) Fitting instructions for resilient mounting of GenSets
Edition 29

L23/30H, L27/38

If all internal buffers Then Measuring of steel shim and chockfast

Can move freely Let conical elements settle 10) The steel shim should be at least 10 mm high.
for 48 hours.
Note!
Cannot be moved Turn the three jacking bolts
in the supporting steel shim Check the minimum permitted thickness of chock-
clockwise, or anticlockwise fast for the load and surface of this application with
and slacken the four hold- chockfast supplier.
down bolts to release the
internal buffer.
Fabricating steel shim
Adjustment of conical elements after 48 Make sure that the minimum height of the steel
hours settling shim is 10 mm.

After the conical elements have been deflected 11) Drill the mounting holes in the steel shim
under static load for 48 hours, the laden height (H1) according to the mounting holes in the conical
see fig 2, should be measured and compared to the base casting and in the supporting steel shim.
recommended laden height.
9) Care must be taken, during levelling of the Adjustment of internal buffer
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 be foundation.
less. The laden height can be measured
13) Turn the internal buffer anticlockwise (upwards)
between top and base casting at H, on two
until it obtains contact with the base casting.
sides (see fig 1).

This must be four full turns.

14) Turn the internal buffer two full turns clockwise

(downwards) and check with a feeler gauge
between the base casting of the conical ele-
ment and the steel shim that the internal buffer
(2), see fig 1, does not touch the steel shim or
foundation.
15) Lock the internal buffer by remounting the top
If Then lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
Difference exceeds 2 mm Level the conical element washer (8), see fig 1.
by adjusting the jacking
bolts - commencing with
the conical element with Mounting of conical elements on the
the largest deviation. foundation
Difference does not exceed The height of the steel shim 16) Drill four mounting holes in the foundation for
2 mm and the chockfast can be
each conical element according to the support-
measured.
ing steel shim/steel shim, either
⇨ Mark the positions of the mounting holes on
The difference between the two sides of a conical the foundation through the conical element
mounting should not be more than 0.6 mm. and the steel shims.
(Re)move the set completely so that the
markings can be reached by drilling with
conventional tools.

2003.12.08 - Method 3
 MAN Diesel & Turbo
519-03.00 Work Card
Fitting instructions for resilient mounting of GenSets Page 4 (4)
Edition 29

L23/30H, L27/38
Place the set on its former position by align-
ing it with the drilled holes.

or
⇨ Drill the mounting holes in the foundation by
means of the drilling pattern.
The drilling has to be done on beforehand
and the set must be aligned with the foun-
dation holes before the work starts to avoid
further removal of the set.
17) Make sure that the mounting bolts are isolated
from the chockfast.

Note!
After completion of all works, the buffer clearance
must be checked, see points 12, 13, 14 and 15.

2003.12.08 - Method 3
MAN Diesel & Turbo
Work Card 519-03.05
Page 1 (2) Replacement of conicals
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Replacement of conicals.

Starting Position Hand Tools

Safety precautions. Hydraulic jack

Related Procedure
Fitting instructions for resilient
mounting.

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : 2 51903 013 4/E

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

1999.05.16
 MAN Diesel & Turbo
519-03.05 Work Card
Replacement of conicals Page 2 (2)
Edition 03

L27/38

Replacement of conicals
Warning!
Use protective gloves

A One pair

Figure 1: The conicals must be replaced in pairs

1) Loosen all the holding down-bolts for the coni-
cals in one side.
2) Mount a jack under the base frame, see fig 2.
3) Lift the GenSet until the steel shim can be
removed. This will give enough space for
removing damaged conical.
4) Mount the GenSet conical.

Note!
Conicals should only be replaced in pairs, see
fig 1and plate 51903.
5) Lower the GenSet again. 1 Screw 2 Conical

6) Repeat items 1-5 for the other side. 3 Adjusting screw 4 Chock

7) Adjust the conicals, please see working card 5 Screw / nut 6 Bracket
519-03.00 "Fitting instructions for resilient 7 Deck
mounting of GenSet.
Figure 2: Removal of conicals

1999.05.16
MAN Diesel & Turbo
Work Card 519-03.10
Page 1 (2) Maintenance of conicals
Edition 03

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Control and adjustment of conicals.

Starting Position Hand Tools

Ring and open-end spanner.
Feeler gauge, 2 mm.

Related Procedure

Qualified Manpower Replacement and wearing parts

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

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

1999.04.26
 MAN Diesel & Turbo
519-03.10 Work Card
Maintenance of conicals Page 2 (2)
Edition 03

L27/38

Visual check
What to check

Warning!
Use protective gloves

1) Check for oil deposits on the rubber element.

2) Check for loose mounting bolts.
3) Check for damage in the rubber element.
Result of visual check
If Then
1 Foundation 2 Steel shim
everything is OK continue to next conical
3 Base casting 4 Internal buffer
oil deposits on rubber ele- clean rubber element
ment are observed 5 Rubber element 6 Top casting

loose mounting bolts fasten mounting bolts 7 Top locking ring 8 Spring washer
9 Fixing bolt 10 Protective cap
damage to conicals is replace conical according to
observed Working card 519-03.05
Figure 1: Conical

Clearance check Adjustment of conicals

What to check 5) Remove protective cap (10).
4) Check clearance on all conicals between steel 6) Remove fixing bolt (9) and top locking ring (7).
shim and internal buffer through the slot in the
7) Turn buffer clockwise until it makes contact with
base casting of the conical (see fig 1) with a
the steel shim (2).
feeler gauge of approx. 2 mm.
8) Turn buffer anti-clockwise until it makes contact
Result of clearance check
with the conical base casting (3). This must be
If Then done in four full rotations.
everything is OK check is completed 9) Turn buffer two full rotations clockwise. This will
ensure full vertical movement for the buffer.
everything is not OK adjust conicals which do not
comply with the clearance 10) Check all conicals again.
demands acc. to item 5-11. 11) Replace top locking ring, fixing bolt and protec-
Recheck all conicals acc. to tive cap etc.
item 4.
everything is still not OK replace conicals acc. to
Working card 519-03.05

1999.04.26
 MAN Diesel
Plate
Page 1 (2) Flexible External Connections 51902-13H

L27/38

Item
Fig. Designation Connection
no

Fuel oil, inlet A1 018

Fuel oil, outlet A2

Waste oil, outlet A3 043

Lubricating oil from separator, C3 079

inlet

Lubricating oil to separator, C4

outlet

Drain from lub. oil sump, C14

outlet

Lub. oil overflow, outlet C15 092

Oil vapour discharge, outlet C13 126

Venting to expansion tank/ F3/F4 163

Fresh water for preheating
08028-0D/H5250/94.08.12

06.18 - ES0
MAN Diesel
Plate
51902-13H Flexible External Connections Page 2 (2)

L27/38

Item
Fig. Designation Connection
no

HT freshwater, inlet F1 209

HT frashwater, outlet F2

LT freshwater/raw water, G1
inlet

LT freshwater/raw water, G2
outlet

LT freshwater/raw water, G9 222

inlet

LT freshwater/raw water, G10

outlet

Compressed air, inlet K1 271

Exhaust gas, long, P2 305

outlet (DN450)

Exhaust gas, short, P2 378

outlet (DN450)

Exhaust gas, outlet (DN500) P2 317

Exhaust gas, long, P2 330

outlet (DN600)
08028-0D/H5250/94.08.12

Exhaust gas, short, P2 391

outlet (DN600)

06.18 - ES0
 MAN Diesel
Plate
Page 1 (2) Conical Element 51903-03H

L27/38
08028-0D/H5250/94.08.12

99.14 - ES0
MAN Diesel
Plate
51903-03H Conical Element Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

013 1/M Conical element, Konisk understøtning,

complete komplet

025 4/M Screw Skrue

049 1/M Protecting cap Beskyttelseskapsel

050 1/M Fixing ring Fikseringsring

062 1/M O-ring O-ring

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

99.14 - ES0
 MAN Diesel
Plate
Page 1 (2) Conical Element 51903-07H

L27/38

CL - Engine
074

013

025
08028-0D/H5250/94.08.12

Note! When ordering be aware that conical ele- Bemærk! Ved bestilling af conicals elementer skal
ments always should be replaced in pairs. State conicals elementer altid udskiftes parvis. Opgiv
manufacturing No of existing conical elements. fabrikationsnr. på eksisterende conicals elementer.

07.48 - ES0
 MAN Diesel
Plate
51903-07H Conical Element Page 2 (2)

L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

013 1/M Conical element, Konisk understøtning,

complete komplet

025 4/M Screw Skrue

074 4/M Screw Skrue

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

07.48 - ES0
Tools

520/620
MAN Diesel & Turbo
Work Card 520-01.05
Page 1 (6) Function of the Hydraulic Tools
Edition 02

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

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Safety hints and function of hydraulic tools.

Starting Position Hand Tools

Application of hydraulic tools 520-01.06

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : -

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

1999.10.18. - ES0
 MAN Diesel & Turbo
520-01.05 Work Card
Function of the Hydraulic Tools Page 2 (6)
Edition 02

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

Function of the Bolt Tensioning Device 10) During the pressurization when tensioning or
loosening the bolt connection, always watch the
In order to achieve an optimal result with one or admissible stroke of the device. Exceeding this
several devices, some rules have to be considered. stroke is connected with insufficient generating
We expressly point out that a conscientious han- of tensioning force because the device is ten-
dling of the device as well as the accessories is of sioned in itselve or the hydraulic pressure is
highest importance. To ignore these rules or sepa- bleeded automaticly.
rate hints means danger to life or danger of injuries!
See Safety Hints. 11) On principle, when connecting high-pressure
hoses it has to be taken care that the connec-
tions are correct (see also separate hints).
Safety Hints
12) The hydraulic hoses have to be installed in a
Beside regarding the general accident-prevention way that they are not run over by vehicles or
rules, the safe handling of the device and the unnecessarily walked over by people. Never lay
hydraulic accessories demand especially the con- hoses across sharp objects (danger of cuts)
sideration of the following hints. When disregarding and never bend or jam them in.
even single items, you can cause danger to life and/
or danger of injuries! 13) Never hold or transport the device by using the
high-pressure hoses.
1) When leakages occur during the pressurization,
bleed pressure immediately and seal the leak- 14) An incorrect working manometer that doesn´t
age or replace defect parts. show the right pressure leads to overstressing
of the parts and to an incorrect bolt connection.
2) In case of repair, use exclusively original spare Apart from damaged parts an incorrect bolt
parts. Inexpert substitution of damaged parts by connection can also cause conditions that are
non-original spare parts is prohibited. danger to life. Therefore take care that the man-
3) All assembly parts are to be handled in corre- ometer shows the right value or the tensioning
spondence to the working cards only. A change force is checked in an other way (for example
in the procedure or another operation of the by using a master manometer). Tensioning
device is not allowed. forces can be checked for example by measur-
4) Make sure that the components to be ten- ing the linear deformation. Damaged manome-
sioned do not exceed the admissible strain. ters have to be exchanged immediately.

5) In order to use the device, the thread has to be

sufficiently exceeding in order to avoid that the Working Hints
turn of a thread cracks, see item 4. In order to achieve a bolt connection of high preci-
6) During the pressurization the people involved sion, it is vital to consider the following working
have to remain in an appropriate distance. Stay- hints:
ing in direction towards the bolt axis is forbid- ▪ Prior to setting the device, clean all threads and
den. remove possible damages in order to avoide a
7) Tensioning pressures or tensioning forces are to “freeze on”.
be given or changed by authorized personnel ▪ The base plate for the device must be plain and
only while considering the admissible compo- free of dirt. Further check the squareness
nent loads, see item 4. towards the bolt axis in order to avoid that the
8) The operation and handling of the device are to bolt has a bending stress during the pressuriza-
be carried out by expert staff only. tion (tensioning).
9) The given max. operation pressure is not to be ▪ The stroke of the device may not at any point
exceeded in any case and is to be watched at be exceeded.
the manometer of the pressure generator during ▪ For transporting the device it is necessary to
the complete tensioning or loosening proce- uncouple all high-pressure hoses.
dure. When having achieved the given pressure, ▪ After each pressurization, bring the device back
stop the pressurization immediately. to zero, see also Piston Return Stroke.

1999.10.18. - ES0
MAN Diesel & Turbo
Work Card 520-01.05
Page 3 (6) Function of the Hydraulic Tools
Edition 02

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

▪ For oiling the parts, use exclusively hydraulic oil.
Turnable Connection Unit ▪ For replacements, use exclusively new seals.
In order to simplify the connection of the hydraulic
hose, a turnable connection unit is mounted on Coupling of the High-Pressure Hoses
some devices. ▪ Only couple when the hydraulic system is in a
The turnable connection unit consists of the follow- pressureless condition.
ing components:
▪ To produce a high-pressure connection, put
▪ bolt nipple one coupling and one nipple into each other
▪ disc while the coupling socket is pulled back. When
▪ seal letting the coupling socket go, there is a form fit
barring the connection.
▪ securing ring
▪ By drawing the hose with a manual force of
Furthermore, an entry guide is available or con- about 100 N make sure that the connection is
tained in the scope of supply, see fig.1. correctly barred.
▪ For decoupling the high-pressure hose in a
pressureless condition, first pull back the cou-
pling socket and then take off the hose.

Figure 2: Coupling of the high-pressure hoses.

Hoses with fast-lock coupling sockets avoid, also

when uncoupled, that oil runs out. When the hoses
get heated, there can be an inside pressure in the
uncoupled condition making a coupling impossible.
By loosening one screw connection (see fig. 2) the
pressure can be bleeded
Figure 1: Turnable connection unit ▪ To avoid a contamination use protecting caps
for the sockets.

Exchange of the Seals Tensioning Procedure

Should leakages show up at the connection unit, it Prior to the tensioning procedure make sure that
might be necessary to exchange the seals. the components to be tensioned are correctly posi-
For doing so, loosen the securing ring and take the tioned towards each other. Then screw the device
disc off the bolt nipple. Having removed the seals, onto the bolt.
clean the components with fluff-free cleaning mate- First put the support sleeve on the bolt and align it
rial. You can also apply compressed air. Having centrically to the bolt axis. When screwing on the
checked the components for damages and oiled device take care that the support sleeve at the cyl-
them slightly, apply new seals by help of the entry inder is correctly centered (consider centering
guide and reassemble the turnable connection unit. shoulder).
Hint:
▪ For the cleaning, never use aggressive cleaning
liquids.

1999.10.18. - ES0
 MAN Diesel & Turbo
520-01.05 Work Card
Function of the Hydraulic Tools Page 4 (6)
Edition 02

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

Screw the device until the support sleeve or the During the pressurization, a slight turn-back
support cylinder fits exactly to the flange. The piston momentum is applied to the main nut with the
of the device must be at its zero position. Further- adjusting rod. At the moment, when the main nut
more, take care that the hydraulic connector and can be loosened, interrupt the pressurization.
the window for the adjusting rod is well accessible. Should it not be possible to loosen the main nut
If necessary, turn back the device, but make sure when achieving the original tensioning pressure,
that the max. admissible stroke of the device is not interrupt the pressurization immediately. Find the
exceeded. Beside that, it has to be ensured that the cause with expert staff.
cylinder and the support sleeve remain centrically Having achieved the loosening pressure, turn back
towards each other (consider centering shoulder). the main nut by the value that the bolt and the com-
Having made all hydraulic connections correctly, ponents spring back during the loosening proce-
see fig. 2, start the pressurization for the tensioning dure. The slit measure, however, must be lower
procedure. If the necessary pressure is achieved than the slit measure adjusted at the device before,
stop pressurization. The inducted force causes the see also hint b.
bolt to extend or an edging of the components to The main nut may never be turned back until it fits
be tensioned so that the main nut is lifted from the to the piston or the cylinder since then the device
flange. Screw it back to the flange, see fig. 3. can be tensioned in itself.
Check by help of a feeler gauge leaf whether the Having turned back the main nut, the pressure can
main nut really fits tight to the flange. After that, be bled. The bolt connection is loosened. Before
bleed hydraulic pressure. Now the connection is unscrewing the device, bring the piston back to its
tensioned. zero position, see fig. 4. After that, the hydraulic
Having brought the piston to its zero position, see hoses can be decoupled. In order to prevent impur-
fig. 4, the hydraulic hoses can be decoupled. In ities, it is advisable to close coupling sockets and
order to prevent impurities, it is advisable to close coupling nipples at once by protecting caps. The
coupling sockets and coupling nipples at once by device can be unscrewed from the bolt.
protecting caps. The device can be unscrewed ▪ Make sure that no operational forces (e.g. inner
from the bolt. pressure) affect the components to be loosened
▪ Always consider the safety and working hints! since only part of the bolts take over these
forces and thus the bolts, which are not yet
Loosening Procedure loosened, might be overburdened.
▪ The pressure when the main nut can be loos-
In order to loosen an existing bolt connection,
ened may never exceed the tensioning pressure
screw the device onto the bolt. First put the support
by help of which the connection was tensioned!
sleeve on the bolt and align it centrically to the bolt
Should it not be possible to loosen the main nut
axis. When screwing on the device take care that
when reaching the original tensioning pressure
the support sleeve at the cylinder is correctly cen-
interrupt the pressurization immediately. Find
tered (consider centering shoulder).
the cause with expert staff.
The piston of the device must be at its zero posi-
▪ Always consider the safety and working hints!
tion. Having screwed the device down until the sup-
port sleeve or the support cylinder fits tight to the Hint:
flange, turn back the device by at least the value (slit 1. Should it be impossible to unscrew the device
measure) which the bolt and the components after the depressurization, it has been turned
spring back elastically during the loosening proce- back by a too low measure prior to the pressur-
dure. ization. Pressurize again until the original ten-
Hint: sioning pressure is reached, turn the main nut
The adjusted slit measure may never exceed the and bleed the pressure again (tensioning proce-
admissible stroke of the device! Furthermore, take dure). Now you can turn back the device fur-
care that the window for the adjusting rod are well ther. (Attention: consider the admissible stroke
accessible. of the device!) Now repeat the loosening proce-
Having made all hydraulic connections correctly, dure explained above.
see fig. 2, start the pressurization.

1999.10.18. - ES0
MAN Diesel & Turbo
Work Card 520-01.05
Page 5 (6) Function of the Hydraulic Tools
Edition 02

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

2. Should it be impossible to loosen the main nut In order to enable the oil to flow back to the tank of
after the depressurization, it has been turned the pressure generator, the corresponding hydraulic
back by a too low measure prior to the pressur- connections must be done.
ization. Pressurize again and turn the main nut The piston return stroke is done by a screw-down
further back. Bleed the pressure again. at the bolt itself before the device is taken off.
Hint: Hint:
Never screw the main nut back until it fits to the pis- When using fast lock coupling elements, the oil’s
ton since the device can be tensioned in itself. running out and thus a piston return stroke in an
uncoupled condition is impossible!
Adjustment and Turn Back of the Main Nut During the piston return stroke, considerable back-
During the pressurization of the device, the bolt is pressures can occur in the piston area of the device
being extended by the tensioning force and the since quite large quantities of oil have to flow back
components are being edged. The result is that the through the small cross sections of the high-pres-
main nut does no longer fit to the flange. sure connections.
Having achieved the necessary pressure, adjust the In order not to unnecessarily increase the force for
main nut - when tensioning - until it fits to the flange the piston return stroke turn the piston slowly. On
again before bleeding the pressure, see Tensioning principle the piston of the device has to be pushed
Procedure. When loosening the bolts, turn back the back until it fits to the cylinder again.
main nut after the pressurization according to the
bolt and component deformations, (see Loosening
Procedure.
Hint:
During the loosening procedure, never turn back
the main nut until it fits to the piston or the cylinder
since the main nut sticks after the depressurization.
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.
Figure 4: Piston return stroke

Exchange of the Seals

Should leakages occur at the piston of the device,
an exchange of the seals might be necessary.
Drive out the piston by carefully beating with a ham-
mer while using a plastic spacer in order to protect
the device from unnecessary damages. After
removing the hydraulic connector, you can also
carefully lead compressed air into the piston area.
Figure 3: Adjustment and turn back of the main nut. Attention:
Sudden input of compressed air can lead to the pis-
ton’s uncontrolled outlet.
After removal of the piston, the seals and the
Piston Return Stroke backup rings can be removed from the piston and
After each pressurization it must be ensured that the cylinder.
the piston of the device is brought back to its zero Carefully clean the components with fluff-free mate-
position. On principle, it has to be considered that rial and check them for damages. If necessary, use
hydraulic oil is being displaced from the piston area. compressed air for the cleaning, but never aggres-

1999.10.18. - ES0
 MAN Diesel & Turbo
520-01.05 Work Card
Function of the Hydraulic Tools Page 6 (6)
Edition 02

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

sive cleaning liquids. After that, slightly oil these – Prior to the device’s operation, repair possi-
components with hydraulic oil and assemble new ble damages and clean the device.
backup rings as well as new seals to the piston and – Check the components of the device and
the cylinder according to the drawing. its accessories for completion.
– The operating manual has to be read by all
users.

Figure 5: Exchange of the seals

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 put-
ting the components together. By slightly hammer-
ing 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 assem-
bling the piston it has to be taken care that the air
can come out of the piston area.

Maintenance and Storage

Regular maintenance of the device is not neces-
sary, but you should consider the following points:
▪ Storage
– After each operation, repair possible dam-
ages and clean the device in order for it to
be ready for the next operation immediately.
In order to avoid a corrosion it is advisable
to oil the device and especially its thread. All
coupling nipples, coupling sockets and also
loosened screw connections are to be
closed by protecting caps.
– In addition, check the components of the
device and its accessories for completion.
Keep the device in the tool box also offering
protection from mechanical damages.
The temperature must be between -20 C
and +70 C in order to exclude a damage of
the seals.
▪ Start-up of the device

1999.10.18. - ES0
MAN Diesel & Turbo
Work Card 520-01.06
Page 1 (5) Application of hydraulic tools
Edition 05

L27/38

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air - - See page 2-4
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Application of hydraulic tools.

Starting Position Hand Tools

Function of hydraulic tools 520-01.05

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : -

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

2001.08.06 - ES0
 MAN Diesel & Turbo
520-01.06 Work Card
Application of hydraulic tools Page 2 (5)
Edition 05

L27/38

Description
This working card gives the information for applica-
tion of hydraulic tools, to be used in connection with
working card 520-01.05.

Figure 1: Counter weight

2001.08.06 - ES0
MAN Diesel & Turbo
Work Card 520-01.06
Page 3 (5) Application of hydraulic tools
Edition 05

L27/38

Figure 2: Cross bolt and tierod

Figure 3: Cylinder head

2001.08.06 - ES0
 MAN Diesel & Turbo
520-01.06 Work Card
Application of hydraulic tools Page 4 (5)
Edition 05

L27/38

Figure 4: After main bearing

2001.08.06 - ES0
MAN Diesel & Turbo
Work Card 520-01.06
Page 5 (5) Application of hydraulic tools
Edition 05

L27/38

Figure 5: Connection rod

2001.08.06 - ES0
MAN Diesel & Turbo
Work Card 520-01.07
Page 1 (4) Hand Lever Pump
Edition 01

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

Safety precautions Special tools

Engine stopped Plate No. Item No. Note
Shut-off starting air
Shut off cooling water
Shut off fuel oil
Shut-off cooling oil
Stop lub. oil circulation
Press Blocking - Reset

Short Description
Application of hydraulic tools.

Starting Position Hand Tools

Related Procedure

Qualified Manpower Replacement and wearing parts

Duration in h : - Plate No. Item No. Quantity
Number : -

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

2008.08.25. -ES0
 MAN Diesel & Turbo
520-01.07 Work Card
Hand Lever Pump Page 2 (4)
Edition 01

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

Description Turn the carrying handle with counter-clockwise

rotation out of his fixing. Then turn it into the hand
Warning: lever of the pump against the stopping face.
The hand lever pump is not equipped with a pres-
sure relief valve. Attention:
Never use the pump without a mounted manome- If the carrying handle is not srewed-in into the hand
ter. Always pay attention to the given pressure of lever, it can cause injuries while using the pump.
the connected pressure consumers. Do never Open the oil filler cap and check the oil level. If nec-
exceed this pressure or the max. pressure of the cessary, fill up the tank with hydraulic oil according
hand lever pump. to IS0 VG 32. Never overfill the tank. Close the oil
Important: filler cap.
Except for hydraulic oil, never use different liquids Open the tank breather with the square wrench
such as petrol, water, diesel oil, alcohol or brake liq- (included in the scope of supply) by about one turn.
uid, since these can lead to damages or even to Now loosen the breather screw at the pump on the
destruction of the pump and/or the parts connected left side on the pump housing with an allen key SW
with it. Choose a place of assembling and operation 2,5 by about one turn. Close the depressurization
where the pump can always stand safe and firm on valve tightly. Seal the nipple on the pump with a
a horizontal plain. There should always be sufficient hose and pump at the hand lever until oil flows out
space for operating the pump. of the breather screw bladder-free. Only then are
Never handle the pump lever with oiled hands and you allowed to close the breather screw. The pump
never use hand lever extensions. Never expose the is now vented and ready for operation.
pump to great heat, fire or extreme coldness, since After each operation and for the transport, close the
this leads to damages or even destruction. Protect tank breather in order to avoid the hydraulic oil’s
the pump from falling objects and avoid hard blows running out.
or pushes.
Attention - Danger to life Pressurization
Check the manometer of the pump for the needed
▪ Open the tank breather with the square wrench
hydraulic pressure, given by an authorized person,
approx. one turn.
not to be exceeded. Make sure that the pressure
you want to generate is also admissible for all con- Remark:
nection parts. The pump is only to be operated with open tank
breather.
All pressure connections and connecting elements
have to be clean and undamaged. High-pressure ▪ Close the depressurization valve at the pump
connections from the pump to the tools have to be when turning clockwise by handoperation.
established correctly prior to any pressurization. Remark:
Disregard leads to danger to life. Please see work- The depressurization valve is designed for manual
ing card 520-01.06. operation. The use of any tools at the depressuriza-
Attention - Danger on injuries tion valve could cause damages of the valve or the
Loads being lifted by the pump may never be held valve seat.
by the pump valves alone. Use additional non- ▪ Pump at the hand lever until the wanted pres-
return valves or safety relief valves and secure the sure is achieved. Check the pressurization at
load by sufficient support against falling. the manometer and take care of possible leak-
ages.
Initial Start-up and Venting Remark:
In general and venting The pump works with two stages. The change from
the first stage to the second stage happens auto-
Please make sure that all parts of the pump, espe-
matical at a system pressure of about 30 bar.
cially the manometer and the pressure port, are in a
perfect condition. Defect parts are to be exchanged
against new ones immediately.

2008.08.25. -ES0
MAN Diesel & Turbo
Work Card 520-01.07
Page 3 (4) Hand Lever Pump
Edition 01

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

Attention: Analysis and Correction of Malfunction
The pump is not equipped with an internal pressure
relief valve. The use of a manometer and the control Correction of malfunctions
of the system pressure during pressurization is In case of malfunctions at the pump, the following
indispensable. points are to help you with the analysis of the prob-
lem and correcting it yourself.
Attention: For this, uncouple or unscrew all consumer and
Do not stand directly over the moving line of the high-pressure hoses from the pump.
pump lever. Under arising circumstances the lever
can “hit back”. To avoid accidents stand sideways Malfunction Correction
the pump. No pressurization 1. Check the oil level and, if
Attention - High-pressure hydraulic necessary, fill it up as descri-
On principle, tihen leakages occur during the pres- bed in chapter maintenance
surization, immediately release the hydraulic pres- and storage.
sure and seal the leakage or renew defect parts. 2. Close depressurization
valve.
Depressurization 3. Visual inspection whether
there are leakages. If so, seal
▪ Open the depressurization valve slowly by a them.
turn to the left.
4. Vent the pump as descri-
▪ Make sure that the hydraulic pressure at the bed in chapter initial start-up
manometer has been completely released. and venting.
Consider the returning time of the hydraulic oil.
Insufficient pressurization 1. Check the oil level and, if
(prior to any corrections, necessary, fill it up, as
Adjustment of change-over pressure from
open de-pressurization valve described in chapter main-
stage 1 to stage 2 and release hydraulic pres- teance and storage.
sure completely) 2. Close depressurization
In exeptional case, it can be useful to adjust the
change-over pressure from stage 1 to stage 2 (fac- valve.
tory adjusted at approx. 30 bar). 3. Visual inspection whether
ther are leakages. If so, seal
Below of the pressure relief valve is an adjusting
them.
screw with inner hexagon (wrench size 10 mm).
Turning out counter-clockwisely the adjusting screw 4. Vent the pump as descri-
minimizes the change-over pressure, turning in bed in chapter initial start-up
clockwise maximizes the change-over pressure. and venting.

Attention: Pressure drop 1. Visual inspection whether

Inside of the adjusting screw is another grub screw (prior to any corrections, there are leakages. If so, seal
with inner hexagon (wrench size 4 mm) to limit the open de-pressurization valve them.
stroke of the change-over piston inside of the pump and release hydraulic pres- 2. Close depressurization
block. It is absolutely necessary, to screw out the sure completely) valve.
grub screw approx. 2 times before turning the If the problem cannot be solved, please contact MAN Die-
adjusting screw! sel & Turbo
The regulation of the adjusting screw follows gradu-
ally in approx. 10° - steps. After everv adjusting
step the grub screw is to screw in until it fits closely Pressure Port
and approx. a l/4 turn to loosen. The pressure port of the pump is produced accord-
Check by carefully pumping if the change-over ing to our customers’ wishes. In addition, there is a
pressure wanted has been reached. If necessary, variety of possibilities to connect the pump with one
repeat the procedure as described above. or more pressure consumers.

2008.08.25. -ES0
 MAN Diesel & Turbo
520-01.07 Work Card
Hand Lever Pump Page 4 (4)
Edition 01

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

Attention - Danger to life
Prior to the pump’ s start-up please make sure that,
no matter which pressure port you chose, all con-
nection elements are in a perfect condition. Con-
vince yourself of the fact that these are correctly
connected and suitable for the necessary pressure.
Attention - High-pressure hydraulic
On principle, when leakages occur during the pres-
surization, immediately release the hydraulic pres-
sure and seal the leakane or renew defect parts.

Maintenance and Storage

The pump should be lubricated frequently at the
movable parts. Protect it from contamination
because dirt in the oil or in the pressure port can
lead to the pump’ s failure. A dry storage avoids the
steel parts’ getting rusty.
The storage and transport of the pump should
always be done in a horizontal position. Thus, you
avoid a possibly necessary venting of the pump
during its start-up.
For checking the oil level, please open the depres-
surization valve and let the oil completely flow back
into the tank. Open the oil filler cap and fill up
hydraulic oil according to IS0 VG 32, if neccessary.
Do not overcharge the tank. Close the oil filler cap.
The use of the pump in a dirty area requires a regu-
lar oil change. Fill the pump with clean hydraulic oil
and lubricate all moving parts (hinges) regulary.

2008.08.25. -ES0
MAN Diesel & turbo

Plate
Page 1 (9) Standard Tools for Normal Maintenance 52000-16

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Valve spring tightening 1 52000 014

device

Lifting tool for cylinder 1 52000 038

unit

Removing device for 1 52000 021

flame ring

Guide bush for piston 1 52000 045

14.01 - ES1 - Tier II - Stationary

 MAN Diesel & Turbo

52000-16 Standard Tools for Normal Maintenance Plate

Page 2 (9)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Fit and removal device 1 52000 069

for conn. rod bearing,
incl. eye screws (2 pcs)

Lifting device for cylin- 1 52000 082

der liner

Lifting device for piston 1 52000 104

and connecting rod

Piston ring opener 1 52000 190

14.01 - ES1 - Tier II - Stationary

MAN Diesel & turbo

Plate
Page 3 (9) Standard Tools for Normal Maintenance 52000-16

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Supporting device for ø316 1 52000 212

connecting rod and
piston in the cylinder
liner

153

Fork 1 52000 221

Feeler gauge 1 52000 010

Socket wrench 311 1 52000 652

218

482.5
Socket wrench and 1 52000 664
torque spanner 1 52000 676

Dismantling tool for 1 52000 035

main bearing upper
shell

14.01 - ES1 - Tier II - Stationary

 MAN Diesel & Turbo

52000-16 Standard Tools for Normal Maintenance Plate

Page 4 (9)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

444.5
Tool for fixing of marine 1 52000 060
head for counterweight

83.5

Eye screw for lifting 1 52000 036

Container complete 1 51205 318

for water washing of
compressor side

Blowgun for dry clea- 1 51210 136

ning of turbocharger

14.01 - ES1 - Tier II - Stationary

MAN Diesel & turbo

Plate
Page 5 (9) Standard Tools for Normal Maintenance 52000-16

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Water washing of tur- 1 52000 481

bine side, complete

Broad chissel 1 52000 473

Cleaning tool for fuel 1 52000 013

injector

Pressure testing tool, 050 1 52000 050

incl item 051, 053, 054 051 054

Clamping bracket for fuel 1 52000 051

injector
053
Fuel pipe 1 52000 053

Pressure pump 1 52000 054

14.01 - ES1 - Tier II - Stationary

 MAN Diesel & Turbo

52000-16 Standard Tools for Normal Maintenance Plate

Page 6 (9)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

200
Grinding device for 1 52000 074
nozzle seat

Grinding paper 1 52000 747

747
Plier 1 52000 759
637

759
Loctite 1 52000 760

760
Loctite

Extractor device for 1 52000 407

injector valve

Eye screw for lifting 1 52000 032

Combination spanner, 1 52000 772

36 mm

Crow foot, 36 mm 1 52000 784

14.01 - ES1 - Tier II - Stationary

MAN Diesel & turbo

Plate
Page 7 (9) Standard Tools for Normal Maintenance 52000-16

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Hydraulic tools com-

plete consisting of the
following 3 boxes: 52000 806

Pressure pump box 1,

consisting of:
023
Pressure pump, com- 024
1 52000 011
plete
025

Manometer 1 52000 023

026

Gasket 1 52000 024

Quick coupling 1 52000 025

Distributor 1 52000 026

059 118 633

Hydraulic tools box 2 52000 633
consisting of:

Pressure part, long 4 52000 059

M39 x 2

Pressure part, short 2 52000 072

M39 x 2

Tension screw 4 52000 118

M39 x 2

Hydraulic tightening 4 52000 263

cylinder M39 x 2
263 072

14.01 - ES1 - Tier II - Stationary

 MAN Diesel & Turbo

52000-16 Standard Tools for Normal Maintenance Plate

Page 8 (9)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

w) Hydraulic tools box 3 143 383 167 358 180/202 52000 581
consisting of:

Pressure part 2 52000 096

M24/27 x 2 581

Tension screw 2 52000 131

M24/27 x 2 096

Distribution piece, cylin- 1 52000 143

der head 371

Distribution piece, main 131 1 52000 167

bearing
246
Hose with unions for 4 52000 180
cylinder head

Hose with unions for 1 52000 202

connecting of oil pump
and distributing block

Spare parts for hydrau- 275 287 556 334 226 1 52000 226
lic tool M39 x 2 238
251
322
Spare parts for hydrau- 1 52000 238
lic tool M36 x 2

Spare parts for hydrau- 1 52000 251

lic tool M30 x 2

Spare parts for hydrau- 1 52000 322

lic tool M24 x 2

Hydraulic tightening 2 52000 246

cylinder M24/27 x 2

Hydraulic tightening 2 52000 275

cylinder M36 x 2

Hydraulic tightening 2 52000 287

cylinder M30 x 2

14.01 - ES1 - Tier II - Stationary

MAN Diesel & turbo

Plate
Page 9 (9) Standard Tools for Normal Maintenance 52000-16

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Angle piece 2 52000 358

Tommy bar 1 52000 334

Tommy bar 1 52000 556

Pressure part 2 52000 371

M36 x 2

Pressure part 2 52000 383

M30 x 2

14.01 - ES1 - Tier II - Stationary

MAN Diesel & Turbo

Plate
Page 1 (11) Additional tools 52002-06

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Fitting and removal of mono- 1 52002 031

block cylinder

Dissambly tools 1 52002 043

Fitting / removing device 1 52002 055

for injection pump

2014.03.12 - ES1 - TierII + Stationary

 MAN Diesel & Turbo

52002-06 Additional tools Plate

Page 2 (11)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Fit and removal device 1 52000 069

for conn. rod bearing,
incl. eye screws (2 pcs)

Lifting device for cylin- 1 52000 082

der liner

Lifting device for piston 1 52000 104

and connecting rod

Plier for piston pin lock 1 52000 759

ring

2014.03.12 - TierII + Stationary

MAN Diesel & Turbo

Plate
Page 3 (11) Additional tools 52002-06

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Piston ring opener 1 52000 190

ø316

Supporting device for

connecting rod and pi-
ston in the cylinder liner 1 52000 212
153

Fork 1 52000 221

221

Dismantling tool for 1 52000 035

main bearing upper
shell

Tool for fixing of marine 1 52000 060

head for counterweight

Eye screw for lifting of 1 52000 036

charge air cooler

2014.03.12 - ES1 - TierII + Stationary

 MAN Diesel & Turbo

52002-06 Additional tools Plate

Page 4 (11)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Eye screw for lifting lub- 1 52000 032

ricating oil cooler

Grinding tool for cylin- 1 52002 126

der head/liner

Max. pressure 1 52002 138

indicator, 0-250 bar
0 250

appr. 87
Handle for indicator 1 52002 498
valve
appr. 230

Testing mandrel for 1 52002 151

piston ring grooves,
6.43 mm

Testing mandrel for 1 52002 163

piston ring grooves,
8.43 mm

2014.03.12 - TierII + Stationary

MAN Diesel & Turbo

Plate
Page 5 (11) Additional tools 52002-06

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Crankshaft alignment, 1 52002 067

gauge (autolog)

1 52002 508
Mandrel for lubricating
oil cooler

Fitting device for lubri- 1 52002 521

cating oil cooler

Resetting device for 1 52002 092

hydraulic cylinder

2014.03.12 - ES1 - TierII + Stationary

 MAN Diesel & Turbo

52002-06 Additional tools Plate

Page 6 (11)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Measuring device 2 52002 533

Lifting straps for main 1 52002 545

bearing cap

Lifting handle for main 1 52002 557

bearing cap

Fit and removing de- 1 52002 569

vice for connecting rod
bearing

2014.03.12 - TierII + Stationary

MAN Diesel & Turbo

Plate
Page 7 (11) Additional tools 52002-06

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Support for connecting 1 52002 570

rod

Turning device for cylin- 1 52002 114

der unit

Grinding machine 1 52002 199

for valve seat rings

Supporting spider 1 52002 208

208
Mandrel 1 52002 209
209

Cutting tool 1 52002 210

Carbide cutting insert 1 52002 211

210 211
Wooden box
L x B x H = 450 x 380 x 190 mm

2014.03.12 - ES1 - TierII + Stationary

 MAN Diesel & Turbo

52002-06 Additional tools Plate

Page 8 (11)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Grinding machine 1 52002 222

for valve seat rings

Stone 1 52002 234

Guide 1 52002 246

234

246

Fit and removing device 1 52002 258

for valve guides

Touching bow for inlet 1 52002 582

valve

Touching bow for 1 52002 594

exhaust valve

2014.03.12 - TierII + Stationary

MAN Diesel & Turbo

Plate
Page 9 (11) Additional tools 52002-06

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Grinding tool for 1 52002 283

valves

Fitting device for valve 1 52002 295

seat rings

Plate 1 52002 317

(used with item 329)

Extractor for valve seat 1 52002 329

rings

2014.03.12 - ES1 - TierII + Stationary

 MAN Diesel & Turbo

52002-06 Additional tools Plate

Page 10 (11)

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Fit and removing 1 52002 342

device for fuel injection
pump

Setting device for 1 52002 366

fuel injection pump

Cleaning needles for fuel 1 52002 378

injector (5 pcs)

Fit and removing de- 1 52002 401

vice for cooler insert

Micrometer screw 1 52002 425

2014.03.12 - TierII + Stationary

MAN Diesel & Turbo

Plate
Page 11 (11) Additional tools 52002-06

L27/38

Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare

Closing cover (TCR20) 1 52002 486

(standard with only one
propulsion engine)

Closing cover (TCR18) 1 52002 450

(standard with only one
propulsion engine)

Lifting tool for cylinder 1 52002 474

unit (low dismantling
height)

Assembly device for 1 52002 689

sealing ring, complete

Assembly cone 1 52002 690

Expanding sleeve 1 52002 700

690 700

Assembly cone 712 724 1 52002 712

Sizing sleeve 1 52002 724

Air driven high pressure 1 52002 653

pump for hydraulic valve

2014.03.12 - ES1 - TierII + Stationary

MAN Diesel & Turbo

Plate
Page 1 (2) Hand Tools 52004-02

L16/24
L21/31, L27/38

Socket spanner set

019 Designation Size [mm]
Rachet
Extension 125
Extension 250
Universal
Socket - double hexagon 10
Socket - double hexagon 13
Socket - double hexagon 17
Socket - double hexagon 19
Socket - double hexagon 22
Socket for internal hexagon 5
Socket for internal hexagon 6
Socket for internal hexagon 7
Socket for internal hexagon 8
Socket for internal hexagon 10
Socket for internal hexagon 12
Socket - screwdriver 1.6 x 10
Socket - cross head screw 2
Socket - cross head screw 3
Item Size [mm] Socket - cross head screw 4
331 7
343 8
355 Hexagon key Combination spanner
10
367 12
379 14 Item Size [mm]
380 17 032 10
392 19 044 12
056 13 139
068 14
223 16
081 17
235 18
093 19
103 22
140 272 115 24
284 127 30
296

152

164 176 188 247 259 260

24 mm 30 mm 36 mm 8 mm 10 mm 12 mm

11.01 - ES0
 MAN Diesel & Turbo

Plate
52004-02 Hand Tools Page 2 (2)

L16/24
L21/31, L27/38
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse

019 1/E Set of tools Topnøglesæt 260 1/E Bit, hexagon socket Unbrakotop, str 12
screw, square drive
032 1/E Combination spanner, Ring-gaffelnøgle,
10 mm 10 mm 272 1/E Torque spanner, Momentnøgle,
20-120 Nm - 1/2" 20-120 Nm - 1/2"
044 1/E Combination spanner, Ring-gaffelnøgle,
12 mm 12 mm 284 1/E Torque spanner, Momentnøgle,
40-200 Nm - 1/2" 40-200 Nm - 1/2"
056 1/E Combination spanner, Ring-gaffelnøgle,
13 mm 13 mm 296 1/E Torque spanner, Momentnøgle,
30-320 Nm - 1/2" 30-320 Nm - 1/2"
068 1/E Combination spanner, Ring-gaffelnøgle,
14 mm 14 mm 331 1/E Hexagon key 7 mm Unbrakonøgle 7 mm

081 1/E Combination spanner, Ring-gaffelnøgle, 343 1/E Hexagon key 8 mm Unbrakonøgle 8 mm
17 mm 17 mm
355 1/E Hexagon key 10 mm Unbrakonøgle 10 mm
093 1/E Combination spanner, Ring-gaffelnøgle,
19 mm 19 mm 367 1/E Hexagon key 12 mm Unbrakonøgle 12 mm

103 1/E Combination spanner, Ring-gaffelnøgle, 379 1/E Hexagon key 14 mm Unbrakonøgle 14 mm
22 mm 22 mm
380 1/E Hexagon key 17 mm Unbrakonøgle 17 mm
115 1/E Combination spanner, Ring-gaffelnøgle,
24 mm 24 mm 392 1/E Hexagon key 19 mm Unbrakonøgle 19 mm

127 1/E Combination spanner, Ring-gaffelnøgle,

30 mm 30 mm

139 1/E Tee handle 1/2" square T-greb 1/2"

drive

140 1/E Ratchet, 20 mm Skralde, 20 mm

152 1/E Extension bar Forlænger

164 1/E Socket spanner, squa- Top, str 24

re drive, size 24

176 1/E Socket spanner, squa- Top, str 30

re drive, size 30

188 1/E Socket spanner, squa- Top str 36

re drive, size 36

223 1/E Combination spanner, Ring-gaffelnøgle,

16 mm 16 mm

235 1/E Combination spanner, Ring-gaffelnøgle,

18 mm 18 mm

247 1/E Bit, hexagon socket Unbrakotop, str 8

screw, square drive

259 1/E Bit, hexagon socket Unbrakotop, str 10

screw, square drive

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 /
not avail separately ikke tilgængelig alene
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder

11.01 - ES0
Operating manual

Test rig GXO-G010a / GXO-G011a

 Technical Operating manual
documentation for test rig
GXO-D001 GXO-G010a / GXO-G011a

Die Betriebsanleitung ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher
vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses
Verwendungszwecks darf die Betriebsanleitung ohne unsere vorherige Zustimmung nicht benutzt, vervielfältigt
oder Dritten sonstwie zugänglich gemacht werden.
Änderungen bleiben vorbehalten

The owner should make this operating manual available to maintenance and operating staff who should follow
the instructions it contains to prevent malfunctions or damage during operation. Other than for this purpose, the
operating manual may not be reproduced, used or disclosed to third parties by any other means without our
prior consent.
Subject to alterations and amendments

Änderungsdienst/Amendments service!

Falls Sie in den Änderungsdienst von L'Orange aufgenommen werden möchten, können Sie
uns das mit einer Postkarte an untenstehende Adresse mit folgenden Angaben mitteilen:

If you would like to be included in the L'Orange amendments service, send a postcard to the
address below including the following details:

Name / Name Betriebsanleitung für GXO-G010a / -G011a

Firma / Company
Straße / Street GXO-D001
Postfach / PO Box Operating manual for GXO-G010a / -G011a
PLZ / Postcode / Zip code
Ort / City GXO-D001/E
Land / Country
Betriebsanleitungs-Nr. / Operating manual No.

© 2007
L'Orange GmbH
Abteilung KVAM
Postfach 40 05 40
70405 Stuttgart
Germany
 Technical Operating manual
documentation for test rig
GXO-D001 GXO-G010a / GXO-G011a
Contents

Section Page
1 Structure of the test rig (exterior) .....................................................................................................1
2 Structure of test rig (interior) ............................................................................................................2
3 Handling the test rig.........................................................................................................................5
4 Maintenance ....................................................................................................................................6
5 General safety instructions ..............................................................................................................7
5.1 Use in accordance with purpose.............................................................................................7
5.2 Handling the system ...............................................................................................................7
5.2.1 Hazards in handling the test rig ..........................................................................................7
5.2.2 Safety measures in normal operation .................................................................................7
5.2.3 Hazards from electrical energy ...........................................................................................7
5.2.4 Hazards from hydraulic energy...........................................................................................8
5.2.5 Servicing – Maintenance – Troubleshooting.......................................................................8
5.2.6 Organizational measures....................................................................................................8
5.3 Staff ........................................................................................................................................9
5.3.1 Notes relating to staff..........................................................................................................9
5.3.2 Outside normal operation ...................................................................................................9
5.4 General operating instructions................................................................................................9
5.4.1 How to behave....................................................................................................................9
5.4.2 Rules for operation .............................................................................................................9
6 Commissioning ..............................................................................................................................10
6.1 Transport ..............................................................................................................................10
6.2 Setting up .............................................................................................................................12
6.2.1 General information ..........................................................................................................12
6.2.2 Bench-top mounting (GXO-G011a) ..................................................................................12
6.2.3 Floor mounting (GXO-G010a) ..........................................................................................14
6.3 Commissioning the hydraulic system ...................................................................................16
6.4 Commissioning the electrical system....................................................................................17
6.5 Preparations for commissioning the test rig..........................................................................18
7 Technical data ...............................................................................................................................22
7.1 GXO-G010a (floor-mounted system)....................................................................................22
7.2 GXO-G011a (bench-top system) ..........................................................................................22
8 Parts list and exploded drawing.....................................................................................................23
 Technical Operating manual
documentation for test rig
GXO-D001 GXO-G010a / GXO-G011a

1 Structure of the test rig (exterior)

Item Part Item Part Item Part

1.4 Selector switch for mode 5 Relief valve 17.3 Plexiglass tube
(sight glass)
3 Pressure gauge 15.1 Cover 17.6 Extraction
(pressure display bar/psi) (tray) (spray container)
4 Hand lever 15.2 Knurled screw 17.9 Oil collector
(hand pump) (to fix cover in position)

a Rotary receiver d Release lever f Oil sight glass

(pump/valve) (rotating mechanism)
b Height adjustment e Storage compartments g Switch
(extraction)
c Socket
(test line)

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2 Structure of test rig (interior)

Item Part Item Part Item Part

1 Booster 4 Hand pump 15.4 Mesh filter

a Rotary receiver (pump/valve) b Test oil reservoir c Oil sight glass

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Item Part Item Part Item Part

6 Tube 9 Tube 13b Hose
Pump – booster Booster – pressure gauge Oil container – pump
7 Tube 13a Hose 13c Hose
Booster – test line connection Relief valve – test oil reservoir Booster – test oil reservoir
8 Tube
Booster – relief valve

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The test rig was developed for checking leaks, pressure-testing injection, measuring the
pressure drop of injection valves and for assembling/dismantling all L'O devices for medium-
speed large diesel engines.

There are two versions: GXO-G010a has a base for mounting directly to the floor, whilst
GXO-G011a is intended to be fitted to a bench. Both devices have identical functions and
operation.

GXO-G010a GXO-G011a

The test rig has a safety valve (integrated in the booster) which opens at 900 bar!

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3 Handling the test rig

This operating manual applies primarily to the professional assembly/dismantling of L'O

devices, in particular injection pumps and injection valves. The instructions below must be
followed.

• In the event of malfunctions, the test rig must be professionally examined and repaired
with the utmost care by specialist staff. We therefore recommend that you make use of
the fitter service set up by L'Orange or take the test rig to a L'Orange customer service
center.

• L'Orange is unable to accept any liability for any damage caused by independent
assembly or repair work performed on the test rig.

• In the event of special circumstances requiring immediate work on the test rig, proceed in
accordance with the instructions in Assembly Instruction GXO-D002.

• The components of hand pump GCO-G005d are precision-engineered to match and can
consequently only be replaced as an entire unit (paired).

• Repair work may only be performed using the tools intended for the purpose.

• The test rig serves solely for testing, assembling and dismantling components up to a
maximum weight of 120 kg. All components are to be professionally attached to the
receiver and secured against rotation using the locator angle and screws.

• All locator angles for the preceding type (GUO, GXO) will fit the new test rigs without
modification.

• The function test (pressure drop time, opening pressure, leak test) of injection valves is
meaningful only up to a needle diameter of Ø 12 mm (e.g. VVO, VWM). The function test
on larger injection valves should be performed on test rig GXO-G004.

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4 Maintenance

The test rig is largely maintenance-free. Moving parts are subject to natural wear which
experience shows is very limited. However, the wear characteristics of the components
depend largely on the test rig being handled and cared for properly. To ensure smooth
operation of the test rig in the long term, please note and comply with the following care and
maintenance instructions.

• Clean the outside of the test rig after every use.

• Subject all components to a visual inspection once a month – damaged or worn

components should be replaced by specialist staff if required.

• All electrical components should be inspected for damage once a month. Likewise check
monthly that plug connections are tight – damaged components should be replaced by
specialist staff if required.

• Check all hydraulic lines and components once a month for pressure loss and damage.
The lines must be located firmly in their screwed connections to prevent them coming
loose – damaged components should be replaced by specialist staff if required.

• Check six-monthly that mechanical components have not come loose and are tight – if
required, components should be adjusted and tightened up.

• Check once a month that safety devices are working properly.

• All moving parts on the device should be greased. The locking bolt and sliding bar on the
spray container should also be oiled occasionally.

• Check the oil collector daily. Empty the collector if necessary. Used oil must be disposed
of properly and may not, under any circumstances, be reused.

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5 General safety instructions

5.1 Use in accordance with purpose

The test rig is solely for assembling/dismantling injection pumps which do not exceed a total
maximum weight of 120 kg (injection pump incl. valve) and for testing injection valves up to
size "VVO".

The owner of the system is responsible for those setting up, operating or maintaining the
device and for third parties following the safety precautions outlined in this operating manual.

L'Orange hereby refuses to accept any liability for damage to those operating or setting up
the device, to maintenance staff, to the company and/or to other third parties if the system is
used in any way not covered by "use in accordance with purpose", unless L'Orange causes
such damage deliberately or as a result of gross negligence.

5.2 Handling the system

5.2.1 Hazards in handling the test rig

The test rig is built in accordance with the state of the art and satisfies recognized safety
regulations. Nevertheless, its use can still present a hazard to the life and limb of the user or
of third parties, as well as damage to the system or to other material resources. The system
should therefore only be used in accordance with purpose and when it is in a perfectly safe
condition. Faults which may impair safety should be eliminated immediately and avoided
during operation.

5.2.2 Safety measures in normal operation

Operate the test rig only if all the safety devices are fully functional. Check the system for
externally visible damage and always check that the safety devices are working before
starting operation.

Before assembling, dismantling or modifying any circuit:

switch off the power supply and depressurize the test rig.
Follow the general safety instructions of DIN 58126 and VDE 0100.

5.2.3 Hazards from electrical energy

Once maintenance work is complete, check that the safety devices are working properly.
Only a professional trained electrician or electronics engineer may perform any work on the
electrical supply.

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5.2.4 Hazards from hydraulic energy

Keep away from the spray jet during the function test (pressure build-up) – risk of blood
poisoning!

Observed the permitted opening pressure for the injection valve in question (see catalogue
sheet).

5.2.5 Servicing – Maintenance – Troubleshooting

During the warranty period, servicing and maintenance work will be performed within the
scope of the maintenance contract. Make sure that the specified setting and servicing work is
performed at the prescribed intervals. Secure the hydraulic and electrical systems from being
switched on unintentionally.

The test rig must be disconnected from the power supply and depressurized for all
maintenance, servicing and repair work. Check that all screwed connections undone in the
course of maintenance, servicing and repair work are firm.

5.2.6 Organizational measures

All safety devices provided are to be checked regularly.

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5.3 Staff

5.3.1 Notes relating to staff

• The test rig may only be operated by persons who have received instruction. This applies
to both operation and the safety devices of the test rig.
• Wear safety footwear when working on the test rig.
• Wear oil-resistant clothing.
• Wear safety glasses.
• Wear oil-resistant gloves and clothing.
• Avoid several people working on maintenance and set-up tasks at the same time.
• Naked flames and smoking are forbidden within a radius of 5 m of the test rig!

5.3.2 Outside normal operation

Activities involved in maintaining, servicing or repairing the system may be performed only by
people with adequate specialist qualifications.

5.4 General operating instructions

The test rig demands some rules of operation which must be complied with. If these rules are
ignored, it is possible for faults to arise in the testing process and hazards to physical health
cannot be ruled out. You are strongly advised to follow the rules below.

5.4.1 How to behave

• Naked flames and smoking are absolutely prohibited at the test rig and within a radius of
5 m.
• It is prohibited to reach into the spray container (plexiglass tube) during the testing
process.
• Stations should be made safe by mechanical means in the event of relatively large groups
of spectators.
• It is prohibited to pull out any live cable connection.
• Water of any kind is to be kept away from the system.
• Test lines should be carefully examined for cracks or leaks before each use.

5.4.2 Rules for operation

• The test rig may only be operated by people who have received instruction.
• Operation should be in accordance with the operating manual.
• Prevent unsupervised operation of any equipment.

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GXO-D001 GXO-G010a / GXO-G011a
6 Commissioning

6.1 Transport

When the test rig is delivered, ensure that it is only transported using suitable transportation
equipment. The GXO-G010a weighs approx. 150 kg and the GXO-G011a approx. 75 kg.
The routes to be taken should be cleared for transport and be accessible for the
transportation equipment. If appropriate, put up warning signs or barrier tape.

Take care when opening the transport box, preventing extra components like the test oil
supplied from falling out. Once the transport box is open and any additional components
have been removed, the test rig can be removed and taken to its final location.

Please check that all screwed connections are tight. Vibration during transport may have
caused them to come loose. The test rig may not be gripped by its feet and certainly not
under the feet – increased risk of crushing or trapping.

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State in which GXO-G010a delivered

Canister [b] containing the test oil is in the

base of the test rig.

The lever for the pump is enclosed with the

delivery and needs to be fitted for com-
missioning [a].

State in which GXO-G011a delivered

The lever for the pump is enclosed with the

delivery and needs to be fitted for com-
missioning [a].

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6.2 Setting up

6.2.1 General information

The test rig should be screwed to the floor (GXO-G010a) or bench (GXO-G011a) at its
intended location. In addition, the workbench should likewise be affixed to the floor to prevent
tipping over. A loadbearing/solid floor is a prerequisite for smooth assembly and operation.

An appropriate gap should be planned between the test rig and the wall.
Keep dust and dirt away from the test rig (cover).

6.2.2 Bench-top mounting (GXO-G011a)

• Remove screw [15.2].

• Remove cover [15.1].

• Fit dismantling aid [a] and hold the body

[15] steady using a crane.

• Undo and remove screws [b].

• Carefully lift body [15] using the crane

and place it aside.

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• The baseplate [a] is now in front of you

ready for assembly.

• Transfer the bores in the baseplate as

shown in the sketch to the workbench
and drill into the worktop using a
Ø 12 mm bit.

Line A represents the edge of the bench!

• Screw the baseplate firmly to the bench

using M10 screws (length depending on
the thickness of the workbench). The
screws must be pushed in from above
and tightened up from underneath with
washers and a nut.

• Put body [15] on the baseplate and

attach with screws [b].

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6.2.3 Floor mounting (GXO-G010a)

• Remove screw [15.2].

• Remove cover [15.1].

• Align the test rig and transfer the bore

positions for baseplate [1] to the floor.

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• Fit dismantling aid [a].

• Carefully lift subframe [20] using a crane

and place it aside.

• Drill holes in the floor.

• Use the crane to return subframe [20] to

its assembly position.

• Remove the dismantling aid [a].

• Depending on the substrate, attach the

baseplate of the test rig with four screws
[a].

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6.3 Commissioning the hydraulic system

The owner commissions the rig independently. The procedure required to do so is described
below. A prerequisite is that the test rig is already firmly screwed as described in the previous
section.

• Remove transport sealing plug [a].

• Fit filter [15.4].

• Pour Fuchs Renotest test oil into the test

oil reservoir to at least oil sight glass [a]
(capacity approx. 3.5 liters).

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• Fit cover [15.1] and fix in position with

screw [15.2].

• Pump lever [4] until test oil escapes from

connection [a] without bubbles.

6.4 Commissioning the electrical system

• Connect the cable for non-heating

appliances supplied to socket [a] and
supply with electrical power.

Extraction operates at a voltage of 230 V

and cannot be switched to 110 V!

The fitted plug can be changed if

required, but this should be done only by
a qualified specialist. The connection for
this must be fused at a rating to suit the
consumers. To prevent problems in oper-
ation, we strongly recommend separate
fuse protection for the test rig.

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6.5 Preparations for commissioning the test rig

If rotary receiver [1] needs to be swivelled, follow the instructions below.

• 360° rotation

The swivel restriction can be released

using release lever [b]. If the lever is
moved to the right and held there, rotary
receiver [a] can be turned through 360°.

Warning, risk of injury!

The valve can rotate in an uncontrolled
manner once the swivel restriction is
released.

• 12.5° rotation

If lever [b] is moved only briefly to the

right and then returned to the left-hand
position, rotary receiver [a] can be turned
through 12.5°.

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Make the following preparations every time you use the test rig.

• Follow the safety instructions!

• Only staff who have received instruction

may operate the test rig.

• The test rig must be depressurized com-

pletely using relief valve [5].

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• Use height adjuster [c] to move the spray

container right to the bottom and secure
the lever in the lowest latching position
[b].

• Fit valve receiver on rotary receiver [a].

• Fit valve in receiver.

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• Connect the injection valve to connector

[a] of the test rig using the corresponding
test line. Tighten screwed connections
firmly!

• Use height adjuster [b] to move the spray

container upwards until the injection
nozzle of the valve is inside the plexi-
glass tube. Secure the lever in one of the
latching positions!

• Switch on extraction.

• You can now select operating mode.

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7 Technical data

7.1 GXO-G010a (floor-mounted system)

Purpose: medium-speed diesel engines

Weight: GXO-G010a = 146 kg
Dimensions: height: 1130 mm
width: 440 mm excl. spray container
width: 670 mm incl. spray container
depth: 510 mm excl. spray container
depth: 560 mm incl. spray container
Piston diameter: 8 mm
Safety valve: opening pressure = 900 bar
Pressure gauge: display up to 1000 bar / 14400 psi
Test oil: Fuchs Renotest LO
Test oil viscosity: 4.5 cSt/40°C
Test oil reservoir: approx. 3.5 liters
Test oil line: connecting thread 24 x 1.5
Maximum load: 120 kg (receiver)

7.2 GXO-G011a (bench-top system)

Purpose: medium-speed diesel engines

Weight: GXO-G011a = 71 kg
Dimensions: height: 330 mm excl. spray container
height: 1120 mm incl. spray container
width: 440 mm excl. spray container
width: 670 mm incl. spray container
depth: 510 mm excl. spray container
depth: 560 mm incl. spray container
Piston diameter: 8 mm
Safety valve: opening pressure = 900 bar
Pressure gauge: display up to 1000 bar / 14400 psi
Test oil: Fuchs Renotest LO
Test oil viscosity: 4.5 cSt/40°C
Test oil reservoir: approx. 3.5 liters
Test oil line: connecting thread 24 x 1.5
Maximum load: 120 kg (receiver)

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8 Parts list and exploded drawing

GXO-G011a GXO-G010a

Weight Weight
Item Pcs. Part L'O-No. g
Item Pcs. Part L'O-No. g

Test rig GXO-G011a (replacement for all GUO-G...) 71000 15,2 Screw D464-M8x16 10
1 Booster, compl. GXO-U058 13500 15,3 Perforated plate GXO-T133 700

1,1 Booster GXO-U056 12000 15,4 Filter screw GCO-T065 60

1,2 4 Connection piece GXO-T173 30 15,5 Mesh filter FSH-1 5

1,3 2 Screw D912-M10x40-12.9 35 17 Spray container GXO-U065 7150

1,4 Valve actuator GXO-U057 1350 17,1 Cover GXO-U067 1100

3 Gauge FMA-160.1000AH 1100 17,2 Perforated plate GXO-T159 700

4 Hand pump Ø8 GCO-G005d 2700 17,3 Plexiglass tube GXO-T155 1350

5 Relief valve GXO-U059 350 17,5 3 Screw D7380-M8x25 15

6 Tube GXO-T126 110 17,6 Spray container GXO-U066 3900

7 Tube GXO-T127 130 17,8 Screw D7380-M8x20 12
8 Tube GXO-T128 130 17,9 Collector GUO-T041 75

9 Tube GXO-T129 125

10 9 Screw D7380-M6x20 7 Test rig GXO-G010a (replacement for all GXO-G003...) 146000

11 2 Screw D7380-M5x12 5 20 Lower section GXO-U055 57500

12 2 Screw D912-M8x60-12.9 30 20,1 4 Screw D912-M10x20-10.9 25

13 3 Hose GXO-T130 L = 1200 mm 50 20,2 Screw D7380-M8x25 15
15 Body GXO-U062 44150

15,1 Oil tray GXO-U063 2150 not specified items like GXO-G011a 06/07

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