L28 32H Manual PDF

Instruction Book
Engine Type
L28/32H
Ed.03H,94.47
Order No
Instruction book for:
STX-MAN B&W Diesel Identification No for Instruction Book.

Identification No for Descriptions: 000.00
Function
Section No
Identification No for Working Cards: 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 600.50
This book must not, neither wholly nor party, be copied, reproduced, made public or in any other way made available to
any third party without the written consent of stx-corporation.
If the instruction books are delivered in other languages than English and doubts about the content arise, the English text
is valid.
08031-0D/H5250/94.09.07
HEAD OFFICE DIESEL ENGINE SALES AFTER SERVICE (A/S) PART SALES
641-315 641-315 641-050 641-315

80,Seongsan-Dong 80,Seongsan-Dong 452-7,Nae-Dong 80,Seongsan-Dong
Changwon,Kyungnam Changwon,Kyungnam Changwon,Kyungnam Changwon,Kyungnam
Korea(ROK) Korea(ROK) Korea(ROK) Korea(ROK)
Tell: 82-55-280-0114 Tell: 82-55-280-0540 Tell: 82-55-280-0600 Tell: 82-55-280-550 ~558

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95.02
INSTRUCTIONS FOR ENGINE TYPE L28/32H
Introduction
This instruction book has been prepared to provide general guidance on operation and maintenance and
to give a description of the design of a standard version of the above engine type. Deviations may be
found in a specific plant. The book may also be used for reference purposes when ordering spares.
The first five sections (600-604) of the book serve as a guide on the operation of the engine, and the next
fifteen sections (605-619) contain technical descriptions, spare parts illustrations with pertaining parts lists
as well as overhauling procedures. The last section (620) comprises tools. The engine is divided into a
number of main components/assemblies, each one described in a section of this book (sections 605-619).
Each of these sections is prefaced by a short technical description, followed by spare parts illustrations
and parts lists. Later the overhauling procedures are to be found, each initiated by a Data-sheet
specifying the data relevant for the specific procedure.
As reliable and economical operation of the diesel engines is conditional on correct operation and
maintenance, it is essential that the engine-room personnel is fully acquainted with the contents of this
book.
This book, or parts of it, must not be copied without the written permission of MAN B&W Diesel A/S,
Holeby.
ORDERING OF SPARE PARTS, ENGINE TYPE L28/32H
Whenever spare parts are ordered (or reference is made in correspondance etc.) the following data must
be indicated for the particular engine:
1. Name of plant
2. Engine No. - -, built by
3. Illustration plate number (complete with Ed. figures)
4. Item No.
5. Quantity required (and description)
This data is used by us to ensure supply of the correct spare parts for the individual engines, even though
the spare parts illustrations contained in this book may not always be in complete accordance with the
individual components of a specific engine.
Index
Page 1 (1) Engine Data 600S
L28/32H
Description
Main Data for GenSets ....................................................................................................... 600.00
Introduction ................................................................................................................ 600.01(06H)
Safety ........................................................................................................................ 600.02(06H)
Cross Section ............................................................................................................ 600.05(02H)
Key for Engine Designation ....................................................................................... 600.10(01H)
Designation of Cylinders ........................................................................................... 600.11(01H)
Engine Rotation Clockwise ........................................................................................ 600.12(01H)
Code Identification for Instruments ........................................................................... 600.20(01H)
Introduction to Planned Maintenance Program ......................................................... 600.24(02H)
Planned Maintenance Program ................................................................................. 600.25(16H)
Operating Data and Set Points .................................................................................. 600.30(22S)
Data for Pressure and Tolerance .............................................................................. 600.35(08H)
Data for Torque Moment ............................................................................................ 600.40(15S)
Declaration of Weight ................................................................................................ 600.45(05H)
Ordering of Spare Parts ............................................................................................ 600.50(01H)
Service Letters .......................................................................................................... 600.55(01H)
Conversion Table ...................................................................................................... 600.60(01H)
Basic Symbols for Piping ........................................................................................... 600.65(01H)
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Page 1 (1)
Main Data for GenSets 600.00
Main Data for Engine Type ...................................................... L28/32H

...................................
Engine Nos. ........................................... x
...................................
.............................................................. ...................................
Number of cylinders .............................. x
...................................
Cycle ..................................................... 4 stroke
...................................
Cylinder bore ......................................... 280 mm
...................................
Stroke .................................................... 320 mm
...................................
Engine speed ........................................ x
...................................
Engine output (on flywheel) ................... x
...................................
Compression ratio ................................. 13.3 : 1
...................................
Max. combustion pressure .................... 130 bar
...................................
Firing order ............................................ x
...................................
Rotation ................................................. x
...................................
Main Data for Alternator Make ..................................................... x

...................................
Type ...................................................... x
...................................
Serial No. for engine No. x .................... ...................................
Serial No. for engine No. x .................... ...................................
Serial No. for engine No. ....................... ...................................
Capacity ................................................ x
...................................
Rating .................................................... x
...................................
Voltage .................................................. x
...................................
Frequency ............................................. x
...................................
Power factor .......................................... x
...................................
Main Data for Turbocharger Make ..................................................... MAN

...................................
Type ...................................................... x
...................................
Serial No. for engine No. x .................... x
...................................
...................................
08028-0D/H5250/94.08.12
Main Data for Governor Make ..................................................... Woodward

...................................
Type ...................................................... x
...................................
...................................
...................................
92.06
Description
Introduction 600.01
Page 1 (1)
Edition 06H
General
Description
This instruction book earn the purpose to provide Reliability and operation economy of the plant will to
general information for operation and maintenance, a great extent depend on correct operation and
to describe the design and to be used for reference proper maintenance.
when ordering spare parts.
Therefore it is essential that the engine room per-
sonnel in addition to basic knowledge of diesel
engine machinery installations is fully acquainted
with the contents of the instructions.
The book is a basic instruction manual for the

particular engine supplied with plant-adapted infor-
Section 605-619 mation such as principle media-system drawings,
electric wiring diagrams and test bed reports.
Spare parts plates
The first five sections (600-604) of the book serve as

a guide on the operation of the engine, and the next
Working card
fifteen sections (605-619) contain technical descrip-
tions, spare parts illustrations with pertaining parts
lists as well as working cards.
Description
The last section (620) comprises tools.
The engine is divided into a number of main compo-

nents/assemblies, each of which is described in a
section of this book (section 605-619).
Each of these sections starts with technical de-

scriptions of the systems/components, followed by
Fig. 1. Structuring of instruction book.
working cards. Later the spare parts illustration
plates and parts lists are to be found.
08028-0D/H5250/94.08.12
91.12 - ES0S
Description
Safety 600.02
Page 1 (2)
Edition 06H
General
General Spares
Proper maintenance, which is the aim of this book, Large spare parts should, as far as possible, be
constitutes the crucial point in obtaining optimum placed well strapped near the area of application and
safety in the engine room. The general measures accessible by crane. The spare parts should be well
mentioned here should therefore be a natural routine preserved against corrosion and protected against
to the entire engine room staff. mechanical damage. The stock should be checked
at intervals and replenished in time.
Cleanliness
Light
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the Ample working light should be permanently installed
engine room when the ship is in port, the ventilation at appropriate places in the engine room, and port-
should be stopped and ventilating ducts, skylights, able working light, in explosion-proof fittings, should
and doors in the engine room should be closed. be obtainable everywhere.
In particular, welding or work which causes spread-

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

liquids or gases. The dismantling of parts may cause
If the crankcase is opened before the engine is cold, springs to be released.
welding and the use of naked light will involve the risk
of explosions and fire. The same applies to inspec- The removal of fuel valves (or other valves in the
tion of oil tanks and the space below the fooler. cylinder head) may cause oil to run down to the
Attention is furthermore drawn to the danger of fire piston crown, and if the piston is hot, an explosion
when using paint and solvents with a low flash point. may then blow out the valve.
Porous insulating material drenched with oil from
leakages is easily inflammable and should be re- When testing fuel valves with the hand pump, do not
newed. See also: "Ignition in crankcase" in section touch the spray holes, as the jet may pierce the skin.
603. Think out beforehand which way the liquids, gases or
flames will move, and keep clear.
08028-0D/H5250/94.08.12
Order
Crankcase work
Hand tools should be placed easily accessible on
tool boards. Special tools should be fastened to tool Check beforehand that the starting air supply to the
panels (if supplied) in the engine room close to the engine is shut off.
area of application. No major objects must be left
unfastened, and the floor and passages should be
kept clear.
91.12 - ES0U
600.02 Safety Description
Edition 06H Page 2 (2)
General
Feeling over Turning with air
Whenever repairs or alterations have been made to After prolonged out-of-service periods or overhaul
the running gear, apply the "Feel-over sequence" work which may involve a risk of accumulation of
until ensured that there is no undue heating, oil-mist liquid in the combustion spaces, turning with open
formation, blow-by, or failure of cooling water or indicator cocks should always be effected, through
lubricating oil systems. at least two complete revolutions.
Feel-over sequence Check and maintain
Feel-over after 5-15 and 30 minutes' idle running and Lubricating oil condition, filter elements and
finally when the engine is running at full load. See measuring equipment.
also "Starting-up sequence" in the section 602.
91.12 - ES0U
Description 600.05
Page 1 (1) Cross Section Edition 06H
L28/32H
08028-0D/H5250/94.08.12
99.40 - ES1
Description 600.10
Page 1 (1) Key for Engine Designation Edition 01H
General
Engine Type Identification
The engine types of the MAN B&W Holeby programme are identified by the following figures:
6 L 28/32 H MCR
No of cylinders
5, 6, 7, 8, 9
12, 16, 18
Engine Type
L : In-line
V : V-built
Cyl. diam/stroke
16/24 : 160/240
23/30 : 225/300
27/38 : 270/380
28/32 : 280/320
32/40 : 320/400
Design Variant
Rating
08028-0D/H5250/94.08.12
MCR : Maximum continuous rating

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

08028-0D/H5250/94.08.12
89.17 - ES1S-L
Description
Engine Rotation Clockwise 600.12
Page 1 (1) Edition 02H
General
08028-0D/H5250/94.08.12
98.18 - ES1
Description
Code Identification for Instruments 600.20
General
Symbol explanation:
Measuring device
TI
Locally reading
40
Temperature Indicator
No. 40 *
Measuring device
PI Sensor mounted on engine/unit
22 Reading/identification mounted in a panel on the engine/unit
Pressure Indicator
No. 22 *
Measuring device
TAH Sensor mounted on engine/unit
12 Reading/identification outside the engine/unit
Temperature Alarm High

No. 12 *
* Refer to standard location and text for instruments on the following pages.
Specification of letter code for measuring devices
1 st letter Following letters
F Flow A Alarm
L Level D Differential
P Pressure E Element
S Speed H High
08028-0D/H5250/94.08.12
T Temperature I Indicating
U Voltage L Low
V Viscosity S Switching, Stop
Z Position T Transmitting
X Failure
92.03 - ES1U
600.20 Code Identification for Instruments Description
General
Standard text for instruments
Diesel engine/generator
LT Water System
01 inlet to air cooler 05 outlet from alternator

02 outlet from air cooler 06 outlet from fresh water cooler (SW)
03 outlet from lub. oil cooler 07 inlet to lub. oil cooler
04 inlet to alternator 08 inlet to fresh water cooler (SW)
09
HT Water System
10 inlet to engine 15
11 outlet each cylinder 16 outlet turbocharger
12 outlet from engine 17 outlet fresh water cooler
13 18 inlet fresh water cooler
14 19
Lubricating Oil System
20 inlet to cooler 25 prelubricating

21 outlet from cooler / inlet to filter 26 inlet rocker arms and roller guides
22 outlet from filter / inlet to engine 27 intermediate bearing / generator bearing
23 inlet to turbocharger 28 level in base frame
24 sealing oil - inlet engine 29 main bearings
Charging Air System
30 inlet to cooler 35 surplus air inlet

31 outlet from cooler 36 inlet to turbocharger
32 jet assist system 37
33 outlet from TC filter / inlet to TC compressor 38
34 39
Fuel Oil System

08028-0D/H5250/94.08.12
40 inlet to engine 45
41 outlet from engine 46
42 leakage 47
43 inlet to filter 48
44 outlet sealing oil pump 49
92.03 - ES1U
Description
Code Identification for Instruments 600.20
General
Cooling Oil System
50 inlet to fuel valves 55

51 outlet from fuel valves 56
52 57
53 58
54 59
Exhaust Gas System
60 outlet cylinder 65
61 outlet turbocharger 66
62 inlet turbocharger 67
63 68
64 69
Compressed Air System
70 inlet to engine 75 micro switch for turning gear

71 inlet to stop cylinder 76
72 inlet to balance arm unit 77
73 control air 78
74 inlet to reduction valve 79
Load Speed
80 85 micro switch for overload

81 overspeed 86
82 87
83 88 index - fuel-pump
84 89 turbocharger speed
90 engine speed
Miscellaneous
91 Natural gas - inlet to engine 95 voltage

92 96
08028-0D/H5250/94.08.12
93 97
94 98
99
92.03 - ES1U
Description
Introduction to Planned Maintenance Programme 600.24
Page 1 (1)
Edition 02H
General
General 4. Related procedures - indicates other works,

depending on this work - or works which would be
The overhaul intervals are based on operation on a 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
for accomplishing the work.
In the long run it is not possible to obtain a secure and
optimal economic running without an effective main- The stated consumption of hours is only intended as
tenance system. guide.
With the structure and amount of information in the Experience with the specific station/crew may lead to
maintenance programme, it can be integrated in the a bringing up-to-date.
entire ship's/power station's maintenance system or
it can be used separately. 6. Refers to data, which are required for carrying
out the work.
The crux of the maintenance system is the key
diagram, see page 600.25, indicating the inspection 7. Special tools, which must be used. Please note
intervals for the components/systems, so that the that not all tools are standard equipment.
crew can make the necessary overhauls, based on
the engines' condition and/or the time criteria. 8. Various requisite hand tools.
The stated, recommended intervals are only for 9. Indicates the components/parts, which it is
guidance as different service conditions, the quality advisible to replace during the maintenance work.
of the fuel oil and the lubricating oil, treatment of the Please note, that this is a condition for the intervals
cooling water, etc, will decisively influence on the stated.
actual service results and thus the intervals between
necessary overhauls.
Experience with the specific plant/crew is to be used

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

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

if any, before the maintenance work can start.
Fig 1. Guidance instruction for working cards.
94.35 - ES0S
Description
Operation Data & Set Points 600.30
L28/32H
Normal Value at Full load Alarm Set point Autostop of engine

Temp. before cooler SAE 30 TI 20 60-75° C TAH 20 90° C
(outlet engine) SAE 40 TI 20 65-82° C TAH 20 100° C
Temp. after cooler SAE 30 TI 22 45-65° C TAH 22 75° C TSH 22 85° C
(inlet engine) SAE 40 TI 22 50-72° C TAH 22 85° C TSH 22 95° C
Pressure after filter (inlet eng) PI 22 3-4 bar PAL 22 3 bar PSL 22 2.5 bar
Elevated pressure i.g. when
centrifugal filter installed PI 22 4-5 bar PAL 22 4 bar PSL 22 2.5 bar
Pressure drop across filter PDAH 21-22 0.5-1 bar PDAH 21-22 1.5 bar
Prelubricating pressure PI 25 0.1-0.5 bar LAL 25 level switch
Pressure inlet turbocharger PI 23 1.5 ±0.2 bar
Lub. oil, level in base frame LAL 28/LAH 28 low/high level
Temp. main bearings TE 29 75-85° C TAH 29 95° C
Fuel Oil System

Pressure after filter MDO PI 40 2-3 bar PAL 40 1.5 bar
HFO PI 40 (A) PAL 40 4 bar
Leaking oil LAH 42 leakage
Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar (C)
Press. nozz. cool. oil, outlet eng. TI 50 80-90° C (C)
Cooling Water System

Press. LT-system, inlet engine PI 01 1-2.5 bar PAL 01 0.4 bar + (B)
Press. HT-system, inlet engine PI 10 1-3.0 bar PAL 10 0.4 bar + (B)
Temp. HT-system, inlet engine TI 10 60-75° C
Temp. HT-system, outl. cyl.units TI 11 70-85° C
Temp. HT-system, outlet engine TAH 12 90° C TSH 12 95° C
Temp. raise across cyl. units max. 10° C
Exhaust Gas and Charge Air

Exh. gas temp. before TC TI 62 425-475° C TAH 62 550° C
Exh. gas temp. outlet cyl. TDAH 60 average ±50° C
Exh. gastemp. after TC TI 61 275-350° C TAH 61 500° C
Ch. air press. after cooler PI 31 2-2.5 bar
Ch. air temp. after cooler TI 31 35-55° C TAH 31 65° C

Press. inlet engine PI 70 7-9 bar PAL 70 7 bar
08028-0D/H5250/94.08.12
Speed Control System

GenSets for 60 Hz
Mechanical SSH 81 825 rpm
Elec. SI 90 720 rpm SAH 81 815 rpm SSH 81 815 rpm
GenSets for 50 Hz
Turbocharger speed SI 89
Specific plants will not comprise alarm equipment and autostop for all parameters listed above.
For specific plants additional parameters can be included.
For remarks to some parameters, see overleaf.
*** To be chosen after test running on test bed and site.
02.43 - ES1
600.30 Operation Data & Set Points Description
L28/32H
Remarks to individual Parameters B. Cooling Water Pressure, Alarm Set Points.
As the system pressure in case of pump failure will

A. Fuel Oil Pressure, HFO-operation. depend on the height of the expansion tank above
the engine, the alarm set point has to be adjusted to
When operating on HFO, the system pressure must 0.4 bar plus the static pressure.
be sufficient to depress any tendency to gasification
of the hot fuel.
C. Nozzle Cooling Oil System
The system pressure has to be adjusted according
to the fuel oil preheating temperature. The nozzle cooling oil system is only applied for
stationary engines.
08028-0D/H5250/94.08.12
02.43 - ES1
Description
Operation Data & Set Points 600.30
L28/32H
Normal Value at Full load Alarm Set point Autostop of engine

Temp. before cooler SAE 30 TI 20 60-75° C TAH 20 90° C
(outlet engine) SAE 40 TI 20 65-82° C TAH 20 100° C
Temp. after cooler SAE 30 TI 22 45-65° C TAH 22 75° C TSH 22 85° C
(inlet engine) SAE 40 TI 22 50-72° C TAH 22 85° C TSH 22 95° C
Pressure after filter (inlet eng) PI 22 3-4 bar PAL 22 3 bar PSL 22 2.5 bar
Elevated pressure i.g. when
centrifugal filter installed PI 22 4-5 bar PAL 22 4 bar PSL 22 2.5 bar
Pressure drop across filter PDAH 21-22 0.5-1 bar PDAH 21-22 1.5 bar
Prelubricating pressure PI 25 0.1-0.5 bar LAL 25 level switch
Pressure inlet turbocharger PI 23 1.5 ±0.2 bar
Lub. oil, level in base frame LAL 28/LAH 28 low/high level
Temp. main bearings TE 29 75-85° C TAH 29 95° C
Fuel Oil System

Pressure after filter MDO PI 40 2-3 bar PAL 40 1.5 bar
HFO PI 40 (A) PAL 40 4 bar
Leaking oil LAH 42 leakage
Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar (C)
Press. nozz. cool. oil, outlet eng. TI 50 80-90° C (C)

Press. LT-system, inlet engine PI 01 1-2.5 bar PAL 01 0.4 bar + (B)
Press. HT-system, inlet engine PI 10 1-3.0 bar PAL 10 0.4 bar + (B)
Temp. HT-system, inlet engine TI 10 60-75° C
Temp. HT-system, outl. cyl.units TI 11 70-85° C
Temp. HT-system, outlet engine TAH 12 90° C TSH 12 95° C
Temp. raise across cyl. units max. 10° C
Exhaust Gas and Charge Air

Exh. gas temp. before TC TI 62 425-475° C TAH 62 550° C
Exh. gas temp. outlet cyl. TDAH 60 average ±50° C
Exh. gastemp. after TC TI 61 275-350° C TAH 61 500° C
Ch. air press. after cooler PI 31 2-2.5 bar
Ch. air temp. after cooler TI 31 35-55° C TAH 31 65° C

Press. inlet engine PI 70 7-9 bar PAL 70 7 bar
08028-0D/H5250/94.08.12
Speed Control System

GenSets for 60 Hz
GenSets for 50 Hz
Turbocharger speed SI 89
Specific plants will not comprise alarm equipment and autostop for all parameters listed above.
For specific plants additional parameters can be included.
For remarks to some parameters, see overleaf.
*** To be chosen after test running on test bed and site.
02.43 - ES1
600.30 Operation Data & Set Points Description
L28/32H
Remarks to individual Parameters B. Cooling Water Pressure, Alarm Set Points.
As the system pressure in case of pump failure will

A. Fuel Oil Pressure, HFO-operation. depend on the height of the expansion tank above
the engine, the alarm set point has to be adjusted to
When operating on HFO, the system pressure must 0.4 bar plus the static pressure.
be sufficient to depress any tendency to gasification
of the hot fuel.
C. Nozzle Cooling Oil System
The system pressure has to be adjusted according
to the fuel oil preheating temperature. The nozzle cooling oil system is only applied for
stationary engines.
08028-0D/H5250/94.08.12
02.43 - ES1
Description
Data for Pressure and Tolerance 600.35
L+V28/32H
Section Description mm. / bar
605 Safety valve to be adjusted to 170 bar

Maximum inner diameter, valve guide 18.35 mm.
For grinding of valve spindle and valve seat ring
(see also working card 605-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H" 1 6.5 mm.
Maximum height of spindle above cylinder head, "H" 2 108.0 mm
606 Piston and piston ring grooves (see working card 606-01.10)
Clearance between connecting rod bush and piston pin 0.15 - 0.20 mm.
Maximum ovalness in big-end bore (without bearing) 0.10 mm.
New cylinder liner, inside diameter 280.03 - 280.08 mm.
Maximum inside diameter cylinder liner 280.60 mm.
607 Clearance between camshaft and camshaft bearing 0.13 - 0.22 mm.
Maximum clearance between camshaft and camshaft bearing 0.35 mm.
Clearance between tooths on intermediate wheel 0.20 - 0.30 mm
608 Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm.
Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.90 mm.
Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm.
609 Clearance between pick-up and impulse wheel 1 ±0.3 mm

Adjustment of Lambda controller.
(see working card 609-10.00)
610 Clearance between main bearing cap and frame,

before tightening of bracing screw (side screw) 0.06 ± 0.01 mm.
Deflection of crankchaft (Autolog) (see working card 610-01.00)
Clearance between crankshaft and sealing ring, (upper and lower part) 0.30 - 0.40 mm.
611 Opening pressure of safety relief valves (on crankcase), max: 0.20 bar
614 Maximum combustion pressure at full load 130 ± 3 bar

Individual cylinders; admissible deviation from average ± 3 bar
A change of the height of the thrust piece spacer ring of 0.10 mm.
will change the maximum pressure by 1 bar
1° turning of camshaft gear wheel changes max. pressure by approx 3 bar
Measurement "X" between thrust piece and roller guide housing 11 ± 1.0 mm
Opening pressure of fuel valve 320 bar
Pressure testing, cooling oil sealing, on fuel valve 100 bar
01.15 - ES0
Description 600.40
Page 1 (2) Data for Torque Moment Edition 15H
L+V28/32H
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
605 Cylinder head stud (in frame) Stud M 39 200 Loctite 243
Nut for cylinder head stud Nut M 39 x 3 700 Oil / Molykote
(Unimol gl 82)
606 Connecting rod screw

(see working card 606-01.25) Molykote
Connecting rod screw (hydraulic Stud M 39 x 3 (Unimol gl 82)
tightening) Nut M 39 x 3 700 –
Molykote
607 Camshaft assembling Nut M 12 50 (Unimol gl 82)
Gear wheel on camshaft Screw M 12 50 –
Intermediate wheel shaft Nut M 22 x 1.5 250 –
Intermediate wheel assembling Nut M 12 40 –
Gear wheel on crankshaft Nut M 12 50 –
608 Housing for valve gear Screw M 16 160 –

Rocker arm bracket Nut M 12 40 –
610 Main bearing stud (in frame) Stud M 56 200 Loctite 243
Molykote
Nut for main bearing stud Nut M 52 x 3 900 (Unimol gl 82)
Main bearing side screw - L28/32H Screw M 24 350 –
Main bearing side screw - V28/32H Screw M 30 600 –
Counterweight on crankshaft Screw M 26 x 1.5 300 –
Vibration damper on crankshaft Nut M 30 500 –
Flywheel mounting (fitted bolt)
- L28/32H Nut M 30 480 –
- V28/32H Nut M 30 360 –
Gear rim on flywheel Screw M 16 75 –
611 Frame / baseframe Nut M 24 500 –

08028-0D/H5250/94.08.12
(3 x cross-tightening
614 Fuel-pump connecting piece Screw M 10 60 20 - 40 - 60 Nm) –
Fuel-pump top flange (barrel) Screw M 12 100 –
Fuel-pump cavitation plugs Plug M 20 x 1.5 100 - 120 –
Fuel-pump mounting Screw M16 150 –
Fuel-valve (nozzle nut) Nut M 26 x 1.5 100 - 120 –
Fuel-valve mounting Nut M 16 30 –
Fuel-valve (lock nut) Nut M 16 x 1.5 100 –
High pressure pipe Nut M 22 x 1.5 60 –
99.38 - ES0U
600.40 Description
Edition 15H
Data for Torque Moment Page 2 (2)
L+V28/32H
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
Molykote
615 Gear wheel on lub. oil pump Nut M 30 x 2 400 (Unimol gl 82)
616 Impeller and gear wheel on fresh-

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

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

- V28/32H
Upper mounting Screw M 16 165 –
Lower mounting Screw M 16 165 –
08028-0D/H5250/94.08.12
99.38 - ES0U
Description
Ordering of Spare Parts 600.50
Page 1 (2)
Edition 01H
General
Whenever spare parts are ordered (or reference is This data is used by us to ensure supply of the
made in correspondance etc.) the following data correct spare parts for the individual engines, even
must be indicated for the particular engine: though the spare part illustrations contained in this
book may not always be in complete accordance
1. Name of plant with the individual components of a specific engine.
2. Engine type and engine No. ----, built by
3. Illustration plate number (complete with ed. Note: For ordering of spare parts for Governor,
figures). Turbocharger and Alternator, please see special
4. Item No. instruction book for these components.
5. Quantity required (and description)
Information found on page 600.15 or on the nameplate on the engine(s):
Example: Name of plant Eng. type Eng. No. Built by

DANYARD 6L28/32H 20433 MAN B&W Holeby
Information found on each plate:
Plate No. Edition Item No. Qty. (and description)

60601 13H 10 10 pcs (Piston ring)
Pla
Page te
1 (2)
Piston
and Conn
ecting
Rod
60601-
13H
L/V28/
08
32H
09
10
11
12
01
02
03
04
05
607
608
609
06
610
08028-0D/H5250/94.08.12
611
13
612
07
3
61
4
91.4
61
6 - ES
0S
14
5
61
6
61
7
61
8
61
9
61
0
62
91.46 - ES2S
Description
Ordering of Spare Parts 600.50
General
Name of Plant:
Engine type: Engine Number: Built by:
Plate No. Ed. No. Item No. Description Qty.

08028-0D/H5250/94.08.12
91.46 - ES2S
Description Service Letters 600.55
General
Description great importance to the operation of the plant, we

recommend that engine staff file them to supplement
In order to ensure the most efficient, economic, and the relevant chapters of this instruction book.
up-to-date operation of our engines, we regularly send
out "Service Letters", containing first-hand information
regarding accumulated service experience.
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 instruction
book editions.
Therefore, since New Service Letters could be of

08028-0D/H5250/94.08.12
91.14 - ES0S
Description 600.60
Page 1 (3) Conversion Table Edition 01H
General
SI Base Units Length (m)
Quantity Name Symbol 1 in (inch) 25.40 mm = 0.0254 m
1 ft (foot) = 12 inches 0.3048 m
lenght metre m 1 yd (yard) = 3 ft = 36 inches 0.9144 m
mass kilogram kg 1 statute mile = 1760 yds 1609 m
time second s 1 n mile (international nautical mile) 1852 m
electric current ampere A
absolute temperature* kelvin K
amount of substance mole mol SI Prefixes

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

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

plane angle radian rad 3
10 kilo k 10-12 pico p
solid angle steradian sr 102 hecto h 10-15 femto f
10 deca da 10-18 atto a
Derived Si Units with Special Names

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

frequency hertz Hz 1 Hz = 1 s-1
force newton N 1N = 1 kg m/s2
pressure, stress pascal Pa 1 Pa = 1 N/m2* Volume (1 m3 = 1000 l)

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

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

1 kn (knot) = 1 nautical mile/h 1.852 km/h = 05144 m/s
plane angle degree ° 1° = (p/180) rad
For other conversions, see table for length
volume litre l 1l = 1 dm3
pressure bar bar 1 bar = 105 Pa
92.16 - ES0U
600.60 Conversion Table Description
General
Mass (kg) Dynamic viscosity (N s/m2)
1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)
1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg 1 poundal s/sq.ft 1.488 N s/m2
1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg 1 lbf/sq.ft 47.88 N s/m2
1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg poise is a special name taken from the CGS system. 1 P = 0.1 Pa s
1 slug* 14.59 kg 1 cP = 1 mPa s = 10-3 Pa s
* Unit and mass in the ft-lb-s system
Kinematic viscosity (m2/s)

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

1 lbf (pound force) 4.448 N 1 kpm 9.807 J
* Can occasionally be found stated as kgf (kilogram force). 1 hph (metric) 2.648 x 106 J = 0.7355 kWh
Standard acceleration of free fall gn = 9.80665 m/s2 1 ft. lbf 1.356 J
** Unit of force in the ft-lb-s system 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
* Exact value: 4.1868 J

Pressure I.T. = International Steam Table
(1 N/M2 = 1 Pa, 1 bar = 105 Pa, 1 mbar = 10-3 bar)
1 kp/cm2 = 1 at = 0.9678 atm 98.07 x 10 3 Pa = 0.9807 bar
1 at = 735.5 mm Hg* = 10 m H2O** (T = 277 K) Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W)

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

G = W = mass in kg D = Diameter of gyration
R = Radius of gyration
92.16 - ES0S
Description 600.60
Page 3 (3) Conversion Table Edition 01H
General
Specific fuel consumption* (g/kWh) Some physical data in SI units

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

range
1 °C (Celsius) 1K
1 °F (Fahrenheit) 5/9 K Water 18 999 4.18 x 103
Lubricating oil (approx.)* 15 900 1.96 x 103
Atmosphereric air (dry) (p= 1 bar) 0 1.276 998 0-150 1005
Exhaust gas 200-400 1080
Temperature levels (K) (see "Derived SI Units with special
Names) * Viscosity: 100-140 cSt at 40°C
750 mm Hg = 1 bar = 105 Pa
t °C (Celsius) tc + 273.15 = K 1 atm (standard pressure at sealevel) = 760 mm Hg = 1013 mbar
t°F (Fahrenheit) 5/9(tf - 32) + 273.15 = K Gas constant for air and exhaust gas = 287 J/(kg x K)
Celsius from Fahrenheit: tc = 5/9(tf - 32) Water, heat of evaporation 100°C 1.013 bar 2.256 x 106 J/kg
Fahrenheit from Celcius: tf = 9/5 x tc + 32 Fuel oil. Lower caloric value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)
Specific heat capacity (J/(kg K))

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

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

1 calI.T./(cm x s x °C) 41.87 x 103 W/(m2 K)
1 kcalI.T./(m" x h x °C) 1.163 W/(m2 K)
1 BTU*/(ft2 x h x °F 5.678 W/(m2 K)
08028-0D/H5250/94.08.12
92.16 - ES0U
Description
Basic Symbols for Piping 600.65
General
No. Symbol Symbol designation No. Symbol Symbol designation
1. GENERAL CONVENTIONAL SYMBOLS 2.14 Spectacle flange
1.1 Pipe 2.15 Orifice
1.2 Pipe with indication of direction of flow 2.16 Orifice
1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint
1.4 Appliances 2.18. Snap-coupling
1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere
1.6 High pressured pipe 3. VALVES, GATE VALVES, COCKS AND FLAPS
1.7 Tracing 3.1 Valve, straight through
Enclosure for several components as-

1.8 sembled in one unit 3.2 Valve, angle
2. PIPES AND PIPE JOINT 3.3 Valve, three-way
2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight
2.2 Crossing pipe, connected 3.5 Non-return valve (flap), angle
2.3 Tee pipe 3.6 Non-return valve (flap), straight screw
2.4 Flexible pipe 3.7 down
2.5 Expansion pipe (corrugated) general 3.8 Non-return valve (flap), angle, screw
2.6 Joint, screwed 3.9 down
2.7 Joint, flanged 3.10 Safety valve
2.8 Joint, sleeve 3.11 Angle safety valve

08028-0D/H5250/94.08.12
2.9 Joint, quick-releasing 3.12 Self-closing valve
2.10 Expansion joint with gland 3.13 Quick-opening valve
2.11 Expansion pipe 3.14 Quick-closing valve
2.12 Cap nut 3.15 Regulating valve
2.13 Blank flange 3.16 Ball valve (-cock)
92.47 - ES0S
600.65 Basic Symbols for Piping Description
General
4. CONTROL AND REGULATION PARTS

3.17 Butterfly valve
4.1 Han-operated
3.18 Gate valve
4.2 Remote control

3.19 Double-seated changeover valve
4.3 Spring
3.20 Suction valve chest
4.4 Mass
3.21 Suction valve chest with non-return
4.5 Float
3.22 valves
4.6 Piston
3.23 Double-seated changeover valve, straight
4.7 Membrane
3.24 Double-seated changeover valve, angle
4.8 Electric motor

3.25 Cock, straight through
4.9 Electro-magnetic
3.26 Cock, angle
4.10 Manual (at pneumatic valves)

3.27 Cock, three-way, L-port in plug
4.11 Push button

3.28 Cock, three-way T-port in plug
4.12 Spring
3.29 Cock, four-way, straight through in plug
4.13 Solenoid
3.30 Cock with bottom connect.
4.14 Solenoid and pilot directional valve

3.31 Cock, straight through, with bottom conn.
4.15 By plunger or tracer

3.32 Cock, angle, with bottom connection
5. APPLIANCES
3.33 Cock, three-way with bottom connection
5.1 Mudbox
3.34 Thermostatic valve
08028-0D/H5250/94.08.12
5.2 Filter or strainer

3.35 Valve with test flange
5.3 Magnetic filter

3.36 3-way valve with remote control
5.4 Separator
3.37 (actuator)
5.5 Steam trap

3.38 Non-return valve (air)
On/off valve controlled by solenoid and
5.6 Centrifugal pump
pilot directional
3/2 spring returnvalve andnormally
valve, with spring
closed
3.39
return
2/2 spring return valve, normally closed

92.47 - ES0S
3/2 spring return valve contr. by solenoid
Description
Basic Symbols for Piping 600.65
General
5.7 Gear or screw pump 6. FITTINGS
5.8 Hand pump (bucket) 6.1 Funnel / waste tray
5.9 Ejector 6.2 Drain
5.10 Various accessories (text to be added) 6.3 Waste tray
5.11 Piston pump 6.4 Waste tray with plug
5.12 Heat exchanger 6.5 Turbocharger
5.13 Electric preheater 6.6 Fuel oil pump
5.14 Air filter 6.7 Bearing
5.15 Air filter with manual control 6.8 Water Jacket
5.16 Air filter with automatic drain 6.9 Overspeed device
5.17 Water trap with manual control 7. READING INSTR. WITH ORDINARY DESIGNATIONS
5.18 Air lubricator 7.1 Sight flow indicator
5.19 Silencer 7.2 Observation glass
Fixed capacity penumatic motor with on

5.20 7.3 Level indicator
direction of flow
5.21 Single acting cylinder with spring returned 7.4 Distance level indicator
5.22 Double acting cylinder with spring 7.5 Recorder
5.23 returned
Steam trap
08028-0D/H5250/94.08.12
92.47 - ES0S
Index
Page 1 (1) Operation of Engine 601S
L28/32H
Description
Operating..................................................................................................................... 601.01(21H)
Out-of Service ........................................................................................................... 601.05(17H)
Starting-up after Out of Service Periods ................................................................... 601.10(17H)
Guidelines for Longterm Low-load Operation on HFO .............................................. 601.15(01H)
Working Card
Plates
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Operating 601.01
Page 1 (3)
Edition 21H
L+V28/32H
Preparations for Starting
The following describes what to do before starting, 4. Open the fuel oil supply to the feed pump.
when the engine has been out of service for a longer
period of time, or if major overhauls has been made. Starting on HFO: circulate preheated fuel through
the pumps until correct working temperatures has
1. Check the oil level in the base frame (or in the been obtained. Takes normally 30-60 minutes.
lub. oil tank if the engine is with dry sump), air
lubricator and in the govenor. 5. Check the pressure in the starting air
receiver(s) and open the starting air supply (blow-off
Start-up the prelubricating pump. water, if any, drain the starting air system before
opening.
The engine shall be prelubricated at least 2 minutes
prior to start. 6. Check that the sealing oil system for the injec-
tion pumps are working correct.
Check oil pressures before and after the filter.
7. Check in the regulating gear:
2. Open the cooling water supply, start separate
cooling water pumps where installed, and check the - That all fuel pumps are at index "0" when the
cooling water pressure. regulating shaft is in the STOP position.
Note: To avoid shock effects owing to large tempe- - That each fuel pump can be pressed by hand
rature fluctuations just after the start, it is recom- to full index when the regulating shaft is in the STOP
mended: position, and that the pumps return automatically to
the "0" index when the hand is removed.
a) to preheat the engine, cooling water of at least
60 °C should be circulated through the frame and - That the spring-loaded pull rod is working
cylinder head for at least 2 hours before start. correctly.
- either by means of cooling water from engines - That the stop cylinder for regulating shaft
which are running or by means of a built-in preheater works properly, both when stopping normally and at
(if installed). overspeed and shut down.
or - Testing is made by simulating these situations.
b) When starting without preheated cooling wa- 8. Open the indicator valves and turn the engine
ter, the engine must only be started on MDO (Ma- some few revolutions, check that no liquid is flowing
rine Diesel Oil). out from any of the indicator valves during the
turning.
The engine should not be run up to more than 50%
load to begin with, and the increase to 100% should Slow-turning must always be carried out, before the
take place gradually over 5 to 10 minutes. engine is started after prolonged out of-service pe-
riods and after overhauls, which may involve a risk of
Note: When starting on HFO (Heavy Fuel Oil), only liquid having collected in the cylinders.
item "a" should be used.
9. Close the indicator valves.
3. Open the nozzle cooling oil supply (only when
started on HFO), circulate preheated oil through the 10. Disengage the turning gear, if fitted. Check
nozzles for at least 15 minutes. that it is locked in the "OUT" position.
96.30 - ES0U
601.01 Description
Edition 21H
Operating Page 2 (3)
L+V28/32H
Starting 6. The exhaust gases should be free from smoke

at all loads. For normal exhaust temperatures, see
1. Start the engine, by activating the start buttom. the test sheet from shop and sea trials.
2. Check the lubricating oil pressure, cooling 7. Keep the charging air pressure and tempera-
water pressure, fuel oil feed pressure. Check that the ture under control. For normal values, see the test
prelubricating oil pump is stopped. sheet from shop and sea trials.
3. Check that all alarms are connected. 8. Recharge the starting air recivers when the
pressure has dropped to about 20 bar. Stop rechar-
See also "checks after starting-up". ging at 30 bar.
9. To ensure the greatest possible operational

Tending during running liability, condition of the engine should be contin-
uously observed in order that preventive mainte-
When the engine is running, the planned maintenance work can be carried out before serious break-
nance program and the following should be checked: downs occour.
1. The lubricating oil pressure must be within the

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

value, and the filter must be cleaned before the Start and Stop on HFO
pressure drop across the filter reaches the stated
maximum value. Start and stop of the engine should take place on
HFO in order to prevent any incompatibility problems
4. The cylinder cooling water temperature must by change-over to MDO.
be kept within the limits indicated and the tempera-
ture rise across the engine should not exceed 10°C. MDO should only be used in connection with main-
tenance work on the engine or longer periods of
5. The cooling water temperature at the charging engine standstill.
air cooler inlet should be kept as low as possible;
however, not as low as to produce condensation Before starting on HFO the engine must be properly
water in the charging air space. preheated. as described in "Preparations for star-
ting" and as below.
Adjustment takes place in the external system outside
the engine, and the amount of cooling water must be Stopping the engine on HFO is no problem, but it
so adjusted that the temperature rise across the should be ensured that the temperature of fuel pipes
charging air cooler is 3 - 5 °C. not are reduced to a level below the pour point of the
fuel, otherwise reestabilishing of the circulation might
cause problems.
96.30 - ES0U
Description
Operating 601.01
L+V28/32H
Starting on MDO
For starting on MDO there are no restrictions except

lubricating oil viscosity may not be higher than 1500
cSt (5° C SAE 30, or 10° C SAE 40).
Initial ignition may be difficult if the engine and

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

laboratory for immediate analysis.
in periods, duringe stand-still of the engine (not in
stand-by position) it is recommended, that the prelub- 4.7. Drain plugs are unscrewed from the bottom of
ricating oil pump is startet minimum 10 minutes once turbochargers, or the drain cock is opened, if there is
every week and that the engine during the prelubricating installed drain fasilities in the exhaust gas system this
period is turnd 2-3 revolutions.. should be opened.
3. Laid-up Vessels 5. Works during Repairs
During the lay-up period (and also when laying-up the The following should be made during the major repairs.
vessel), we recommend that our special instructions
for preservation of the engines, are followed. 5.1. Retighten all bolts and nuts in the crankcase
and check their locking devices. Also retighten
foundation bolts.
4. Works before Major Repairs
5.2. Check the various gear wheel drives for the
4.1 After stopping the engine, while the oil is still camshaft(s).
warm, start the electrically driven prelubrication pump,
open up the crancase and camshaft housing and 5.3. Remedy leakages of water and oil in the engine,
check that the oil is flowing freely from all bearings. and blow through blocked-up drain pipes.
Also take off the top covers on the cylinder heads and
make sure that oil is not supplied for lubrication of 5.4. Drain starting air pipes of water.
rocker arms, as non-return valves are fitted which do
not open until the oil pressure at the inlet to the rocker 5.5. Empty the oil sump of lubricating oil and remove
arms exceeds 1 bar. the sludge, if not done within a period of one year. Very
thoroughly clean the sump and subsequently coat
08028-0D/H5250/94.08.12
After overhaul of pistons, bearings, etc. this check with clean lubricating oil.
should be repeated before starting the engine.
4.2. After stopping the prelubricating pump, check 6. Works after Repairs
the bottom of the oil sump for fragments of babbitt
from bearings, and check crankpin and main bearings 6.1. If an opening-up of engine or lubricating oil
clearances with a feeler gauge. Measure the bearing system may have caused ingress of impurities,
clerance at the top, at the bottom, and 10 degrees cleaning should be carried out very carefully before
above and below the joints at both sides. starting the engine.
The differential pressure across the lub. oil filter must
92.02 - ES0U
601.05 Description
Edition 17H
Out-of Service Page 2 (2)
General
be watched very carefully after cleaning and starting- reaching normal oil temperatures in governor and
up the engine. Be sure to replace filter cartridges in engine, increase the load instantaneously to about
due time. 80% ( by starting major pump or compressor). This
must not cause the frequency to fall by more than
6.2. After restoring normal lubricating oil circulation, some 8%, and the engine must return to a constant
turn the engine at least two revolutions by means of r.p.m. about 3 seconds (although this r.p.m. will be a
the turning rod to check the movability of the relevant little lower than before owing to the speed drop of
parts of the engine. the governor). If the engine is operated in parallel with
other engines, an even sharing of load shall be
6.3. Close drain cocks in the turbocharger (or in the established within about 3 seconds. If the governor
exhaust gas system if mounted). reacts too slowly, compensating adjustment is ef-
fected as indicated in Woodward's instruction manual
6.4. Lubricate bearings and rod connections in the (Compensating adjustment).
manoeuvring gear. Disconnect the governor and move
the rod connections by hand to check that the friction Note: It is a condition for this test that the engine and
in bearings and fuel pumps is sufficiently low. If repair turbocharger are in perfect operating condition, so
of bearings or alignment of engine has been made, that they can be elimated as possible sources of error.
checks 1, 2, and 5 should be repated.
6.7 c) Hunting: Run the engine at synchronous
6.5. Cheks to be made just before starting of the r.p.m., and without load. Provided the governor oil is
engine are mentioned under 601.01. warm, the regulating lever must not perform any major
periodical movments, and neither must there be any
6.6. Add cooling water and check with pressure on variation up and down in the engine speed. If that is
the system for leakage at the upper and lower cy- the case, repeat the compensating adjustment
linder liner sealings and at cooling water connections. according to Woodward's instruction manual.
6.7. Check the governor as follows: 6.7 d) Speed Drop: in case of unsatisfactory load
Start up the engine and run it at the synchronous sharing between two ore more engines this can be
number of revolutions. rectified by increasing the speed drop of the engine
that is subject to the greatest load (or by reducing the
6.7 a) Speed setting: Check before switching-in setting of the other engines).
generator on the switchboard that the servomotor
adjusts the r.p.m. with a suitable quickness after The setting shoul not normally be increased beyond
actuation of the synchronizer knob on the switch- 70 on the scale, and satisfactory parallel operation
board. The range from - 5% to + 5% from the syn- can generally be obtained at settings between 40 and
chronous r.p.m. should be tested. 60.
6.7 b) Adjustment speed: Switch-in generator on

the switchboard and set the load to about 40%. On
08028-0D/H5250/94.08.12
92.02 - ES0U
Description
Starting-up after Out of Service Periods 601.10
Page 1 (1)
Edition 17H
L+V28/32H
The following enumerates checks are to be made After the last feel-over, repeat check 4 page 601.05,
immediately after starting, during load increase, and see also Ignition in Crankcase page 603.04 in
during normal running. The sequence has been section 603.
accordingly.
After repair or renewal of cylinder liners, piston rings
In the following it is assumed that the engine has or bearings, allowance must be made for a running-
been out of service for some time, for instance due in period, i.e. the engine load should be increased
to repairs and gradually as indicated in the tables below. The
engine output is determined on the basis of the fuel
- checks during out of service periods have index and the load on the electric switchboard. The
been carried out as described in the previous chap- turbocharger speed gives some indication of the
ter. engine output, but is not directly proportional to the
output throughout the service period.
When starting after such an out-of-service period,
the following checks must be made in the stated Begin the starting-up sequence at a reduced engine
order in addition to normal surveillance and recor- speed, e.g. 400 rpm, until it can be known for certain
ding. that there areno hot spots in the engine. Then
increase the speed to the normal rpm and connect to
the switchboard and put on load.
1. To be made immediately after starting:
The load increase during the starting-up sequence
1.1. See that the turbocharger is running. may, for instance, be:
1.2. See that the lubricating oil pressure is in order. 25 % load for 2 hours
50 % load for 2 hours
1.3. See that all cylinders are firing (see exhaust 75 % load for 2 hours
temperatures). 100 % load may be put on.
1.4. See that everyting is normal for the engine The pump index indicated in the tables has been
speed, fuel oil, cooling water and system oil. given as a percentage of the index at full load. To
enable the index to be read directly off the fuel pumps
1.5. Check by simulation of the overspeed shut- the following formula can be employed:
down device that the engine stops. The overspeed
setting should be according to " Set Points and I = I% x IF
Operation Data " section 600. 100
IF = Index at full load (from testbed table)

2. To be made during the starting-up, but
only if required after repairs or alterations made: I% = Index expressed as % of full load index
(stated in the preceding starting-up
2.1. If the condition of the machinery is not well- sequence).
08028-0D/H5250/94.08.12
known, especially after repairs or alterations, the

"feel-over sequence" should always be followed. Following the alteration of the pump index of the one
that is: or two cylinders concerned it must be checked that
when in the STOP position the governor is able to
After 5-15 and 30 minutes' idle running, open the move all the fuel pumps to an average pump index
crankcase and the camshaft housing and feel-over not exceeding 2 or 3, thus excluding the possibility of
on the surfaces of all moving parts where friction may racing of the engine when the propeller is declutched.
arise and cause undue heating.
After completing the starting-up sequence, make
Feel: Main bearings, big-end bearings, (alternator), sure that all fuel pumps are set at the same index and
and camshaft bearings, piston pins, cylinder liners, that the governor can cause all fuel pumps to move
roller guides and gear wheels. to "0" index.
96.30 - ES0U
Description
Guidelines for Longterm Low-Load Operation on HFO 601.15
General
Part load/low load operation HFO-operation at loads lower than 20% MCR should
therefore only take place within certain time limita-
In certain ship operation situations the diesel-gen- tions according to the curves.
erator sets are sometimes exposed to part load/low
load operation. After a certain period of HFO-operation at a load
lower than 20% MCR, a change to MDO should take
During manoeuvring all diesel-generator sets are place in order to prevent further retardation of the
often started up for safety reasons, resulting in low engine performance condition, or the engine load
load conditions for all sets. should over a period of 15 minutes be raised to 70%
MCR and maintained here for a certain period of time
During harbour stay even one diesel-generator run- in order to burn off the carbon deposits, thus reestab-
ning could be lowloaded when hotel purposes are lishing adequate performance condition. After such
the only electricity consumers. "cleanburning period" low-load operation on HFO
can be continued.
At part load/low load it is important to maintain
constant media temperatures, i.e. for cooling water, However the operator must be aware of the fact that
lubricating oil and fuel oil, in order to ensure ad- fouwling in the air inlet channels, if any, will not be
equate combustion chamber temperature and thus cleaned with high load running. Extensive low-load
complete combustion. running can therefore result in necessity off manual
cleaning of the inlet channels.
At loads lower than 20% MCR there is risk of timede-
pendant retardation of the engine performance con- If special application conditions demand continuous
dition due to fouling of gas- and air channels, com- HFO-operation at loads lower than 20% MCR. and
bustion chambers and the turbocharger. occasionally performed "clean-burning" periods are
inconvenient or impossible, special equipment and
arrangements must be established.
Load %
20
Admissible low-load operation Necessary operating period
(load percent/period) on HFO. with min. 70% load after low-
load operation on HFO.
15
Running-up period to 70%
load: approx. 15 min.
a b 70% load
10 HFO or MDO
08028-0D/H5250/94.08.12
5
a b
Operating period (h) Operating period (h)

Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to MDO
or b) operate engine for approx. 1.2 hours with 70% rating minimum, in order to burn off residues.
Afterwards low load operation on HFO can be continued.
Fig 1 Low-load operation.
00.11 - ES1
Index
Page 1 (1) Engine Performance and Condition 602
L28/32H
Description
Engine Performance and Condition .......................................................................... 602.01(09H)
Evaluation of Readings Regarding Combustion Condition ....................................... 602.02(07H)
Condensate Amount .................................................................................................. 602.05(08H)
Working Card
Engine Performance Data .................................................................................... 602-01.00(03H)
Plates
08028-0D/H5250/94.08.12
94.47-ES0U
Description Engine Performance and Condition 602.01
General
An increase of charge air temperature involves a
Performance Data and Engine Condition corresponding increase of the exhaust gas temperature
level in a ratio of about 1:1.5 i.e. 1°C higher charge air
During the operation, small alterations of the engine temperature causes about 1.5°C higher exhaust gas
condition continuously take place as a result of the temperature.
combustion, including fouling of the airways and
gasways, formation of deposits, wear, corrosion, etc. Reduction of the charge air pressure results in a
If continuously recorded, these alterations of the corresponding reduction of the compression pressure
condition can give valuable information about the and max. combustion pressure. When checking the
operational and maintenance condition of the engine. max. pressure adjustment of the engine, it is therefore
Continual observations can contribute to forming a to be ensured that the existing charge air pressure is
precise and valuable basis for evaluation lay down the correct.
optimal operation and maintenance programmes for
the individual plant. The injected amount of fuel is equivalent to supplied
energy and is thus an expression of the load and mean
We recommend taking weekly records of the most pressure of the engine. The fuel pump index can
important performance data of the engine plant. At the therefore be assumed to be proportional to the mean
recording (Working Card 602-01.00 can be used), the pressure. Consequently, it can be assumed that the
observations are to be continually compared in order connected values of the pump index are proportional
to ascertain alterations at an early stage and before to the load.
these exert any appreciable influence on the operation
of the plant. The specific fuel consumption, SFOC (measured by
weight) will, on the whole, remain unaltered whether
As a reference condition for the performance data, the the engine is operating on HFO or on marine diesel oil,
testbed measurements of the engine or possibly the when considering the difference in calorimetric
measurements taken during the trial trip at the delivery combustion value. However, when operation on HFO,
of the ship can be used. If considerable deviations the combination of density and calorific value may
from the normal condition are observed, it will, in the result in an alteration of up to 6% in the volumetric
great majority of cases, be possible to diagnose the consumption at a given load. This will result in a
cause of such deviations by means of a total evaluation corresponding alteration in the fuel pump index, and
and a set of measurements, after which possible regard should be paid to this when adjusting the
adjustment/overhauls can be decided and planned. overload preventative device of the engine.
Abrasive particles in the fuel oil result in wear of fuel

Evaluation of Performance Data pumps and fuel valve nozzles. Effective treatment of
the fuel oil in the purifier can limit the content of
For example, fouling of the air side of the air cooler will abrasive particles to a minimum. Worn fuel pumps will
manifest itself in an increasing pressure drop, lower result in an increase of the index on account of an
charge air pressure and an increased exhaust increased loss in the pumps due to leakage.
temperature level (with consequential influence on
the overhaul intervals for the exhaust valves). When evaluating operational results, a distinction is
08028-0D/H5250/94.08.12
to be made between alterations which affect the whole

Fouling of the turbine side of the turbocharger will, in engine (all cylinder units) and alterations which occur
its first phase, manifest itself in increasing turbocharger in only one or a few cylinders. Deviations occuring for
revolutions on account of increased gas velocity a few cylinders are, as a rule, caused by malfunctioning
through the narrowed nozzle ring area. In the long run, of individual components, for example, a fuel valve
the charging air quantity will decrease on account of with a too low opening pressure, blocked nozzle
the greater flow resistance through the nozzle ring, holes, wear, or other defects, an inlet or exhaust valve
resulting in higher wall temperatures in the combustion with wrongly adjusted clearance, burned valve seat
chambers. etc.
The operational observations supplemented by the daily
92.02 - ES0U
602.01 Engine Performance and Condition Description
General
routine monitoring contribute to ensuring that faulty fuel nozzle temperature decreases, it may be
adjustments and other deviations in the performance advantageous at continuous operation to reduce the
of individual components are observed in time to fuel nozzle cooling to avoid corrosion.
avoid operational disturbances and so that normal
routine overhauls can be carried out as scheduled. Abrasive particles in the fuel oil involve a heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
If abnormal or incomprehensible deviations in the Therefore, abrasive particles are, to the greatest
operation are recorded, expert assistance for the possible extent, to be removed at the purification.
evaluation of these should be obtained.
Exhaust Valves
Turbochargers
The overhaul intervals of exhaust valves is one of the
Service experience has shown that the turbine side is key parameters when reliability of the entire engine is
exposed to increased fouling when operating on HFO. to be judged. Operation on HFO has a negative effect
on these intervals. The performance of the exhaust
The rate of fouling and thereby the influence on the valves is therefore extremely informative.
operation of the engine is greatest for small
turbochargers where the flow openings between the Especially under favourable conditions, fuel qualities
guide vanes of the nozzle ring are relatively small. with a high vanadium and sodium content will promote
Deposits especially occur on the guide vanes of the burning of the valve seats. Combinations of vanadium
nozzle ring and on the rotor blades. In the long run, and sodium oxides with a corrosive effect will be
fouling will reduce the efficiency of the turbocharger formed during the combustion. This adhesive ash
and thereby also the quantity of air supplied for the may, especially in the case of increased valve
combustion of the engine. A reduced quantity of air temperatures, form deposits on the seats. An
will result in higher wall temperatures in the combustion increasing sodium content will reduce the melting
spaces of the engine. point and thereby the adhesive temperature for the
ash, which will involve a greater risk for deposits. This
Detailed information and instructions regarding water condition will be especially unfavourable when the
washing of the turbocharger are given in the section weight ratio Na increases beyond 1:3.
612. Va
The exhaust valve temperature depends on the actual

Fuel Valves maintenance condition and the load of the engine.
With correct maintenance, the valve temperature is
Assuming that the fuel oil is effectively purified and kept at a satisfactory low level at all loads. The air
that the engine is well maintained, the operational supply to the engine (turbocharger/air cooler) and the
conditions for the fuel valves and the overhaul intervals maximum pressure adjustment are key parameters in
will not normally be essentially altered when operating this connection.
on HFO.
It is important for the functioning of the valves that the
08028-0D/H5250/94.08.12
If, for any reason, the surface temperature of the fuel valve seats are overhauled correctly in accordance
valve nozzle is lower than the condensation with our instructions.
temperature of sulphuric acid, sulphuric acid
condensate can form and corrosion take place (cold The use of rotocaps ensures a uniform distribution of
corrosion). The formation of sulphuric acid further temperature on the valves.
depends on the sulphur content in the fuel oil.
Normally, the fuel nozzle temperature will be Air Inlet Valves

higher than the approx. 180°C, at which cold
corrosion starts to occur. At low load where the The operational conditions of the air inlet valves are not
substantially altered when using residual fuel.
92.02 - ES0U
Description Engine Performance and Condition 602.01
General
might involve corrosive attack and influence the
Fuel Pumps overhaul intervals for the exhaust valves.
Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room is
operation of the fuel pumps will not be very much to correspond to approximately 1.5 times the air
affected. consumption of the engines and possible boilers in
operation. Sub-pressure in the engine room will involve
The occurrence of increasing abrasive wear of plunger an increased exhaust temperature level.
and barrel can be a consequence of insufficient
purification of the fuel oil, especially if using a fuel The exhaust back-pressure measured after the
which contains residues from catalytic cracking. turbochargers at full load should not exceed 250-300
Water in the fuel oil involves an increased risk of mm water gauge. An increase of the exhaust back-
cavitation in connection with pressure impulses pressure will also involve an increased exhaust valve
occurring at the cutting-off of the fuel pump. A fuel temperature level.
with a high asphalt content has deteriorating lubricating
properties and can, in extreme cases, result in sticking
of the fuel pump plungers.
Engine Room Ventilation, Exhaust System
Good ventilation of the engine room and a

suitable location of the fresh air intake on the
deck are important. Seawater in the intake air
08028-0D/H5250/94.08.12
92.02 - ES0U
Description Evaluation of Readings Regarding 602.02
Page 1 (1) Combustion Condition Edition 07H
L+V28/32H
PRESSURE DROP
INCREASING
(limit 50%)
Air filters
Fouled.
PRESSURE DROP
INCREASING
(limit 50%)
Air side of
cooler fouled.
ALL CYLINDERS
Exhaust temp. increasing:
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 AIR

Exhaust temp. in- PRESSURE:
creasing: Fuel valve Decreasing air amount.
needs overhaul. Fouled turbocharger,
Compression too low air filter or charge
owing to leakage of air cooler (air side).
exhaust valve or piston
08028-0D/H5250/94.08.12
ring blow-by.
Pcomp and Pmax ARE MEASURED by means
of max. pressure gauge.
Pcomp too low: Leaky combustion chamber,
charging air pressure too low.
See also:
Pmax too low:
P comp too low, ignition too late. Engine Performance
and Condition 602.01
00.44 - ES0S-G
Description
Condensate Amount 602.05
General
Ambient air temperature (1 bar)
(Above atmospheric)
10 20 30 40 50 60 70
0.10
of air in kg water / kg air
r
ba
1.0
r
0.08
ba
0
2.
air pressure
0.06
r
ba
Max. water content
Charge
0
of atmosphere
3.
Water content
I %
%
0%
%
%
60
70
80
90
10
0.04
A B
in air tank
Pressure
0.02
II
30 bar
III
Relative 0
air humidity 30 40 50 60 70
Charge air temperature after cooler.

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

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

pressure and temperature of the air. 6L28/32H, 720 rpm (P) 1260 kW
Ambient air condition:
air temperature 35 °C
Amount of Condensation Water in The Charge Air relative air humidity 90 %
Receiver Charge air temperature 50 °C
Charge air pressure 2.6 bar
Both higher pressure and lower temperature reduce
the ability to absorb water. A turbocharged diesel As a guidance, an air consumption of 8.2 kg/kWh (Le)
engine takes air from outside, compresses and cools at full load can be used for MAN B&W Diesel A/S,
the air. Then, normally, the air cannot absorb the Holeby engines.
same amount of water as before.
91.37 - ES1S
602.05 Condensate Amount Description
General
Solution according to diagram:
The volume of condensate in the air tank is determin-
Water content of air (l) 0.033 kg/kg ed by means of the curve at the bottom to the right of
Max. water cont. of air (ll) 0.021 kg/kg the diagram, representing an operating pressure of 30
bar.
Amount of condensate in charge air recceiver.
Example:
= (l - ll) x le x P
= (0.033 - 0.021) x 8.2 x 1260 = 123 kg/h Amount of condensate in air tank.
Volumetric capacity of tank(V) 4000 dm³

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

Amount of Condensate Water in Air Tanks. Max. water cont. of air (lll) 0.0015 kg/kg
Amount of condensate in air tank
= (I - III) x m.
= (0.033 - 0.0015) x 138 = 4.35 kg.
08028-0D/H5250/94.08.12
91.37 - ES1S
Working Card 602-01.00
Page 1 (4) Engine Performance Data Edition 03H
L+V28/32H
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water 62005-01 10 Max. pressure
Shut-off fuel oil indicator
Shut-off cooling oil
Stopped lub. oil circul.
Description:
Measurements of engine performance data.
Hand tools:
Starting position:
Engine is running.
Related procedure:
08028-0D/H5250/94.08.12
Man power:
Replacement and wearing parts:
Working time : ½ hour
Capacity : 1 man Plate no. Item no. Qty. /
Data:
Data for pressure and tolerance (Page 600.35)

Data for torque moment (Page 600.40)
Declaration of weight (Page 600.45)
96.37 - ES0U
602-01.00 Engine Performance Data Working Card
L+V28/32H
Engine Performance Data
M/V Engine Type Engine No. Date/Year Hour Total Engine
1 2 3 4 5 6 running Hours
Engine RPM Fuel Type Turbocharger Turbocharger

7 8 Visc. Density 9 Type Serial No. 10 RPM
Switchboard
Effect (kW) Voltage (V) Current (A) cos j /kVAr
11 12 13 14
Cylinder Data
Ave-
15 Cylinder No. 1 2 3 4 5 6 7 8 9 16 rage
17 Fuel Pump Index A

B
18 Maximum Pressure (bar) A

B
19 Compress. Pressure (bar) A

B
20 Exhaust Temp. (° C) A
B
21 Cooling Water (°C) A

B
Turbocharger
Temp. inlet blower (° C) Pressure before blower (mmWC) Temp. after blower (° C)
22 23 24
Ñ
Press. air cooler (mmWC) Temp. charge air (° C) Press. charge air (bar)
25 26 27
Temp. exhaust gas before TC (° C) Temp. exhaust gas after TC (° C) Press. exhaust gas after TC (mmWC)
28 29 30

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

08028-0D/H5250/94.08.12
LT temp. inlet air cooler (° C) LT temp. outlet air cooler (° C) LT press. inlet air cooler (bar)
37 38 39
LT temp. inlet lub. oil cooler (° C) LT temp. outlet lub. oil cooler (° C) LT temp. inlet alternator (° C)
40 41 42
LT temp. outlet alternator (° C) HT FW temp. inlet engine (° C) HT FW press. inlet engine (bar)
43 44 45
Fuel Oil System

Fuel oil temp. inlet engine (° C) Fuel oil press. before engine (bar)
46 47
Nozz. cool. oil press. inlet engine (bar) Nozz. cool. oil temp. outlet engine (° Sign.
48
C) 49 50
96.37 - ES0U
Working Card
Engine Performance Data 602-01.00
L+V28/32H
The Instruction for Filling in the Diagram 14. Cos j/kVAr - can be read on the switchboard.
"Engine Performance Data".
The numbers in the instruction are commensurate Cylinder Data.

with the numbers on the diagram.
15. Cylinder no. - can be read on engine plate.
The automatic symbols mentioned in the instruction A/B is used for V-engines.
TI 01, TI 03, PI 01 etc, refer to the diagrams printed
in the instruction books for specified plants and page 16. Average for all engine cylinders for point: 17-
600.20. 18-19-20-21.
17. Fuel pump index - can be read on each of the

Engine Performance Data. high pressure fuel oil injection pumps.
1. Name of ship, if stationary name of plant. 18. Max pressure (bar) can be read for each
cylinder by means of indicator or Pmax gauge.
2. Engine type.
19. Compression pressure (bar) - can be read for
3. Engine no. each cylinder by means of the indicator measure-
ment, which is carried out during idling by nominal
4. Date/year of observations. RPM.
5. Hour, time of observations. 20. Exhaust temperature (°C)

- Thermometer TI 60.
6. Total engine running hours - engineer's log-
book. 21. Water outlet cylinder (°C) (jacket cooling)
7. Engine revolutions per minute (RPM) - can be
read on tachometer SI 90.
Turbocharger.
8. Fuel oil type: The viscosity must be stated (in
cSt) and the temperature by which the viscosity has 22. Thermometer inlet blower (°C) can be read
been measured f.inst. 180 cSt/50°C. Density must by means of a thermometer placed in the engine
be stated: g/cm³. room near the air filter of the TC.
9. Turbocharger: Type and serial number are 23. Pressure before blower (mmWC) - can be
stated on the rating plate of turbocharger and page read by means of a mmWC instrument placed in the
600.00. engine room near the TC.
10. Turbocharger revolutions per minute (RPM) - 24. Temperature after blower (°C) - can be read
08028-0D/H5250/94.08.12
can be read on the tachometer SI 89. by means of a thermometer TI 30.
25. D Pressure air cooler (mm/WC).

Switchboard.
26. Charge air temperature (°C). Temperature of
11. Effect alternator (kW) - can be read on the the charge air in the charge air receiver.
main switchboard. - Thermometer TI 31.
12. Voltage (V) - can be read on the switchboard. 27. Pressure charge air (bar). Pressure of the
charge air in the charge air receiver.
13. Current (A) - can be read on the switchboard. - Pressure gauge PI 31.
96.37 - ES0U
602-01.00 Engine Performance Data Working Card
L+V28/32H
28. Tempereture of the exhaust gas before TC 40. Temperature of the low temperature (LT) cool-
(°C) - Thermometer TI 62. ing water (sea, raw or fresh) at inlet lub. oil cooler (°C)
29. Temperature of the exhaust gas after TC (°C)
- Thermometer TI 61. 41. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at outlet lub. oil cooler
30. Pressure of the exhaust gas after the TC (bar) °C)
- Pressure gauge PI 61. - Thermometer TI 03.
42. Temperature of the low temperature (LT) cool-

Lubricating Oil System. ing water (sea, raw or fresh) at inlet alternator (°C)
31. Temperature of the lub. oil inlet cooler (°C)
- Thermometer TI 20. 43. Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at outlet alternator (°C)
32. Pressure of the lub. oil before the filter (bar) - Thermometer TI 05.
- Pressure gauge PI 21.
44. Temperature of the high temperature (HT)
33. Pressure of the lub. oil after the filter (bar) fresh water (FW) at inlet engine (°C)
The filter element should be replaced with a pressure 45. Pressure of the high temperature (HT) fresh
drop across the filter of 1.5 bar (see section 615). water (FW) of outlet engine (°C)
34. Temperature of the lub. oil inlet engine (°C)
Fuel Oil System.
35. Pressure of the lub. oil before the turbocharger
(bar). 46. Temperature of the fuel oil at inlet engine (°C)
47. Pressure of the fuel oil before engine (bar)

Cooling Water System. - Pressure gauge PI 40.
37. Temperature of low temperature (LT) cooling 48. Nozzle cooling oil pressure at inlet engine
water (sea, raw or fresh) at inlet charge air cooler (bar)
(°C) - Pressure gauge PI 50.
49. Nozzle cooling oil pressure at outlet engine
38. Temperature of low temperature (LT) cooling (bar)
08028-0D/H5250/94.08.12
water (sea, raw or fresh) at outlet charge air cooler - Pressure gauge PI 51.
(°C)
- Thermometer TI 02. 50. Signature.
39. Pressure of the low temperature (LT) cooling

water (sea, raw or fresh) at inlet charge air cooler
(bar)
- Pressure gauge PI 01.
96.37 - ES0U
Index
Page 1 (1) Trouble Tracing 603
L28/32H
Description
Starting Failures ........................................................................................................ 603.01(08H)
Faults in Fuel Oil System .......................................................................................... 603.02(08H)
Disturbances during Running .................................................................................... 603.03(08H)
Ignition in Crankcase ................................................................................................. 603.04(09H)
Trouble Shooting Guide for Centrifugal By-pass Filter ............................................. 603.05(08H)
Trouble Shooting Guide for Turbine Starter .............................................................. 603.06(09H)
Trouble Shooting for Cooling Water System ............................................................. 603.09(08H)
Trouble Shooting for Lubricating Oil Cooler .............................................................. 603.10(01H)
Working Card
Plates
08028-0D/H5250/94.08.12
95.12-ES0U
Description
Starting Failures 603.01
Page 1 (1)
Edition 08H
General
Trouble Possible cause Trouble shooting
Engine turns as soon as shut-off Faults in electrical system Check electrical parts
valve is opened, without start but-
ton being activated
Engine does not turn when start Air pressure in starting air receiver Start compressors, re-charge air
button is activated too low receiver
Main valve(s) closed Open valve at receiver and stop

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

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

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

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

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

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

manoeuvring gear fuel pump index is corresponding
to "Adjustments after trials" in
testbed chart
Engine turns on starting air, but Incorrect adjustment of limiter Adjust setting of limiter cylinder
no fuel is injected owing to cylinder
failures in fuel system
Fuel oil service tank empty Pump oil into the tank
Air in fuel pumps and fuel injection Vent the fuel pumps unitl fuel
valves (2) with-out air bubbles appears. If
ignition fails in just one cyl., vent
the re-spective fuel injection
valve. If igni-tion still fails, install a
spare valve before attempting to
start the engi-ne again.
08028-0D/H5250/94.08.12
Worn-out fuel pump Change fuel pumps
Defective fuel injection valves or Change defective fuel valves

valve nozzles (4)
Too low pressure before fuel Increase the fuel oil feed pump
injection pumps (3) pressure
Engine turns on starting air, fuel Water in the fuel Drain off water and repeat
is injected, but ignition fails venting of fuel pumps
Fuel valves or nozzles defective Change defective fuel valves,

(4) see Working Card 614-01.10.
Cont.
02.47 - ES0
603.02 Faults in Fuel Oil System Description
L+V28/32H
Compression during start too low Check intake and exhaust valve
(5) for tight closing. Check cyl. wear
and piston rings
Incorrect timing of camshaft (6) Check fuel pump timing advance,

and fuel valve opening pressure
as well as camshat adjustment
First ignitions are too violent Oil has collected on piston crown Slow turning with open indicator
(safety valves are opening). (7) valves, to locate defective fuel
Engine runs erratically val-ve, remove oil
Sluggish movement of manoeuvring Lubricate and mobilize rod

gear connections and bearings in
manoeuvring gear
Fuel pump index to high Check rod connection in

manoeuvring gear. Check that
governor is working properly.
Limiter cylinder to be set lower
Remarks
1) If the shut-down function is due to overspeed, 4) If the fuel is forced into the cylinder through a
the shut-down activation is cancelled by resetting defective fuel valve or through worn-out atomizer
the overspeed device and thus venting the holes, no or too sluggish atomization may
Lambda controller/air cylinder. prevent ignition, possibly followed by too violent
ignition.
2) Whether air is present in the fuel oil system is

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

that no oil has collected on the piston crown. Air
in the fuel oil system may also be the result of 6) Major alterations of the combustion charac-
the fuel oil feed pump sucking-in air through a teristics of the fuel may demand adjustment of
defective stuffing box or a leaky seal. the timing of the fuel pumps. One or more cam-
shaft sections may be incorrectly fitted (after
dismantling). Too high opening pressure of the
3) If the fuel oil pressure drops, the filter may be fuel valves will also delay the injection.
clogged up, or the by-pass at the feed pump
may have opened.
02.47 - ES0
Description
Faults in Fuel Oil System 603.02
L+V28/32H
7) Oil on the piston crown will in most cases have
leaked down from a defective fuel valve. As
these oil accumulations are dangerous, the lea-
kage should be found and remedied before the
engine is started again.
08028-0D/H5250/94.08.12
02.47 - ES0
Description
Disturbances during Running 603.03
Page 1 (3)
Edition 08H
L+V28/32H
Exhaust temperature(s) (All cyls.) Increased charging air See Working Card 612-01.00.
increase(s) temperature due to ineffective air
coolers
(All cyls.) Fouling or air and gas Reduce load and water-wash tur-
passages bine. Clean air filters and coolers
(All cyls.) Insufficient cleaning of See Description 604.25.

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

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

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

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

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

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

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

(5) Cont.
96.30 - ES0U
603.03 Disturbances during Running Description
L+V28/32H
Engine stops Shut-down Check pressure and temperatures.

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

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

of cooling (especially during hea- nozzle-cooling
vy-oil operation) (6)
Exhaust valve knocking Adjsuting screw for valve setting Inspect and replace defective parts
loose. Push rod thrust disc da- as necessary
maged
Rising cooling water temperature Pump stopped. Increased friction Stop the engine. Check the cooling
(7) water. Find cause of increased
friction and remedy fault
Lubricating oil pressure fails Lubricating oil pump defective. (8) Stop the engine. For further details,
Filters/cooler fouled see "Ignition in crankcase"
Remarks
1) This manifests itself by rise of the exhaust 2) Blow-by means a serious danger of piston
temperature and falling of the compression and seizure, and the engine must if possible be stopped
08028-0D/H5250/94.08.12
maximum combustion pressure of the respective and the piston in question pulled. If this is not
cylinder. possible, the fuel pump index must, as described
above, be moved to stop. Leaky piston rings will
To limit the damage to the valves, these should be normally result in a heavy excess pressure in the
changed immediately, if possible, or the fuel pump of crankcase.
the cylinder concerned should be put out of opera-
tion by moving the index to stop and locking it in this
position.
96.30 - ES0U
Description
Disturbances during Running 603.03
L+V28/32H
3) If this happens the fuel pump barrel and plunger 6) If the cooling of the atomizers fails (if arranged
must be changed, and if, to obtain full load of the for oil cooling) while running, carbon deposits will
respective cylinder, it is necessary to increase the build up round the nozzle holes, sometimes in the
fuel pump index by more than 10 index degrees, the shape of small cones or trumpets which causes the
fuel pump is in most cases worn out. Usually this is engine to smoke, or ot will cause sticking of the valve
confirmed by inspection of the fuel pump plunger on spindle. For this reason the nozzle cooling should be
which the helical cut-off edge will show a pitted and well maintained.
corroded area where material is plucked out. In that
case the pump can be provided with a new barrel and
plunger. 7) If the cooling water temperature for the entire
engine has risen to 90-100° C, it should be checked
- by opening the test cocks, if fitted on the discharge
4) The governor will not reduce the fuel pump from cylinders - whether steam has developed. If this
delivery to zero in case of, for instance, failure of the is the case, there is no water on the cooling surfaces,
governor oil pump, but the engine speed will start which may therefore be heated unduly. To avoid
fluctuating. heat stresses arising in cylinder liners and cylinder
heads, if the water returns too early, the engine
When the governor is defective the engine is pro- should be stopped and left to cool, while the discharge
tected against racing by the overspeed trip, i.e. the valve is closed. After 15 minutes it is opened a little
engine is stopped automatically in case of excessive to allow the water to rise slowly in the cooling jackets.
speed. It is essential, therefore, that the overspeed Check filling at test cocks. Make crankcase inspection
trip is kept in perfect order. Regarding governor to ascertain that internal water leakage has not
failure, see special instruction book. arisen. Remember slow turning withopen indicator
valves at subsequent starting-up.
5) Usually a bearing failure will not slow down the

engine appreciably, but the seizure of a piston in the 8) If the lubricating oil pressure drops below the
cylinder liner might do so. If a PG-governor is minimum mentioned in Data; Find the cause of the
employed, the index will increase and exhaust pressure drop and remedy the defect before re-
temperatures rise. If such cases occur, repair is starting the engine. Feel over 5-15-30 minutes after
necessary before starting the engine again. Feel starting, and again when full load is obtained. See
over and look out for oil mist. section 602.
08028-0D/H5250/94.08.12
96.30 - ES0U
Description
Ignition in Crankcase 603.04
Page 1 (1)
Edition 09H
L+V28/32H
Cause 1. Stop the engine
During running, the atmosphere in the crankcase 2. Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of coarse oil drops is flung around everywhere.
If undue friction and thus heating arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is transmitted otherwise to after stopping of 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 on to it. When do not smoke.
the oil vapours condense they form a multitude of
minute drops suspended in the atmosphere, i.e. a 3. Take off all doors on one side of the crankcase.
milky white oil mist is formed, able to nourish and Cut off starting air. Engage turning gear, if fitted.
spread a flame if ignited. Such ignition may be
caused by the same "hot spot" which produced the 4. Locate the hot spot. Powerful lamps should be
oil mist. If a large quantity of oil mist has developed employed at once (in explosion-proof fittings). Feel
before ignition, the burning may cause considerable over all sliding surfaces (bearings, liners, pistons,
pressure rise in the crankcase, forsing the relief roller guides, etc.).
valves to open. In a few cases, when presumably the
whole crankcase has been filled with oil mist, the Look for squeezed-out bearing metal and discolo-
consequential explosion has thrown off crankcase ration by heat (blistered paint, burned oil, heated
doors and caused fire in the engine room. steel).
Every precaution should therefore be taken to (A) 5. Prevent further heating, preferably by making
avoid "hot spots" and (B) discover oil mist in time. a permanent repair. Special attention should be
given to ensure lubricating oil supply and satisfactory
condition of the frictional surfaces involved. It is
A. "Hot spots" in crankcase. equally important to replace filter elements in time.
Overheating of bearings is a result of too bad or 6. Start electrically driven lubricating oil pump
failing lubrication possibly caused by pullution of the and check oil flow from all bearings and splash pipes
lubricating oil. in crankcase while turning the engine through at
least two revolutions. See Description 601.05, Point
It is therefore important that the lubricating oil filtra- 4.1.
tion equipment is in perfect condition. Filter cartrid-
ges must not be used again, if they have been 7. Stop and feel over. Look out for oil mist.
removed from the filter. Check of the oil condition by
analysis is recommended. Especially the frictional surfaces that caused the
heating should be felt over (5-15-30 minutes after
starting, and again when full load is obtained). See
B. Oil mist in crankcase. Description 601.10, Point 2.
08028-0D/H5250/94.08.12
Presence of oil mist may by noted at the vent pipe, 8. In case it has not been possible to locate the
which is usually fitted to the top of the engine frame. hot spot, point 7 should be intensified and repeated
until the cause of the oil mist has been found and
Measures (in case of white oil mist). remedied. In very rare cases oil mist could be due to
"atomization" of lubricating oil by the action of an air
Warning: Keep away from doors and relief valves on jet (for instance blow-by, or blow-by through cracked
crankcase. Do not stay unnecessarily in doorways piston).
near doors of the engine room casing.
96.30 - ES0U
Description 603.06
Page 1 (2) Trouble Shooting Guide for Turbine Starter Edition 09H
L+V28/32H
Motor will not run. No air supply. Check for blockage or damage to air
supply lines or tank.
Damaged motor assembly (12). Inspect motor assembly and power

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

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

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

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

Lubricate relay valve.
Exhaust flow restricted. Check for blocked or damaged

piping. Clean or replace piping.
Check for dirt or foreign material and
clean or remove. Check for ice build-
up. Melt ice and reduce moisture
build-up to starter.
Damaged motor assembly. Replace motor assembly.
Drive (36) of (57) will not engage. No pressure to drive housing port. Check air supply.
Internal drive housing ports blocked. Remove blockage.
Fluid in drive unit components.

Remove fluid.
Damaged or worn piston assembly
(54), o-rings or seals. Replace damaged or worn parts.
O-rings and seals dry. Relubricate o-rings and seals.

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

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

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

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

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

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

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

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

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

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

tank
Air cannot escape on delivery side Vent the system
Leaking shaft seal Check the shaft seal
Pump capacity drops after Air leakages of shaft seal Overhaul the shaft seal
normal operation
Fouled impeller Clean the impeller
Pump does not give maximum Suction valve not fully open Open the suction valve
delivery
Defective seals Replace the seals
Worn impeller and worn wear rings Overhaul the pump
Note! Running troubles with the pump, apart from

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

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

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

procede with phase 2.
Leakage. Fouled or deformed plates. Separate the plate heat exchanger 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 very care-
fully all plates and gaskets.
Assemble the plate heat exchanger
and start it up again.
Note! Even tiny impurities such as
sand grains may cause leakage.
Leakage. Gaskets. Separate the plate heat exchanger.

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

(The fluids get mixed) Corrosion or fatigue fracture. in the following way:
(Phase 1) Remove one of the lower pipe 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 sev-
eral 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
penetrant.
Check defective plates and gaskets.
Before assembling, clean all plates
and gaskets.
and check to find more defective plates,
if any, by putting one side under pres-
sure.
Start up again.
Leakage. Holes in plates.

(The fluids get mixed) Corrosion or fatigue fracture. Close down the plate heat exchanger.
(Phase 2) Separate the plate heat exchanger.
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 chan-
nels unpressurised and free from liq-
uid!
Stop the circulation after a few minutes
08028-0D/H5250/94.08.12
of operation and open the plate heat

exchanger 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 pen-
etrant!
Replace defective plates and gaskets.
Before assembling, clean all plates
and gaskets.
and check to find more defective plates,
if any, by putting one side under pres-
sure.
Start up again.
If the unit is still leaking, check all plates 92.08 - ES0U
with a dye penetrant!
Index Specification and Treatment
Page 1 (1) 604
Lubricating Oil, Fuel Oil and Cooling Water
L28/32H
Description
Lubricating Oil Specification ..................................................................................... 604.01 (09H)
Maintenance of Lubricating Oil Condition ................................................................ 604.03 (07H)
Criteria for Cleaning/Exchange of Lubricating Oil .................................................... 604.04 (09H)
Lubricating Points ..................................................................................................... 604.05 (01H)
Lubricating Oil in Base Frame .................................................................................. 604.06 (09H)
Fuel Oil Specification ................................................................................................ 604.20 (03H)
Fuel Oil Quality ......................................................................................................... 604.25 (01H)
Nomogram for Determination of CCAI ..................................................................... 604.26 (01H)
Analysis Data ........................................................................................................... 604.27 (01H)
Fuel Oil Cleaning ...................................................................................................... 604.30 (01H)
Freshwater System Treatment ................................................................................. 604.40 (01H)
Working Card
Plates
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Lubricating Oil Specification 604.01
General
Requirement Guiding Values
This document is valid for the following engine types: Based on typical load profile for marine GenSet (50-
L16/24, L21/31, L23/30H, L27/38, L28/32H, V28/32H, 60% of rated power)
V28/32S
Oil type TBN TBN TBN
For the engines, a HD-lub. oil (heavy duty) corre- (initial) (equilibrium) (min. level)
sponding to at least type CD Comercial Class D after
API service system (meets MIL-L-2104 C and D) has Gas oil 8-12 6-8 6
to be used.
Marine diesel 10-15 8-10 8
The oil should be rust and oxidation inhibited. Heavy fuel (S<1.5) 10-15 8-10 8
When selecting a lubricating oil, attention must be Heavy fuel (1.5<S<2.5) 15-20 10-14 8
paid to the fuel oil sulphur content.
Heavy fuel (2.5<S<3.5) 20-25 10-14 8
Due to generating running mode for HOLEBY's en- Heavy fuel (3.5<S<4.5) 20-25 10-14 8
gines, where the lub. oil consumption depends on
running time and the fuel oil consumption and follow-
ing the sulphur input to the lub. oil depends on the Based on typical load profile for stationary GenSets
load, a lower TBN-value (Total Base Number) than (50-100% of rated power)
normal for main engines is needed.
(initial) (equilibrium) (min. level)
Viscosity
Gas oil 8-12 6-8 6
Marine
Engine SAE class Heavy fuel (S<1.5) 15-20 8-10 8

L23/30H, L+V28/32H
30* 105 mm2/sec at 40° C Heavy fuel (1.5<S<2.5) 20-25 10-14 8
L16/24, L21/31, L27/38
Heavy fuel (2.5<S<3.5) 20-30 10-14 8
40 145 mm2/sec at 40° C
Heavy fuel (3.5<S<4.5) 20-30 10-14 8
Stationary
L16/24, L21/31, L27/38 Based on typical load profile for variable speed
L23/30H, L+V28/32H, V28/32S engine, pumps (10-100% of rated power)
40 145 mm2/sec at 40° C
08028-0D/H5250/94.08.12
* At cooling water temperatures above 32° C SAE 40 (initial) (equilibrium) (min. level)
oil can be used. In this case, please contact MAN
B&W, Holeby. Gas oil 10-14 6-8 6

If load profile is different, this should be taken in
consideration. Heavy fuel (S<1.5) 15-20 8-10 8
In the long run though, the operation results are the Heavy fuel (1.5<S<2.5) 20-30 10-14 8
criteria that prove which TBN is the most economical
Heavy fuel (2.5<S<3.5) 20-30 10-14 8
one for efficient engine operation.
Heavy fuel (3.5<S<4.5) 25-30 10-14 8
01.24 - ES1
Description 604.03
Page 1 (2) Maintenance of Lubricating Oil Condition Edition 09H
General
General A more economical solution is to maintain the condi-
tion by continuous treatment. Experience has proved
During operation of trunk engines the lubricating oil that centrifuging is superior to other methods of
will be contaminated slowly by small particles origi- cleaning lubricating oils.
nating from the combustion.
The optimum cleaning effect is achieved by keeping
The burning of heavy fuels will normally increase this the lubricating oil in a state of low viscosity for a long
contamination due to the increased content of car- period in the centrifuge bowl.
bon residues and other impurities.
Low viscosity is obtained by preheating the lubricat-
Contamination of lubricating oil with water, fresh or ing oil to a temperature of 85°C - 95°C.
salt, can also take place.
Slow passage of the lubricating oil through the
A certain amount of contaminants can be kept sus- centrifugal separator is obtained by using a reduced
pended in the lubricating oil without affecting the flow rate and by operating the separator 24 hours a
lubricating properties. day, stopping only when cleaning of the bowl is
necessary.
But the condition of the lubricating oil should be kept
under observation by analyzing oil samples. See When treating detergent type lubricating oil, the flow
also 504.04 "Criteria for Cleaning/Exchange of rate is usually recommended to be reduced to 15-
Lubricating Oil". 25% of the rated flow of the separator.
The engine bearings are protected by the full-flow In order to keep the amount of lubricating oil in the
lubricating oil filter built onto the engine, the filter engine in good condition, it is necessary to treat 0.3-
cartridges having a fineness of 15 micron and the 0.4 l/kw per hour.
safety filter a fineness of 60 micron.
A centrifuge for treating this amount of lubricating oil
The condition of the lubricating oil can be main- under the aforementioned derated flow conditions
tained/reestablished by exchanging the oil at fixed should have a rated capacity of 1.5-2.5 l/kw per hour,
intervals or based on analysis results. but in each case the separator manufacturer's rec-
ommendations for capacity and operating instruc-
tions should be followed.
Operation on Marine Diesel Oil (MDO)
For engines with cartridge-type oil filters (depth
The built-on full-flow dept filter cleans the oil thor- filters), continuous and efficient purification of the oil
oughly. For operation on MDO we recommend to in the separator is essential to ensure a long service
install a built-on centrifugal by-pass filter too. life for the cartridge filters.
For cleaning of the lubricating oil system after over-

Operation on Heavy Fuel Oil (HFO) hauls and inspection of the lubricating oil piping
system, see section 515.
08028-0D/H5250/94.08.12
For engines operating on HFO a lub. oil centrifugal

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

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

will generally rise.
Water washing of HD oils must not be carried out.
A high temperature will also arise in electrical preheat-
ers if circulation is not continued for 5 minutes after
the heating has been stopped, or if the heater is only Water in the Oil
partly filled with oil.
If the TAN is low, a minor increase in the fresh water
content of the oil is not immediately detrimental while
Catalytic Action the engine is running. Naturally, it should be brought
down again as quickly as possible (below 0.2%
Oxidation of the oil will be accelerated considerably water content, which is permissible). If the engine is
if catalytic particles are present in the oil. Wear stopped while corrosion conditions are unsatisfac-
particles of copper are especially harmful, but also tory it should be turned just over 1/2 revolution once
ferrous particles and rust are active. Furthermore, every hour (i.e. stop in different positions) while the
the lacquer and varnish-like oxidation products of oil circulation and purifying at a high preheating
the oil itself have an accelerating effect. Continuous temperature continue to remove water. Water in the
cleaning of the oil is therefore important to keep the oil may be noted by steam formation on the sight
sludge content low. glasses, by appearance, or ascertained by immers-
ing a piece of glass or a soldering iron heated to 200-
300°C in an oil sample. If there is a hissing sound,
08028-0D/H5250/94.08.12
Signs of Deterioration water is present. If a large quantity of water has

entered the oil system, it may be profitable to suck up
If circulating oil of inferior quality is used and the sedimented water from the bottom of the tank. Taste
oxidative influence becomes grave, prompt action is the water for salt. If salty, an oil sample should be
necessary as the last stages in the deterioration may analysed immediately for chloride ions.
develop surprisingly quickly, i.e. within one or two
weeks. Even if this seldom happens, it is wise to be
acquainted with the signs of deterioration.
02.16 - ES0 - G
Description
Criteria for Cleaning/Exchange of Lubricating Oil 604.04
General
Replacement of Lubricating Oil 3. Water Content
It is not possible to predict the expected life time for Limit value : < 0.5
lubricating oil, as it is not possible for the engine preferred < 0.2 (higher value is
manufacturer to know which fuel and lubricating oil permissible in a shorter period)
qualities will be used and under which operation
conditions the engine will be operated. Possible test
method : Patable test unit or gas chrom-
A replacement of lubricating oil is required when the atography (or infra red distil).
oil's identification values have changed no that the If the limit value is exceeded, a
lubricating cleaning and neutralization properties no supplementary test for chlorides
longer are sufficient. (ASTM D-878) can be made.
Exchange of the lub. oil has to be based on the oil

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

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

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

actual dispersant value and the
increase in viscosity.
08028-0D/H5250/94.08.12
96.44 - ES1
Description 604.04
Page 1 (2) Criteria for Cleaning/Exchange of Lubricating Oil Edition 14H
General
Replacement of Lubricating Oil 3. Water Content
It is not possible to predict the expected life time for Limit value : < 0.5
lubricating oil, as it is not possible for the engine preferred < 0.2 (higher value is
manufacturer to know which fuel and lubricating oil permissible in a shorter period)
qualities will be used and under which operation
conditions the engine will be operated. Possible test
method : Patable test unit or gas chrom-
A replacement of lubricating oil is required when the atography (or infra red distil).
oil's identification values have changed no that the If the limit value is exceeded,
lubricating cleaning and neutralization properties no a supplementary test for
longer are sufficient. chlorides (ASTM D-878) can
be made.
Exchange of the lub. oil has to be based on the oil
suppliers evaluation of samples of oil in service.
Samples should be forwarded at appropriate inter- 4. Total Base Number (TBN-Number)
vals at least once every three months depending of
running-mode and results of last analysis. Unit : mg KOH/g
The oil sample should be taken after the filter and, if Possible test
possible, while the engine is running as this will method : ASTM D-2896
ensure that the test will be representative for the
whole change in the engine. Guiding TBN values for Stationary GenSets:
Evaluation of the Lubricating Oil Condition Oil type TBN TBN TBN
(initial) (equilibrium) (min. level)
For evaluating the conditions of a used oil, the
following guidance conditions are normally suffi- Gas oil 8-12 6-8 6
cient. Anyway, all parameters have to be evaluated
as a whole, and no single can be taken as a criterion Marine diesel 10-15 8-10 8
for changing oil.
Heavy fuel
(S<1,5) 15-20 8-10 8
1. Viscosity
Heavy fuel
Limit value : < ±1 viscosity grade (1,5<S<2,5) 20-25 10-14 8
Units : SAE-units Heavy fuel

(2,5<S<3,5) 20-30 10-14 8
08028-0D/H5250/94.08.12
Possible test
method : ASTM D-445 (modified) Heavy fuel
(3,5<S<4,5) 20-30 10-14 8
2. Flash Point
Limit value : > 185° C

Guiding values are based on a typical load profile for
power plant GenSet in development area (variation
Possible test
50-100% of rated power)
method : Setaflash tests (cut of point
correlates with 204° C i ASTM
If load profile is different, this should be taken in
D-92 (coc)
consideration.
96.10 - ES1
604.04 Criteria for Cleaning/Exchange of Lubricating Oil Description
General
In the long run though, the operation results are the 6. The Total Contamination (insolubles Con
criteria that prove which TBN is the most economical tent) Heptane insolubles.
one for efficient engine operation.
Limit value : < 1.0 generally, depending
The TBN is normally reduced gradually with the time upon actual dispersant value
of operation. The influential elements are the sulphur and the increase in viscosity.
content in the fuel oil, the lubricating oil amount and
the amount of re-filling due to normal consumption. Unit : Weight %
After a certain time of ope-ration, the TBN will
stabilize at a lower value, the TBN equilibrium. Possible test
method : ASTM D-893 procedure B in
Re-filling should be carried out with lubricating oil of n-Heptane.
the initial TBN.
Additionally
test : If the level in n-Heptane
5. Neutralization Number insolub-les is considered high
for the type of oil and applica-
Limit value : 0.4-1.0 above typical level tion, the test could be followed
by a supplementary determi
Unit : mg KOH/g nation in Toluene.
Possible test Also infra red test can be used.

method : ASTM D-974
08028-0D/H5250/94.08.12
96.10 - ES1
Description
Lubricating Points 604.05
General
Lubricating Oil Types used in the Engine.
Description Lub. Oil Type
Engine system lubricating oil. SAE 30 oil according to lubricating oil specification on page 604.01.
Turbocharger Engine system lubricating oil.
Governor See Governor instruction in section 609.
Air lubricator SAE 10W non-detergent oil.
Alternator See special instructions in section 618 or separate instruction.
Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12
92.02 - ES0U
Description
Lubricating Points 604.05
General
Lubricating Oil Types used in the Engine.
Description Lub. Oil Type
Engine system lubricating oil. SAE 40 oil according to lubricating oil specification on page 604.01.
Turbocharger Engine system lubricating oil.
Governor See Governor instruction in section 609.
Air lubricator SAE 10W non-detergent oil.
Alternator See special instructions in section 618 or separate instruction.
Hydraulic tools Hydraulic oil or turbine oil. (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12
93.05 - ES0U
Description
Lubricating Oil in Base Frame 604.06
L28/32H
Type L28/32H 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.
Min. level H1 (mm) 265 265 265 265 265

08028-0D/H5250/94.08.12
Max. level H2 (mm) 365 365 365 365 365
Min. litre 792 935 1078 1220 1362
Max. litre 1111 1311 1511 1710 1910
99.03 - ES1
Description
Fuel Oil Specification 604.20
General
Commercially available fuel oils with a viscosity up to The data refer to the fuel as supplied, i.e. before
700 cSt at 50° C corresponding to 55 cSt at 100° C any on-board cleaning.
can be used for MAN B&W Holeby 4-stroke medium
speed diesel engines.
For guidance on purchase, reference is made to ISO Property Units Value

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

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

drawn up the guiding HFO-specification shown below.
If heavy fuel oils, with analysis data exceeding the
Heavy fuel oils limited by this specification have, to above figures, are to be used, especially with regard
the extent of the commercial availability, been used to viscosity and specific gravity, the engine builder
with satisfactory results on MAN B&W GenSets. should be contacted for advice regarding possible
changes in the fuel oil system.
01.34 - ES1
604.20 Fuel Oil Specification Description
General
Fuel Oil Condition, when Entering the Engine
As practically all fuel oil specifications including the For fuels above 180 cSt/50° C a pressurerized fuel
above standards refer to the same fuel type as oil system is necessary to avoid boiling and foaming
supplied, the fuel supplied to a ship has to be treated of the fuel.
on board before use. For running on the oil quality
mentioned above it is necessary that equipment The viscosity leaving the heaters should be 10-15
exists on board, which can treat, viz clean and cSt and approx. 12-18 cSt entering the engine. The
preheat, the fuel oil with optimum efficiency. maximum temperature of oil after preheater should
be 150° C to avoid to rapid fouling of preheater.
In B 11 00 0 "Cleaning Recommendations" our
recommendations are outlined. The preheating chart on page 3 illustrates the expect-
ed preheating temperature as function of the specific
For economical HFO operation the fuel oil condition fuel oil viscosity.
at engine inlet should be as recommended below.
Property Units Max. value
Water % by volume max. 0.2
Solid
particles ppm (mg/kg) max. 20
Particle size Micron max. 5
Viscosity cSt Range 12-18
08028-0D\H5250\94.08.12
01.34 - ES1
Description
Fuel Oil Specification 604.20
General
Fuel oil - preheating chart
Approx. viscosity
after preheater
Temperature sec.
cSt
after preheater °C Rw.
7 43
170
160 10 52
Normal preheating limit 12 59

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

200 400 800 1500 3500 7000 sec. Rw/100° F
08028-0D\H5250\94.08.12
Viscosity of fuel
This chart is based on information from oil suppliers regarding typical marine fuels with viscosity index 70-80.
Since the viscosity after the preheater is the controlling parameter, the preheating temperature may vary,
dependent on the viscosity and viscosity index of the fuel.
01.34 - ES1
Description
Fuel Oil Quality 604.25
General
General Considerations Combustion Quality
The quality of a fuel oil is stated, in analysis data, in Combustion quality is the ability of the fuel oil to ignite
terms of physical and chemical properties, which are and burn in a proper way. The ignition quality,
decisive to the suitability of the fuel oil for different combustion intensity, and length and completeness
applications. For diesel engine fuels the combustion of combustion are properties influenced by the
quality, the content of impurities and the handling chemical combustion and structure of the fuel oil.
properties are the main quality criteria.
Ignition quality relates to ignition delay, i.e. the time
Since residual fuels are traded and designated elapsed between the start of injection and the start of
according to viscosity, it has become common combustion.
practice to associate viscosity with quality. This
practice can be very misleading, especially with Ignition quality is expressed by the cetane number,
modern residual fuels, as a fuel oil of low viscosity diesel index or cetane index. In all cases the higher
can often be just as bad, or even worse, than other the value, the better the ignition quality. For diesel oil
fuel oils of very high viscosity. the ignition quality is expressed by the cetane number
determined by a specified method in a standard
The quality of refinery residues is dependent on the engine running under standard conditions.
origin of the crude oil, the grade of utilization when
refining the crude oil, and the refinery technique For residual fuels the ignition quality can be expressed
used. by the diesel index or cetane index, both to be
calculated from physical properties such as the
Some of the residues used in fuel oil production are aniline point, specific gravity and mid-distillation
of a viscosity requiring visbreaking, a process which temperature. The cetane number, diesel index or
will reduce the viscosity without improving the quality cetane index of a certain fuel oil will show reasonable
at all. correlation between the numerical values.
When producing residual fuels from visbreaked, A FIA cetane number test is also good for evaluation
cracked residues and from "straight run" residues, of the combustion quality.
the final adjustment of viscosity to fulfil the
requirements of the different grades of intermediate The combustion condition of the fuel oils is normally
fuels is achieved by adding gas oil. evaluated from Conradson Carbon residue and the
asphaltene contents.
However, it must be noted that considerable reduction
of the viscosity is achieved by adding a relatively
small amount of gas oil, which will give only a minor Content of Impurities
improvement of the quality of the blend. This means
that the quality to a major extent depends on residues The content of impurities of diesel engine fuels
present in the blend. Therefore the quality also should be kept as low as possible, and harmful and
08028-0D/H5250/94.08.12
depends on the density, see 504.26. unwanted impurities should, to the greatest possible
extent, be removed in the pre-treatment system in
As a consequence of the possible variations in the order to minimize wear and corrosion of engine
quality of residues and the influence of adding gas components. Impurities derive from the crude oil
oil, the quality of blended fuels can vary, even for fuel itself, from refinery processes and from handling and
oils of equal nominal viscosity. storage of oils. Some impurities, such as sulphur and
vanadium, are oil soluble and therefore impossible
to remove in a conventional mechanical fuel oil
treatment system, while the amount of water and
solid impurities can be reduced by centrifuging and
filtration.
02.16 - ESO - G
604.25 Fuel Oil Quality Description
General
Sand, rust, metal oxides and catalyst particles can The flash point is related to the volatility of the
be found as solid particles in fuel oil. amount and nature of lighter fractions in the fuel oil,
and might thus be used to estimate the propensity of
Fuel-related wear and corrosion in diesel engines gasification in non-pressurized parts of the fuel
take the form of mechanical wear and chemically system.
induced corrosion, the latter in the form of high and
low temperature corrosion. The pour point defines the temperature at which wax
crystallization will take place and prevent the fuel oil
The solid impurities and particles produced during from flowing and from being pumped.
combustion, collectively known as ash, cause
mechanical wear of engine components. Therefore, the pour point must be taken into account
when deciding the presence and capacity of heating
Especially catalyst particles, silicone and aluminium coils in bunker tanks.
oxides and silicates in the form of sand are very
abrasive. From vanadium and sodium corrosive ash
in the form of oxides, carbonates and sulphates, is Quality Fuel Oil Main Effects
created during combustion. Criteria Characteristics
Combustion Conradson carbon Ignition ability.

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

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

liners and piston rings.
The nominal viscosity is decisive for the preheating
temperature necessary to achieve adequate viscosity Viscosity Temperatures, pressures,
Density and capacities of fuel oil
for pumping, settling, centrifuging and injection.
Handling Pour point systems for storage,
properties pumping and pre-treatment.
The density influences the gravitational settling of
water and solid contaminants in settling tanks. Flash point Safety requirements.
Specific gravity is also an important parameter in the
centrifuging process. The flash point is, for safety Table 1. Fuel properties affecting diesel engine and fuel systems.
reasons, limited to a minimum of 60°C (140°F) by
classification societies and other authorities.
02.16 - ES0 - G
Description
Nomogram for Determination of CCAI 604.26
General
08028-0D/H5250/94.08.12
Fig 1 Nomogram for determination of CCAI.
01.34 - ES1
604.26 Nomogram for Determination of CCAI Description
General
Example: Ignition quality is an important fuel parameter. The

reason why it does not appear in the international
Viscosity: 180 cSt at 50°C specifications is that there are no standardized testing
Density: 990 kg/m³ at 15°C method is non-existent. Therefore, parameters such
as the Calculated Carbon Aromaticity Index (CCAI)
The combining straight line across density (990 kg/ are resorted to as an aid which is derived from
m³) and viscosity (180 cSt) of a heavy fuel oil results determinable fuel parameters. According to our
in CCAI (859). From CCAI, conclusions may be experience, only a rough assessment of the ignition
derived with regard to the ignition qualities. quality of the heavy fuel oil is possible with the help
of this method.
CCAI may be calculated with the aid of the following
formula: However, the CCAI has become so well-known in
widespread publications that, in spite of the
CCAI = D - 141 log (log (v + 0.85)) - 81 reservations mentioned above. We were compelled
to classify the respective MAN B&W Diesel A/S,
Holeby engines according to CCAI-rating, too.
08028-0D/H5250/94.08.12
01.34 - ES1
Description
Analysis Data 604.27
General
Comments on Analysis Data for Fuel Oils Asphaltenes also influences the lubricating proper-
ties of the fuel oil and, in extreme cases, high
Carbon Residue asphalteness content may lead to fuel injection
pump sticking.
The carbon residue of a fuel oil indicates its coke-
forming tendency and can be used to determine the Fuel oils with a high asphalteness content will have
tendency to form deposits in the combustion cham- a tendency to form sludge, especially if the water
ber and gasways. The higher the carbon residue content is also high. The asphaltenes content of a
value, the higher the fouling tendency. fuel oil is influenced by pre-treatment. The heaviest
semi-solid asphaltenes, and asphaltenes bound to
Some changes in the combustion process, requiring water as sludge, can be separated by centrifuging.
adjustment of the maximum pressure, may also be
attributed to a high carbon residue content. The
value is measured by standardized tests, such as Diesel Index
the Conradson or Ramsbottom tests which give
similar results. Diesel index is a calculated value to determine the
ignition quality of a fuel oil. The ignition quality is
The non-vaporized residue from the carbonizing test related to the hydrocarbon composition, paraffin
consists of carbonaceous material and inorganic being of high quality, n-heptanes of moderate quality
impurities and is expressed as percentage weight of and aromatics of low quality.
the fuel sample tested. Carbon residue and
asphaltenes content generally move in parallel, both With certain exceptions the properties of the aniline
in relation to the carbon-to-hydrogen ratio, with in- point and the specific gravity reflect the hydrocarbon
creasing values for a higher ratio. composition of a fuel oil, and are therefore used in
the following simple formula as an expression of
The carbon-to-hydrogen ratio and thus also the ignition quality:
carbon residue depends on the source of the crude
oil and the type of refinery processing used. Diesel index = (aniline point °F x API gravity) x 0.01.
The effect of carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment of the fuel oil, as centrifuging equal volumes of the fuel and aniline become just
only influences solid inorganic contaminants and miscible. The test relies on the fact that aromatic
hard asphalts, which are only small amounts of the hydrocarbons mix completely with aniline at com-
percentage weight called carbon residue. paratively low temperatures, whereas paraffins re-
quire considerably higher temperatures before they
are completely miscible.
Asphaltenes
A high aniline point thus indicates a highly paraffinic
Asphaltenes is defined as the part of a fuel oil sample fuel, and consequently a fuel oil of good ignition
which is insoluble in heptane. The content of quality. Similarly, a high API gravity number denotes
08028-0D/H5250/94.08.12
asphalteness is expressed as percentage weight of a low specific gravity and high paraffinicity, and
the fuel oil sample tested. again a good ignition quality.
Asphaltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea of the
solid hydrocarbon compounds dispersed in the fuel ignition quality, but generally gives figures slightly
oil, has a similar effect on the combustion process to above the cetane number.
the carbon residue, the main impact being fouling of
gasways. The stability of the fuel oil is related to the Fuel oils with poor ignition quality and a low diesel
asphaltenes content. index might in particular cause problems in starting
diesel engines and running at low load.
02.16 - ES0 - G
604.27 Analysis Data Description
General
In addition to starting difficulties, a prolonged ignition Especially if the weight ratio of sodium to vanadium
delay may give rise to alternations in the maximum exceeds 1:3, ash with a very low melting point and
pressure, leading to increased mechanical or ther- stiction temperature is formed, giving rise to high
mal load. temperature corrosion of exhaust valves and de-
posit formation in turbochargers.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling It is possible to reduce the tendency for formation of
of gasways. detrimental vanadium-sodium ash by effective cen-
trifuging, which will remove sodium salts together
with water. If a very low content of sodium is ensured,
Sulphur a relatively high vanadium content might be accept-
able.
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free Water
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low The water content of fuel oil is measured by a
temperature corrosion. During combustion, sulphur standardized distillation test and is expressed as
oxides are produced in the form of gases. Since percentage volume of the sample tested. Water in
humidity is also present sulphur and sulphuric acid the fuel oil may lead to several detrimental effects on
may be formed on components in the combustion the fuel oil system, and corrosion and cavitation of
chamber and in the gasways, where the temperature fuel injection pumps and fuel valves, and cause
is below that of the dew point for sulphuric acid. fouling of exhaust systems and turbochargers.
The detrimental effect of sulphur in fuel oil is counter- Due to its content of sodium, salt water in combina-
acted by maintaining an adequate temperature of tion with vanadium contributes to the formation of
the combustion chamber components and by using low-melting corrosive ash, which attacks exhaust
alkaline lubricating oil to neutralize the sulphuric acid valves and turbochargers. When it disturbs the fuel
produced during combustion. atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
It is possible to reduce the water content of a fuel oil
Vanadium and sodium are constituents of the ash primarily by centrifuging, and this should be done to
content. The amounts of these are measured by the widest possible extent in order to avoid the
analyzing the residue from the combustion test used detrimental effects of water in the fuel oil.
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil Ash
sample being tested for ash content. Vanadium
08028-0D/H5250/94.08.12
derives from the crude oil itself and, being oil soluble, Ash content is a measure of the non-combustible
cannot be removed from the fuel oil by conventional material present in the fuel oil. The ash content is
pre-treatment. Sodium derives from the crude oil, determined by a combustion test and it is expressed
and also from contamination with salt water during as a percentage weight residue from complete com-
storage and transport of the fuel oil. Sodium is water- bustion of the oil sample tested.
soluble and, regardless of derivation, tends to com-
bine with the water present in the fuel oil. Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
Owing to its water solubility, it is possible to remove contamination of the fuel oil.
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.
02.16 - ES0 - G
Description
Analysis Data 604.27
General
Ash-forming materials exist both as solid contami- Viscosity of Marine Gas Oil (MGO) and Marine
nants and in soluble compounds. The solid contami- Diesel Oil (MDO) are expressed in centistokes (cSt)
nants may lead to abrasive wear in the fuel injection at 40° C.
system. Ash formed during combustion may lead to
abrasive as well as corrosive wear of combustion Viscosity is an important parameter in connection
chamber components and give rise to formation of with pumping, pre-treatment and injection of fuel oil,
detrimental deposits. It is therefore essential, to the since the possibility and efficiency of these processes
greatest possible extent, to reduce the amount of to a large extent depend on adequate viscosity.
ash-forming materials by centrifuging.
Adjustment of viscosity to adequate values is possible
Solid contaminants such as sand, rust, certain metal by taking advantage of the interdependence between
oxides and catalyst fines can be removed by centri- the temperature and viscosity index of the fuel oil.
fuging, and the same goes for water-soluble salts
such as sodium. The nominal viscosity of a fuel oil is the factor
determining the preheating temperatures necessary
Some of the components included in the ash content to obtain adequate viscosity for pumping, centrifug-
have been found to be particularly harmful and are ing and injection of the fuel oil, and thus also the
therefore stated individually in the analysis data. factor determining the capacity of the preheating
equipment in the fuel oil system.
Silicium and Aluminium Oxides

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

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

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

Installation- Density g/ml fire risk during storage, handling and transportation,
Relevant Flash Point °C fuel oils for shipboard use must meet the classifica-
Properties Pour Point °C
tion societies' requirements of flash point, limited to
a minimum of 60°C (140°F).
Table 2 Analysis data for fuels.
08028-0D/H5250/94.08.12
02.16- ES0 - G
Description
Fuel Oil Cleaning 604.30
General
Purification Recommendations. RW/100°F) the highest possible temperature 98°C
(208°F) should be maintained in the centrifuge oil
Fuel oils are always contaminated and should therefore preheater.
be thoroughly cleaned for solid as well as liquid
contaminants before use. The solid contami-nants in The fuel is kept in the centrifuge as long as possible
the fuel are mainly rust, sand, dust and re-finery by adjusting the flow rate through the centrifuge so
catalysts. Liquid contaminants are mainly water, i.e. that it corresponds to the amount of fuel required by
either fresh water or salt water. the engine without excessive re-circulating.
Consequently, the centrifuge should operate for 24
The impurities can cause damage to fuel pumps and hours a day except during necessary cleaning.
fuel valves, can result in increased cylinder liner wear
and deteriorate the exhaust valve seats. Also increased Taking today's fuel qualities into consideration the
fouling of gas ways and turbocharger blends may need for cleaning centrifuges ("shooting frequency")
result from the use of inadequately cleaned fuel oils. should not be underestimated. Correct choice and
adjustment of the regulating screws and/or the gravity
Effective cleaning can only be ensured by means of discs are of special importance for efficient water
a centrifuge. We recommend the capacity of the removal. The centrifuge manual states the disc or
installed centrifuges to be at least according to the screw adjustment which should be chosen on the
centrifuging maker's recommendations. To obtain basis of the specific gravity of the fuel.
optimum cleaning it is of the utmost importance to
operate the centrifuge with as low a viscosity of the Normal practice is to have at least two centrifuges
fuel oil as possible and allow the fuel oil to remain in available for fuel cleaning. Results from experimental
the centrifuge bowl as long time as possible. work on centrifuges, treating today's qualities of
residual fuel, have shown that the best cleaning
Especially for fuels above 180 cST/50°C (1500 sec. effect, especially as regards removal of catalyst fines
is achieved when the centrifuges are operated in
series, in purifier/clarifier mode.
Cleaning of H.F.O. by Centrifuging
Therefore - series operation of centrifuges ensuring a

Operating Single centrifuge as purifier.
maximum of safety is a fully accepted alternative to
options Two centrifuges in parallel.
the previously recommended parallel operation,
Two centrifuges in series.
provided the operating capacity of each individual
Optimum operating configurations centrifuge can handle the total amount of fuel required
by the engine, without exceeding the flow rate
Water content Parallel operation recommended by the centrifuge maker for the operating
below 1 % Purifier / Purifier mode in question.
Normal
conditions or
Density at 15°C Series operation If the installed centrifuge capacity is on the low side
below 0.991 Purifier + Clarifier corresponding to the specific viscosity of the used
fuel oil and if more than one centrifuge is available,
parallel operation in order to obtain an even lower flow
08028-0D/H5250/94.08.12
Water content
below 1 % Parallel operation rate may be considered. However, in view of the
above results and recommendations serious
Extreme Density at 15°C Purifier / Purifier considerations should be given to installing new
conditions below 0.991 equipment in correspondance with today's fuel
qualities and flow recommendation.
High content Series operation
of catalyst fines Purifier + Clarifier For the determination of centrifuging capacity, we
Table 1. Cleaning of HFO.
92.04 - ES0S
604.30 Fuel Oil Cleaning Description
General
generally advise to follow the recommendations of the

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

capacity of centrifuge.
08028-0D/H5250/94.08.12
92.04 - ES0S
Description
Freshwater System Treatment 604.40
General
Protection against Corrosion in Freshwater Cleaning agents emulsified in water as well as slightly
Cooling System alkaline cleaning agents can be used for the degrea-
sing process, whereas ready-mixed cleaning agents
The engine fresh water must be carefully treated, which involve the risk of fire must obviously not be
maintained and monitored so as to avoid corrosion or used. For descaling with acid, especially products
the formation of deposits which can result in insuffi- based on amino-sulphonic acid, citric acid, and tar-
cient heat transfer, it is necessary to treat the cooling taric acid are recommendable, as these acids are
water. MAN B&W recommend that this treatment is usually obtainable as solid substances, easily solu-
carried out according to the following procedure: ble in water, and do not emit poisonous vapours.
The cleaning agents should not be directly admixed,

– Clean the cooling water system. but should be dissolved in water and then added to the
cooling water system.
– Fill up with deionized or distilled cooling water
(for example from the freshwater generator) Normally, cleaning can be executed without any
with corrosion inhibitor added. dismantling of the engine. We point out that the water
should be circulated in the engine to achieve the best
– Carry out regular checks of the cooling water possible result.
system and the condition of the cooling water.
As cleaning can cause leaks to become apparent in
poorly assembled joints or partly defective gaskets,
Observance of these precautions, and correct ven- inspection should be carried out during the cleaning
ting of the system, will reduce service difficulties process. The acid content of the system oil should
caused by the cooling water to a minimum. also be checked immediately after cleaning, and 24
hours afterwards.
Cleaning of the Cooling Water System

Cooling Water - Inhibitors
Before starting the inhibition process, any existing
deposits of lime or rust, or any oil sludge, should be The filling-up with cooling water and the admixture of
removed in order to improve the heat transfer and to the inhibitor is to be carried out directly after the
ensure uniform protection of the surface by means of cleaning in order to prevent formation of rust on the
the inhibitor. cleaned surfaces.
The cleaning should comprise degreasing to remove Raw Water

oil sludge, and descaling with acid afterwards to
remove rust and lime deposits. The formation of lime stone on cylinder liners and in
cylinder heads may reduce the heat transfer, which
Ready-mixed cleaning agents, specially made for will result in unacceptably high temperatures in the
cleaning the cooling water system, can be obtained material.
08028-0D/H5250/94.08.12
from companies specializing in cooling water treat-

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

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

A clear record of all measuring results should be kept,
Evaporated cooling water is to be replaced with so that the actual condition and trend of the system
noninhibited water, whereas a loss of water through may be currently ascertained and evaluated.
leakage must be replaced with inhibited water.
A sudden or gradual increase in the chloride content
When overhauling individual cylinders, a new dosage of the cooling water may be indicative of salt water
of inhibitor must, if necessary, be added im-mediately leakages. Such leakages are to be traced and repai-
after completing the job. red at the first opportunity.
00.11- ES1
Description
General
A chloride content in the cooling water higher than the The cooling water system must not be kept under
50 ppm specified might, in exceptional cases be pressure.
tolerated. However, in that case the upper limit speci-
fied by the individual inhibitor supplier must not be Check, and repair any leaks.
exceed.
Drain the system and fill up completely with clean tap
A clear record of all measuring results should be kept, water, in order to flush out any oil or grease from the
so that the actual condition and trend of the system tank.
may be currently ascertained and evaluated.
Circulate the water for 2 hours, and drain again.
A sudden or gradual degrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased by Descaling with Acid Solution
adding inhibtor; however, if major quantities are ne-
cessary, the water should be replaced. Fill up with clean tap water and heat to 70-75° C.
Every third month a cooling water sample should be Dissolve the necessary dosage of acid compound in
sent ashore for laboratory analysis, in particular to a clean iron drum with hot water.
ascertain the contents of inhibtor, sulphate, and iron,
as well as the total salinity of the water. Fill the drum half up with water and slowly add the acid
compound, while stirring vigorously. Then fill the drum
up completely with hot water while continuing to stir
Cleaning and Inhibiting Procedure (e.g. using a steam hose).
The engine must not be running during the cleaning Be careful - use protective spectacles and gloves.
procedure, as this may involve the risk of overheating
when draining. For engines which have been treated before the trial
trip, the lowest concentration recommended by the
supplier will normally be sufficient.
Degreasing
For untreated engines, a higher concentration - de-
Use clean tap water for filling-up. The cooling water in pending on the condition of the cooling system - will
the system can be used, if it does not contain normally be necessary.
inhibitors.
Drain some water from the system and add the acid
Heat the water to 60° C and circulate the water solution via the expansion tank.
continuously.
The cooling water system must not be put under
Drain to lowest water level in expansion tank. pressure.
08028-0D/H5250/94.08.12
Add the amount of degreasing chemical specified by Keep the temperature of the water between 70° C and
the supplier, preferably from the suction side of the 75° C, and circulate it constantly. The duration of the
freshwater pump. treatment will depend on the degree of fouling. Nor-
mally, the shortest time recommended by the supplier
Drain to lowest water level in the expansion tank will be sufficient for engines which are treated before
directly afterwards. the trial trip. For untreated engines, a longer time must
be reckoned with. Check every hour, for example with
Circulate the cleaning chemical for the period speci- pH-paper, that the acid in the solution has not been
fied by the supplier. used up.
00.11- ES1
604.40 Freshwater System Treatment Description
General
A number of descaling preparations contain colour Adding of Inhibitors

indicators which show the state of the acid solution.
If the acid content is exhausted, a new acid solution Fill up the cooling water system with water from the
can be added, in which case, the weakest recom- evaporator to the lowest water level in the expansion
mended concentration should be used. tank.
The solubility of acids in water is often limited. Weight out the quantity of inhibitors specified by the
Therefore if, in exceptional cases, a large amount is supplier and dissolve in a clean iron drum with hot
required, descaling can be carried out in two stages water from the evaporator.
with a new solution of compound and clean water.
Normally the supplier will specify the maximum solu- Add the solution via the expansion tank to the sys-
bility. tem. Then fill up to normal water level with water from
the evaporator.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized with Allow the engine to run for not less than 24 hours to
clean tap water containing 10 kg soda per ton of water. ensure that a stable protection of the cooling surfaces
Circulate the mixture for 30 minutes, then drain and is formed.
flush the system.
Subsequently, test the cooling water with a test kit
The cooling water system must not be put under (available from the inhibitor supplier) to ensure that an
pressure. adequate inhibitor concentration has been obtained.
Continue to flush until water used is neutral (pH This should be checked every week.
approx. 7).
The acid content of the system oil is to be checked
directly after the descaling with acid, and again 24
hours afterwards.
08028-0D/H5250/94.08.12
00.11- ES1
Description
General
Nitrite-borate corrosion inhibitors

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

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

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

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

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

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

Marine Chemicals Rocor NB Liquid Liquid 10 l/1000 l
Oslo, Norway
* Initial dosage may be larger

08028-0D/H5250/94.08.12
The list is for guidance only and must not be The suppliers are listed in alpabetical order.
considered complete. We undertake no responsibil-
ity for difficulties that might be caused by these or Suitable cleaners can normally be supplied by these
other water inhibitos/chemicals. firms.
00.11- ES1
Index
Page 1 (1) Cylinder Head 605
L28/32H
Description
Cylinder Head ........................................................................................................... 605.01 (14H)
Working Card
Dismantling of Cylinder Head .............................................................................. 605-01.00 (01H)
Inspection of Inlet Valve, Exhaust Valve and Valve Guide .................................. 605-01.05 (04H)
Reconditioning of Valve Spindle Seat and Valve Seat Ring ................................ 605-01.10 (01H)
Valve Rotator ....................................................................................................... 605-01.15 (01H)
Replacement of Valve Guide ............................................................................... 605-01.20 (01H)
Safety Valve ......................................................................................................... 605-01.25 (04H)
Indicator Valve ..................................................................................................... 605-01.26 (02H)
Replacement of Sleeve for Fuel Injector ............................................................. 605-01.30 (01H)
Replacement of Valve Seat Ring ......................................................................... 605-01.35 (01H)
Mounting of Cylinder Head .................................................................................. 605-01.40 (01H)
Inspection of Cylinder Head Cooling Water Space ............................................. 605-01.45 (01H)
Plates
Cylinder Head ............................................................................................................... 60501-13H
Valve Spindles and Valve Gear .................................................................................... 60502-21H
Safety Valve and Indicator Valve .................................................................................. 60508-11H
Cylinder Head, Top Cover ............................................................................................ 60510-12H
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Cylinder Head 605.01
Page 1 (1)
Edition 14H
L/V28/32H
General Valve Rotator
The cylinder head is made of cast iron and is The retainer body of the valve rotator (1) has a
tightened to form a gas-tight seal against a sealing number of pockets, arranged in circumferential
ring on the cylinder liner by means of 6 nuts and 6 direction, with balls that are forced against the upper
studs, which are screwed into the engine frame. The end of an inclined race by coil springs acting in
nuts are tightened by means of hydraulic jacks. tangential direction. The ball race (3) serves as ball
track in the opposite direction. The spring washer (4)
Each cylinder head is equipped with two air inlet and seats against the inner rim of the retainer body and
two exhaust valves which are actuated by rocker is encased by the seating collar (5) which overlaps
arms running in bearings on a shaft supported in a it. The assembled valve rotator is held together,
bracket on top of the cylinder head. when removed, by the retaining ring (6).
The fuel injection valve (see section 614) is located

in a interchangeable sleeve in the center of the
cylinder head.
7
Furthermore the cylinder head is equipped with an
indicator valve and a safety valve. 1
2
3
The cylinder head has a screwed-on coaming which
encloses the valves. The coaming is closed with a
top cover and thus provides an oil tight enclosure for 4
the valve gear. The coaming is equipped with an 5
inspection cover for the rotators.
6
1 Retainer body 4 Spring washer

Air Inlet and Exhaust Valves 2 Balls 5 Seating collar
3 Ball race 6 Retainer ring
The inlet valve spindles are identical to the exhaust 7 Valve spindle
spindles.
Fig. 1. Valve rotator
The valves are made of heat-resistant material.
Hard metal is welded on to the valve spindle seats
to avoid depressions by combustion particles.
As the valve starts to open, the increasing valve
The valve spindles are fitted with valve rotators spring-load causes the spring washer to flatten, and
which turn the spindles a little each time the valves the load applied to the balls in the pockets of the
open. retainer body forces the balls in the ball race to roll
down the inclined races. The transfer of the reaction
08028-0D/H5250/94.08.12
The cylinder head is equipped with interchangeable load of the ball race to the spring washer reduces the
seat rings and valve guides for inlet and exhaust reaction load of the spring washer on the inner rim
valves.The valve seat rings and valve guides for of the retainer body. Ball race, spring washer,
inlet and exhaust valves are identical. seating collar and valve springs are, however, force-
locked by friction grip. The reaction load of the balls
The seat rings are made of heat-resistant steel, on the inclined races induces rotation to the retainer
directly hardened on the seating surface and the seat body and valve with relation to the seating collar and
rings are directly water cooled in order to assure low the valve springs. As the valve closes, load is
valve temperature. released from the spring washer and thus from the
balls, allowing them to be returned to their original
positions without rolling by the tangential force of the
coil springs.
90.44 - ES0S
Working Card
Dismantling of Cylinder Head 605-01.00
L/V28/32H

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

Related procedure:
Dismounting of piston and connecting

rod, 606-01.00
Dismounting and inspection of inlet valve,
exhaust valve and valve guide, 605-01.05
Safety valve, 605-01.25
Dismantling, overhaul and test
pressure of fuel oil valve, 614-01.10
08028-0D/H5250/94.08.12
Man power: Replacement and wearing parts:
Working time : 1 Hour Plate no. Item no. Qty./

Capacity : 2 men
Data:

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

V28/32H
7) Remove the thermometer attachment branch L28/32H
(cooling water outlet pipe).
Fig. 2
Fig. 1
08028-0D/H5250/94.08.12
91.45 - ES0S
Working Card
Inspection of Inlet Valve, Exhaust Valve and 605-01.05
Page 1 (3) Valve Guide Edition 06H
L+V28/32H
Safety precautions Special tools
Stopped engine Plate no Item no Note

Shut-off fuel oil 62005 05
Shut-off cooling oil 62005 25/30 Extra tools
Stopped lub. oil circul. 62005 55
Description
Dismounting of inlet and exhaust valve, inspec-

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

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

and valve seat ring, 605-01.10
Valve rotator, 605-01.15
Replacement of valve guide, 605-01.20
Replacement of valve seat ring, 605-01.35
Mounting of cylinder head, 605-01.45
08028-0D/H5250/94.08.12
Man power Replacement and wearing parts
Working time : 1 hour Plate no Item no Qty. /

Capacity : 1 man
60501 017 4/cyl.
Data

00.43 - ES0
605-01.05 Inspection of Inlet Valve, Exhaust Valve and Working Card
Edition 06H Valve Guide Page 2 (3)
L+V28/32H
Dismantling of Inlet and Exhaust Valve 3) Turn back the rocker arm and remove the
Spindles spring-loaded valve bridge over the valve spind-
les.
1) Land and fasten the cylinder head upon the
special work table and remove the lifting tool. 4) After having removed the valve bridge and
turned the rocker arm back, the tool should be
fitted by means of the screws (A), see fig 2
Or as an Alternative: tightened in the threaded holes in the cylinder
head.
Land the cylinder head on the floor upon wooden
supports and remove the lifting tool.
2) Mount the supporting devices for the valve

spindle heads on the work table.
Or as an Alternative:
Place wooden blocks under the valve spindle heads.
V28/32H
L28/32H
Fig 2
5) Now compress the valve springs by tightening

the nut (B), after which the cone rings can be
re-moved, see fig 3.
08028-0D/H5250/94.08.12
Fig 1 Fig 3
00.43 - ES0
Working Card Inspection of Inlet Valve, Exhaust Valve and 605-01.05
Page 3 (3)
Valve Guide Edition 04H
L+V28/32H
6) Release the springs again. Remove the nut (B) Inspection of valve guide
and the traverse (C). Now valve rotator and
springs can be removed. 10) Too much clearance between valve spindle
and spindle guide may cause increased lub. oil
7) Remove the supporting devices under the consumption, fouling up of the spindle guide
work table and take out the valve spindle. and thus give the risk of a sticking valve
spindle.
8) Repeat point 4 - 7 to remove the two other
valve spindles. Too much clearance also means insufficient
guid-ance of the valve spindle, and thus bad
alignment between spindle head and valve
Inspection of Valves/Valve Seats seat ring. In connection with overhaul of the
cylinder head, the valve spindle guides should
9) A slight grinding of valve/valve seat can be be cleaned, inspected and measured for wear.
carried out by means of the handle as shown, If the inner diameter of the valve spindle guide
see fig 4. exceeds the tolerance, see page 600.35 the
valve spindle guide must be replaced. See
If the valve seat is heavily burnt or scarred, it should working card 605-01.20.
be ground using the valve seat grinder according to
working card 605-01.10. 11) For mounting of valve spindle follow the
instructions in point 4 - 7 in reversed order.
08028-0D/H5250/94.08.12
Fig 4 Fig 5
00.43 - ES0
Working Card Reconditioning of Valve Spindle Seat 605-01.10
Page 1 (3) and Valve Seat Ring Edition 01H
L/V28/32H

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

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

the tools box for grinding machine.
Starting position:
Valve spindle has been removed, 605-01.05
Related procedure:
Mounting of valve spindle, 605-01.05

08028-0D/H5250/94.08.12
Working time : 6 Hours Plate no. Item no. Qty./

Capacity : 1 man
Data:

91.45 - ES0S
605-01.10 Reconditioning of Valve Spindle Seat Working Card
Edition 01H and Valve Seat Ring Page 2 (3)
L/V28/32H
Reconditioning of Valve Seat Ring. However when the seat "S" has been ground to such
an extent, that the recess "R" disappears, the valve
Reconditioning of valve seat rings by machining is seat ring has to be scrapped and a new one to must
carried out by means of a grinding machine, the pilot installed, see working card 605-01.35
spindle of which is to be mounted in the valve spindle
guide. For operation of the grinding machine, see
separate instructions. Reconditioning of Valve Spindle.
The grinding of the valve seat ring should be carried Reconditioning by machining is carried out with the
out according to the following sequence: valve spindle being rotated in a turning lathe and a
special grinding machine mounted on the tool post of
1) The seating surface itself is ground with a feed the turning latch.
at an angle "A" of 30° ± 0,10°.
0.
For operation of the grinding machine, see separa-
The grinding should be continued until a clean and ted instructions.
uniform surface condition has been obtained.
1) The seating surface itself is ground with a feed
Carry out the final grinding with a feed in direction at an angel "A" of 30° ± 0.0,25°.
from inside to outwards, as normally the best surface
quality is obtained in this way. 2) The grinding shoud be continued until a clean
and uniform surface condition has been obtained.
3) After completing the grinding, the height "H"1

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

ped.
08028-0D/H5250/94.08.12
"H"1
Fig. 1.
0
"A" 30° ± 0,25°
2) Normally the valve seat ring can be recondi-

tioned several times.
Fig. 2.
91.45 - ES0S
Working Card Reconditioning of Valve Spindle Seat 605-01.10
Page 3 (3) and Valve Seat Ring Edition 01H
L/V28/32H
After assembling the valves, check - on account of

the valve motion - that distance "H"2 between the
upper edge of the cylinder head and the upper edge
of the valve spindle does not exceed the maximum
value, see page 600.35.
"H"2
Fig. 3.
08028-0D/H5250/94.08.12
91.45 - ES0S
Working Card
Valve Rotator 605-01.15
L/V28/32H

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

rotator. Hand tools:
Small screw driver.

Starting position:
Valve spindles has been removed, 605-01.05
Related procedure:
Mounting of valve spindles, 605-01.05

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

Capacity : 1 man
Data:

91.45 - ES0S
605-01.15 Valve Rotator Working Card
L/V28/32H
Inspection of Rotocap. When inserting the balls and the tangential springs,
note that all balls on the inclined races of the ball
Dirt especially in the ball pockets due to residues in pockets point in the same direction, see fig. 1.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and hinder the
movement of the balls.
Rotocap valve rotators need no servicing under

normal operating conditions.
Unusual operating conditions may lead to disturban-

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

condition it should be placed in clean lubricating oil
Valve rotators should be cleaned and inspected for for a short period of time.
wear and ball impressions whenever the valves are
removed. The individual parts can be disassembled
after removal of the retaining ring, by means of which Mounting of Rotocap
the seating collar is fastened to the retainer body.
See working card 605-01.05, point 3 to 6 , opposite
Parts showing wear grooves or depressions formed direction.
by the balls should be replaced.
08028-0D/H5250/94.08.12
91.45 - ESOS
Working Card
Replacement of Valve Guide 605-01.20
Page1 (2) Edition 05H
L+V28/32H

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

and exhaust valve. Hand tools
Hammer.
Nitrogen (N2), or similar.
Starting position
Valve spindle has been removed, 605-01.05
Related procedure

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

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

00.43 - ES0
605-01.20 Replacement of Valve Guide Working Card
L+V28/32H
If the clearance exceeds the shown max. limit, (see 3) Before mounting the new valve guide, it has to
page 600.35), the valve guide must be replaced. be cooled down to approx. -70°C with nitrogen
or similar.
Dismounting of valve guide When the new valve guide has been inserted
into the bore be sure that the shoulder bears
1) The valve guide is knocked out from the bot- against the cylinder head, by knocking slightly
tom of the cylinder head,by means of a mandrel, with the mandrel and a hammer.
which has a shoulder turning that fits into the
valve guide, see fig. 1. 4) Before mounting of the valve spindle insert a
new o-ring in the valve guide.
Valve seat ring
Mandrel
Fig 2.
Valve guide
08028-0D/H5250/94.08.12
Correct mounting can easily be done by the use of

two valve spindles as mounting tool, one spindle to
be used as support and the other spindle to be used
Fig 1 for pushing the o-ring downwards.
Screw drivers or other sharp tools should never be

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

Shut-off cooling water 62014 01 Pressure test
Shut-off fuel oil pump.
Shut-off cooling oil 62014 04 Pipe for fuel
Stopped lub. oil circul. injector
Description:
Dismantling, inspection, reassembling and

pressure testing of safety valve. Hand tools:
Open end spanner, 32 mm.

Small hammer.
Copaslip.
Starting position:
Related procedure:
Indicator valve 605-01.26
Man power:
08028-0D/H5250/94.08.12
Working time : 1 hour Replacement and wearing parts:

Capacity : 1 man
Plate no Item no Qty. /
60508 14 1/cyl.
Data:

96.27 - ES0S
605-01.25 Safety Valve Working Card
L+V28/32H
Maintenance and Checking. 2. Reassembling.
During extended periods of standstill and at general 2.1 Lubricate the threads on valve housing (2)
engine overhauls, the safety valves should be tho- with copaslip or similar.
roughly cleaned.
2.2 Reassemble the safety valve, reverse
Note: Do not attempt to stop a safety valve from sequence of operations outlined above, point 1.1 to
leaking by increasing the spring load. 1.5.
The setting of the opening pressure is stamped onto

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

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

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

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

OK Continue with point 3.5.
Scrap the valve.

08028-0D/H5250/94.08.12
1.2 Clamp valve in vice. below 135 bar or
1.3 Unscrew cap nut (1). Lap the valve cone and
seat.
1.4 Remove pressure spring (3), valve spindle
(4) and valve cone (6).
1.5 Inspect and carefully clean all parts and

condition valve, if necessary.
96.27 - ES0S
Working Card
Safety Valve 605-01.25
L+V28/32H
Test of Opening Pressure 4. Adjustment of Opening Pressure
3.5 Increase the pressure to the opening pres- 4.1 Increase the pressure to the opening pres-
sure. sure.
4.2 Turn the cap nut (1) to the correct opening

pressure.
If the opening pressure is Then
4.3 Drill a new hole for mounting of split pin (5).
OK The procedure is ended.
5. Mounting of Safety Valve

Not OK The valve must be
adjusted, see point 4. 5.1 Lubricate the threads on the valve housing
(2) with copaslip or similar.
5.2 Mount the safety valve on the cylinder head.

08028-0D/H5250/94.08.12
96.27 - ES0S
Working Card
Indicator Valve 605-01.26
L+V28/32H
Stopped engine Plate No Item No Note

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

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

Steel brush
Copaslip
Starting position:
Related procedure:
Safety valve 605-01.25
Man power:
08028-0D/H5250/94.08.12
Working time : 1/2 hour

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

Data for torque momen (Page 600.40)
94.26 - ES0S
605-01.26 Indicator Valve Working Card
L+V28/32H
Maintenance
By normal working conditions the indicator valve

require very little maintenance except an inspection
in connection with the normal cylinder cover overhaul.
Inspection of the Indicator Valve:
1. Disassemble the indicator valve.
2. Check the valve seat and the cone for "burning

through".
If the valve seat in the housing is "burned", the entire

valve is to be replaced.
1. Indicator valve, complete
3. Clean and lubricate all components before 2. Connecting piece
remounting.
4. Ensure that the spindle is in "OPEN" position

when assembling the valve. Fig 1 Indicator valve.
NOTE: Otherwise cone and seat may be damaged.
08028-0D/H5250/94.08.12
94.26 - ES0S
Working Card
Replacement of Sleeve for Fuel Injector 605-01.30
L+V28/32H

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

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

08028-0D/H5250/94.08.12

Capacity : 1 man
60501 125 1/cyl.
Data 60501 137 1/cyl.
60501 149 1/cyl.
00.43 - ES0
605-01.30 Replacement of Sleeve for Fuel Injector Working Card
L+V28/32H
Dismounting of Sleeve for Fuel Injector 4) Coat the sealing ring zone in the bore with
grease or lub. oil.
1) Remove the snap ring by means of two screw
drivers.
2) The sleeve can now be driven out of the bore Snap ring
by use of a brass mandrel and a hammer. O-ring
Sleeve
Loctite 572
Brass mandrel
Fig 2
5) Install new sealing rings on the sleeve.
6) Coat the sealing surfaces on the sleeve with

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

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

head. Any marks which could prevent mounting
of the sleeve, should be gently smoothed.
08028-0D/H5250/94.08.12
00.43 - ES0
Working Card
Replacement of Valve Seat Ring 605-01.35
L/V28/32H

Shut-off fuel oil 62021 50 1 piece
Shut-off cooling oil 62005 45 Extra tools
Stopped lub. oil circul. 62005 50 Extra tools
62021 46 1 piece
Description:
Replacement of valve seat ring, for inlet and

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

removed, 605-01.05
Hammer.
Loctite, 648.
Lub. oil.
Related procedure:

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

Capacity : 1 man
60501 27 4/cyl.
Data: 60501 28 4/cyl.

91.45 - ES0S
605-01.35 Replacement of Valve Seat Ring Working Card
L/V28/32H
Dismounting of Valve Seat Rings. Dismounting of a Valve Seat Ring is Carried out
According to Following Procedure:
When reconditioning of a valve seat ring no longer is
possible due to dimensions exceeding the scrapping 1) By means of the guide pin (7) in the guide disc
criteria, the seat ring has to be replaced. (5) lead upright through the valve seat ring, and is
lifted up again so that the guide disc (5) is guided in
Dismounting of a valve seat ring is carried out by the valve seat ring, see fig. 2. After that is the stud (1)
means of a special extractor tool set comprising screwed through the disc (5) until it is guided in the
following components, see fig. 1. valve guide.
9
3
5
10
6
8
08028-0D/H5250/94.08.12
1 Stud 6 Eye screw

Fig. 2.
2 Collar nut hexagon 7 Guide pin
3 Guide disc 8 Valve guide
4 Disc 9 Hydraulic jack
5 Guide disc 10 Valve seat ring
2) The guide disc (3) is positioned so that it bears
against the bottom of the cylinder head, and the
hydraulic jack is clamped with the disc (4) and collar
Fig. 1. nut hexagon (2), see fig. 1. The hydraulic jack is the
one used for main bearing caps.
91.45 - ESOS
Working Card
L/V28/32H
3) By pumping up the pack, se working card 620- 3) To facilitate mounting of the valve seat ring is
01.05 for the use of hydraulic tools, the valve seat is it cooled down, however to no more than -25°C or the
pressed out max. 6 mm, and the pressure is released o-ring can be damaged.
again. The collar nut hexagon is tightened and the
operation is continued until the valve seat ring can be 4) Place the o-ring on the valve seat ring and coat
removed. with oil/loctite as shown in fig. 4, just before positioning
it in the bore.
Mounting of Valve Seat Rings:
1) Prior to mounting of a new valve seat ring, the

bore must be cleaned thoroughly and inspected for Coat with
marks. Marks that can hinder mounting of the valve loctite 648
seat ring must be removed.
Valve seat ring
2) Tools for mounting of valve seat rings are

shown in fig. 3. O-ring
Coat with oil
Fig. 4.
5) The valve seat ring is positioned in the bore,

handle with stud inserted as shown in fig. 5, and
1 washer with screw is screwed tight.
3
4
08028-0D/H5250/94.08.12
1 Handle 2 Stud
3 Washers 4 Hexagon nut
with collar
Fig. 5.
Fig. 3.
91.45 - ES0S
L/V28/32H
6) By knocking on the handle and at the same

time tightening the nut (4), the valve seat ring slides
in place in the bore and it is felt on the knocks when
it bears in the bore.
7) Prior to mounting of the valve spindle the valve

seat ring must be ground, to ensure correct cente-
ring af valve guide and valve seat ring. This can be
done according to working card 605-01.05 or 605-
01.10.
08028-0D/H5250/94.08.12
91.45 - ESOS
Working Card
L+V28/32H

Shut-off fuel oil 62021 50 1 piece
62021 46 1 piece
Description
Replacement of valve seat ring, for inlet and

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

removed, 605-01.05
Hammer.
Loctite, 648.
Lub. oil.
Related procedure

08028-0D/H5250/94.08.12

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

00.43 - ES0
L+V28/32H
Dismounting of Valve Seat Rings Procedure for Dismounting a Valve Seat

Ring
When reconditioning of a valve seat ring no longer is
possible due to dimensions exceeding the scrapping 1) By means of the guide pin (7) the guide disc (5)
criteria, the seat ring has to be replaced. is led vertically through the valve seat ring.
Then the guide disc (5) is lifted with the guide
Dismounting of a valve seat ring is carried out by pin (7) until the latter is guided by the valve seat
means of a special extractor tool set somprising ring. The stud (1) is then screwed in until it rests
following components, see fig 1. in the valve guide.
9
3
5
10
6
8
08028-0D/H5250/94.08.12
1 Stud 6 Eye screw

2 Collar nut hexagon 7 Guide pin Fig 2
3 Guide disc 8 Valve guide
4 Disc 9 Hydraulic jack
5 Guide disc 10 Valve seat ring
2) The guide disc (3) is positioned so that it bears

against the bottom of the cylinder head, and
the hydraulic jack is clamped with the disc (4)
Fig 1
and collar nut hexagon (2), see fig 1. The
hydraulic jack is the one used for main bearing
caps.
00.43 - ES0
Working Card
L+V28/32H
3) By pumping up the pack, see working card

620-01.05 for the use of hydraulic tools, the 3) To facilitate mounting of the valve seat ring it is
valve seat is pressed out max. 6 mm, and the cooled down, however to no more than -25°C
pressure is released again. The collar nut or the O-ring can be damaged.
hexagon is tightenied and the operation is
continued until the valve seat ring can be 4) Place the O-ring on the valve seat ring and
removed. coat with oil/loctite as shown in fig 4, just before
positioning it in the bore.
Mounting of Valve Seat Rings
1) Prior to mounting of a new valve seat ring, the

Coat with
bore must be cleaned thoroughly and inspected
loctite 648
for marks. Marks that can hinder mounting of
the valve seat ring must be removed. Valve seat ring
2) Tools for mounting of valve seat rings are

shown in fig 3. O-Ring
Coat with oil
Fig 4
5) The valve seat ring is positioned in the bore,

handle with stud inserted as shown in fig 5, and
1 washer with screw is screwed tight.
3
4
08028-0D/H5250/94.08.12
1 Handle 2 Stud
3 Washers 4 Hexagon nut
with collar
Fig 5
Fig 3
00.43 - ES0
L+V28/32H
6) By knocking on the handle and at the same

time tightening the nut (4), the valve seat ring
slides in place in the bore and it is felt on the
knocks when it bears in the bore.
7) Prior to mounting of the valve spindle the valve

seat ring must be ground to ensure correct
centering of valve guide and valve seat ring.
This can be done according to working card
605-01.05 or 605-01.10.
08028-0D/H5250/94.08.12
00.43 - ES0
Working Card
Mounting of Cylinder Head 605-01.40
L+V28/32H

Shut-off cooling oil 62021 50 6 Pieces
Stopped lub. oil circul. 62021 51 1 Piece
62021 15
62005 01
62010 01
Description 62021 25
62014 15
Mounting of cylinder head after inspection and/or
overhaul.
Hand tools
Starting position
Cylinder head is completely Ring and open end spanner, 17 mm.
assembled, 605-01.05 to 605-01.35 Ring and open end spanner, 24 mm.
Valve gear of respective cylinder is in right posi- Lub. oil and copaslip.
tion (valve closed).
Control of the surface on the
cylinder liner, 606-01.45
Related procedure
Adjustment of valve clearance 608-01.10
Replacement and wearing parts

08028-0D/H5250/94.08.12
Man power
Plate no. Item no. Qty. /
Working time : 1 1/2 Hour
Capacity : 2 men 60501 269 2/cyl.
60510 08 1/cyl.
Data 60610 01 2/cyl.
61202 31 1/cyl.
Data for pressure and tolerance (Page 600.35) 61625 01 2/cyl.
00.44 - ES0
605-01.40 Mounting of Cylinder Head Working Card
L+V28/32H
1) Check the jointing surfaces of the cylinder Place the spacer ring around the nuts with the slot in
head/cylinder liner to see that they are clean such a position that the tommy bar can be used.
and without damage marks, see working card
606-01.45, Fit new o-rings on the water pas- Tighten the hydraulic jacks and make sure that the
sage, lubricate the o-rings with a little oil. cylinder of the jacks bears firmly against the spacer
ring. Tighten up all the nuts, see page 600.40. For
2) Check all contact faces on the cylinder head using the hydraulic tools, see working card 620-
and nuts, including threads, and make sure 01.05.
that these are plane and smooth and absolutely
free from foreign particles.
3) Attach the lifting tool to the cylinder head that

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

must be tightened and loosened three times, in
order to compensate for deformation of the
thread and in order to ensure a safe minimum
load of the studs through the tightening.
8) Adjust the valve clearance, see working card

608-01.10.
Fig 1
9) Fit the pipes for fuel oil, lub. oil, cooling oil.
cooling water and the flange for exhaust pipe.
08028-0D/H5250/94.08.12
4) Make sure that the nuts run easily on the

threads and that they bear on their entire 10) Prior to start up check for leakages, and after
contact surfaces. start up check for leakages and oil flow.
5) Coat threads and contact faces with copaslip 11) Mount the cover for rocker arm and the front
before fitting the nuts. cover for fuel pump.
6) Screw nuts onto the studs and tighten lightly

with the tommy bar.
00.44 - ES0
Working Card
Inspection of Cylinder Head Cooling Water Space 605-01.45
L/V28/32H

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

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

from engine, 605-01.00
Related procedure:
Man power:
Working time : ¼ Hour

08028-0D/H5250/94.08.12
Capacity : 1 man Replacement and wearing parts:
Plate no. Item no. Qty./
Data:

93.20 - ES0S
605-01.45 Inspection of Cylinder Head Cooling Water Space Working Card
L/V28/32H
Inspection of Cylinder Head Cool. Water Space.
1) Inspect the cooling water inlet at the bottom

and the cooling water outlet in the top of the cylinder Cooling water,
head, see fig. 1. outlet
2) Remove all possible deposits.
3) Pour water into the cooling water outlet and

make sure, that water is coming out of all the cooling
water inlet bores at the bottom of the cylinder head.
4) Clean if necessary the cooling water inlet and

outlet by means of a steel brush. Flush the cooling
water space after cleaning.
Cooling
5) Should the cylinder head cooling water space water, inlet
contrary to expectation be blocked with deposits,
contact MAN B&W Diesel, Holeby for further instruc-
tions. Fig. 1. Cylinder Head
08028-0D/H5250/94.08.12
93.20 - ES0S
Plate
Page 1 (2) Cylinder Head 60501-19H
L+V28/32H
091
125
101
113 137
149
101
017
113 029
054 162
174
066
186
078
198
208
270
221
233
245
030
042 257
269
304
282
294
95.39 - ES0S
Plate
60501-19H Cylinder Head Page 2 (2)
L+V28/32H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
017 4/C O-ring O-ring 304 Cylinder head (as 294) Cylinderdæksel (som
with brackets and 294) monteret med
029 4/C Valve guide, inlet and Ventilstyr, indstr. og rockerarms installed bukke og vippearne.
exhaust udstr.
030 6/C Plug screw Propskrue
042 6/C Gasket Pakning
054 2/C Nut Møtrik
066 2/C Distance pipe Afstandsrør
078 2/C Stud Tap
091 2/C Thrust collar Trykflange
125 1/C Snap ring Låsering
137 1/C Sleeve for fuel valve Foring for br. ventil
149 1/C O-ring O-ring
162 8/C Nut Møtrik
174 8/C Stud Tap
186 4/C Stud Tap
198 4/C Spring pin Fjederstift
221 2/C Screw Skrue
233 2/C Coupling Kobling
257 4/C Valve seat ring, Ventilsædering,

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

valve guide sleeve for ret med spindelstyr, for-
fuel valve and valve ing for br. ventil og
seat rings ventilsæderinge
294 Cylinder head (as 283) Cylinderdæksel (som

with valve spindles 283), monteret med ven-
installed tilspindler
When ordering spare parts, see also page 600.50. Ved bestilling af reservedele, se også side 600.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
95.39 - ES0S
Plate
Page 1 (2) Valve Spindles and Valve Gear 60502-21H
18
L+V28/32H
19
20
21
32
03
27
28
29
01
34
30
02
35
36 31
32 13
19
04
14
05
06
06 07
07
15
16
08 17
08
09
09
10 10
11
11
33
08028-0D/H5250/94.08.12
22/23
25
26
12
12
97.44 - ES0S
Plate
60502-21H Valve Spindles and Valve Gear Page 2 (2)
L+V28/32H
Item Item
01 2/C Thrust piece Trykstykke 29 2/C Thrust screw Trykskrue
02 2/C Nut Møtrik 30 2/C Bearing bush Lejebøsning
03 4/C Plug screw Propskrue 31 2/C Thrust pin Trykskrue
04 1/C Valve bridge, inlet Ventilbro, indstrømning 32 /I Loctite 572 Loctite 572
05 2/C Thrust screw Trykskrue 33 1/C Cylinder head as Cylinderdæksel som

Plate 60501 + Plate 60501 +
06 4/C Circlip Fjederring Plate 60502 Plate 60502
07 4/C Thrust piece Trykstykke 34 1/C Valve bridge, inlet Ventilbro, indstrømning
complete incl. item komplet inkl. item
08 4/C Conical ring in 2/2 Konisk ring 2/2 01, 02, 04, 05, 06, 07, 01, 02, 04, 05, 06, 07,
14, 15, 16 and 17 14, 15, 16 og 17
09 4/C Rotocap, complete Rotationsgiver, komplet
incl. item 22, 23, 25, 26 inkl. item 22, 23, 25, 26 35 1/C Valve bridge, exhaust Ventilbro, udstødning
complete incl. item komplet inkl. item
10 4/C Inner spring Indvendig fjeder 01, 02, 05, 06, 07, 13, 01, 02, 05, 06, 07, 13,
14, 15, 16 and 17 14, 15, 16 og 17
11 4/C Outer spring Udvendig fjeder
36 4/C Screw Skrue
12 4/C Valve spindle, inlet Ventilspindel, inds.
and outlet og uds.
13 1/C Valve bridge,exhaust Ventilbro, udstødning
14 2/C Thrust piece Trykstykke
15 2/C Spring Fjeder
16 2/C Ball guide Kuglestyr
17 2/C Securing ring Sikring
18 4/C Spring pin Spændstift
19 4/C Rocker arm Buk for vippearm

Bracket
20 2/C Rocker arm shaft Aksel for vippearm
21 2/C Rocker arm, compl. Vippearm, komplet

(Item 03, 27, 28, 29, (Item 03, 27, 28, 29
30, 31) 30, 31)
23 24/C Ball Kugle

08028-0D/H5250/94.08.12
25 4/C Spring washer Fjederskive
26 4/C Retainer ring Låsering
27 2/C Nut Møtrik
28 2/C Rocker arm Vippearm
Qty./ = Qty./Individual Antal/I = Antal/Individuelt
97.44 - ES0S
Plate
Page 1 (2) Safety Valve and Indicator Valve 60508-11H
L+V28/32H
18
16
17
15
94.25 - ES0S
Plate
60508-11H Safety Valve and Indicator Valve Page 2 (2)
L+V28/32H
Item Item
03* 1/C Valve cone Ventilkugle
06* 1/C Pressure spring Trykfjeder
13 1/C Safety valve, com- Sikkerhedsventil,

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

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

incl. item Nos. inkl. pos. nr.
01, 02, 05, 06 01, 02, 05, 06
09 6/C Spring pin Fjederstift
10 1/C Coaming Karm
13 18/C Washer Skive
15 18/C Screw Skrue
93.47 - ES0S
Index
Page 1 (1) Piston, Connecting Rod and Cylinder Liner 606S
L28/32H
Description
Piston, Connecting Rod and Cylinder Liner ............................................................. 606.01 (10H)
Working Card
Dismounting of Piston and Connecting Rod ....................................................... 606-01.00 (01S)
Seperation of Piston and Connecting Rod .......................................................... 606-01.05 (03S)
Piston ................................................................................................................... 606-01.10 (02H)
Piston (with flame ring) ........................................................................................ 606-01.10 (09H)
Connecting Rod ................................................................................................... 606-01.15 (01H)
Criteria for Replacement of Commenting Rod Big-end and
Main Bearing Shells ............................................................................................ 606-01.16 (02S)
Mounting of Piston and Connecting Rod ............................................................. 606-01.20 (01S)
Tightening and Check of Connecting Rod Screw s(Hydraulic Tightened) .......... 606-01.25 (04H)
In-situ Inspection of Connecting Rod Big-end Bearing ....................................... 606-01.30 (01S)
Inspection and Honing of Cylinder liner .............................................................. 606-01.40 (01H)
Replacement of Cylinder Liner ............................................................................ 606-01.45 (01H)
Grinding of Seal Face on Cylinder Liner and Cylinder Head .............................. 606-01.45 (01H)
Dismounting of Piston and Cylinder Liner at Low Overhaul Heights .................. 606-01.50 (01H)
Plates
Piston and Connecting Rod (Hydraulic Tightened) ...................................................... 60601-21H
Piston and Connecting Rod (with flame ring/Hydraulic Tightened) .............................. 60601-22H
Cylinder Liner and Water Guide Jacket ..................................................................... S60610-17H
Cylinder Liner and Water Guide Jacket ..................................................................... S60610-19H
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Piston, Connecting Rod and Cylinder Liner 606.01
Page 1 (1)
Edition 10H
L/V28/32H
Piston
The piston, which is oil-cooled and of the monobloc

type made of nodular cast iron, is equipped with 3 The big-end bearing is of trimetal type, i.e. steel
compression rings and 1 scraper ring. shells lined with tin-aluminium or lead-bronze coated
with a running layer. Design as plain type or rillen-
By the use of a combination of compression rings type. The bearing shells are of the precision type and
with different barrel-shaped profiles and chrome- are therefore to be fitted without scraping or any
plated running surface on all rings, the piston ring other kind of adaption.
pack is optimized for maximum sealing effect and
minimum wear rate. The small-end bearing is of trimetal type and is
pressed into the connecting rod.
The piston has a cooling oil space close to the piston
crown and the piston ring zone. The heat transport
and thus the cooling effect is based on the shaker Cylinder Liner
effect arising during the piston movement. As coo-
ling oil is used oil from the engine's lubricating oil The cylinder liner is made of fine-grained, pearlite
system. cast iron and is fitted in a bore in the engine frame.
Between the liner and the cylinder head and between
the liner and the frame there are fitted replaceable
Piston Pin cast iron sealing rings. The liner is clamped by the
cylinder head and is guided by a bore at the bottom
The piston pin is fully floating which means that it can of the cooling water space of the engine frame. The
turn freely in the pin bosses of the piston as well as liner can thus expand freely downwards, when
in the connecting rod bush. The piston pin is upwords heated during the running of the engine. Sealing for
in place in axial direction by two circlips (seeger the cooling water is obtained by means of silicone
rings). rubber rings which are fitted in grooves machined in
the liner.
Connecting Rod Tell-tale borings in the frame, starting from a level

between the sealing rings and leading to the exterior
The connecting rod is die-forged. The big-end has an will reveal any sealing malfunction by sign of leaking
inclined joint in order to facilitate the piston and water or lubricating oil mist.
connecting rod assembly to be withdrawn up through
the cylinder liner. The joint faces on connecting rod
and bearing cap are serrated to ensure precise
location and to prevent relative movement of the
parts.
08028-0D/H5250/94.08.12
90.43 - ES0U
Working Card
Dismounting of Piston and Connecting Rod 606-01.00
L28/32H

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

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

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

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

Capacity : 2 men
Data:

96.06 - ES0S
606-01.00 Dismounting of Piston and Connecting Rod Working Card
L28/32H
1) Clean the upper part of the cylinder, if not, the e) Turn the piston in top, in order to push the
piston may get stuck during removal in the carbon flame ring out of the cylinder by means of the tool.
deposited in this area.
Info: It is the used piston ring which pushes the flame
If the liner is mounted with a flame ring then start with ring out of the cylinder, while the flame ring tool
item No a to e. guides the piston ring out against the cylinder liner.
If the liner is not mounted with a flame ring then 2) Remove the gangway, if any installed, in order
continue with item No 2. to improve the access conditions.
a) Turn the piston to the buttom. 3) Turn the crankshaft to bring the crank throw
concerned into a position approx. 50 degrees before
b) Mount the tool for dismounting of the flame ring TDC.
in the cylinder at the top of the piston.
This position is identifiable by the connecting rod
c) Place a used piston ring on top of the flame ring shaft being very close to cylinder liner shirt, see fig.
tool. 1.
d) Mount the tube (for holding down the cylinder 4) Clean the threaded hole in the piston top, and
liner during the piston withdrawal) on one of the mount the eye screw.
cylinder head studs, screw on the nut and tighten it
slightly. Mount the tube (for holding down the cylinder liner
during the piston withdrawal) on one of the cylinder
head studs, screw on the nut and tighten it slightly.
08028-0D/H5250/94.08.12
Fig. 2. Removal of bearing cap.
5) Attach a wire rope to the eye bolt by means of

Fig. 1. Mounting of tools. (placing). a shackle, hook the wire on to a tackle and pull the
wire rope tight.
96.06 - ES0S
Working Card
Dismounting of Piston and Connecting Rod 606-01.00
L28/32H
Fig. 3. Removal of upper big-end bearing shell.
If minor adjustment of the crank throw position

appears necessary for acces to the connecting rod
screws, the wire rope must be slackened before
turning of the crankshaft and tightened up again in
the new crank throw position.
6) Unload the connecting rod screws and un-

screw one of the upper screws.
7) Mount the guide pin for the bearing cap in one Fig. 4. Lift of piston and connecting rod assembly.
of the threaded holes and fit a screwdrive or similar
in the hole in the guide pin, and unscrew the screws.
8) Remove the screwdriver from the guide pin, 11) Lift the piston and connecting rod assembly up
and dismount the bearing cap by sliding it along the through the cylinder liner and out of the engine, see
guide pin, see fig. 2. fig. 4.
9) Remove the guide pin from the connecting rod. NOTE: The purpose of the guide pin is to prevent any
damage of crank journal, joint faces or bearing
08028-0D/H5250/94.08.12
10) Pull the piston and connecting rod assembly surface to occur during dismounting of the bearing
upwards and remove the upper big-end bearing cap, and to facilitate easy handling when removing
shell, see fig. 3. the bearing cap from the crankcase.
96.06 - ES0S
Working Card
Separation of Piston and Connecting Rod 606-01.05
L/V28/32H

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

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

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

Capacity : 1 man
Data:

92.08 - ES0S
606-01.05 Separation of Piston and Connecting Rod Working Card
L/V28/32H
Separation of the Piston and Connecting Rod: Wooden wedges should be used to prevent the
connecting rod from swinging out and thus impact
1) Land the piston and connecting rod carefully the piston skirt during the lifting into upright position.
on wooden support to prevent damage of piston and
scraper ring, see fig. 1 or 2. 5) Place a wire around the big-end of the connec-
ting rod, attach a tackle and tighten the wire rope,
see fig. 3
6) Take out the securing ring, (seeger circlips),

push out the piston pin and lift the connecting rod
away.
Fig. 1. L28/32H
2) The bearing cap should be mounted with the

screws tightened only by hand, in order to protect the
serrated joint faces during handling of the assembly,
see fig. 1 or 2.
Fig. 3.
Assembly of the Piston and Connecting Rod.

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

see point 1-6 in opposite direction.
3) Remove the shackle and eye screw/lifting tool
from the piston crown, see fig. 1 or 2.
8) Lubricate the piston pin before assembling.
4) Place the piston and connecting rod assembly
in upright position resting on the top face of the piston
crown, see fig. 3.
92.08 - ES0S
Working Card
Piston 606-01.10
L+V28/32H

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

connecting rod 606-01.05
Related procedure:
Mounting of piston and

08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

95.49 - ES0S
606-01.10 Piston Working Card
L+V28/32H
Removal of Piston Ring: Inspection of Piston
For removal of piston rings, which are to be used 1) Remove the piston and scraper rings.
again, and for all mounting of rings, only the special
ring opener which prevents local over stressing of 2) Clean and examine the piston rings to
the rings should be used. determine if reuse is acceptable, see page 3.
Straps to expand the ring gap or tools working on the 3) Clean the piston outside and inside.
same principle must not be used, as this would result
in permanent deformation which might cause blow- 4) Inspect the piston ring and scraper ring grooves
by or broken rings. for wear, see page 3.
08028-0D/H5250/94.08.12
95.49 - ES0S
Description
Piston 606-01.10
L+V28/32H
The piston has to be scrapped if:
Piston and oil New ring
Ring grooves.
scraper ring. grooves.
Max. wear limit.
Nominal size. Tolerances.
A) The wear limit on the testing mandrel is
exceeded, see fig 1A
Piston ring New +0.18
5.0 mm 5.43 mm
no 1 5.0 mm +0.16
or
B) The clearance between the new piston/scraper 5.0 mm 5.43 mm
no 2 5.0 mm +0.12
ring and ring groove is exceeded, see fig 1B.
5.0 mm 5.43 mm
no 3 4.95 mm +0.12
Note: At each piston overhaul:
New +0.12
- The piston and scraper ring must be Scraper ring 8.0 mm 8.43 mm
8.0 mm +0.10
exchanged.
- The cylinder liner must be honed according Table 1. Nominal size, new ring groove tolerance and wear
to the instructions. limit for ring grooves.
A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove
If the wear limit (2 mm mark) on the testing

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

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

with the nominal size.
08028-0D/H5250/94.08.12
Fig 1. Wear limits for ring grooves.
95.49 - ES0S
606-01.10 Description
Edition 07H Piston Page 4 (4)
L+V28/32H
Position of Piston and Scraper Rings
Piston Ring No 1:
marked with ident.
no "top 891501-9"
or "0949".
Piston Ring No 2:
marked with ident.
no "top 891500-7"
or "0951".
Piston Ring No 3:
marked with ident.
no "top 891503-2"
or "0950".
Scraper ring:
marked with ident.
no "top 891502-0"
or "0121".
Marking of Piston and Scraper Rings

08028-0D/H5250/94.08.12
Marking
Identification marks to face upwards against the piston crown when mounted.
Note: The marking may include other figures than mentioned above, for instance trade mark and
production codes.
95.49 - ES0S
Working Card
Connecting Rod 606-01.15
L/V28/32H

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

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

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

08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

97.24 - ES0S
606-01.15 Connecting Rod Working Card
L/V28/32H
Cleaning and Inspection of Big-end Bore. Screws, which are damaged as mentioned above or
cannot be turned into the threaded holes by hand,
The connecting rod is cleaned on all machined must be renewed.
surfaces.
The serrated joint faces and threaded screw holes Measurement of Big-end Bore.
are to be degreased with a volatile solvent and blown
dry with working air.
The serrated joint faces are inspected.
The serration on the connecting rod may, due to

relative movements between the mating surfaces,
show damages in form of wear marks and pittings or
even cracks in highly loaded zones.
Observed damages should be registered in the

schem "Connecting Rod Inspection". See page 4.
Wear marks are visible but not appreciable at a

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

Fig. 1. Point of measurement
be gently smoothed by careful, local treatment with
a file.
For check of roundness the big-end bore has to be
The serration on the connecting rod and on the measured in a condition, where the connecting rod is
bearing cap can be damaged by improper handling mounted with the bearing cap but without bearing
during dismounting, transport and overhaul work. shells, and the connecting rod screws are tightened
up with the prescribed torque, see working card 606-
Note ! The connecting rod and bearing cap must 01.25.
therefore be handled with care.
Note ! The ident no. on the connecting rod and the
Single dent marks caused by impact can be rectified bearing cap, must always be the same, see fig. 3.
by gentle and careful local treatment with a file.
Measurements must be taken 30 mm from seration
In case of damage of the serration, reuse must be centerline. See fig. 1.
rejected, and a new connecting rod assembly includ-
ing new bearing shells must be mounted in the The measuring is executed with an inside micro-
engine. meter.
08028-0D/H5250/94.08.12
The connecting rod screws are to be carefully clean- Five different diameters are measured in the middle
ed. of the boring, see fig. 1 and registered in the scheme
"Connecting Rod Inspection". See page 4.
The threads are inspected for seizures and tested in
the threaded holes in the connecting rod. The test The maximum ovalnees is calculated as the diffe-
must confirm, that the screws can be turned into rence between biggest and smallest diamenter
bottom position by hand. The contact surface of the measured. For maximum allowable ovalness see
screw heads is inspected for seizure and pittings. page 600.35.
97.24 - ES0S
Working Card
Connecting Rod 606-01.15
L/V28/32H
If the ovalness exceeds this value, reuse must be Please note that squares for statement of informa-
rejected and a new complete connecting rod, inclu- tion and identification, should also be properly filled
ding new screws and new bearing shells has to be in.
mounted in the engine.
Connecting Rod Bush.
Inspect the surface of the piston pin and the connec-

ting rod bush. Measure the clearance between the
piston pin and bush, max. clearance between pin
and bush, see page 600.35.
- 0,5 - 3,0
- 2,0 - 7,0 In case the specified clearance is exceeded, contact
- 1,5 - 5,0 MAN B&W Diesel A/S, Holeby for replacement.
+ 5,0 + 5,5
+ 3,0 + 3,5
7,0 12,5 Bearing Shells for Big-end.
Criteria for replacement of connecting rod big-end

bearing, see working card 606-01.16.
to be to be
reused rejected
Fig. 2. "Connecting rod inspection".
The example, see fig. 2 shows measurements and

damage observations for two connecting rods, on
the scheme "Connecting Rod Inspection", (In case
the specified maximum ovalness is exceeded, con-
tact MAN B&W Diesel A/S, Holeby for overhaul).
Connecting rod
For connecting rod no. 1 the maximum ovalness is Ident no.
08028-0D/H5250/94.08.12
0,07 mm and reuse thus acceptable.
For connecting rod no. 2 the maximum ovalness is

0,125 mm and therefore the connecting rod is being Fig. 3.
rejected.
97.24 - ES0S
606-01.15 Connecting Rod Working Card
L/V28/32H
08028-0D/H5250/94.08.12
97.24 - ES0S
Working Card
Mounting of Piston and Connecting Rod 606-01.20
L28/32H

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

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

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

Capacity : 2 men
60601 09 1/cyl.
Data: 60601 10 1/cyl.
60601 11 1/cyl.
91.49 - ES0S
606-01.20 Mounting of Piston and Connecting Rod Working Card
L28/32H
1) Mount the lifting device comprising eye screw, A crank throw position of approx 50 degrees before
shackle and wire rope on the piston. TDC will ensure this and also be suitable for the
further mounting procedure.
2) Lift up the piston and connecting rod and
mount the piston and scraper rings, see point 14, and 6) Lower the piston further down, lubricate the
working card 606-01.10. ends of the bearing shells (a in fig. 2) with copaslip,
molycote pasta or similar and mount the upper shell
3) Remove the backstop for cylinder liner and of the big-end bearing.
place the piston guide ring on top of the cylinder liner,
see fig. 1.
4) When the piston approaches the guide ring,

stop the lowering, coat guide ring, piston, piston
rings and scraper ring, with clean lubricating oil in
order to minimize friction during the subsequent
lowering of the assembly.
Fig. 2.
08028-0D/H5250/94.08.12
7) Coat the crank journal with clean lubricating

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

5) Make sure that the crank throw is in a position ly into correct landing on the journal.
allowing the connecting rod to go clear of both crank
journal and cylinder liner skirt during further lower- During this the connecting rod must be guided by
ing. hand to ensure correct approach and landing on the
journal, see fig. 3.
91.49 - ES0S
Working Card
Mounting of Piston and Connecting Rod 606-01.20
L28/32H
9) Mount the bearing cap with inserted lower

shell of the big-end bearing, using the guide pin, see
fig. 4.
10) Lubricate threads and contact face of the

connecting rod screws with copaslip, molycote pasta
or similar.
11) Mount the screws and tighten them slightly

using an open end spanner.
12) Slacken the tackle and dismount the eye screw/

shackle from the piston.
Fig. 3.
Note ! The ident no. on the connecting rod and on the

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

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

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

Con. Rod - Ident No. fitted to the piston by the use of a special tool, the
socalled piston ring opener.
Fig. 4.
91.49 - ES0S
606-01.20 Mounting of Piston and Connecting Rod Working Card
L28/32H
If the rings are opened further than necessary there Before fitting the coil spring loaded scraper ring, the
is a risk of overstressing, which means that rings will coil spring is dismantled from the ring by removal of
become permanently distorted and will not confirm the joint pin. The coil spring is placed and assembled
to the cylinder inner running surface. in the ring groove then the scraper ring is fitted in the
groove in such a way that the ring joint is approxima-
The piston rings should be installed with the identifi- tely 180° offset to the spring joint.
cation mark, which is stamped into the ring close to
the ring joints, facing upwords. Ascertain correct assembling by checking the back
clearance.The back clearance is suffient when the
face of the ring is below the groove edge, when the
ring is pressed against the bottom of the groove.
When installed on the piston, the rings should be

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

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

joints the piston rings should be turned into positions
offsetting the ring joint 180° to each other.
Fig. 6.
08028-0D/H5250/94.08.12
91.49 - ES0S
Working Card
Tightening and Check of Connecting Rod Screws 606-01.25
Page 1 (3)
Edition 01H
L/V28/32H

Shut-off cooling water 62006 28 140 - 760 Nm
Shut-off fuel oil
Shut-off cooling oil Tools combinations for tightening of connecting
Stopped lub. oil circul. rod screws, see working card 620-01.20.
Description:
Tightening procedure for connecting rod screws.

Check of connecting rod screws, tightening con- Hand tools:
dition.
Open end spanner, 32 mm.
Starting position:
Piston, connecting rod, bearing shells

and bearing cap preassembled 606-01.20
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 2 men
Data:

91.22 - ES0S
606-01.25 Tightening and Check of Connecting Rod Screws Working Card
Page 2 (3)
Edition 01H
L/V28/32H
Tools combinations for tightening of connecting rod

screws, see working card 620-01.20.
Tightening of Connecting Rod Screws:
1st Step.
Mark on the
screw collar
Tightening the screws in tightening order as illustrat-
ed in fig. 1 using an initial torque of 400 Nm. Mark on
bearing cap
60°
Fig. 2.
4th Step.
Check the screw tightening in prescribed order using

a torque of 700 Nm.
Proper tightening condition is present, if the screws

are not turned further during this test.
5th Step.
Check that the bearing can easily be moved on the

journal.
Check of Connecting Rod Screws, Tightening

Condition:
Fig. 1.
Check of the tightening condition of connecting rod
screws has to be executed within a short running
2nd Step. period after remounting/mounting of the connecting
rod.
Once more tightening the screws in prescribed tigh-
08028-0D/H5250/94.08.12
tening order, still using a torque of 400 Nm. This check can be fulfilled after only a few running
hours at max. rpm at full load but has to be fulfilled not
later then 200 running hours after starting up.
3rd Step.
The tightening condition is checked with a torque af
Mark the four screws and the bearing cap felt-tippen 700 Nm executed in prescribed screw tightening
as illustraded in fig. 2. order, see fig. 1.
Tightening order by turning through a 60° ± 2° angle Proper tightening condition is present if the screws
i.e. until the marks on screws collar and connecting are not turning further during the test.
rod coincide radially.
91.22 - ES0S
Working Card
Tightening and Check of Connecting Rod Screws 606-01.25
Page 3 (3)
Edition 01H
L/V28/32H
In order to ensure observation of any movement, the Any turning of the screws during the 700 Nm test
screws and the connecting rod should be applied indicates insufficient tightening condition, and in this
with coinciding filt-pen marks prior to the test, see fig. case the big-end assembly has to be dismantled and
3. investigated for evaluation and correction of failure.
As part of recommended overhaul and routine work,

the tightening condition of connecting rod screws
should also be checked, for each, see page 600.24
running hours.
Mark on the
screw collar
Coinciding
mark on
bearing cap
700 Nm
Fig. 3.
Fig. 4.
08028-0D/H5250/94.08.12
91.22 - ES0S
Working Card
Hydraulic Tightening of Connecting Rod Screws 606-01.25
L+V28/32H
Safety Precautions: Special Tools:

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

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

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

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

Capacity : 2 men
Data:

97.43 -ES0S
606-01.25 Hydraulic Tightening of Connecting Rod Screws Working Card
Edition 04H Edition 2 (2)
L+V28/32H
1) Tighten the screw pos. 3 home to the connecting

rod by hand.
2) Mount the lower part pos. 2 and fasten the

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

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

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

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

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

Please see Working Card 620-01.10
08028-0D/H5250/94.08.12
97.43 - ES0S
Working Card
In-situ Inspection of Connecting Rod Big-end Bearing 606-01.30
L28/32H

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

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

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

Starting position:
Fuel injector dismounted, 614-01.00

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

big-end bearing 606-01.16
Tightening and check of connecting
rod screws, 606-01.25
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.22 - ES0S
606-01.30 In-situ Inspection of Connecting Rod Big-end Bearing Working Card
L28/32H
The big-end bearing shells can be inspected and/or

replaced in-situ i.e. without dismounting the piston
and connecting rod assembly from the engine.
Dismounting.
1) The crankshaft of the engine is turned into a

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

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

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

the especially long eye bolt is mounted. It is inserted
through the fuel injector sleeve and is screwed into
the thread hole in the piston, see fig. 2. Then by
means of a tackle it is slightly tightened.
91.22 - ES0S
Working Card
In-situ Inspection of Connecting Rod Big-end Bearing 606-01.30
L28/32H
While lowering the connecting rod, it must be guided

by hand to ensure correct approach and landing on
the journal, see fig. 4.
4) Mount the bearing cap with inserted lower big-

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

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

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

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

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

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

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

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

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

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

lower the piston and connecting rod assembly slowly
into correct landing on the journal.
91.22 - ES0S
Working Card
Inspection and Honing of Cylinder Liner 606-01.35
L+V28/32H

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

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

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

removed, 606-01.00
Related procedure:

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

Capacity : 1 man
Data:

96.04 - ES0S
606-01.35 Inspection and Honing of Cylinder Liner Working Card
L+V28/32H
Measurement of Cylinder Diameter. Prior to the honing, deposits of coke and possible
wear edges in the top of the liner must be removed
While the piston is removed from the cylinder, the by scraping.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, If the cylinder is of the flame ring type, the used flame
with measuring points at TDC-position for upper- ring has to be cleaned in water. Subsequently, the
most piston ring, halfway down and at the bottom of flame ring is remounted in the cylinder before carry-
the cylinder liner, see fig. 1. ing out the honing process.
Note: After the honing process has taken place the

used flame ring is discarded. A new flame ring is
always mounted in the cylinder when replacing a
piston ring.
80-160 rpm.
Fig. 1.
The measurements should normally be taken in

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

has the approximately same temperature as the
liner. When the wear of a cylinder liner exceeds the
08028-0D/H5250/94.08.12
value indicated on page 600.35, i.e. when it becomes

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

The honing is made by means of a flex-honer with
The renovation can be made either with dismantled finess grains 80-120. A revolution speed between 80
liner in the workshop or with liner mounted in the and 160 rpm is chosen.
engine frame and by the use of the belonging funnel.
96.04 - ES0S
Working Card
Inspection and Honing of Cylinder Liner 606-01.35
page 3 (4) Edition 01H
L+V28/32H
In order to achieve the required angle between the

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

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

with honing oil or cutting oil.
Fig. 3.
After the honing, the liner is carefully cleaned with
gas oil, and make sure that all abrasive particles
have been removed.
08028-0D/H5250/94.08.12
96.04 - ES0S
606-01.35 Inspection and Honing of Cylinder Liner Working Card
L+V28/32H
08028-0D/H5250/94.08.12
96.04 - ES0S
Working Card
Replacement of Cylinder Liner 606-01.40
L/V28/32H

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

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

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

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

Capacity : 2 men
60610 04 1/cyl.
Data: 60610 07 12/cyl.
60610 08 2/cyl.
Declaration of weight (Page 600.45) See also plate 60610.
91.22 - ES0S
606-01.40 Replacement of Cylinder Liner Working Card
L/V28/32H
Dismounting of Cylinder Liner.
1) Dismount the cooling water guide jacket.

L28/32H
2) Prior to mounting of the lifting tool and dis- V28/32H
mounting from the frame, it must be ensured that the
liner and frame have been marked to match, for the
sake of a posible remounting of the liner, see fig. 1.
Hole for charging air
Hole for roller guide house
Marking scratch frame
Marking scratch liner
Fig. 2.
Fig. 1.
5) Attach a tackle hook to the eye nut or the wire
and the cross bar, and lift the liner out from the
3) Mount the lifting tool as shown, see fig. 2. engine frame and stand it careful onto wooden
supports.
4) Turn the lifting eye nut to pull out the liner, until
the upper edge of the liner lie aligned against the 6) Clean all parts and inspect for damage and
copper protecting pieces of the cross bar. wear, according to the description. For measure-
08028-0D/H5250/94.08.12
ment of cylinder liner, see working card 606-02.00.
91.22 - ES0S
Working Card
Replacement of Cylinder Liner 606-01.40
L/V28/32H
Mounting of Cylinder Liner. 12) Mount the cooling water jacket, (for torque
moment see page 600.40), piston/connecting rod
7) Check that the sealing surfaces on engine, and cylinder head according to working card 606-
cylinder liner, and sealing rings are perfectly clean. 01.20 and 605-01.40.
8) Mount the lifting tool, attach a tackle hook to 13) When preparing the start-up, check for possible
the eye nut or to the wire in the cross bar and lift the leakages of water and oil, including the inspection
liner. hole in the frame, see fig. 3.
9) Check that the o-ring grooves are clean. Mount

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

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

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

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

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

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

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

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

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

91.45 - ES0S
606-01.45 Grinding of Seal Face on Working Card
Edition 01H Cylinder Liner and Cylinder Head Page 2 (2)
L/V28/32H
Note: The grinding tool is used for both grinding the

groove in the liner flange (1) and the seating surface
on the cylinder head (2), see fig. 1.
Fig. 3.
Fig. 1.
3) After grinding, remove all traces of abrasive

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

Fig. 2.
To do so, move the tool back and forth and lift it out
from time to time, to allow the grinding compound to Fig. 4.
distribute evenly.
91.45 - ES0S
Working Card Dismounting of Piston and Cylinder Liner 606-01.50
Page 1 (2)
at Low Overhaul Heights Edition 01H
L+V28/32H

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

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

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

94.38 - ES0S-G
606-01.50 Dismounting of Piston and Cylinder Liner Working Card
Edition 01H at Low Overhaul Heights Page 2 (2)
L+V28/32H
Dismantling of Piston at Low Overhaul Heights. Dismantling of Cylinder Liner at Low Overhaul
Heights.
1) Lift up the piston and the connecting rod through
the cylinder liner until the piston is clear of the 1) Mount normal lifting tool for cylinder liners.
liner.
2) Carefully pull the cylinder liner half-way out of
2) Mount collar on the connecting rod, see plate the frame.
62050, item 1896.
3) Mount special lifting tool for cylinder liners at
3) Place the piston with the collar on the cylinder low overhaul heights, see plate 62050, item
liner. 1895.
4) Mount pull-lifts on the collar. 4) Attach pull-lifts on the lifting tool for the cylinder
liner, see plate 62050, item 1895
If Then
5) Take out the liner over the camshaft side.
The overhaul height is Dismount the piston from
too low to pull out piston the connecting rod, re-
and connecting rod in move the piston and pull
one piece. out the connecting rod by
the pull-lifts.
The overhaul height is Remove the piston and

sufficient to pull out the connecting rod by means
piston and the connect- of the pull-lifts.
ing rod in one piece.
08028-0D/H5250/94.08.12
94.38 - ES0S-G
Plate
Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 60601-21H
L28/32H
96.35 - ES0S
Plate
60601-21H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)
L28/32H
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse
01 1/C Piston pin incl. Stempelpind inkl.

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

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

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

bearing 2/2 leje 2/2
15 2/C Connecting rod stud Plejlstangsbolt
16 2/C Nut Møtrik
96.35 - ES0S
Plate
Page 1 (2) Cylinder Liner and Water Guide Jacket 60610-07H
L28/32H
12
13
01
14
02
01
03
04
05 15
06
07
08
09
07
08
10
11
91.22 - ES0S
Plate
60610-07H Cylinder Liner and Water Guide Jacket Page 2 (2)
L28/32H
Item Item
02 1/C Sleeve Muffe
03 1/C Water guide Kølekappe

jacket
05 6/C Sealing ring Tætningsring
08 2/C Sealing ring Tætningsring
09 6/C Cooling water Kølevands-

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

incl. item no. 05 and 05 og 06.
06.
91.22 - ES0S
Index
Page 1 (1) Camshaft and Camshaft Drive S607
L28/32H
Description
Camshaft and Camshaft Drive ................................................................................. 607.01 (05H)
Working Card
Camshaft and Camshaft Drive ............................................................................ 607-01.00 (01H)

Inspection and Replacement of Camshaft Bearing ............................................. 607-01.05 (01H)
Adjustment of Camshaft ...................................................................................... 607-01.20 (01H)
Plates
Intermediate Wheel ...................................................................................................... 60701-06H

Camshaft and camshaft bearing ............................................................................... S60705-11H
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Camshaft and Camshaft Drive 607.01
Page 1 (1)
Edition 05H
L28/32H
General The lubricating oil pipes for the gear wheels are
equipped with nozzles which are adjusted to apply
The camshaft which controls the actuation of inlet the oil at the points where the gear wheels are in
valves, exhaust valves and fuel injection pumps is mesh. The position of the nozzles is determined by
driven by a gear wheel on the crankshaft through an direction of rotation of the engine.
intermediate wheel, and rotated by a speed which is
half of that of the crankshaft, see fig. 1.
The camshaft is placed in the engine frame at the Engine seen from aft - fly wheel end
control side, (left side, seen from the flywheel end)
and is carried in bearing bushes which are fitted in
bores in the engine frame, each bearing is replace-
able and locked in position in the engine frame by
means of lock screws.
The camshaft is built-up of sections, one for each

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

sections are identical and therefore interchange-
able. The foremost section is equipped with a clutch
for driving the fuel oil feed pump (if mounted). The
gear wheel for driving the camshaft as well as a gear
wheel connection of governor are screwed on the Clockwise rotation direction
aftmost section.
Fig. 1. Intermediate wheel

08028-0D/H5250/94.08.12
91.03 - ES0S
Working Card
Camshaft and Camshaft Drive 607-01.00
L/V28/32H

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

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

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

Capacity : 1 man
60705 12 6/eng.
Data: 60705 24 3/eng.
61106 11 1/cyl.
Data for torque moment (Page 600.40) 61106 14 1/eng.
92.13 - ES0U
607-01.00 Camshaft and Camshaft Drive Working Card
L/V28/32H
1) Dismount the covers which give access to the 3) Examine all lubricating oil spray pipe nozzles.
gear wheels, camshaft and crankcase.
4) Start the electrical lubricating oil pump and
Examine all gear wheels for cracks, wear and defor- check the oil flow everywhere. Be particularly careful
mations. While turning the engine to enable inspec- to check that the oil jet hits the gear wheels correctly
tion allover the circumference of the gear wheels. at the points where the wheels mesh.
2) Check all screws, nuts and bolted connec-

tions, including locking devices everywhere in the
gear wheel housing, camshaft housing and crank-
case to check that they have not worked loose.
Tightening torques, see page 600.40.
08028-0D/H5250/94.08.12
92.13 - ES0U
Working Card
Inspection and Replacement of Camshaft Bearing 607-01.05
L/V28/32H

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

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

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

08028-0D/H5250/94.08.12

Capacity : 2 men
60705 01 1/eng.
Data: 60705 03 1/cyl.
60705 21 1/cyl.
92.13 - ES0S
607-01.05 Inspection and Replacement of Camshaft Bearing Working Card
L/V28/32H
To Check Roller Path of Cams.
1) While turning the engine, examine the cam Camshaft bearing

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

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

cannot be checked without dismounting the cam- Locating screw
shaft. However, ab-normal wear of one or more
Frame
bearings will become apparent in the form of burrs of
white metal at the circumference of the camshaft
journal, and in that case the bearing will in no doubt
be discoloured, as well. Fig. 1.
The bearing clearance is measured with a feeler

gauge, see data sheet 600.35. Mount a new camshaft bearing in the bore and make
sure that the hole for insertion of the locating screw
in the bearing is in a correct position. Lock the
To Replace Camshaft Bearing. bearing by means of the locating screw, which is to
be provided with a new gasket. To facilitate the fitting
3) If one or several of the camshaft bearings of the bearing it can be cooled down with Co2.
should be replaced the camshaft must be wholly or
partly dismantled. Inspect the camshaft journal for seizures.
Dismount the fuel oil feed pump, if mounted and If necessary, the camshaft section must be entirely
check that the camshaft sections are marked in removed from the engine, and the journal concerned
relation to each other. Disassemble the camshaft aft must be polished.
(toward flywheel) of the bearing that is to be replaced.
Dismount all roller guides that are located forward of Coat all the journals of the camshaft section with
the disassembling position, see working card 608- clean lubricating oil and push the camshaft into
01.00 and 608-01.05. position, making sure that the marks on the flanges
coincide.
08028-0D/H5250/94.08.12
Pull the disconnected sections of the camshaft so far

a head that the bearing which is to be replaced is Assemble the sections and fit the bolts (coated with
free. copaslip or similar).
Take out the locating screw of the camshaft bearing Tighten the nuts with a torque spanner, see data
concerned and push the bearing out of the bore in the sheet 600.40.
engine frame, see fig. 1.
Mount all roller guides as well as the fuel oil feed
Check the lubricating oil ducts to the bearing for free pump.
flow.
92.13 - ES0S
Working Card
Adjustment of Camshaft 607-01.20
L28/32H

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

camshaft in relation to crankshaft). Hand tools:
Depth gauge.
Starting position:
Camshaft assembled as per timing order, moun-

ted in frame and roller gear house.
Related procedure:
Adjustment of the maximum

combustion pressure, 614-05.01
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

96.30 - ES0S
607-01.20 Adjustment of Camshaft Working Card
L28/32H
If the intermediate wheel has been dismantled a

nominal adjustment of the camshaft compared to the
crankshaft (timing) must be made as follows: "Nominal
size"
1) The crankshaft is turned to TDC (top dead
centre) for cylinder no. 1.
Cylinder numbering, see page 600.11.
2) Roller guide for fuel oil pump cylinder no. 1 is

mounted and the camshaft is turned in a position
where the roller guide rests on the cicular part af the
cam, see fig. 1.
Roller guide
Cam for
exhaust valve
Cam for fuel Fig. 2.
oil pump
4) The camshaft is turned - in the engines direc-

tion of rotation (see page 600.12) - until the "nominal
size" (as described in item 3) is reduced with the
lead, mentioned in "Lead of Fuel Pump".
Seen from front edge
Note: "Lead of fuel pump" is shown in the table
"Adjusment after the trail" in the Shop Test Protocol.
Fig. 1. 5) When items 1 - 4 are completed and correct

the intermediate wheel can be mounted and tighte-
ned up again (torque moment, see page 600.40).
3) The "nominal size" is measured with a depth
gauge, i.e. the distance from the upper edge of the For adjustment of the single fuel oil pumps (separa-
roller guide house to the thrust gauge pressed into tely and assembled), see working card 614-05.01.
the roller guide, see fig. 2.
08028-0D/H5250/94.08.12
96.30 - ES0S
Plate
Page 1 (2) Intermediate Wheel 60701-06H
L28/32H
09
10
01
02
07
03 11
04
12+
05 08+
06
91.41 - ES0S
Plate
60701-06H Intermediate Wheel Page 2 (2)
L28/32H
Item Item
01 6/E Screw Skrue
02 6/E Lock plate Sikringsplade
03 3/E Gasket Pakning
04 1/E Union Vinkelforskruning
05 1/E Pipe Rør
06 1/E Union Vinkelforskruning
07 1/E Spray pipe Sprøjterør
08+ 3/E Fitted bolt Pasbolt
09 3/E Self locking Selvlåsende

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

complete
12+ 1/E Axle journal Lejetap
+ Item No. 08 and 12 + Item nr. 08 og 12 kræ-

require an individual ver en individuel tilpas-
matching, before ning, før montering kon-
mounting, contact takt MAN B&W, Holeby
MAN B&W, Holeby
Qty./E = Qty./Engine Antal/E = Antal/Motor
91.41 - ES0S
Plate
Page 1 (2) Camshaft and Camshaft Bearing 60705-21H
L28/32H
11
06
13
04
05 19
06
07
08
01 20
02
03 03
14
15 21
22
14
16
03
23
06
25
02.35 - ES0
Plate
60705-21H Camshaft and Camshaft Bearing Page 2 (2)
L28/32H
Item Item
01 1/E Camshaft bearing Styreakselleje 23 1/E Coupling flange Koblingssflange

"Aft" "Agter"
25 6/E Screw Skrue
02 1/E Camshaft section Styreakselssektion
"aft" "agter"
03 1/C Camshaft bearing Styreakselleje
04 1/E Hub Nav
05 6/E Screw Skrue
06 24/E Disc spring Skivefjeder
07 1/E Guide ring Styrering
08 1/E Shaft pin Akseltap
11 12/E Screw Skrue
13 1/E Gear wheel Tandhjul
14 Self locking nut Selvlåsende møtrik

50/E 5 cyl. engine 5 cyl. motor
15 Screw Skrue
16 1/E Camshaft "Fore" Styreaksel "For"
19 10/E Screw Skrue
20 1/C Camshaft, Styreaksel,

intermediate mellem
21 Gasket Pakning
22 Guide screw Styreskrue

02.35 - ES0
Index Operating Gear for Inlet Valves,
Page 1 (1) 608S
Exhaust Valves and Fuel Injection Pumps
L28/32H
Description
Operating gear for Valves and Fuel Injection Pumps ............................................... 608.01 (12H)
Working Card
Inspection of Valve Roller Guides ....................................................................... 608-01.00 (01S)

Inspection of Fuel Injector Pump Roller Guide .................................................... 608-01.05 (01H)
Control and Adjustment of Valve Clearance ....................................................... 608-01.10 (01H)
Plates
Roller Guide and Push Rods ........................................................................................ 60801-14S

08028-0D/H5250/94.08.12
94.47-ES0U
Description
Operating Gear for Valve and Fuel Injection Pumps 608.01
Page 1(1)
Edition 12H
L/V28/32H
Roller Guides
The fuel injection pumps and the rocker arms for inlet
and exhaust valves are operated by the cams, on the
camshaft through roller guides. The roller guides for Valve bridge Rocker arm
fuel pump, inlet and exhaust valves are located in
bores in a common housing for each cylinder, this
housing is bolted to the engine frame.
The roller runs on a bush fitted on a pin that is pressed

into the roller guide and secured by means of a lock
screw.
Operating Gear for Fuel Injection Pumps

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

which is fixed between the roller guide and the foot housing
plate of the fuel injection pump.
Roller guide
Operating Gear for Inlet and Exhaust Valves Pin
The movment from the roller guides for inlet and Roller
exhaust is transmitted via the push rods the rocker
arms and spring-loaded valve bridges to each of the
two valve sets. The bridge is placed between the Camshaft
valve spindles and in the one end it is provided with
a pressed-on thrust shoe and in the other end it is
fitted with a thrust screw for adjustment of the valve
clearance. Fig. 1. Valve Operating Gear.
On its top the bridge is controlled by a spherical

thrust shoe on the rocker arm and at the bottom by
a guide which rests in a spherical socket in the
cylinder head.
08028-0D/H5250/94.08.12
91.13 - ES0S
Working Card
Inspection of Valve Roller Guides 608-01.00
L/V28/32H

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

mounting of valve roller guides.
Inspection of roller guide housing. Hand tools:

Starting position: Socket spanner, 24 mm.
Allen key, 3 mm.
Top cover for cylinder head and cover for fuel Ratchet spanner.
injection pump removed. Hammer.
Drift.
Related procedure:
Inspection of fuel injection pump

roller guide, 608-01.05
Control and adjusting of valve
clearance, 608-01.10
08028-0D/H5250/94.08.12

Capacity : 1 man
60801 04 4/cyl.
Data: 60801 08 2/cyl.
60801 09 1/cyl.
Data for torque moment (Page 600.40) See also plate 60801.
91.45 - ES0S
608-01.00 Inspection of Valve Roller Guides Working Card
L/V28/32H
Dismounting of Roller Guide. 5) Dismount the screws (3) which secure the
roller guide top cover, take off the cover, and lift out
1) Turn the engine so that the roller, rests on the the roller guide (5).
circular part of the cam.
Disconnect any pipes that may be in the way (lub. oil
2) Unscrew the nuts which secure the rocket arm and fuel oil pipes).
brackets, and lift off the rocker arm with brackets.
6) If the roller guide housing is to be dismantled,
3) Remove the push rods (1), see fig. 1. the fuel injection pump and the fuel injection pump
roller guide are to be dismounted, see working card
614-01.05 and a number af lubricating oil and fuel oil
pipes are also to be disconnected.
1
The roller guide housing (6) cannot be dismantled
with the roller guides fitted.
7) If the event of any marks or scores from
sezures, these must be polished away.
2
8) Inspect the spherical stud for deformations
(replace as necessary).
3
Examine the surface of the roller for marks and other
4 deformations.
6 Make sure that there is free ply between the roller

and the bush and the shaft pin, and replace the bush,
if necessary.
Replacement of Roller, Bush and Shaft Pin.

5
9) Remove the lock screw which secures the
roller guide shaft pin and push out the shaft pin.
The roller, shaft pin, and bush can now be replaced

as required.
10) Blow through the lubricating ducts in roller

guide and roller guide housing, and clean the lubri-
cating grooves.
08028-0D/H5250/94.08.12
Mounting of Roller Guide.
11) When assembling the parts, which is carried

Fig. 1. out in the reverse order to the above care must be
exercised not to damage the o-rings when mounting
the proctecting tube.
4) Loosen the lock screw for the push rod protec-
ting tube, see plate 60801, item 07, on the roller 12) Adjusting of valve clearance, see working card
guide top cover and lift up and remove the protecting 608-01.10.
tube (2).
91.45 - ES0S
Working Card
Inspection of Fuel Injection Pump Roller Guide 608-01.05
L/V28/32H

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

mounting af roller guide for fuel injection pump. Hand tools:
Allen key, 3mm.

Hammer.
Drift.
Starting position:
Cover for fuel injection pump removed.

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

combustion pressure, 614-01.20
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.02 - ES0S
608-01.05 Inspection of Fuel Injection Pump Roller Guide Working Card
L/V28/32H
Dismounting of Roller Guide. 3) Inspect the spherical stud for deformations

(replace as necessary).
1) Remove the support ring (1) and spring (2) and
take up the roller guide (3), see fig. 1. Examani the surface of the roller for marks and other
deformations.
Make sure that there is free ply between the roller

and the bush and the shaft pin, and replace the bush
if necessary.
1
Replacement of Roller, Bush and Shaft Pin.
2
4) Remove the lock screw which secures the
roller guide shaft pin and push out the shaft pin.
3
The roller, shaft pin, and bush can now be replaced
as required.
5) Blow through the lubricating ducts in roller

guide and roller guide housing, and clean the lubri-
cating grooves.
Mounting of Roller Guide.
6) When assembling the parts which is carried

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

sezures, these must be polished away.
08028-0D/H5250/94.08.12
91.02 - ES0S
Working Card
Control and Adjusting of Valve Clearance 608-01.10
L/V28/32H

Shut-off cooling water 62008 02 Exhaust
Shut-off fuel oil 62008 01 Inlet
Description:
Control and/or adjusting of valve clearance.

Hand tools:

Big screw driver.
Starting position:
Cover for rocker arm are removed.

All indicator valves open.
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:
Data for pressure and tolerance (Page 600.35) See also plate 60502.
91.45 - ES0S
608-01.10 Control and Adjusting of Valve Clearance Working Card
L/V28/32H
Adjusting of Inlet Valve Clearance.
1) Turn the engine so that the roller, rests on the

circular part of the cam, i.e. the inlet valves and the
exhaust valves are closed.
2) Loosen the adjustment screws on valve bridge

and rocker arm, see fig. 1.
Fig. 2.
8) Check that the clearance is correct simulta-

neously at both valve spindles.
Adjusting af Exhaust Valve Clearance.
Fig. 1. 9) Carry out adjusment in the same way as

deseribed for the inlet valves, but using the feeler
gauge for exhaust valve clearance o,90 mm.
3) Clearance between valve bridge and valve
spindle, see page 600.40.
4) Place the feeler gauge marked with "correct"

o,4 mm above the valve spindle nearest to the rocker
arm bracket, see fig. 1.
5) Adjust the clearance between valve bridge

and valve spindle by means of the adjustment screw
on the rocker arm (above the push rod) and tighten
08028-0D/H5250/94.08.12
the lock nut.
The feeler gauge is to remain in this position when

adjusting the clearance of the other valve.
6) Place another feeler gauge, at the same size

o,40 mm above the other valve spindle, see fig. 2.
Fig. 3.
7) Adjust the clearance between valve bridge
and valve spindle by means of the adjusment screw
on the valve bridge, and tighten the lock nut, see fig.
2.
91.45 - ES0S
Working Card
Control and Adjusting of Valve Clearance 608-01.10
L/V28/32H
10) The feeler gauges for checking the clearance

have two gauges which are marked "incorrect" and
"correct", the latter to be used when adjusting the
valve clearance, see fig. 4.
After tightening up the counter nuts on rocker arms

and valves bridge, be sure that the feeler gaugs
marked "correct" can be inserted into the two clear-
ances simultaneously as where it must not be pos-
sible to insert the gauges marked "incorrect".
Fig. 4.
08028-0D/H5250/94.08.12
91.45 - ES0S
Plate
Page 1 (2) Roller Guide and Push Rods 60801-14H
L+V28/32H
08028-0D/H5250/94.08.12
99.41 - ES0
Plate
60801-14H Roller Guide and Push Rods Page 2 (2)
L+V28/32H
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse
01 4/C Thrust piece Trykstykke 27 1/C Roller guide for Rullestyr for brænd-
fuel injection pump, selspumpe, komplet
02* 2/C Pipe Rør complete incl. item 12, inkl. item 12, 13, 14, 15,
13, 14, 15, 22, 23, 24, 22, 23, 24, 25
03 2/C Protecting tube Skærmrør 25
04 4/C Sealing ring Tætningsring 28 4/C Screw Skrue
05 4/C Screw Skrue 38 2/C Push rod, complete Stødstang, komplet inkl.
incl. item 01, 02 item 01, 02
06 2/C Cover Dæksel
07 2/C Screw Skrue
08 2/C Gasket Pakning + Item no 20 require + Item nr. 20 kræver

an individual match- en individuel tilpasning
09 1/C Gasket Pakning ing before mounting, før montering, kontakt
contact MAN B&W, MAN B&W, Holeby
10 2/C Ball pin Kugletap Holeby
11 2/C Roller guide Rullestyr
12 3/C Pin Tap
13 3/C Stop screw Stopskrue
14 3/C Bush Foring
15 3/C Roller Rulle
16 1/C Washer for spring Skive for fjeder
18 2/C Guide pin Styrestift
19 8/C Screw Skrue
20+ 1/C Housing for Hus for

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

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

08028-0D/H5250/94.08.12
valve gear, complete vægelse, komplet inkl.

incl. item 10, 11, 12, item 10, 11, 12, 13, 14,
13, 14, 15 15
99.41 - ES0
Index Control and Safety Systems
Page 1 (1) 609S
Automatics and Instruments
L28/32H
Description
Control and Safety SystemB(Lambda) ........................................................................ 609.01(14S)

Instruments and Automatics ........................................................................................ 609.05(11H)
Lambda Controller ....................................................................................................... 609.10(12H)
Starting Box ................................................................................................................. 609.35(02H)
Converter for Ehgine-and Turbocharger RPM signal .................................................. 609.40(01H)
Working Card
Functional Test and Adjustment of Safety, Alarm, and Monitoring Equipment ...... 609-01.00(01H)
Functional Test and Adjustment of Overspeed Trip ............................................... 609-01.05(01H)
Adjustment and Test of On/Off Pressostate(Dampos) ........................................... 609-05.00(02H)
Adjustment and Test of On/Off Pressostate(Trafag) .............................................. 609-05.00(02S)
Adjustment and Test of On/Off Thermostate(Dampos) .......................................... 609-05.01(02H)
Adjustment and Test of On/Off Thermostate(Trafag) ............................................. 609-05.01(02S)
Function and Test of Level Switch(LAL25) ............................................................. 609-05.02(02H)
Adjustment and Test of Analogous Pressure Transmitter(Darrpos) ....................... 609-05.03(02H)
Adjustment and Test of Analogous Pressure Transmitter(Trafag) ..........................609-05.03(028)
Adjustment and Test of Analogous Temperature Transmitter ................................ 609-05.04(02H)
Adjustment and Lambda Controller ........................................................................609-10.00(10H)
Adjustment and Lambda ControIler ....................................................................... 609-10;00(11H)
Plates
Governor and Governor Drive ....................................................................................... 60901-07H

Regulation Mechanism .................................................................................................. 60602-18H
Fuel Unit Cylinder and Pneumatic Cylinder(Only Jet system) ...................................... 60602-15H
Overspeed Device ......................................................................................................... 60903-34H
Fuel Oil Leakage Alarm(LAH42) ....................................................................................60905-09S
Prelubricating Oil Alarm(LAH25) ................................................................................... 60905-13H
Instrument Panel ........................................................................................................... 60905-21H
Level Switch in Oil Sump(LAL/LAH28) .......................................................................... 60905-26H
Level Switch in Oil Sump(LAL28) ...................................................................................60905-28S
Level Switch in Oil Sump(LAL/LAH28) .......................................................................... 60905-35H
Thermometer(Dal type) ..................................................................................................60907-01S
Pressostate, Thermostate, Diff.Press.and Pressure Transmitter(Dampos) .................. 60907-02H
Pressostate, Thermostate, Diff.Press.and Pressure Transmitter(Trafag) ......................60907-02S
Lambda Controller ......................................................................................................... 60910-03H
Starting Box ................................................................................................................... 60935-01H
08028-0D/H5250/94.08.12
95.53-ES0U
Description
Control and Safety Systems 609.01
Page 1 (2)
Edition 14H
L+V28/32H
Governor Should a fuel pump plunger seize in its barrel, thus

blocking the regulating guide, governing of the
The engine speed is controlled by a hydraulic go- remaining fuel pumps may continue un impaired
vernor. The purpose of the governor is to regulate owing to the spring-loaded linkage between the
the rate of delivery from the fuel pumps, so that the blocked pump and the regulating shaft.
engine speed is kept within certain limits, indepen-
ding on the load.
Shut Down Function
Information about the design, function and operation
of the governor is found in the special governor The shut down function is carried out by the Lambda
instruction book. controller. In case of an shut down situation e.g.
overspeed lubricating oil pressure low or high
The governor is mounted on the fly wheel end of the temperature for H.T. water, compressed air will
engine and is driven from the camshaft via a cy- press the piston in the Lambda controller downwards
lindrical gear wheel and a set of bevel gears. and force the index at the fuel pumps to zero. See
also Description 609.10.
Pick-up for Engine RPM

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

Regulating Shaft loaded fly weight (1), see fig. 1, will move outwards
and press down the arm (2).
The governor movements are transmitted through a
spring-loaded pull rod to the fuel pump regulating The arm is locked in its bottom position by the lock
shaft which is fitted along the engine. pin (3) which is pressed in by the spring (4).
The spring-loaded pull rod permits the governor to At the same time the arm (2) presses down the
give full deflection even if the stop cylinder of the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keep the fuel pump regulating whereby compressed air will be led to the Lambda
shaft at "no fuel" position. cylinder , see Description 609.10, in which the piston
is pressed forward and turns the fuel pump regulating
Each fuel pump is connected to the common, lon- rod to STOP position, thereby the engine stops, the
gitudinal regulating shaft by means of a two-piece, spring-loaded pull rod connection to the governor
spring-loaded arm. being compressed.
97.08 - ES0S
609.01 Description
Edition 14H
Control and Safety Systems Page 2 (2)
L+V28/32H
The engine can be stopped manually by pressing The overspeed alarm (SAH 81) is activated by
down the button (7), see fig. 1, which will activate the means of the micro switch (9).
spring-loaded fly weight (1) through the lever (8).
If the overspeed has been activated the overspeed

must be reset before the engine can be started.
Reset is done by means of the button (10).
3 8
1
5
2
6
1. Flyweight
1
2. Arm
3. Lock pin
9
4. Spring
5. Spindle
Normal Overspeed 6. Pneumatic valve
poisition activated 7. Button
8. Lever
9. micro switch
10. Button
2 5 3 4 10 10
Fig 1 Mechanical overspeed (SSH 81).
97.08 - ES0S
Description
Instruments and Automatics 609.05
L28/32H
Main instrument panel
As standard the engine is equipped with an instru- The instrument panel is mounted flexibly on rubber
ment panel, comprising instruments for visual indi- elements and all manometer connections are con-
cation of the most essential pressures. nected to the panel by means of flexible hoses, as
Illustrated on fig. 1. shown on fig. 2.
Flexible hose
Rubber element
Valves
Push button
On the engine is as standard mounted an instrument panel.
The following incorporating pressure gauges for the most

essential pressures. Fig. 2. Cross section of instrument panel
Pressure gauge for:

08028-0D/H5250/94.08.12
PI 01 LT fresh water, inlet to air cooler

PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter The connecting pipes to the manometers are equip-
PI 23 Lub. oil, inlet to turbocharger ped with valves which make it possible to replace the
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
manometers during operation.
PI 50 (*) Nozz. cool. oil, inlet to fuel valves
Switch for PI 21/22 In the charging air and nozzle oil piping damping
(*) If nozzle cooling oil applied only.
filters are inserted for levelling out pressure fluctua-
tions.
Fig. 1. Lay-out of instrument panel
94.28 - ES2S
609.05 Instruments and Automatics Description
L28/32H
Instrumentation - too high press. drop across lub. oil filter

- too high HT FW temperature - outlet engine
As standard the engine is supplied with the following - too low starting air pressure - inlet engine
instrumentation mounted local on the engine: - too high engine speed (overspeed)
Thermometer TI 01 LT water - inlet air cooler The actual number and type of the alarm- and shut-
Thermometer TI 02 LT water - outlet from air cooler down switches for the plant can be seen in the list
Thermometer TI 03 LT water - outlet from lub. oil cooler "Engine Automatic part list" in this section.
Thermometer TI 10 HT fresh water - inlet to engine
Thermometer TI 11 HT fresh water - outlet each cylinder
Thermometer TI 20 Lubricating oil - inlet to cooler Leakage Alarm (LAH 42)
Thermometer TI 22 Lubricating oil - outlet from filter
Thermometer TI 30 Charge air - inlet to cooler Waste and leak oil from the comparement, for the
Thermometer TI 31 Charge air - outlet from cooler injection equipment, fuel valves, high-pressure pipes
Thermometer TI 40 Fuel oil - inlet to engine and engine feed pump (if mounted) is led to a fuel
Thermometer*) TI 51 Nozz. cool. oil - outlet from fuel valves leakage alarm unit.
Thermometer TI 60 Exhaust gas - outlet each cylinder
Thermometer TI 61 Exhaust gas - outlet turbocharger
*) If nozzle cooling oil applied only. Normal leakage
C
The actual number of the instrumentation for the
plant can be seen on the diagrams for the specific
plant in the sections 612-613-614-615-616.
For code identification see 600.20. B
Leak alarm
Normal level
Pressostates and Thermostates
The engine is supplied with a number of alarm- and

shut-down functions. The alarms shall via the alarm
panel worn against an abnormal working condition, A
which can lead to break down and the shut-down
functions shall stop the engine before a break down.
I.e. a shut-down is "worse" than an alarm because High level
a shut-down is given if the engine could be severe
damage by running on these conditions.
Leakoil
As standard the engine is equipped with:

08028-0D/H5250/94.08.12
Alarm
Shut-down Switches for Normal
- too low lubricating oil pressure - inlet engine

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

Waste oil outlet
- leaking fuel oil
- too low lubricating oil pressure - inlet engine
- too low prelubricating oil pressure (level alarm) Fig. 4. Fuel oil leakage alarm.
94.28 - ES2S
Description
Instruments and Automatics 609.05
L28/32H
The alarm unit consist of a box with a float switch for Alarm for Prelubricating (LAL 25)
level monitoring, see fig. 4.
Alarm for missing prelubricating, when the engine is
The supply fuel oil to the engine is led through the unit stopped is given by means of a level switch (LAL 25)
in order to keep heated up, thereby ensuring free mounted in the main lubricating oil pipe.
drainage passage even for high-viscous waste/leak
oil.
Alarm and Shut-down for Overspeed
Under normal conditions there will always be a
smaller amount of waste/leak oil from the compare- When the mechanical overspeed is activated, see
ment, this will be led out through the bore "A" in the 609.01 fig. 2, a micro-switch will release the alarm
pipe "B" as illustrated. for overspeed (SAH 81) and activate the shut-down
solenoid in the governor.
In case of a larger then normal leakage, the level in
the box will rise and the level switch "C" will be The latter function is a back-up for the mechanical
activated. The larger amount of leak oil will be lead overspeed.
out through the top of the pipe "B".
08028-0D/H5250/94.08.12
94.28 - ES2S
Description
Lambda Controller 609.10
L28/32H
Purpose At a 50% load change the system will be activated for

about 3-8 seconds.
The purpose with the lambda controller is to prevent If the system is activated more than 10 seconds, the
injection of more fuel in the combustion chamber solenoid valve will be shut off and there will be a
than can be burned during a momentary load in- remote signal for "system failure".
crease. This is carried out by controlling the relation
between the fuel index and the charge air pressure.
Fuel oil limiting during start procedure
The Lambda controller is also used as stop cylinder.
During the start procedure the lambda controller is
used as an index limiter.
Advantages
Hereby heavy smoke formation is prevented during
The lambda controller has the following advantages: start procedure and further the regulating device
cannot over-react.
- Reduction of visible smoke in case of sudden
momentary load increases. The jet system is blocked during the starting proce-
dure until the engine has reached 710 RPM.
- Improved load ability.
- Less fouling of the engine's exhaust gas ways.

1. Regulating arm
2. Switch (Pick-up)
- Limitation of fuel oil index during starting 3. Piston
procedure. 4. Solenoid valve

5. Lambda controller
6. Overspeed device
(mecanical activated 3/2 valve)
Principles for functioning 6
Figure 1 illustrates the controller's operation mode.

In case of a momentary load increase, the regulating
device will increase the index on the injection pumps
and hereby the regulator arm (1) is turned, the switch
(2) will touch the piston arm (3) and be pushed 5 Charge air
receiver
downwards, whereby the electrical circuit will be
closed. 3
2
Thus the solenoid valve (4) opens. The jet system is
activated, the turbocharger accelerates and increases 1
the charge air pressure, thereby pressing the piston ~
(3) backwards in the lambda cylinder (5). When the
lambda ratio is satisfactory, the jet system will be de- 4 Engine's
compression
activated. air system
Fig 1. Principle drawing of lambda controller
96.26 - ES0S
Description 609.35
Page 1 (1) Starting Box Edition 02H
L+V28/32H
Description Engine / Turbocharger RPM
The starting box is mounted on the engine's control By activating the "Engine RPM/TC RPM" button, the
side. On front of the box there are the following indication is changed.
indications/pushbuttons:
Engine RPM indication is green light-emitting diodes
- Indication of engine or turbocharger RPM and turbocharger RPM indication is red light-emitting
- Indication of electronic overspeed diodes.
- Pushbutton for "Manual Start"
- Pushbutton for "Manual Stop" External Indications
- Pushbutton for "Remote" *
- Pushbutton for "Local" * There are output signals for engine RPM and
- Pushbutton for "Blocking" * turbocharger RPM.
- Pushbutton for change-over between engine Engine: 0 - 1200 RPM ~ 4-20 mA
and turbocharger RPM TC: 0 - 60000 RPM ~ 4-20 mA
* The function chosen is indicated in the pushbutton. The pushbuttons for "Remote", "Local" and "Blocking"
See fig 1. have potential free switches for external indication.
Manual Start All components in the starting box are wired to the
built-on terminal box.
The engine can be started by means of the start
button, but only if the button "Local" is activated.
The manual, local start is an electrical, pneumatic

start, i.e. when activating the start button a solenoid
valve opens for air to the air starter, thereby enga-
ging the starter and starting the diesel engine.
Throughout the starting cycle the start button must
be activated.
The air starter is automatically disengaged when the

diesel engine exceeds 140 RPM. If the start button
is disengaged before the diesel engine has exceeded
140 RPM, further starting cycles are blocked, until 5
sec. after the engine is at standstill.
Remote Start
Remote start can only take place if the pushbutton

for "Remote" is activated.
08028-0D/H5250/94.08.12
Manual Stop
The "Manual Stop" button is connected to the stop

coil on the governor.
Blocking
If "Blocking" is activated, it is not possible to start the

diesel engine. Fig 1. Starting box
94.20 - ES2S
Description 609.40
Page 1 (1) Converter for Engine- and Turbocharger RPM Signal Edition 01H
L+V28/32H
Engine RPM signal The "engine run" signals will be given through a
relay. One for synchronizing and one for start/stop of
For measuring the engine's RPM, a pick-up mounted pre. lub. oil pump or alarm blocking at start/stop.
on the engine is used giving a frequency depending
on the RPM. To be able to show the engine's RPM
on an analogue tachometer, the frequency signal is Safe start
sent through an f/I converter (frequency/current
converter), where the signal is transformed into a When the safe start signal is activated the engine
proportional 4-20 mA ~ 0-1200 RPM signal. can start. When the engine reach 140 RPM the air
starter will be shut-off.
Further, the converter has following signals:
Further, the safe start signal is a blocking function for
- overspeed the air starter during rotation.
- engine run
- safe start
- tacho fail Tacho fail
The tacho fail signal will be on when everything is

normal. If the pick-up or the converter failes the
signal will be deactivated. E.g. if there is power
supply failure.
The converter for engine RPM signal is mounted in

the terminal box on the engine.
Turbocharger RPM signal
For measuring the turbocharger RPM, a pick-up

mounted on the engine is used giving a frequency
depending on the RPM. To be able to show the
Fig 1. Converter for engine RPM. turbocharger's RPM on an analogue tachometer,
the frequency signal is sent through a f/I converter
(frequency/current converter), where the signal is
Overspeed transferred into a proportional 4-20 mA ~ 0-60000
RPM.
When the engine speed reach the setpoint for
electronic overspeed the converter gives a shutdown
signal and a alarm signal through a relay.
08028-0D/H5250/94.08.12
Engine run
When the engine speed reach 710 RPM or 200 RPM

+ 10 seconds, the converter gives a "engine run"
signal.
Fig 2. Converter for TC RPM.
The engine run signal will be deactivated when the
speed is 640 RPM. If the engine speed haven't been
over 710 RPM the signal will be deactivated at 200 The converter is mounted in the terminal box on
RPM. engine.
96.30 - ES2S
Working Card Functional Test and Adjustment of Safety, 609-01.00
Page 1 (2) Alarm and Monitoring Equipment Edition 01H
General

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

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

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

Capacity : xxx man
Data:

92. 04 - ES0U
609-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 01H Alarm and Monitoring Equipment Page 2 (2)
General
Maintenance of monitoring and safety systems. It is recommended that all functions are tested every
three month according to the mentioned working
One of the most important parameters in the pre- cards.
ventive work is that the alarm system as well as the
shutdown and overspeed devices are functioning The extent of the alarm and safety functions is vari-
100%. able from plant to plant.
If some of these functions are out of operation, they For check of these functions use the working cards
have to be repaired immediately. If this is not pos- mentioned under related procedure on page 1.
sible because of the present working situation, the
engine has to be under constant observation until it
can be stopped.
08028-0D/H5250/94.08.12
92.04 - ES0U
Working Card
Functional Test and Adjustment of Overspeed Trip 609-01.05
General

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

Hand tools:
Allen key, 4 mm.

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

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

Capacity : 1 man
Data:

91.45 - ES0S
609-01.05 Functional Test and Adjustment of Overspeed Trip Working Card
General
1) The engine is run up manually, (on governor Turn the engine until the adjusting screw is opposite
"synchronizer") and at no load, while watching the the opening on the side of the housing. Now loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular pin spanner supplied, se fig. 2.
On reaching the revolution number indicated on
page 600.30 or in "Test Report", the overspeed
tripping device must function, thus actuating the stop
cylinders. The fuel injection pump control rods are
now moved to zero index, and the engine stops.
2) If the overspeed divice trip at a revolution

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

weight spring) to reduce the revolution number. Be
careful not to screw the adjusting screw so far out
that it may touch the release arm. Tighten the lock
screw and test the overspeed device again.
4) Refit the covers when the overspeed device

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

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

overspeed tripping device, see fig. 1. 6) It is recommended now and then, while the
engine is at a standstill, to move the flyweight by
means of the push button to ensure that the flyweight
can always move with sufficient ease.
91.45 - ES0S
Working Card
Function and Test of Level Switch (LAL 25) 609-05.02
General

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

lubricating oil system. Hand tools:
Starting position:

Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.03 - ES0S
609-05.02 Function and Test of Level Switch (LAL 25) Working Card
General
The level switch LAL 25, which is mounted on the

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

main lubricating oil pipe will be filled with lubricating
oil, which means that the level switch is lifted and the
alarm is disconnected.
Level switch
2) When the prelubricating is interrupted, the lub.
oil will run out of the system through the bearings, Main lubricating oil pipe
which means that level switch is lowered and the
alarm starts.
Fig. 1.
Test:
The test is carried out when the engine is stopped.
3) Start the lubricating oil pump, and let the pump

run about 5 min.
4) Stop the prelubricating oil pump. The alarm

must be released after 0 - 5 min., depending of the
oil viscosity.
08028-0D/H5250/94.08.12
91.03 - ES0S
Working Card Adjustment and Test of 609-05.04
Page 1 (2) Analogous Temperature Transmitter Edition 02H
L+V28/32H

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

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

Related procedure:

Capacity : 1 man
Data:

96.26 - ES0S
609-05.04 Adjustment and Test of Working Card
Edition 02H Analogous Temperature Transmitter Page 2 (2)
L+V28/32H
The PT 100 sensor consist of a resistance wire which the alarm plant gives any alarm, when the alarm limit
changes resistance depending on the temperature. which is stated on page 600.30 is exceeded (if the
alarm plant is adjusted).
Look and design varify depending on the place of
measurement and manufacture. 5) The sensor is mounted again.
Adjustment:
1) The PT 100 sensor connot be adjusted, but the

alarm limit must be set on the alarm plant.
Set point, see page 600.30.
Test:
2) The functional trial of the PT 100 sensor can be

carried out according to the following procedure.
3) Take out the sensor of the pocket.
4) Test the sensor by diving the sensor in the

water. Compare the signal from the sensor with the
water temperature.
If the alarm plant has an instrument unit, the tempe-

rature can be read on this. Fig. 1.
Otherwise the test can be carried out by watching if
96.26 - ES0S
Working Card
Lambda Controller 609-10.00
L28/32H

Shut off starting air
Shut off cooling water
Shut off fuel oil
Shut off cooling oil
Adjustment of lambda controller. Allen key.
Starting position:
Related procedure:
Manpower: Replacement and wearing parts:

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

Capacity : 1 man
Data:

95.29 - ES0S
609-10.00 Working Card
Edition 11H
Lambda Controller Page 2 (2)
L28/32H
Lambda Controller
Normally the lambda controller does not need ad-

justment. The only time adjustment is needed, is
when the controller or the governor has been dis-
mantled. The adjustment is to be carried out in
standstill position.
1. Check that the free space between the pick-up

and the band steel on the regulating arm is min 1 mm,
see fig 1.
Fig 3.
2. Set the index of the fuel pumps at 27 by means

of governor arm, see plate 60902-18H, item 15.
Note: Set the "load limit" control knob at max in order

to protect the governor.
3. Fit the adjustment screw (4), fig 2, until the

piston has contact with the spring without com-
pressing the spring.
Fig 1.
4. Fasten the adjustment screw.
5. Adjustment finished.
Adjustment of the stop screw.
6. Remove pipe for charge air pressure, see fig 3.

08028-0D/H5250/94.08.12
7. Supply air pressure until the piston rod reaches

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

according to the test bed, plus 1.5 index.
Use the index arm on the fuel pump nearest to the
lambda controller as control for the index.
9. Adjustment finished.
Fig 2.
95.29 - ES0S
Plate
Page 1 (2) Governor and Governor Drive 60901-07H
L28/32H
09
01
For governor, see spe-

cial instruction book
10
11
12
13
14
15
16
02
17
03 18
19+
20
04
05
21
06
22
07
08
23
24
25
26
30 27
28
29
94.28 - ES0S
Plate
60901-07H Governor and Governor Drive Page 2 (2)
L28/32H
Item Item
01 1/E Synchronnizing Synchroniserings- 29 1/E Wear disc Slidskive

motor motor
30 1/E Key Feder
02 1/E Plug screw Propskrue
03 1/E Gasket Pakning + Item No. 19 require + Item nr. 19 kræver en

an individual matching individual tilpasning
04 4/E Nut Møtrik (by shims) before (med shims) før monte-
mounting, contact, ring, kontakt MAN B&W,
05 2/E Stud Tap MAN B&W, Holeby Holeby.
06 1/E O-ring O-ring
07 1/E Castle nut Kronemøtrik
08 1/E Split pin Split
09 1/E Shut down Shut-down

solenoid spole
10 1/E Governor Regulator
11 4/E Screw Skrue
12 1/E Shim (set 0,1 - Mellemlæg (sæt 0,1 -

0,3 - 0,5 - 1,0 mm) 0,3 - 0,5 - 1,0 mm)
13 1/E Disc Skive
14 1/E Ball bearing Kugleleje
15 1/E Bevel gear wheel Konisk tandhjul
16 1/E Key Feder
17 1/E Castle nut Kronemøtrik
18 1/E Split pin Split
19+ 1/E Housing Hus
20 2/E Stud Tap
21 2/E Pin Stift
22 1/E Plug Prop
23 1/E Plug Prop
24 1/E Axle journal Akseltap
25 1/E Bush Bøsning
26 1/E Bevel gear wheel Konisk tandhjul
28 1/E Pointed screw Pinolskrue
94.28 - ES0S
Plate
Page 1 (2) Regulation Mechanism 60902-18H
L28/32H
Governor Plate 60901
17
15
18
01 13
19 16
02
03
04
05 14
19
06 25 20
07 18
26
08 27 17
28 21
09
24 22
10
25 23
11
12
64
13
65
02
66
67
56
68
48
49 69
57
50
58 51
52
55 53
61 54
62 59
63
60
94.36 - ES0S
Plate
60902-18H Regulation Mechanism Page 2 (2)
L28/32H
Item Item
01 1/R Split pin Split 48 1/C Linkage Lænkeled
02 2/R Pull rod head Trækstangshoved 49 1/C Pin Stift
03 1/R Pull rod end Trækstangsende 50 1/C Spring Fjeder
04 1/R Cylindrical pin Cylindrisk stift 51 1/C Spring arm Fjederarm
05 1/R Spring housing Fjederhus 52 3/C Spring pin Fjederstift
06 1/R Pointed screw Pinolskrue 53 1/C Arm holder Armholder
07 1/R Spring Fjeder 54 1/C Screw Skrue
08 1/R Pull rod Trækstang 55 1/C Spring loaded Fjederbelastet

lever, complete arm, komplet
09 1/R Cylindrical pin Cylindrisk stift
56 1/E Regulating shaft Reguleringsaksel
10 1/R Guide ring Styrering
57 1/C Split pin Split
11 1/R Guide ring Styrering
58 1/C Pin Stift
12 1/R Nut Møtrik
59 1/C Bushing Bøsning
13 2/R Locking plate Låseblik
60 1/C Bearing bracket Lejeblik
14 1/R Spring loaded pull Fjederbelastet træk-
rod, complete stang, komplet 61 2/C Screw Skrue
15 1/R Governor arm Regulator arm 62 2/C Washer Skive
16 1/R Screw Skrue 63 2/C Spring pin Fjederstift
17 2/R Split pin Split 64 1/E Stop ring Stopring
18 2/R Self locking nut Selvlåsende møtrik 65 1/E Screw Skrue
19 2/R Screw for ball head Skrue for kuglehoved 66 2/E Screw Skrue
20 1/R Arm Arm 67 2/E Screw Skrue
21 1/R Spring pin Fjederstift 68 1/E Bracket Konsol
22 1/R Locking plate Låseblik 69 2/E Nut Møtrik
23 1/R Screw Skrue
24 1/R Bearing housing Lejehus
25 2/R Bush Bøsning
26 2/R Screw Skrue
27 2/R Washer Skive
28 2/R Spring pin Fjederstift
Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme
94.36 - ES0S
Plate
Page 1 (2) Overspeed Device 60903-38H
L+V28/32H
08028-0D/H5250/94.08.12
98.14 - ES0S
Plate
60903-38H Overspeed Device Page 2 (2)
L+V28/32H
Item Item
01 1/E Socket Muffe 32 1/E Button Knap
02 1/E Button Knap 33 1/E Nipple Nippel
03 1/E Spring pin Fjederstift 34 1/E Spindle Spindel
04 1/E Spring Fjeder 35 1/E Spring (left) Fjeder (venstre)
05 4/E Screw Skrue 36 1/E Spindle Spindel
06 1/E Screw Skrue 37 2/E Washer Skive
07 1/E Cover Dæksel 38 2/E Screw Skrue
08 1/E Spindle Spindel 39 1/E Ball bearing Kugleleje
09 1/E Spring pin Fjederstift 40 1/E Elastic coupling Elastisk kobling
10 1/E Cylindrical pin Cylindrisk stift 41 1/E Spring (right) Fjeder (højre)
11 1/E Lever Arm 42 1/E Valve attachment Ventilholder
12 1/E Screw Skrue 43 4/E Screw Skrue
13 1/E Flyweight housing Hus for svingvægt 44 1/E Pneumatic valve Pneumatisk ventil
14 1/E Adjusting screw Justeringsskrue 45 1/E Silencer Lyddæmper
15 1/E Spring Fjeder 46 1/E Overspeed device, Overspeed anordning,

complete excl. item komplet eksl. item 27,
16 1/E Circlip Sikringsring 27, 37, 38, 44 37, 38, 44
17 1/E Flyweight Svingvægt 47 1/E Spare parts kit for Reservedelskit for
item 44 item 44
18 1/E Key Not
19 1/E Ball bearing Kugleleje
20 1/E Housing Hus
22 4/E Washer Skive
23 4/E Screw Skrue
24 1/E Pin Stift
25 1/E Lever Arm
26 1/E Nut Møtrik

08028-0D/H5250/94.08.12
30 1/E Spindle Spindel
31 1/E Spring Fjeder
98.14 - ES0S
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 60905-09H
L28/32H
01
02
03
04
05-06
08 07
91.41 - ES0S
Plate
60905-09H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L28/32H
Item Item
01 1/E Cable union Kabel union
02 1/E Mounting plug Monteringsprop
04 1/E Level switch Niveaukontakt
07 1/E Fuel oil leakage Fuel-olie lækage

alarm, complete alarm, komplet
08 1/E Ball valve Kugleventil
91.41 - ES0S
Plate
Page 1 (2) Instrument Panel 60905-21H
L28/32H
46-46A 19 07 07
17
01
06 08
16
07 06
15
04-05
03 02-02A
14
09
10
11
43-44-45 20 20
12 23 21
13
14 22 22
PI 01 LT fresh water, inlet to air cooler

PI 10 HT fresh water, inlet engine
PI 21/22 Lubricating oil, inlet/outlet to filter
PI 23 Lub. oil, inlet to turbocharger
PI 31 Charge air, outlet from cooler
PI 40 Fuel oil, inlet to engine
94.28 - ES0S
Plate
60905-21H Instrument Panel Page 2 (2)
In-Line
Item Item
01 1/E Housing for instru- Hus for instrument 23 1/E Damper (charging air) Dæmper (ladeluft)
ment panel panel
43 4/E Screw Skrue
02 1/E Bracket for instrument Konsol for instrument
panel , L23/30H panel, L23/30H 44 4/E Lock washer Skrue
02A 1/E Bracket for instrunent Konsol for instrument 45 4/E Nut Låseskive
panel, L28/32H panel, L28/32H
46 1/E Instrument panel, Møtrik
03 4/E Rubber clutch Gummikobling complete, L23/30H
Instrument panel,
04 8/E Nut Møtrik 46A 1/E Instrument panel, komplet, L23/30H
complete, L28/32H
05 8/E Spring locks Fjedrende skive Instrument panel,
komplet, L28/32H
06 2/E Pressure gauge 0-3 Manometer 0-3 bar
bar (PI 31 and PI 23) (PI 31 og PI 23)
07 3/E Pressure gauge 0-6 Manometer 0-3 bar,

bar, PI 01, PI 10, PI 21- PI 01, PI 10, PI 21-22
22
08 1/E Pressure gauge 0-10 Manometer 0-10 bar

bar (PI 40) (PI 40)
09 6/E Needle valve Nåleventil
10 1/E 3-way valve for 3-vejsventil for

PI 21-22 PI 21-22
11 1/E Washer Skive
12 1/E Steel pipe Stålrør
13 1/E Screwed connection Forskruning
14 2/E Union Forskruning
15 2/E Pressure gauge hose Manometer slange

140 mm 140 mm

195 mm 195 mm

340 mm 340 mm
20 2/E Reduction adapter Reduktionsforskruning
21 1/E Damper (fuel oil) Dæmper (fuel oil)
22 2/E Coupling for mano- Kobling for manometer

meter
93.04 - ES0S
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 60905-35H
L+V28/32H
08028-0D/H5250/94.08.12
95.21 - ES0S
Plate
60905-35H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
L+V28/32H
Item Item
01 1/E Level alarm Niveaualarm
02 1/E Plate Plade
03 1/E Packing Pakning
04 4/E Hexagon screw Hexagonskrue
05 4/E Nut Møtrik
06 1/E Pipe Rør
07 1/E Pipe Rør
08 2/E Level switch Niveaukontakt
09 2/E Reduction adaptor Reduktionsadapter
10 1/E Dipstick complete Pejlestok komplet
08028-0D/H5250/94.08.12
95.21 - ES0S
Plate
Page 1 (2) Prelubricating Oil Alarm (LAL 25) 60905-46H
L+V28/32H
08028-0D/H5250/94.08.12
97.44 - ES0S
Plate
60905-46H Prelubricating Oil Alarm (LAL 25) Page 2 (2)
L+V28/32H
Item Item
02 1/E Packing ring Pakningsring
03 1/E Loctite 577 Loctite 577
04 1/E Level switch Niveauafbryder
08028-0D/H5250/94.08.12
97.44 - ES0S
Plate
Page 1 (2) Thermometer 60907-01H
L28/32H
Scale Length Item

Fig. Code
°F °C L L1 No.
40-240 0-120 110 100 TI 01 01
TI 02
TI 31
L 40-240 0-120 110 63 TI 22 02
TI 20
40-600 0-300 150 100 TI 30 03

L1
40-400 0-200 110 40 TI 40 04
TI 51
40-220 0-120 110 100 TI 03 05
TI 10
TI 11
L
L1
91.44 - ES0S
Plate
60907-01H Thermometer Page 2 (2)
L28/32H
Scale Length Item

Fig. Code
°F °C L L1 No.
100-
1300 50-650 100 115 TI 60 06
°C°F
L1
L1
Pocket 115 07
100-
1300 50-650 65 215 TI 61 08
° C° F
Pocket 215 09
91.44 - ES0S
Plate
Page 1 (2) Lambda Controller 60910-03H
L28/32H
94.28 - ES0S
Plate
60910-03H Lambda Controller Page 2 (2)
L28/32H
Item Item
01 1/E Regulating arm, Reguleringsarm,

complete komplet
02 1/E Pick-up, Pick-up,

incl. sleeve incl. afstandsring
03 1/E Lambda cylinder, Lambdacylinder,

complete komplet
94.28 - ES0S
Plate
Page 1 (2) Starting Box 60935-01H
L28/32H
017
029
030
08028-0D/H5250/94.08.12
94.36 - ES0S
Plate
60935-01H Starting Box Page 2 (2)
L28/32H
Item Item
Qty. Designation Qty. Designation
No. No.
017 1E Starting box
029 1/E Terminal box
030 1/E Starting box, complete
When ordering spare parts, see also page 600.50

* = Only available as part of a spare parts kit.
Qty./E = Qty./Engine.
Index
Page 1 (1) Crankshaft and Main Bearings 610
L28/32H
Description
Crankshaft and Main Bearings .................................................................................. 610.01(12H)

Mount of Anti-vibration Block on Flywheel ................................................................ 610.10(01H)
Working Card
Checking of Main Bearing Alignment (Autolog) ................................................... 610-01.00(02H)

Checking of Main Bearing Alignment (Autolog), Hydraulic Tightened
Connecting rod ..................................................................................................... 610-01.00(10H)
Inspection of Main Bearing Shells ........................................................................ 610-01.05(05H)
Inspection of Main Bearing Shells ........................................................................ 610-01.10(05H)
Vibration Damper .................................................................................................. 610-04.00(01H)
Plates
Crankshaft .................................................................................................................... 61001-15H

Resilient Gear Wheel ................................................................................................... 61002-07H
Coupling for Central Driven Lub. Oil Pump .................................................................. 61002-08H
Fly wheel with Flexible Coupling and Gear Rim ........................................................... 61003-01H
Fly wheel with Gear Rim .............................................................................................. 61003-02H
Torsional Vibration Damper .......................................................................................... 61004-05H
Tuning Wheel ............................................................................................................... 61004-06H
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Crankshaft and Main Bearings 610.01
Page 1 (1)
Edition 12H
L/V28/32H
Crankshaft Vibration Damper
The crankshaft, which is a one-piece forging with In special cases a vibration damper is mounted on
ground main bearing and crankpin journals, is sus- the crankshaft to limit torsional vibrations. The dam-
pended in inderslung bearings. The main bearings per consists essentially of a heavy flywheel totally
are equipped with insertion-type shells, which are enclosed in a light casing. A small clearance is
coated with a wearing surface. To attain a suitable allowed between the casing and the flywheel, and
bearing pressure the crankshaft is provided with this space is filled with a highly viscous fluid. The
counterweights, which are attached to the crank- casing is rigidly connected to the front end of the
shaft by means of dovetail joints and secured with a engine crankshaft and the only connection between
centrally placed screw. the crankshaft and the damper flywheel is through
the fluid. Under conditions of no vibration, the casing
At the flywheel end the crankshaft is fitted with a gear and damper flywheel tend to rotate as one unit, since
wheel which through an intermediate wheel drives the force required to shear the viscous film is consi-
the camshaft. Also fitted here is the flywheel and a derable. As the torsional vibration amplitudes
coupling flange for connection of a reduction gear or increase, the casing follows the movement of the
a alternator. At the opposite end there is a claw-type crankshaft but the flywheel tends to rotate uniformly
coupling for the lub. oil pump or a flexible gear wheel by virtue of its inertia, and relative motion occurs
connection for lub. oil and water pumps. between the flywheel and the casing. The viscous
fluid film therefore undergoes a shearing action, and
vibration energy is absorbed and appears as heat.
08028-0D/H5250/94.08.12
91.45 - ES0U
Working Card Checking of Main Bearings Alignment (Deflection) 610-01.00
Page 1 (6) (Hydraulic Tightened Connecting Rod) Edition 10H
L28/32H

Shut-off cooling oil 62010 35 Angle for
Stopped lub. oil circul. mounting on
crank web
Description:
Checking of main bearings alignment (deflection).

Hand tools:
Starting position:
Turning gear in engagement. (If mounted).

Cover for crankshaft has been removed from
frame.
Related procedure:
08028-0D/H5250/94.08.12
Working time : 1 1/2 hours Plate no. Item no. Qty. /

Capacity : 2 men
Data:

99.25 - ES0S
610-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 10H (Hydraulic Tightened Connecting Rod) Page 2 (6)
L28/32H
Alignment of Main Bearings.
The lower main bearing shells should be positioned

so that they keep the main bearing journals of the
crankshaft centered in a straight (ashore horizontal)
line. Deviations from this centre line cause the
crankshaft to bend and increase the load on some
main bearings.
If two adjacent main bearings are placed too low, the

crankshaft centre line will in this place be lowered to
form an arc, causing the intermediate crank throw to
bend in such a way that it "closes" when turned into
bottom position and "opens" in top position.
As the magnitude of such axial lengthening and

shortening during the turning of the throw increases Fig. 1 Placing of dial gauge
in proportion to the difference in the height of the
bearing, it is measured as a check on the alignment
and condition of the bearing.
Checking The Deflection Measurement.
As the crankshafts of medium speed engines are
very stiff, any great deviations in the alignment will The reading is entered in the table page 6, see
result in clearance at the bottom shell of the bearings. example in fig. 2 - 6.
The cause of incorrect main bearing position may be As "bottom" reading is used the mean value of the
wear of the bearings or misalignmnet of the engine. two "near bottom" readings X and Y, fig. 3.
The total deflection ("opening-closing") of the throw

Effecting The Deflection Measurement. during the turning from bottom to top position is
entered in fig. 4.
The deflection measurement is effected by placing a
springloaded dial gauge in the centre punch marks These figures are due to vertical misalignment of the
provided for this purpose, see fig. 1. main bearings.
"Closing" of the throw in top dead centre is regarded Similarly, horizontal misalignment procedures the
as negative, (compression of the gauge). figures in the table fig. 5.
In the example, page 3, the deflection reading is Besides misalignment of the bearings, the readings
therefore negative. can be influenced by ovality or eccentricity of the
journals.
08028-0D/H5250/94.08.12
As during the turning of the throw, the gauge and the

connecting rod will meet near the bottom position of
the throw, the measurement for the bottom position Engines Equipped with Turning Gear.
is to be replaced by the average of the two near by
positions on either side. When taking these deflection readings for the three
aftmost cylinders, the turning gear should at each
The dial gauge is set to zero, when the crank throw stoppage be turned a little backwards to ease off the
is in the near-bottom (x in fig. 8) and during the tangential pressure on the teeth of the turning wheel
turning the throw is stopped in the position horizon- as this pressure may otherwise falsify the readings.
tal-top-horizontal-near bottom (P-T-S-Y in fig. 8) for
reading of the gauge.
99.25 - ES0S
L28/32H
Deflection of crankshaft in 1/100 mm. (0.01 mm).

Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig. 4.
Left side P 2 0 2 0 -1 2
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Bottom stop Y 2 -1 0 1 0 2 Right side - left side

or P - S = H -1 2 0 0 -1 1
Fig. 2. Fig. 5.
Bottom (0,5 x Y) = B 1 -0.5 0 -0.5 0 1 Check on T+B= C 4 -2.5 4 5.5 -2 4

gauge
readings P+S= D 5 -2 4 0 -1 3
Fig. 3.
Fig. 6.
C and D should be nearly the same, reading for cylinder 4 to be repeated.
S P
08028-0D/H5250/94.08.12
Y X
Front end view.

"Closing" of the crankthrow is considered nega- Start in position X.
tive. Turn anti clockwise
Fig. 7. Fig. 8.
99.25 - ES0S
Edition 10H (Hydraulic Tightened Connecting Rod) Pagee 4 (6)
L28/32H
Measurement of Crank Throw Deflections by Means of Dial Indicator (Autolog)
Crank throw deflection = Difference in dial indicator readings in two diametrically

opposite crank throw positions, i.e. two positions dis-
placed 180°.
Vertical deflection = Difference in top-bottom readings.
Horizontal deflection = Difference in side-side readings.
Vertical of Horizontal Deflections of Crank Throws
Unless otherwise stated the values refer to cold engine.
For new or realigned aggregate Aim for + or - 4/100 mm

Acceptable + or - 6/100 mm
For aggregate in service realignment

is recommended if deflections exceed + or -10/100 mm
Vertical Deflection of Crank Throw at Flywheel
Rigid coupling between Flexible coupling between

diesel engine and driven machine diesel engine and driven machine
08028-0D/H5250/94.08.12
For new or realigned For new or realigned

aggregate 0 to + 4/100 mm aggregate Aim for - 7/100 mm
Acceptable - 10/100 mm
For aggregate in service realignment is For aggregate in service

recommended if deflection measured realignment recommendable
on warm engine exceeds - 10/100 mm if deflection exceeds - 14/100 mm
99.25 - ES0S
L28/32H
Process/Proces I.D. no.
Plant/Anlæg Page of/Side af
Engine Type/Motortype Engineer/Operatør Date/Dato
Instruction/Instruktion
Top
Right side Left side
Bottom end/ Bottom start/

1/100 mm Bund slut Bund start
Right side Right side
Cyl. no 1 2 3 Cyl. no 1 2 3
Left side Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
08028-0D/H5250/94.08.12
99.25 - ES0S
Edition 10H (Hydraulic Tightened Connecting Rod) Page 6 (6)
L28/32H
Component/Komponent Type I.D. no.
Process/Proces Page of/Side af
Test place/ Test bed/prøvehal Cold/Kold

Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal
Engine no.:
Motornr.:
Cyl. no. 1 2 3 4 5 6 7 8 9
Bottom X 0 0 0 0 0 0 0 0 0
Left side P
Top T
Right side S
Bottom Y
Bottom
(0.5xY)=B
Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V
Deflection from
horizontal mis-
08028-0D/H5250/94.08.12
alignment.
Left side - Right
side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
99.25 - ES0S
Working Card
Checking of Main Bearings Alignment (Autolog) 610-01.00
L28/32H

Description:
Checking of main bearings alignment (autolog).

Hand tools:
Starting position:
Turning gear in engagement. (If mounted).

Cover for crankshaft has been removed from
frame.
Related procedure:
08028-0D/H5250/94.08.12
Working time : 1 1/2 hours Plate no. Item no. Qty. /

Capacity : 2 men
Data:

01.26 - ES0
610-01.00 Checking of Main Bearings Alignment (Autolog) Working Card
L28/32H
Alignment of Main Bearings.
The lower main bearing shells should be positioned

so that they keep the main bearing journals of the
crankshaft centered in a straight (ashore horizontal)
line. Deviations from this centre line cause the
crankshaft to bend and increase the load on some
main bearings.
If two adjacent main bearings are placed too low, the

crankshaft centre line will in this place be lowered to
form an arc, causing the intermediate crank throw to
bend in such a way that it "closes" when turned into
bottom position and "opens" in top position.
Fig. 1. Placing of dial gauge.
As the magnitude of such axial lengthening and
shortening during the turning of the throw increases
in proportion to the difference in the height of the Checking The Deflection Measurement.
bearing, it is measured as a check on the alignment
and condition of the bearing. The reading is entered in the table page 6, see
example in fig. 2 - 6.
As the crankshafts of medium speed engines are
very stiff, any great deviations in the alignment will As "bottom" reading is used the mean value of the
result in clearance at the bottom shell of the bearings. two "near bottom" readings X and Y, fig. 3.
The cause of incorrect main bearing position may be The total deflection ("opening-closing") of the throw
wear of the bearings or misalignmnet of the engine. during the turning from bottom to top position is
entered in fig. 4.
Effecting The Deflection Measurement. These figures are due to vertical misalignment of the
main bearings.
The deflection measurement is effected by placing a
springloaded dial gauge in the centre punch marks Similarly, horizontal misalignment procedures the
provided for this purpose, see fig. 1. figures in the table fig. 5.
"Closing" of the throw in top dead centre is regarded Besides misalignment of the bearings, the readings
as negative, (compression of the gauge). can be influenced by ovality or eccentricity of the
journals.
In the example, page 3, the deflection reading is
therefore negative.
Engines Equipped with Turning Gear.
08028-0D/H5250/94.08.12
As during the turning of the throw, the gauge and the

connecting rod will meet near the bottom position of When taking these deflection readings for the three
the throw, the measurement for the bottom position aftmost cylinders, the turning gear should at each
is to be replaced by the average of the two near by stoppage be turned a little backwards to ease off the
positions on either side. tangential pressure on the teeth of the turning wheel
as this pressure may otherwise falsify the readings.
The dial gauge is set to zero, when the crank throw
is in the near-bottom (x in fig. 8) and during the
turning the throw is stopped in the position horizon-
tal-top-horizontal-near bottom (P-T-S-Y in fig. 8) for
reading of the gauge.
01.26 - ES0
Working Card
L28/32H
Deflection of crankshaft in 1/100 mm. (0.01 mm).

Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig. 4.
Left side P 2 0 2 0 -1 2
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Bottom stop Y 2 -1 0 1 0 2 Right side - left side

or P - S = H -1 2 0 0 -1 1
Fig. 2. Fig. 5.
Bottom (0,5 x Y) = B 1 -0.5 0 0.5 0 1 Check on T+B= C 4 -2.5 4 5.5 -2 4

gauge
readings P+S= D 5 -2 4 0 -1 3
Fig. 3.
Fig. 6.
C and D should be nearly the same, reading for crank throw 4 to be repeated.
S P
08028-0D/H5250/94.08.12
Y X
Front end view.

"Closing" of the crankthrow is considered nega- Start in position X.
tive. Turn anti clockwise
Fig. 7. Fig. 8.
01.26 - ES0
Pagee 4 (6)
Edition 13H
L28/32H
Measurement of crank throw deflections by means of dial indicator (Autolog)
Crank throw deflection = Difference in dial indicator readings in two diametrically

opposite crank throw positions, i.e. two positions dis-
placed 180°.
Vertical deflection = Difference in top-bottom readings.
Horizontal deflection = Difference in side-side readings.
Vertical and horizontal deflections of crank throws
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 at flywheel
Rigid coupling between Flexible coupling between

diesel engine and driven machine diesel engine and driven machine
08028-0D/H5250/94.08.12
For new or realigned For new or realigned

aggregate 0 to + 3/100 mm aggregate Aim for - 6/100 mm
Acceptable - 8/100 mm
For aggregate in service realignment is For aggregate in service

recommended if deflection measured realignment is recommended
on warm engine exceeds - 8/100 mm if deflection exceeds - 12/100 mm
01.26 - ES0
Working Card
L28/32H
Process/Proces I.D. no.
Plant/Anlæg Page of/Side af
Engine Type/Motortype Engineer/Operatør Date/Dato
Instruction/Instruktion
Top
Right side Left side
1/100 mm
Bottom end/ Bottom start/
Bund slut Bund start
Right side Right side
Cyl. no 1 2 3 Cyl. no 1 2 3
Left side Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
08028-0D/H5250/94.08.12
01.26 - ES0
Page 6 (6)
Edition 13H
L28/32H
Component/Komponent Type I.D. no.
Process/Proces Page of/Side af
Test place/ Test bed/prøvehal Cold/Kold

Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal
Engine no.:
Motornr.:
Cyl. no. 1 2 3 4 5 6 7 8 9
Bottom X 0 0 0 0 0 0 0 0 0
Left side P
Top T
Right side S
Bottom Y
Bottom
(0.5xY)=B
Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V
Deflection from
horizontal mis-
alignment.
08028-0D/H5250/94.08.12
Left side - Right

side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
01.26 - ES0
Working Card
Inspection of Main Bearing Shells 610-01.05
L+V28/32H

Shut-off cooling water 62010 10 2 pieces
Stopped lub. oil circul. 62010 15 2 pieces
62010 30 Extra tools
62021 40 Hydraulic tools
62021 50 2 pieces
Description: 62021 51
62021 20
Dismantling, inspection and/or replacement and
mounting of main bearing shells.
Hand tools:
Allen key, 12 mm.

Starting position: Lead hammer.
Silastene.
Copaslip.
Related procedure:
Inspection of guide bearing shell, 610-01.10

Criteria for replacement of bearings, 606-01.16
Manpower:
08028-0D/H5250/94.08.12
Working time : 2 hours Replacement and wearing parts:

Capacity : 2 men
Plate no Item no Qty/
Data:

96.30 - ES0S-G
610-01.05 Inspection of Main Bearing Shells Working Card
L+V28/32H
Make Ready for Dismantling of the Main Bearing
1) Dismount crankcase covers in front and oppo-

site the bearing concerned.
2) Turn the engine until the crank is in a conveni-

ent position for carrying out the work.
3) Dismount the bracing screw (side screw).
4) Mount the hydraulic tools and loosen the main

bearing stud nuts. For operation of the hydraulic
tools, see working card 620-01.05.
Fig 2. Mounting of Wire Straps.
8) Lift the main bearing cap a little and unscrew

the bearing stud nut.
9) Fit guide tubes on the threads of the bearing

studs and lower the bearing cap to make it rest on the
collar of the guide tubes.
Dismantling of the Main Bearing Shells
10) Remove the locking piece from the bearing

cap and take out the bearing shell.
11) Fit the tool for upper main bearing, for dis-
mantling of upper main bearing shell, in the lubricating
Fig 1. Mounting of Hydraulic Tools. hole in the crankshaft and turn out the upper bearing
shell by turning the crankshaft, see fig 3.
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
Dismantling of the Main Bearing Cap

08028-0D/H5250/94.08.12
6) Fit the eye screws, diagonally, in the threaded

holes in the main bearing cap, see fig 2.
Pass the wire supplied through the eye screw and

attach it as shown, so as to keep the bearing cap in
place when the main bearing stud nuts are removed. Tool for upper main
bearing
7) Work the main bearing cap loose from the

engine frame with a lead hammer or similar. Fig 3. Mounting of tool for upper main bearing.
96.30 - ES0S-G
Working Card
Inspection of Main Bearing Shells 610.01-05
L+V28/32H
Cleaning 17) Insert the lower bearing shell in the bearing

cap and mount the locking piece.
12) Clean all machined surfaces, on frame, bearing
cap, stud, nuts and bearing shells. Lubricate the bearing shell and journal with clean
lubricating oil.
Inspection of Main Bearing Shells

Mounting of the Main Bearing Cap
13) Inspect the main bearing shells according to
working card 606-01.16. 18) Raise the bearing cap into position, dismount
the guide tubes, coat the bearing studs with molyco-
Note: The bearing is marked according to size and te pasta or similar and fit the bearing stud nuts.
when replaced it must be by a new bearing of the
same size. Make sure that the bearing cap and bearing shell are
in their correct position.
Mounting of the Main Bearing Shells 19) Dismantle the wire straps.
14) Push the upper bearing shell as far into posi- 20) Mount the hydraulic tools, see working card
tion as possible. 620-01.05, and tighten the nuts as prescribed on
page 600-40.
15) Fit the tool for upper main bearing in the
lubricating hole in the crankshaft and turn in the 21) Coat the back side of the bracing screws' (side
upper bearing shell by turning the crankshaft. screws') hexagonal head with a thin coat of silastene
or similar.
Make sure that the shell enters its correct position
then remove the tool for upper main bearing. 22) Mount the screws and tighten with a torque
spanner as indicated on page 600.40.
16) Lubricate the end of the bearing shells with
molycote pasta or similar.
08028-0D/H5250/94.08.12
96.30 - ES0S-G
Working Card
Inspection of Guide Bearing Shells 610-01.10
L+V28/32H

Shut-off fuel oil 62010 10 2 pieces
62010 25
62010 15 2 pieces
62010 30 Extra tools
Description 62021 40 Hydraulic tools
62021 50 2 pieces
Dismantling, inspection and/or replacement and 62021 51
mounting of guide bearing shells and thrust 62021 20
washer.
Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Molycote
Related procedure
Inspection of main bearing shells. 610-01.05

Criteria for replacement of bearing
shells. 606-01.16
08028-0D/H5250/94.08.12
Manpower
Working time : 2 hours

Capacity : 2 men Replacement and wearing parts
Data Plate no Item no Qty/

02.47 - ES0
610-01.10 Inspection of Guide Bearing Shells
Working Card
L+V28/32H
Make Ready for Dismantling of the Guide

Bearing
1) Dismount the crankcase covers opposite the

bearing concerned.
2) Turn the engine until the crank is in a convenient

position for carrying out the work.
3) Dismount the bracing screw (side screw).
4) Mount the hydraulic tools, see fig 1, and loosen

the guide bearing stud nuts. For operation of
the hydraulic tools, see working card
620-01.05. Fig 2 Mounting of Wire Straps
8) Lift the guide bearing cap a little and unscrew

the bearing stud nut.
9) Fit guide tubes on the threads of the bearing

studs and lower the bearing cap to make it rest
on the collar of the guide tubes.
Dismantling of the Guide Bearing Shells
10) Remove the locking piece from the bearing

To pump cap and take out the bearing shell.
Fig 1 Mounting of Hydraulic Tools Thrust washer
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
08028-0D/H5250/94.08.12
Dismantling of the Guide Bearing Cap
6) Fit the eye screws, diagonally, in the threaded

holes in the guide bearing cap, see fig 2.
Fig 3 Guide Bearing with Thrust Washer
Pass the wire supplied through the eye screw
and attach it as shown, so as to keep the
bearing cap in place when the guide bearing
stud nuts are removed. The thrust washer of the guide bearing is partially
countersunk into the engine frame and attached by
7) Work the guide bearing cap loose from the means of four screwed-on clamps which are visible
engine frame with a lead hammer or similar. after lowering the bearing cap, see fig 3.
02.47 - ES0
Page 3 (4) Inspection of Guide Bearing Shells Edition 08H
L+V28/32H
In case the guide shell tool is locked between guide
bearing and bearing studs, use the bolt on the back
of the guide shell tool to dislodge it.
Cleaning of Components
14) Clean all machined surfaces, on frame, bearing

cap, stud, nuts and bearing shells.
Inspection of Guide Bearing Shells
15) Inspect the guide bearing shells according to

working card 606-01.16.
Guide for mounting of upper shell.
Fig 4 Dismounting of Upper Shell

Fig 5 Mounting of Upper Shell in Guide Bearing
11) Unscrew the clamns and push out the thrust Mounting of the Guide Bearing Shells
washers.
The bearing shells of the guide bearing, which are
12) Fit the tools for dismantling of upper guide identical to those of the main bearings, are narrower
bearing shell, see fig 4, in the bearing cap and than the bore for the guide bearing and it is therefore
raise the bearing cap into position, making essential that the shells are positioned perfectly
sure that the guide shell is not being damaged. correct in the bore.
08028-0D/H5250/94.08.12
After that, dismount the guide tubes, fit and For this purpose a guide tool is supplied for positioning
tighten the nuts slightly. on the engine frame when the upper bearing shell is
to be fitted, see fig 5.
13) With the guide shell tool, which is guided by the
bearing cap, the upper bearing shell is carefully 16) Push the bearing shell as far as possible into
turned out into the bearing cap. Then dismount position through this guide tool.
the nuts and lower the bearing cap on the collar
of the guide tubes. Take out the bearing shell 17) Insert the guide shell tool in the bearing cap,
and the guide shell tool. which is resting on the collar of the guide tubes.
02.47 - ES0
Edition 08H
Inspection of Guide Bearing Shells Page 4 (4)
L+V28/32H
18) Raise the bearing cap with the guide shell tool Bearing Cap
into its correct position, dismount the guide
tubes, fit and tighten the bearing stud nuts Lubricate the bearing shell and journal with clean
slightly. lubricating oil.
19) Now push the bearing shell into its correct 24) Raise the bearing cap into position, dismount
position with the guide shell tool.Make sure the guide tubes, coat the bearing stud with
that the shell enters its correct position. molycote pasta or similar and fit the bearing
stud nuts.
20) Then unscrew the bearing stud nuts, fit the
guide tubes and lower the bearing cap again. Make sure that the thrust washers, bearing
shell and bearing cap are in their correct
21) Fit the thrust washers and clamps. position.
Note: Clearance in guide bearing axially, see page 25) Dismantle the wire straps.
600.35.
26) Mount the hydraulic tools, see working card
22) Lubricate the end of the bearing shells with 620-01.05, and tighten the nuts as prescribed
molycote pasta or similar. on page 600-40.
23) Insert the lower bearing shell in the bearing 27) Coat the back side of the bracing screws' (side
cap, and mount the locking piece. screws') hexagonal head with a thin coat of
silastene or similar.
28) Mount the screws and tighten with a torque

spanner as indicated on page 600.40.
08028-0D/H5250/94.08.12
02.47 - ES0
Plate
Page 1 (2) CRANKSHAFT 61001-15H
L28/32H
10
11
12
13
09
06
05
04
03
02+
01
07-14
08-14
92.11 - ES0S
Plate
61001-15H CRANKSHAFT Page 2 (2)
L28/32H
Item Item
No. No.
01 1/E Crankshaft
02+ /I Counterweight
03 1/W Locking plate
04 1/W Locking plate
05 2/W Screw
06 1/W Screw for counterweight
07 1/C Plug screw
08 1/E Plug screw
09 12/E Screw
10 12/E Self locking nut
11 12/E Washer
12 1/E Oil throw ring
13 1/E Gear wheel (crankshaft)
14 Loctite 242
+ Item No. 02 require and individual

matching before mounting contact
MAN B&W, Holeby

Qty./E = Qty./Engine
Qty./W = Qty./Counterweight
Qty./I = Qty./Individual
Qty./C = Qty./Cylinder
Plate
Page 1 (2) Resilient Gear Wheel 61002-07H
L28/32H
01
Crankshaft 19+
(Plate 61001)
02
05 03
06
07
18
08
04
09
10 10
11
17 16
15
14
13
12
96.01 - ES0S
Plate
61002-07H Resilient Gear Wheel Page 2 (2)
L28/32H
Item Item
01 1/E Resilient gear Fjedrende tandhjul,

wheel, compl. komplet
02 1/E Axle journal Akseltap
03 4/E Screw Skrue
04 6/E Self locking nut, Selvlåsende møtrik,

for Item No. 03 and 19 for Item nr. 03 og 19
05 1/E Hub Nav
06 6/E Slide shoe Glidesko
07 3/E Distance piece Afstandsstykke
09 12/E Locking washer Låseblik for

for item No. 10 item nr. 10
10 12/E Nut Møtrik
11 4/E Cylindrical pin Cylindrisk stift
12 6/E Spring guide Fjederstyr
13 6/E Spring Fjeder
15 6/E Screw Skrue
16 6/E Locking washer, Låseblik for

for Item No. 15 Item nr. 15
17 1/E Side plate Sideplade
+ Item 19 require an + Item 19 kræver en

individual matching individuel tilpasning
during mounting, før montering, kontakt
contact MAN B&W, MAN B&W, Holeby
Holeby
96.01 - ES0S
Plate
Page 1 (2) Flywheel with Flexible Coupling and Gear Rim 61003-01H
L28/32H
07+
08
10
09
06
04+
05
Crankshaft
(plate 61001)
03
01
02
91.42 - ES0S
Plate
61003-01H Flywheel with Flexible Coupling and Gear Rim Page 2 (2)
L28/32H
Item Item
01 1/E Gear rim 2/2 Tandkrans 2/2
02 18/E Screw Skrue
03 12/E Self locking nut, for Selvlående møtrik for

item no. 04 item nr. 04
05 1/E Flywheel Svinghjul

08 1/E Flexible coupling, Fleksibel kobling,

complet komplet
09 16/E Rubber element Gummi elementer
10 2/E Screw Skrue
+ Item 04 and 07 + Item nr. 04 and 07

require a individual kræver en individuel til-
matching, before pasning, før montering
mounting.
Qty./E = Qty./Engine Qty./E = Antal/Motor
91.42 - ES0S
Plate
Page 1 (2) Flywheel with Gear Rim 61003-02H
L28/32H
10
04+
05
01
Crankshaft
(plate 61001)
03 02
91.43 - ES0S
Plate
61003-02H Flywheel with Gear Rim Page 2 (2)
L28/32H
Item Item
01 1/E Gear rim 2/2 Tandkrans 2/2
02 18/E Screw Skrue

05 1/E Flywheel Svinghjul
10 2/E Screw Skrue
+ Item 04 require + Item nr. 04 kræver

a individual en individuel til-
matching before pasning før
mounting. montering.
Qty./E = Qty./Engine Qty./E = Antal/Motor
91.43 - ES0S
Index
Page 1 (1) Engine Frame and Base Frame 611S
L28/32H
Description
Engine frame and Base Frame .................................................................................. 611.01(07H)
Working Card
Function Test of Crankcase Safety Relief Valves ................................................. 611-01.00(02H)
Plates
Frame with Main Bearings .......................................................................................... S61101-11H

Front Cover for Lubricating Oil Pump ........................................................................... 61102-09H
Front Cover for Lubricating Oil Pump and Cooling Water Pump ................................. 61102-07H
Front Cover for Lubricating Oil Pump and Cooling Water Pump ................................. 61102-10H
Cover on Frame ........................................................................................................... 61106-12S
Safety Valve on Crankcase Cover ................................................................................ 61106-13S
Cover on Frame ........................................................................................................... 61106-14H
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Engine Frame and Base Frame 611.01
Page 1 (1)
Edition 07H
L28/32H
Frame The crankshaft guide bearing is located at the

flywheel end of the engine.
The engine frame is made of cast iron, and is
attached to the top of the base frame by means of On the sides of the frame there are covers for acces
bolts. The cross girders of the frame are provided to the camshaft, the charge air receiver and crank-
with bores for the main bearings in which the case. Some of the covers are fitted with relief valves
crankshaft is underslung, i.e. it is carried by the main which will act, should oil vapours in the crankcase
bearing caps. be ignited, for instance in the event of a hot bearing.
The main bearing caps are attached by means of

studs and nuts, which are loosened and tightened Base Frame
with the aid of hydraulic tools. After mounting, the
main bearing caps are further secured by means of Engine and alternator (gear, pump) are mounted on
bracing screws, which are screwed horizontally into a common base frame which is in welded design.
the sides of the caps and tightened against the sides
of the engine frame. The main bearings are equipped The base frame is used as lubricating oil reservoir
with replaceable shells which are fitted without "wet sump".
scraping.
08028-0D/H5250/94.08.12
91.13 - ES0U
Working Card
Functional Test of Crankcase Safety Relief Valves 611-01.00
General

Shut-off fuel oil
Description:
Functional test of crankcase safety relief valves.

Hand tools:
Allen key, 12 mm.

Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
61101 06 1/cyl.
Data:

91.03 - ES0S
611-01.00 Functional Test of Crankcase Safety Relief Valves Working Card
General
Functional testing of the crankcase safety relief

valves cannot be effected during operation of the
engine, but it must be checked during overhauls that
the valve flap is movable.
Take care when painting the engine, not to block up

the safety relief valves with paint.
The safety relief valves have been set to open at an

excess pressure in the crankcase of, see page
600.35.
If the safety relief valves are actuated, the engine

must be stoppeds immediately, and it must not be
restarted until the cause has been found and the fault
has been rectified, see also describtion 603.04,
ignition in crankcase. Fig. 1.
08028-0D/H5250/94.08.12
91.03 - ES0S
Plate
Page 1 (2) Frame with Main Bearings 61101-11H
L28/32H
01
02
03 05
06
04
03
10 04
11
09
12
13
16 14
17 15
18
21+
19+
20 10
22
23
13 25
27
24
15
14
10
26+
23 22
21+
24
Cover
( Plate 61102)
91.40 - ES0S
Plate
61101-11H Frame with Main Bearings Page 2 (2)
L28/32H
Item Item
01 1/C Wear ring Slidring 27 1/C Cylindrical pin Cylindrisk stift
02 3/C Protective cap, Beskyttelseshætte,

plastic plastik
+ Item No. 19, 21 and + Item nr. 19, 21 og 26
03 6/C Nut for Møtrik for 26 require an kræver en individuel
cylinder cover cylinderdæksel individual tilpasning før montering,
matching before kontakt MAN B&W,
04 6/C Cylinder cover Tap for mounting, contact Holeby
stud cylinderdæksel MAN B&W, Holeby
05 3/C Protective cap, Beskyttelseshætte,

metal metal
10 Loctite 242 Loctite 242
11 Silicone oil Silikoneolie
12 1/E Frame Stativ
13 1/B Main bearing Hovedleje-

shell 2/2 skaller 2/2
14 1/B Locking piece Låsestykke
15 2/B Screw Skrue
16 4/E Safety sleeve Sikkerhedsbøsning
17 4/E Screw Skrue
19+ 1/E Guide bearing cap Styrelejedæksel
20 2/E Thrust bearing Trykleje
21+ 2/B Distance piece Afstandsstykke
22 6/B Screw Skrue
23 2/B Main bearing stud Hovedleje tap
24 2/B Nut for main Møtrik for

bearing stud hovedlejetap
25 2/B Bracing screw Sideskrue
26+ 1/C Main bearing cap Hovedlejedæksel
Qty./C = Qty/Cylinder Antal/C = Antal/Cylinder
Qty./B = Qty/Bearing Antal/B = Antal/Leje
91.40 - ES0S
Plate Front Cover for
Page 1 (2) Lubricating Oil Pump and Cooling Water Pump 61102-07H
L28/32H
Fresh water cooling pump

(Plate 61610)
13
01
14
02
03
12
04 11
10
09
08 04
05+
06
07
08
10
09
10 04
Lub. oil pump

(Plate 61501)
91.40 - ES0S
Front Cover for Plate
61102-07H Lubricating Oil Pump and Cooling Water Pump Page 2 (2)
L28/32H
Item Item
01 4/E Screw Skrue
02 4/E Locking plate Låseskive
03 2/E Spray pipe Sprøjterør
04 52/E Screw Skrue
05+ 1/E Cover Dæksel
06 2/E Guide pin Styrestift
07 2/E Nut Møtrik
10 18/E Screw Skrue
13 2/E Guide pin Styrestift
14 2/E Nut Møtrik
+ Item No. 05 + Item nr. 05 kræver

require an individual en individuel til-
matching before pasning før montering,
mounting, contact kontakt MAN B&W,
MAN B&W, Holeby Holeby
91.40 - ES0S
Plate
Page 1 (2) Covers on Frame 61106-12H
L28/32H
Cover
Plate 61106
26 01
27
02
28
03
09 04
10 05
11
25 09
12 06
22 23
13
21 09
24 08
07
20
19 13
18 17
Frame
+16 Plate 61101
+15
+14
92.07 - ES0S
Plate
61106-12H Covers on Frame Page 2 (2)
L28/32H
Item Item
01 1/E Guard end aft Skærm, agter 26 /I Screw Skrue
02 12/E Washer Skive 27 /I Cover Dæksel
03 12/E Screw Skrue 28 /I Gasket Pakning
04 1/C Intermediate guard Mellemskærm
05 1/C Handle, upper Håndtag, øverst + Item 14, 15 and 16 are + Item 14, 15 og 16 er
only mounted if the kun monteret hvis mo-
06 1/C Handle, lower Håndtag, nederst engine is delivered toren er leveret uden fuel
without fuel oil feed olieforpumpe
07 1/E Guard end fore Skærm, for pump
08 1/C Intermediate gauge Mellemskærm,

complete, Item 04, komplet, Item 04,
05 and 06 05 and 06
09 12/C Screw Skrue
10 1/C Cover for camshaft Dæksel for

housing Kamakselhus
12 /I Cover for Dæksel for

crankcase krumtaphus
+14 6/E Screw Skrue
+15 1/E Cover Dæksel
+16 1/E Gasket Pakning
17 4/D Self locking nut Selvlåsende møtrik
18 4/D Distance pipe Afstandsrør
19 4/D Coach bolt Bræddebolt
20 1/D Housing for Hus for

safety valve sikkerhedsventil
21 1/D Spring Fjeder
22 1/D Valve flap Ventilklap
23 1/D O-ring O-ring
24 1/D Cover Dæksel
25 /I Safety cover Sikkerhedsdæksel,

complete, Item 17, komplet, Item 17,
18, 19, 20, 21, 22, 23 18, 19, 20, 21, 22, 23
and 24 og 24
Qty./D = Qty./Safety cover Antal/D = Antal/Sikkerhedsdæksel
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
92.07 - ES0S
Plate
Page 1 (2) Covers on Frame 61106-14H
L28/32H
04
05
01
02
03
14
13
06 12
07
08
09
11
10
91.41 - ES0S
Plate
61106-14H Covers on Frame Page 2 (2)
L28/32H
Item Item
01 12/E Screw Skrue
02 1/E Sealing ring 2/2 Tætningsring 2/2
03 2/E Guide pin with nut Styrestift med møtrik
05 2/E Screw Skrue
06 6/E Screw Skrue
07 1/E Flange Flange
09 4/E Guide pin with nut Styrestift med møtrik
10 39/E Screw Skrue
11 1/E Cover 2/2 Dæksel 2/2
12 18/E Screw Skrue
91.41 - ES0S
Index
Page 1 (1) Turbocharger System 612S
L28/32H
Description
Turbocharge System ................................................................................................... 612.01(22H)

Turbocharge System ................................................................................................... 612.01(22S)
Cleaning the Turbocharge in Service, Water of Compressor ...................................... 612.05(07H)
Cleaning the Turbocharge in Service, Water of Compressor ........................................ 612-5(13H)
Cleaning the Turbocharge in Service, Dry Cleaning-Turbine ...................................... 612.10(09H)
Cleaning the Turbocharge in Service, water Washing-Turbine Side ............................. 612-5(23H)
Cleaning the Turbocharge in Service, water Washing-Turbine Side ........................... 612.15(02H)
Working Card
Overhaul of Charging Air Cooler ............................................................................ 612-01.00(02H)

Water Washing of Compressor Side –
Turbocharger Type NR15/R-NR20/R-NR24/R-NR26/R .........................................612-05.00(03H)
Water Washing of Compressor Side –
Turbocharger Type NR20/R ................................................................................... 612-05.01(03S)
Water Washing of Turbine Side .............................................................................. 612-15.00(01S)
Dry Cleaning of Turbocharger – Turbine Side ........................................................ 612-10.00(02H)
Plates
Charging Air Cooler-Freshwater ................................................................................... 61201-12H

Charging Air Cooler-Freshwater (with water mist catcher) ........................................... 61201-14H
Exhaust pipe Arrangement ............................................................................................ 61202-23H
Exhaust pipe Arrangement with Welded Compensator ................................................ 61202-28H
Exhaust pipe Arrangement with Welded Compensator ................................................ 61202-32H
Turbocharge System ..................................................................................................... 61203-16H
Water Washing of Compressor Side ............................................................................. 61205-02H
Tool for Water Washing of Turbine Side .........................................................................61205-03S
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Turbocharger System 612.01
Page 1 (2)
Edition 22H
L28/32H
P7 P2 M1 P8
Compressed
air inlet
Exhaust gas to TC
Charging air from TC
Lambda
cylinder
P6
Fig 1 Diagram for Turbocharger System
Turbocharger System The charging air cooler is a compact tube-type

cooler with a large cooling surface. The cooling wa-
The turbocharger system of the engine, which is a ter is passed twice through the cooler, the end
constant pressure system, consists of an exhaust covers being designed with partitions which cause
gas receiver, a turbocharger, a charging air cooler the cooling water to turn.
and a charging air receiver, the latter being inte-
grated in the engine frame. The cooling water tubes are fixed to the tube plates
by expansion.
The turbine wheel of the turbocharger is driven by
the engine exhaust gas, and the turbine wheel dri- From the exhaust valves, the exhaust is led through
ves the turbocharger compressor, which is moun- a water cooled intermediate piece to the exhaust gas
ted on the same shaft. The compressor sucks air receiver where the pulsatory pressure from the indi-
from the engine room, through the air filters. vidual exhaust valves is equalized and passed to the
turbocharger as a constant pressure, and further to
Turbocharger, see separate manual. the exhaust outlet and silencer arrangement.
The turbocharger pumps the air through the char- The exhaust gas receiver is made of pipe sections,
ging air cooler to the charging air receiver. From the one for each cylinder, connected to each other, by
charging air receiver, the air flows to each cylinder, means of compensators, to prevent excessive stress
through the inlet valves. in the pipes due to heat expansion.
94.33 - ES2S
612.01 Turbocharger System Description
L28/32H
In the cooled intermediate piece a thermometer for The turbocharger is equipped with a jet system for
reading the exhaust gas temperature is fitted and supply of extra driving torque to the compressor per-
there is also possibility of fitting a sensor for remote formance. With this system the engine can take up
reading. a large momentary load increase.
To avoid excessive thermal loss and to ensure a The system is activated automatically and only when
reasonably low surface temperature the exhaust gas the engine is exposed to a large momentary load
receiver is insulated. increase, see section 609.
94.33 - ES2S
Description Cleaning the Turbocharger In Service 612.05
Page 1 (1) Water Washing of Compressor Edition 07H
General
Compressor Chemical cleaning will not improve the cleaning

process as this primarily is based on the mechanical
Fouling of the airways depends primarily on the effect from the impact of the water droplets.
purity 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
of the gas and oil tightness of the engines and on the deposits on the compressor wheel, and should under
fresh air ventilation system of the engine room. no circumstances be used.
Fouling of air filter, compressor or charging air The intervals between cleaning by injection of water
cooler may be observed as changes in performance should be adjusted after assessing the degree and
parameters: rate of fouling in the particular plant, i.e. based on
observations and experience.
- Decreasing charging air pressure.
- Decreasing turbocharger rotor speed.
- Increasing exhaust gas temperature.
- Severe fouling of airways may even result in
compressor surge.
Regular cleaning during operation by injection of

water before the compressor wheel will reduce the
fouling rate considerably, and consequently prolong
the intervals between dismantling necessary for
mechanical cleaning.
08028-0D/H5250/94.08.12
94.01 - ES0U
Description Cleaning the Turbocharger in Service 612.15
Page 1 (1) Water Washing - Turbine Side Edition 02H
General
Description Heavily contaminated turbines, which where not

cleaned periodically from the very beginning or after
The tendency to fouling on the gas side of turbo- an overhaul, cannot be cleaned by this method.
chargers depends on the combustion conditions,
which are a result of the load on and the maintenance If vibration in the turbocharger occur after water-
condition of the engine as well as the quality of the washing has been carried out, the washing should be
fuel oil used. repeated. If unbalance still exists, this is presumably
due to heavy fouling, and the engine must be stopped
Fouling of the gas ways will cause higher exhaust and the turbocharger dismantled and manually
gas temperatures and higher surface temperatures cleaned.
of the combustion chamber components and will
also lead to a lower performance. The washing water should be taken from the fresh
water system and not from the fresh cooling water
Tests and practical experience have shown that system or salt water system. No cleaning agents are
radial-flow turbines can be successfully cleaned by solvents need to be added to the water.
injection water into the inlet pipe of the turbine. The
cleaning effect is based on the water solubility of the To avoid corrosion during standstill, the engine
deposits and on the mechanical action of the im- must, upon completing of water washing run far at
pinging water droplets and the water flow rate. least 1 hour before stop so that all parts are dry.
The necessary water flow is dependent on the gas

flow and the gas temperature. Enough water must be Water Washing System
injected per time unit so that, not the entire flow will
evaporate, but about 0.25 l/min. will flow off through The water washing system consists of a pipe system
the drainage opening in the gas outlet. Thus ensuring equipped with a regulating valve, a manoeuvring
that sufficient water has been injected. valve, a 3-way cock and a drain pipe with a drain
valve from the gas outlet, see illustration on work
Service experience has shown that the above card 612-15.00.
mentioned water flow gives the optimal reduced or
disappear. If the recommended water flow is ex- The water for washing the turbine, is supplied from
ceed, there is a certain risk of a accumulation of the external fresh water system through a flexible
water in the turbine casing, which can result in hose with couplings. The flexible hose must be
damage on the turbocharger. disconnected after water washing.
The best cleaning effect is obtained by cleaning at By activating the manoeuvring valve and the regu-
low engine load approx. 20% MCR. Cleaning at low lating valve, water is led through the 3-way cock to
load will also reduce temperature shocks. the exhaust pipe intermediate flange, equipped with
a channel to lead the water to the gas inlet of the
Experience has shown, that washing at regular turbocharger.
intervals is essential to successful cleaning, as
08028-0D/H5250/94.08.12
excessive fouling is thus avoided. Washing at inter- The water which is not evaporated, is led out through
vals of 100 hours is therefore recommended. De- the drain pipe in the gas outlet.
pending on the fuel quality these intervals can be
shorter or longer. However, the turbine must be
washed at the latest when the exhaust gas tempe-
rature upstream of the turbine has risen about 20° C
above the normal temperature.
92.01 - ES0U
Working Card
Overhaul of Charging Air Cooler 612-01.00
L+V28/32H

Shut-off fuel oil
Description:
Overhaul of charging air cooler.

Hand tools:

Starting position: Allen key, 10 mm.
Wire rope.
Tackle.
Related procedure:
08028-0D/H5250/94.08.12
Working time : 3-4 Hours Plate no. Item no. Qty. /

Capacity : 2 men
61203 14 8/cooler
Data: 61203 35 1/cooler
61203 37 1/cooler
Data for pressure and tolerance (Page 600.35) 61203 39 1/cooler
96.30 - ES0S-G
612-01.00 Overhaul of Charging Air Cooler Working Card
L+V28/32H
The charging air cooler is normally cleaned and 4) Clean the cooler element of the water and air
overhauled at the intervals indicated in the "Planned sides.
Maintenance Program", or if observations prove that
the cooler does not work satisfactory, see section After using cleaning agents the manufacting recom-
602. mendting must be followed.
The greatest care must be exercised when dismant-

Overhaul of Charging Air Cooler. ling cleaning and mounting the cooler element, as
the thin fins of the tubes cannot stand impacts and
1) Close the cooling water inlet and outlet valves pressure.
and disconnect the pipes.
If nevertheless, the metal is damaged, it should be
2) Remove the screw (1), fig. 1, which secure the carefully straightened, as bent fins will increase the
end cover of the cooler element to the cooler hous- pressure drop across the cooler considerably.
ing, and pull the cooler element half-way out.
Should one ore more cooler tubes become leaky it/
Place a wire rope round the cooler element and they must immediately be made tight, either by
attach a tackle hook, after which the elements are expending the tube ends into the tube plates or by
lifted and pulled out of the cooler housing and landed blanking of the tube(s) concerned with plugs.
on a couple of wooden planks on the floor.
It is important that the charging air cooler is not leaky
as any sea water that leaks in will be carried along
with the air to the cylinders where the salt contained
in the water will damage valves, piston rings, and
cylinder liners.
5) Also clean end cover and coat it on the inside

5 with an anti-corrosion blocks agent. Inspect the anti-
corrosion (6) and renew if necessary.
4
Note: That paint or similar must not be applied to
6 these blocks.
6) Fouling and deposite in the pipes can be

removed by using a hand or machine operated
circular steel brush. The pipe inner diameter is 13
mm.
3
7) When mounting the air cooler, renew all gas-
kets.
2
08028-0D/H5250/94.08.12
Out of Service Periods.
Fig. 1. At longer periods out of service the air cooler is

drained if the coolant is sea water followed by
flushing with fresh water and left with drain and
3) Remove screws (2) and end cover (3) reversal venting cocks open.
chamber (4) and side plates (5).
At fresh water coolant systems recommendations
for the entire system is followed.
96.30 - ES0S-G
Working Card
Charge Air Cooler Housing - Draining 612-01.05
L+V28/32H
Safety Precautions: Special Tools:

Shut-off fuel oil
Description:
Check of drain from charge air cooler housing.

Hand Tools:
Starting Position:
Related Procedure:
Replacement and Wearing Parts:
Plate No Item No Qty. /

08028-0D/H5250/94.08.12
Man Power:
Working time :
Capacity : 1 person
Data:

97.08 - ES0S
612-01.05 Charge Air Cooler Housing - Draining Working Card
L+V28/32H
In order to prevent water from collecting at the

bottom of the gas outlet of the turbocharger, the
charge air cooler and the charge air receiver, the
charge air cooler is equipped with a drain and an
automatic water discharger.
This installation will prevent water from the charge

air to be sucked into the engine, where it will destroy
the lubricating oil film on the cylinder walls, resulting
in increasing wear. Further, the water will cause
corrosion of the intake components.
Therefore, frequent control of the drain and the

water discharger has to take place to secure that
these components are free of foreign substances
which could foul them.
1) The drain screw at the bottom of the water

discharger has to be loosened and cleaned of
impurities, if any.
Fig 1 Placement of Steam Trap
If, with the drain screw dismounted If, with the drain screw dismounted
- a constant air flow is present: - no constant air flow is present:
1. Everything is all right. 1. Dismount the drain pipe and blow-through the
pipe by means of compressed air.
2. Mount the drain screw at the bottom of the Clean the discharge hole in the charge air
water discharger. cooler in order to secure a clear passage of
water.
08028-0D/H5250/94.08.12
2. Mount the drain pipe and check with your hand

that a constant air flow is present.
3. Mount the drain screw at the bottom of the

water discharger.
97.08 - ES0S
Working Card
Water Washing of Turbine Side 612-15.00
General

Shut-off fuel oil
Description:
Water washing of turbine side, cleaning with

engine in service. Hand tools:
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
See the special instruction for turbocharger.
Data:

91.04 - ES0S
612-15.00 Water Washing of Turbine Side Working Card
General
Cleaning Procedure. 3) Turn the 3-way cock to position 2 "Open", see

fig. 2 and check for free passage. If ok turn to the
1) Adjust the engine load to approx. 20 % and let water wash position 3 "Wash".
the engine stabilize for 10 min.
4) Connect the water supply to the water wash
2) Open the drain cock at the turbocharger outlet system.
and check for free passage, see fig. 1.
5) Activate the manoeuvring valve, see fig. 1.
Then open the regulating valve and adjust the water

flow until the drain flow is approx. 0,25 l/min.
3-way cock
6) Continue the water washing 5 - 10 min. or until
the drain water is free of particles.
Plate with clean-
ing instruction 7) Release the manoeuvring valve and discon-
nect the water supply.
Manoeuvering
valve
Turn the 3-way cock to position 1, "Closed" and
Regulating valve check that the water drain flow has stopped.
Cleaning water
inlet
8) Continue at this load at least 5 min. before
Drain cock increasing the load to the normal condition.
9) After the water washing, the engine should run

for at least 1 hour before stop.
Fig. 1. Arrangement for water washing. Note: The regulating valve has to be opened slowly.
The manoeuvring valve must not be locked in open

position.
The water injection time mentioned in item 6 must be

not exceeded.
For water washing of turbine side, see also descrip-

tion for water washing.
08028-0D/H5250/94.08.12
Fig. 2. 3-way cock.
91.04 - ES0S
Plate
Page 1 (2) Charging Air Cooler - Freshwater 61201-15H
7-8-9L28/32H
08028-0D/H5250/94.08.12
97.06-ES0S
Plate
61201-15H Charging Air Cooler - Freshwater Page 2 (2)
7-8-9L28/32H
Item Item
No. No.
017 1/K Crossmember
029 1/K Crossmember
030 2/K Pipe
042 1/K Cooler block
054 1/K Gasket end cover
066 4/K Plug screw
078 4/K Cu-washer
091 1/K End cover
101 4/K Nut
113 8/K Screw
125 1/K Side plate right
137 1/K Gasket reversing cover
149 1/K Reversing cover
150 32/K Screw
174 5/K Screw
186 5/K Cu-washer
198 5/K Screw
208 1/K Side plate left
221 8/K Screw
233 1/K O-ring
257 1/K Gasket
269 1/K Ring
270 1/K Drain pipe for WMC
282 22/K Screw
294 1/K Water mist catcher
304 1/E Charging air cooler, complete, incl.
Item 017, 029, 030, 042, 054, 066, 078,
091, 101, 113, 125, 137, 149, 150, 174,
186, 198, 208, 221, 233, 269, 270 and
294
08031-0D/H5250/94.09.07

Qty./E = Qty./Engine.
Qty./K = Qty./Cooler
97.06-ES0S
Plate
Page 1 (2) Exhaust Pipe Arrangement 61202-26H
7,8L28/32H
17 08 05 05
06 10 08 10
11 07 05 10 04
09
11
16
14 13
15 12
23 28
22
29
30
20
31
21
22
23
24
25
26 32
27 33
34
91.18 - ES0S
Plate
61202-26H Exhaust Pipe Arrangement Page 2 (2)
7,8L28/32H
Item Item
04 1/E End cover, aft Endeplade, bag 29 1/C Plug screw Propskrue
05 Exhaust pipe Udstødsrør 30 1/C Gasket Pakning

7/E 8 cyl. engine 8 cyl. motor 31 1/C Gasket Pakning
06 1/E Exhaust pipe, Udstødsrør, tilgang 32 1/C O-ring O-ring

inlet TC. turbolader
33 1/C Cooling water Kølevandsnippel
07 1/E Exhaust pipe for Udstødsrør for nipple
cyl. 1 cyl. 1
08 Compensator Kompensator
09 1/E Compensator Kompensator
10 Gasket Pakning
12 Screw Skrue
13 Nut Møtrik
14 8/E Screw Skrue
15 8/E Nut Møtrik
16 16/E Screw Skrue
20 4/C Screw Skrue
23 4/C Plug Prop
24 2/C Screw Skrue
25 2/C Washer Skive
26 1/C Intermediate piece Mellemstykke
28 4/C Screw Skrue
Qty./C = Qty./Cylinder Antal/C = Antal/cylinder
91.18 - ES0S
Plate
Page 1 (2) Turbocharger Arrangement 61203-35H
7, 8L28/32H
99.34 - ES0
Plate
61203-35H Turbocharger Arrangement Page 2 (2)
7, 8L28/32H
Item Item
01 1/E Compensator Kompensator
02 20/E Nut Møtrik
04 20/E Screw Skrue
05 14/E Screw Skrue
06 1/E Exhaust gas outlet Gasudløb
08 22/E Nut Møtrik
09 32/E Screw Skrue
10 8/E Washer Skive
11 1/E Flange Flange
12 8/E Screw Skrue
13 1/E Sealing ring Tætningsring
14 1/E Inlet bend Indstrømningsbøjning
15 15/E Screw Skrue
16 4/E Screw Skrue
18 1/E Plate Plade
19 8/E Screw Skrue
20 4/E Screw Skrue
21 2/E Screw Skrue
22 26/E Screw Skrue
23 1/E Inlet bend Indstrømningsbøjning
24 3/E Nut Møtrik
25 3/E Stud Tap
26 1/E Bracket Konsol
27 1/E Packing-silicone Silastene

paste
28 1/E Charging air Hus for

housing ladeluftkøler
Qty./I = Qty./Individual. Antal/I = Antal/Individuelt
99.34 - ES0
Plate
Page 1 (2) Water Washing of Compressor Side 61205-02H
L+V28/32H
94.01 - ES0S
Plate
61205-02H Water Washing of Compressor Side Page 2 (2)
L+V28/32H
Item Item
01* 1/E Top cover with non- Topdæksel med kontra- 25* 1/E Straight male stud Ligeforskruning
return valve ventil coupling
02* 1/E O-ring for top cover O-ring for topdæksel 26* 1/E Plug in coupling Kobling
03* 1/E O-ring for non-return O-ring for kontraventil 27 1/E Lance complete, incl. Lanse komplet, inkl. item
valve item 24-25 and 26 24-25 og 26
04* 1/E Valve seat Ventilsæde 28 1/E Container complete, Beholder komplet, som
as shown on plate vist på plate
05* 1/E Spring for non-return Fjeder for kontraventil
valve
06* 1/E Cap screw for non-re- Omløber til kontraventil

turn valve
07 1/E Top cover with non- Topdæksel med kontra-

return valve complete, ventil komplet, inkl. item
incl. item 01-02-03-04- 01-02-03-04-05 og 06
05 and 06
08 1/E Safety valve Sikkerhedsventil
09 2/E O-ring O-ring
10 2/E Finger nut Fingermøtrik
11 1/E Cap Top
12 1/E Gasket for the cap Pakning for top
13* 1/E Cable binder Kabelbinder
14* 1/E Strap Gjord
15* 1/E Eye for strap Øje for gjord
16 1/E Strap complete, incl. Gjord komplet, inkl. item

item 13-14 and 15 13-14 og 15
17 1/E Container Beholder
18 1/E Flexible pipe Fleksibel slange
19 1/E Handle with flexible Håndtag med fleksibel

pipe and cap screw slange og omløber
20 1/E Filter insert Filterinsats
21 1/E Gasket for handle Pakning til håndtag
22 1/E Hand valve Håndventil
23 1/E Gasket for hand valve Pakning til håndventil
24* !/E Lance Lanse
94.01 - ES0S
Plate
Page 1 (2) Steam Trap 61208-01H
L+V28/32H
01
05
02
06
03
04
07
97.07 - ES0S
Plate
61208-01H Steam Trap Page 2 (2)
L+V28/32H
Item Item
01 1/E Steam trap, Vandudlader,

complete komplet
02 1/E Packing Pakning
03 1/E Clip Klemme
04 1/E House, bottom Hus, bund
05 1/E House, top Hus, top
06 1/E Swimmer Svømmer
07 1/E Valve Ventil
Qty./E = Qty./Engine Qty./E = Qty./Motor
97.07 - ES0S
Index
Page 1 (1) Compressed Air System 613S
L28/32H
Description
Compressed Air System ............................................................................................. 613.01(20S)
Working Card
Air Filter ................................................................................................................ 613-01.21(01H)

Overhaul, Test and Inspection of Turbine Starter ................................................. 613-01.30(02H)
Main Starting valve ............................................................................................... 613-01.40(01H)
Checking of Compressed Air piping System ........................................................ 613-01.90(02H)
Plates
Turbine Starter .............................................................................................................. 61309-05H

Specification of Lubrication for Air Starter .................................................................... 61309-05S
Main Starting Valve ...................................................................................................... 61310-03H
Starting Valve ............................................................................................................... 61310-03S
Emergency Starting Valve ............................................................................................ 61313-03H
Starting Valve ............................................................................................................... 61314-03H
Main Stop Valve ......................................................................................................... S61315-03H
Main Stop Valve ............................................................................................................ 61315-03H
Air Strainer ................................................................................................................. S61316-03H
Air Strainer .................................................................................................................... 61316-03H
Safety Valve ............................................................................................................... S61319-01H
Safety Valve .................................................................................................................. 61319-01H
ON-OFF Valve for Jet System ...................................................................................... 61320-02H
ON-OFF Valve for Jet System ................................................................................... S61320-02H
Air Filter ........................................................................................................................ 61321-01H
Pressure Reduction Valve ......................................................................................... S61322-01H
Pressure Reduction Valve ............................................................................................ 61322-01H
08028-0D/H5250/94.08.12
94.47 – ES0U
Description
Compressed Air System 613.01
Page 1 (2) Edition 20S
L28/32H
Fig. 1. Diagram for Compressed Air System
General Starting System
The compressed air system on the engine The engine is started by means of a built-on
contains a starting system, starting control air starter, which is of the turbine starter motor
system and safety system. Further, the type with gear box, safety clutch and drive
system supplies air to the jet system. shaft with pinion. Further, the starting system
consists of a main starting valve.
The compressed air is supplied from the
starting air receivers (30 bar) through a
reduction station, where from compressed air Control System
is supplied to the engine.
The air starter is activated electrically with a
To avoid dirt particles in the internal system, a pneumatic 3/2 way solenoid valve (starting
dirt separator is mounted in the inlet line to the value).
08028-0D/H5250/94.08.12
engine.
The valve can be activated manually from the
The intervals between cleaning and draining starting box on the engine, and it can be
will depend on the condition of the air in the arrange for remote control, manual or
main supply system, and has therefore to be automatic.
determined according to service experience
gained with the particular plant. For remote activation, the starting spool must
be connected so that every starting signal to
Note : Due to the safely system, the air the starting spool goes through the converter
supply to the engine must not be interrupted for engine RPM signal or via the engine
during operation of the engine. control box if supplied.
94.23-ES0S
613.01 Compressed Air System Description
Edition 20S Page 2 (2)
L28/32H
Further, the system is equipped with an Safety System

emergency starting function which makes it
possible to activate the air starter manually in As standard the engine is equipped with a
case of a power failure. pneumatically/mechanically overspeed device
which starts to operate if the maximum
permissible RPM is exceeded. This device is
Emergency Starting Function fitted to the end cover of the engine driven
lubricating pump and is driven from the pump
The emergency starting valve is activated by through a resilient coupling, see section 609.
means of a manual override.
When the maximum permissible RPM is
exceeded, the overspeed device will activate
a pneumatically controlled stop cylinder, which
will bring the fuel index to zero and stop the
engine.
Pneumatic Start Sequence
When the starting valve is opened, air will be

supplied to the drive shaft housing of the air
starter.
The air supply will - by activating a piston -

bring the drive pinion into engagement with
the gear rim on the engine fly wheel.
When the pinion is fully engaged, the pilot air

will flow to, and open the main starting valve,
whereby air will be led to the air starter, which
will start to turn the engine.
Simultaneously with air supply for the air

starter, air will be supplied to the fuel limitating
cylinder, thus limiting the fuel supply during
the start sequence.
When the RPM exceeds approx.110, at which

firing has taken place, the starting valve is
closed whereby the air starter is disengaged.
08031-0D/H5250/94.09.07
94.23-ES0S
Working Card
Air Filter 613-01.21
General

Shut-off fuel oil
Description Hand tools
Cleaning and/or maintenance of air filter.
Starting position
Related procedure
08028-0D/H5250/94.08.12
Manpower Replacement and wearing parts
Working time : hours Plate no Item no Qty/

Capacity : man
Data

02.46 - ES0
613-01.21 Air Filter Working Card
General
Cleaning Air Filter To replace filter element
1) Depressurize unit. 7) Depressurize unit.
2) Remove bowl and bowl guard assembly by 8) Remove bowl and bowl assembly by turning
turning counter-clockwise. counter-clockwise.
3) Inspect bowl for damage seals and replace, if 9) Unscrew baffle by turning counter-clockwise.
nessesary.
10) Remove filter element and discard.
4) If bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth or mild detergent. 11) Install new filter element and reassemble in
reverse order.
5) Before returning to service, insure that all
seals have been reinstalled or replaced. 12) Before returning to service, insure that all
seals have been reinstalled or replaced.
6) Reinstall bowl and bowl guard assembly and
rotate bowl guard clockwise to securely lock in 13) Reinstall bowl and bowl guard assembly and
place. Align arrow on bowl guard with arrow on filter rotate bowl guard clockwise to securely lock in
body. place. Align arrow on bowl guard with arrow on filter
body.
08028-0D/H5250/94.08.12
Fig 1 Air Filter
02.46 - ES0
Working Card
Overhaul, Test and Inspection of Turbine Starter 613-01.30
L+V28/32H

Shut-off cooling water 62006 xx 20 - 120 Nm.
Shut-off fuel oil
Description:
Disassembly, overhaul and assembly of the air

starter. Hand tools:
Allen key, 4 mm.

Allen key (long), 8 mm.
Screwdriver.
Starting position: Big screwdriver.
Chisel.
All connection to the air starter have been re- Retaining ring pliers.
moved, and air starter is removed. Plastic hammer.
Lubricating oil.
Copaslip or similar.
Sleeve.
Bearing puller.
Related procedure: Impact Wrench
Bearing pressing tool.
08028-0D/H5250/94.08.12

Capacity : 1 man
See plate 61309.
Data:

96.26 - ES0S-G
613-01.30 Overhaul, Test and Inspection of Turbine Starter
Working Card
L+V28/32H
General Information
1. Always mark adjacent parts on the housing

exhaust cover (1), motor housing (8), intermediate
gear case (13), gear case (28) and drive housing
(38) so these members can be located in the same
relative position when the starter is reassembled.
Note: Do not disassemble the starter any further

than necessary to replace worn or damaged parts.
Never reuse old seals or o-rings.
Never wash the inertia drive in a solvent.
2. Do not remove any part which is a press fit in

or on a subassembly unless the removal of that part
is necessary for replacement or repairs.
3. Always have a complete set of seals and o-

rings on hand before starting any overhaul of the Fig 1.
turbine starter.
4. When grasping a part in a vise, always use 5. Remove the deflector retaining screw (5),
copper-covered vise jaws to protect the surface of deflector retai-ning spring (4) and the splash deflec-
the part and help prevent distortion. This is particu- tor (3) from the housing exhaust cover (1), See fig 2.
larly true of threaded members.
Housing Exhaust Cover, Motor Assembly, and

Motor Housing
1. If replacing the motor assembly (12), remove

both housing plugs (10) and drain the oil from the
gearing before beginning disassembly of the starter.
Inspect the magnetic housing plugs (10) for metal
particles. Very fine metal particles are normal. Re-
move particles and reinstall plugs. Large particles or
chips are an indication of a problem. Disassemble
gear case (28) and inspect.
2. Using a screw driver, unscrew the exhaust

08028-0D/H5250/94.08.12
cover (67) from the housing exhaust cover (1).

Fig 2.
3. Using an 8 mm hex-head wrench, unscrew

and remove the starter assembly cap screws (6) 6. Tap the motor housing with a plastic hammer
and washers (7), See fig 1. to dislodge it from the intermediate gear case (13).
4. Pull the housing exhaust cover (1) from the 7. Grasp the rear of the motor assembly (12) and
motor housing (8). To dislodge the housing exhaust pull it from the rear of the motor housing (8).
cover, rotate it until the ears clear the motor housing. If the motor assembly (12) is difficult to remove,
Using a plastic hammer, tap the ears alternately lightly push the motor pinion which is on the front of
until the housing cover can be removed from the the motor assembly toward the exhaust side of the
motor housing. motor housing in order to free the motor assembly.
96.26 - ES0S-G
Working Card
L+V28/32H
8. Tap the intermediate gear case (13) with a
plastic hammer to dislodge it from the gear case 13. Remove the planet gear frame assembly from
(28). the intermediate gear case. Using a sleeve that
contacts the outer race of the front gear frame
9. Position the intermediate gear case (13) on a bearing (17), press the planet gear frame shaft seal
bench in a copperfaced vise so that the intermediate (16) and the front gear frame bearing (17) from the
pinion (26) is secured in the jaws of the vise. Tighten front end and out of the rear of the intermediate gear
the vise only enough to hold the intermediate pinion case.
securely.
14. Remove the rear gear frame bearing (24) from
10. Loosen the intermediate pinion retaining screw the planet gear frame (18), using a bearing puller
(27) 1-1/2 turns only. Do not remove. and remove the gear shaft retaining washer (23),
See fig. 4.
Warning: If the intermediate gear case is not sup- Remove the planet gear shafts (22), planet gears
ported on a bench and if the intermediate pinion (19), planet gear bearings (20) and bearing spacers
retaining screw is completely removed, the interme- (21).
diate gear case and compoments could fall causing
injury. 15. Remove the front bearing spacer (25), using a
bearing puller and the gear shaft retaining washer
11. Tap the intermediate pinion lightly to back the (23) from the front of the planet gear frame by
planet gear frame assembly out of the intermediate pressing on the front of the planet gear frame shaft.
gear case.
12. Remove the intermediate gear case assem-

bly from the vise and remove the intermediate pinion
(26). Remove the rear gear case o-ring (14) and
front gear case o-ring (15) from the intermediate
gear case (13), See fig 3.
Fig 4.
08028-0D/H5250/94.08.12
Remove the gear shaft retaining washer only if the

washer or front bearing spacer is damaged.
Fig 3. Drive Housing
1. Grasp the drive pinion (63) in a copper-faced

vise with the starter supported on the workbench.
2. Remove the drive pinion retaining screw (61)
96.26 - ES0S-G
613-01.30 Overhaul, Test and Inspection of Turbine Starter Working Card
L+V28/32H
which has a right-hand thread. bearing and/or the seal will always be damaged
when removed from the drive housing.
3. Remove the starter from the vise.
15. Remove the piston ring (55) from the piston
4. Remove the drive pinion washer (62) and the (54).
drive pinion (63).
16. Press the clutch spring cup (50) down and
5. Slide the pinion spring sleeve (64) and the remove the clutch spring cup retainer (49).
pinion spring (65) off the drive shaft (57).
17. Remove the clutch spring cup and clutch
6. Unscrew the drive gear screw (34). Using an spring (51).
impact wrench with a 5/16" (8 mm) x 8" (203 mm) log
hex inserted into the end of the drive shaft. 18. Remove the two clutch jaws (52).
7. Unscrew and remove the drive housing cap 19. Remove the front drive gear bearing (30),
screws (38) and lock washers (39). drive gear cup (36), drive gear lock washer (35),
drive gear screw ring (37) and drive gear screw (34).
8. Tap the drive housing (40) with a plastic ham-
mer to help dislodge it from the gear case (28). 20. Remove the large drive shaft bearing retainer
(53) using a screwdriver.
Warning: Failure to follow this procedure could
result in injury to personnel. 21. Press the rear drive shaft bearing and drive
shaft (57) out of the piston. If the rear drive shaft
9. Place the drive housing (40) in an arbor press, bearing needs to be replaced, proceed as follows:
piston end up. Apply a load to the piston (54) using
the arbor press to compress the piston return spring a. Cut and remove the small drive shaft bear-
(59) before removing the bulkhead retainer (45). Do ing retained in the drive shaft, using a small
not use compressed air to load the piston. chisel.
b. Press the rear drive shaft bearing (58) off
10. Remove the bulkhead retainer (45). Using a the drive shaft.
screwdriver and the arbor press.
22. Place the gear case (28) on a workbench.
Caution: Make sure the tension of the spring pushes
the bulkhead out of the drive housing before remov- 23. Remove the drive gear bearing retainer (32),
ing the drive housing from the arbor press. using retaining ring pliers and working through the
access holes in the gear web, See fig 5.
11. Remove the bulkhead (46) from the piston
(54). 24. Pull the drive gear (29) out of the gear case.
12. Remove the outer bulkhead ring (47) and the Note: Do not disassemble the drive gear and clutch
08028-0D/H5250/94.08.12
inner bulkhead ring (48). parts of the turbine powered starters. If the drive
shaft is defective, install a new or factory-rebuilt unit.
13. Slide the drive shaft (57) from the drive hous-
ing (40). 25. Remove the drive gear shaft bearing retainer
(33), using retaining ring pliers.
14. Pull the piston return spring (59) off the drive
shaft. 26. Remove the rear drive gear bearing (31) from
the drive gear.
Note: Do not remove the front drive shaft bearing
(42) or the drive housing seal (43) unless replace-
ment is necessary and new parts are available. The Assembly of the Starter
96.26 - ES0S-G
Working Card
L+V28/32H
5. Install the drive gear bearing retainer, using

retaining ring pliers and working through the access
holes in the gear web.
6. Lubricated the drive gear with approximately

240 ml of Ingersoll-Rand No. 28 lubricant.
7. Press the rear drive shaft bearing (58) onto

the drive shaft.
8. Slide the small bearing retainer convex side

first, onto the drive shaft. Press it into position in
accordance with the in-structions packaged with the
new retainer.
Fig 5. 9. Assemble the drive gear Schrew (34), drive

gear lock washer (35), drive gear cup (36) and drive
gear screw o-ring (37).
1. Always press on the inner ring of a ball bearing
when installing the bearing on a shaft. 10. Grasp the drive shaft (57) in a vise, external
splined end down. Place assembled drive shaft
2. Always press on the outer ring of a ball bearing screw Unit into the drive shaft, screwhead down.
when pressing the bearing in a bearing recess. Lubricate the inside diameter of the drive shaft with
Ingersoll-Rand No. 28 lubricant.
3. Whenever grasping a part in a vise, always
use leather-covered, copper-covered vise jaws to 11. Slide the drive gear bearing (30) into the drive
protect the surface of the part and help prevent shaft.
distortion. This is particularly true of threaded mem-
bers. 12. Lubricate with Ingersoll-Rand No. 28 lubricant
and install the driving clutch jaw teeth facing up and
4. Always clean every part, and wipe every part driven clutch jaw teeth facing down into the drive
with a thin film of oil before installation. shaft.
13. Insert the clutch spring (51) into the drive

Gear Case shaft.
1. Place the drive gear bearing retainer over the 14. Insert the clutch spring cup (50) into the drive
rear end of the drive gear. shaft.
08028-0D/H5250/94.08.12
2. Press the rear drive gear bearing (31) onto the 15. Press the inserted parts into the drive shaft,
rear end of the drive gear, using an arbor press. and install the clutch spring cup retainer (49).
3. Seat the rear drive gear bearing into the gear Note: If it is necessary to replace the drive housing
case by tap-ping the opposite end of the drive gear, (40) and drive components, make sure that the
using a plastic hammer.
4. Install the drive gear shaft bearing retainer

96.26 - ES0S-G
L+V28/32H
piston seal has been removed from the rear of the

new piston (54).The piston seal must be removed to Note: Feel the underside of the drive housing to
prevent pressure build-up which will cause move- make sure the drive shaft passes through the bear-
ment of the planet gear frame shaft seal (16). If this ing.
conditions occurs, the piston cannot retract and the
drive pinion (63) will remain in engagement with the 26. Install the bulkhead retainer (45), using a
flywheel, causing damage to the starter drive train screwdriver.
and/or starter motor. To remove the piston seal,
insert a screwdriver inside the lip of the seal and pry Warning: Make sure the bulkhead retainer is prop-
it loose from the piston. erly seated in the motor housing groove before
easing off the arbor press. Failure to do so will allow
16. Install the piston (54) onto the drive shaft until improperly retained parts to separate when re-
the rear drive shaft bearing seats into the piston. moved from the arbor press resulting in injury to
personnel.
17. Coil the large drive shaft bearing retainer (53)
into the groove of the piston to retain the outer race 27. Remove the drive housing from the arbor
of the drive shaft bearing, using a thin flat blade press.
screwdriver to assist in this operation.
28. Lubricate and install the drive housing o-ring
18. Lubricate the piston o-ring (55) and install it in (41) in the groove of the drive housing.
the groove of the piston.
29. Position the assembled gear case on a work-
19. Position the drive housing in an arbor press, bench. The as-sembled unit must be upright to
pinion-end down and install the drive housing seal accept the drive housing.
(43) into the drive housing. Using a pressing sleeve Carefully position the assembled drive housing (40)
of the proper size, press the seal into the drive onto the gear case so as not to damage the piston
housing so that the lip of the seal faces away from seal. Align the punch marks of the gear case and
the drive pinion. drive housing.
20. Press the bearing into the drive housing until 30. Install the drive housing cap screw lock wash-
it seats, using a sleeve that contacts the outer race ers (39) and the drive housing cap screws (38) and
of the front drive shaft bearing (42). Drop the piston tighten to 28 Nm torque.
return spring seat (60) on top of front drive shaft
bearing. 31. Tighten the drive gear screw (34) 77.3 Nm
torque, using an impact wrench with a 8 mm x 203
21. Slide the piston return spring (59) onto the mm long hex inserted into the end of drive shaft.
drive shaft and snap it into the front of the piston so
that it is against the large drive shaft bearing retainer 32. Grease and slide the pinion spring (65) and
(53). the pinion spring sleeve (64) over the pinion end of
the drive shaft.
08028-0D/H5250/94.08.12
22. Lubricate and insert the assembled drive shaft

into the drive housing. 33. Grease the pinion end of the drive shaft and
install the drive pinion (63).
23. Lubricate and install the outer bulkhead o-ring
(47) and the Inner bulkhead o-ring (48) on the 34. Grasp the drive pinion in a copper-covered
bulkhead (46). vise with the starter supported on a workbench.
24. Slide the bulkhead onto the piston. 35. Place the drive pinion washer (62) onto drive
pinion retaining screw (61).
25. With the drive housing in the arbor press,
press down on the rear face of the piston. Note: The thread on the drive pinion retaining screw
is right-hand thread.
96.26 - ES0S-G
Working Card
L+V28/32H
Movement of the planet gear frame assembly could

36. Install the drive pinion retaining screw into the dislodge assembled components, making it neces-
end of the drive shaft and tighten it to 108.5 Nm sary to repeat step 5.
torque.
6. Install the other planet gear shaft retaining
washer over the shaft at the rear of the planet gear.
Intermediate Gear Case, Motor Housing, Motor
Assembly and Housing Exhaust Cover 7. Press the rear gear frame bearing (24) on the
shaft at the rear of the planet gear frame, using the
1. Press the front gear frame bearing (17) into proper size bearing inserting tool.
the rear of the intermediate gear case (13), using a
bearing pressing tool of the proper size. 8. Slide the planet gear frame assembly, cou-
pling end first, into the rear of the intermediate gear
2. Press the planet gear frame shaft seal (16) case (13), making sure that the planet gears mesh
into the rear of the intermediate gear case over the with the ring gear. Use care so as to not damage the
front gear frame bearing, using a sleeve which seal.
contacts the outer ring of the seal.
9. Install the intermediate pinion (26), making
Note: Make sure the flat side of the seal is installed sure that the notches at the rear of the pinion align
against the bearing. with the notches and tangs in the shaft of the planet
gear frame.
3. Install the rear gear case o-ring (14) in the
groove at the rear of the intermediated gear case 10. Clean the threads of the intermediate pinion
and the front gear case o-ring (15) in the groove at retaining screw (27) and apply 2-3 drops of
the front of the intermediate gear case. coat both o- Permabond HM 118 to the threads approximately 3
rings. mm from the end of the screw. Install screw and
tighten enough to hold assembly together.
4. Install one gear shaft retaining washer (23) on
the front of the planet gear frame (18). Press the 11. For final tightening, position the intermediate
front bearing spacer (25) on the front shaft of the gear case so the intermediate pinion is secured in
planet gear frame to hold the gear shaft retaining the jaws of the copperfaced vise. Tighten the inter-
washer snugly in position. mediate pinion retaining screw to 122 Nm torque.
Note: Coat the front bearing spacer with gear Lube 12. Remove the intermediate gear case from the
before installing it. Be careful not to gouge or scratch vise and set it on a bench.
the front bearing spacer during installation as this
could result in leakage between the planet gear Note: The intermediate gear case will work in only
frame and gear case. one orientation.
5. Place planet gear frame on a bench, shaft side Align the punch marks on the intermediate gear
08028-0D/H5250/94.08.12
down. Place the planet gear bearing (20) inside of case and gear case and tap the intermediate gear
planet gear (19). Place bearing spacers (21) on top case with a plastic hammer until it seats in the rear
and bottom of bearing and gear. Slide the compo- of the gear case. Make sure the intermediate pinion
nents into the slots in the side of the planet gear meshes with the drive gear.
frame. Align holes in spacers and bearing with holes
in planet gear frame and insert planet gear shaft Coat the o-rings on the motor assembly and the
(22), integral keyed end down, through the spacers inside of the cylinder before installing the motor
and bearing so that the larger portion of the keyed assembly.
end of the shaft contacts the planet gear shaft
retaining washer (23). Repeat the procedure for the 13. Install the motor assembly through the rear of
two remaining planet gears and components. the motor housing with the geared end of the rotor
Note: Do not move or turn over the planet gear

frame until step 6 and 7 have been completed.
96.26 - ES0S-G
613-01.30 Overhaul, Test and Inspection of Turbine Starter
Working Card
L+V28/32H
Fig 6. Turbine Starter.
toward the front. and tap the housing exhaust cover with a plastic
hammer until it seats.
Note: Turn the intermediate pinion so that the gear
on the rotor meshes with the planet gears. Make 18. Install the housing exhaust cover on the rear
sure that the rear of the motor assembly is installed of the motor housing using the starter assembly cap
flush with the rear of the cylinder. screws (6) and cap screw washers (7). Use an 8 mm
hex-head wrench to tighten each a little at a time to
14. Align the punch marks on the motor housing a final torque of 61 to 68 Nm increments.
with the punch marks on the intermediate gear case
and tap the motor housing with a plastic hammer 19. Mount the exhaust cover (68) on the housing
until it seats on the rear of the intermediate gear exhaust cover (1).
case.
Note: Use Intersoll-Rand SMB-441 pipe sealant on
08028-0D/H5250/94.08.12
15. Install the splash deflector (3), deflector re- all plugs.
taining spring (4) and deflector retaining screw (5) in
the rear of the housing exhaust cover. 20. Install the bottom housing plug (10) and the
housing plug inlet boss (11). Put the starter on its
Note: Coat the threads of the deflector retaining side with the side plug hole upward. Add 175 ml
screw with Ingersoll-Rand SMB-441 sealant. automatic transmission fluid through the side plug
hole.
16. Coat the exhaust cover seal (2) and install it in
the groove on the housing exhaust cover. Caution: Do not overfill.
Install the side housing plug (10) and tighten all
17. Align the punch marks on the housing exhaust
cover with the punch marks on the motor housing
96.26 - ES0S-G
Working Card
Page 9 (9)
Edition 02H
L+V28/32H
plugs to 6.8 to 13.6 Nm torque. the the face of the mounting flange. It should be 45.0
+2.0 mm.
Test and Inspection Procedure 4. Motor Action: Secure starter in a vise and
apply 90 psig (6.2 bar/620 kPa) pressure using a 3/
1. Clutch Ratcheting: Turn the drive shaft pin- 8" (9 mm) supply line to the inlet of the motor. starter
ion (63) by hand in the direction of the starter should run smoothly.
rotation. The clutch should rachet smoothly with a
slight clicking action. 5. Motor Seals: Plug the exhaust and slowly
apply 20 psig (1.38 bar/138 kPa) pressure to the
2. Motor and Gearing Freeness: Turn the drive inlet of the motor. Immerse the starter for 30 sec-
shaft pinion (63) opposite the direction of the starter onds in o non-flammable, bubble-producing liquid. If
rotation. The drive shaft pinion should turn by hand. the starter is properly sealed, no bobbles will ap-
pear.
Note: Inadvertent application of air pressure to the
“OUT” port will result in drive malfunction (pinion will 6. Gear Case Seals: Plug the exhaust and slowly
fail to retract). If this condition occurs, loosen the apply 20 psig (1.38 bar/138 kPa) pressure to the
drive housing cap screws (38) to vent gear case inlet of the motor. Immerse the starter for 30 sec-
(28). Also, loosen housing plugs (10) and (11) to onds in o non-flammable, bubble-producing liquid.
vent motor.
There should be no leakage in the housing joints in
3. Pinion Engagement: Apply 50 psig (3.4 bar/ the gear case area or in the shaft seal in the
345 kPa) pressure to the engagement “IN” port. intermediate gear system. If the starter is properly
drive shaft pinion (63) should move outward and air sealed, no bubbles will appear.
should escape from the “OUT” port.
7. Confirm Drive Rotation: Apply low pressure
Plug the “OUT” port and apply 150 psig (10.3 bar/ to the motor and observe rotation. drive pinion (63)
1034 kPa) pressure to the “IN” port. Check and must rotate in the direction stamped on the name-
make sure that no air is escaping. plate. Chamfer on pinion teeth should be on the
trailing edge of the gear tooth.
Measure the dimension from the face of the drive
shaft pinion (63) to the face of the mounting flange.
It should be 69.0 +2.0 mm).
Remove the pressure from the “IN” port. Measure

the distance form the face of the drive shaft pinion
08028-0D/H5250/94.08.12
96.26 - ES0S-G
Working Card
L+V28/32H

62006 xx 20 – 120 Nm
Shut-off fuel oil
Description:
Hand tools:
Disassembly, overhaul and assembly of the air
starter. Allen key, 4 mm
Allen key (long), 8 mm.
Screwdriver.
Big screwdriver.
Starting position: Chisel.
Retaining ring pliers.
All connection to the air starter have been Plastic hammer.
removed, and air starter is removed. Lubricating oil.
Sleeve.
Bearing puller.
Related procedure: Impact Wrench
Bearing pressing tool.

08028-0D/H5250/94.08.12
Working time : 4 Hour Plate no Item no Qty/

Capacity : 1 man
See plate 61309.
Data:

94.34-ES0S-G
L+V28/32H
General Information
1. Always mark adjacent parts on the housing

exhaust cover (1), motor housing (8),
intermediate gear case (13), gear case (28) and
drive housing (38) so these members can be
located in the same relative position when the
starter is reassembled.
Note : Do not disassemble the starter any

further than necessary to replace worn or
damaged parts.
Never reuse old seals or o-rings.
Never wash the inertia drive in a solvent.
2. Do not remove any part which is a press fit

in or on a subassembly unless the removal of
that part is necessary for replacement or repairs.
Fig 1.
3. Always have a complete set of seals and o-
rings on hand before starting any overhaul of the
turbine starter. 5. Remove the deflector retaining screw (5),
deflector retaining spring (4) and the splash
4. When grasping a part in a vise, always use deflector (3) from the housing exhaust cover (1),
copper-covered vise jaws to protect the surface See fig 2.
of the part and help prevent distortion. This is
particularly true of threaded members.
Housing Exhaust Cover, Motor Assembly,

and Motor Housing
1. If replacing the motor assembly (12),

remove both housing plugs (10) and drain the oil
from the gearing before beginning disass-embly
of the starter. Inspect the magnetic housing
plugs (10) for metal particles. Very fine metal
particles are normal. Remove particles and
reinstall plugs. Large particles or chips are an
indication of a problem. Disass-emble gear case
(28) and inspect.
2. Using a screw driver, unscrew the exh-ust Fig 2.

08031-0D/H5250/94.09.07
cover (67) from the housing exhaust cover (1).

6. Tap the motor housing with a plastic
3. Using an 8 mm hex-head wrench, unscrew hammer to dislodge it from the intermediate gear
and remove the starter assembly cap screws (6) case (13).
and washers (7), See fig 1.
7. Grasp the rear of the motor assembly (12)
4. Pull the housing exhaust cover (1) from the and pull it from the rear of the motor housing (8).
motor housing (8). To dislodge the housing If the motor assembly (12) is difficult to remove,
exhaust cover, relate it until the ears clear the lightly push the motor pinion which is on the
motor housing. Using a plastic hammer, tap the front of the motor assembly toward the exhaust
ears alternately until the housing cover can be side of the motor housing in order to free the
removed from the motor housing. motor assembly.
94.34-ES0S-G
Working Card
L+V28/32H
8. Tap the intermediate gear case (13) with a 13. Remove the planet gear frame assembly
plastic hammer to dislodge it from the gear case form the intermediate gear case. Using a sleeve
(28). that contacts the outer race of the front gear
frame bearing (17), press the planet gear frame
9. Position the intermediate gear case (13) on shaft seal (16) and the front gear frame bearing
a bench in a copperfaced vise so that the (17) from the front end and out of the rear of the
intermediate pinion (26) is secured in the jaws of intermediate gear case.
the vise. Tighten the vise only enough to hold
the intermediate pinion securely. 14. Remove the rear gear frame bearing (24)
from the planet gear frame (18), using a bearing
10. Loosen the intermediate pinion retaining puller and remove the gear shaft retaining
screw (27) 1-1/2 turns only. Do not remove. washer (23), See fig. 4.
Remove the planet gear shafts (22), planet
Warning : If the intermediate gear case is not gears (19), planet gear bearings (20) and
supported on a bench and if the intermediate bearing spacers (21).
pinion retaining screw is completely removed,
the intermediate gear case and compoments 15. Remove the front bearing spacer (25), using
could fall causing injury. a bearing puller and the gear shaft retaining
washer (23) from the front of the planet gear
11. Tap the intermediate pinion lightly to back frame by pressing on the front of the planet gear
the planet gear frame assembly out of the frame shaft. Remove the gear shaft retaining
intermediate gear case. washer only if the washer or front bearing spacer
is damaged.
12. Remove the intermediate gear case
assembly from the vise and remove the
intermediate pinion (26). Remove the rear gear
case o-ring (14) and front gear case o-ring (15)
form the intermediate gear case (13), See fig 3.
Fig 4.
08028-0D/H5250/94.08.12
Drive Housing
1. Grasp the drive pinion (63) in a copper-

faced vise with the starter supported on the
Fig 3. workbench.
2. Remove the drive pinion retaining screw

(61) which has a right-hand thread.
94.34-ES0S-G
L+V28/32H
3. Remove the starter from the vise. 15. Remove the piston ring (55) from the piston
(54).
4. Remove the drive pinion washer (62) and
the drive pinion (63). 16. Insert a large screwdriver blade through the
piston seal (56) so that it rests on top of the
5. Slide the pinion spring sleeve (64) and the clutch spring cup (50). Pry the seal out of the
pinion spring (65) off the drive shaft (57). piston.
6. Unscrew the drive gear screw (34). Using Note : This operation will damage the piston
an impact wrench with a 5/16" (8 mm) x 8" (203 seal. Therefore, a replacement piston seal must
mm) log hex inserted into the end of the drive be on hand.
shaft.
17. Press the clutch spring cup (50) down and
7. Unscrew and remove the drive housing cap remove the clutch spring cup retainer (49).
screws (38) and lock washers (39).
18. Remove the clutch spring cup and clutch
8. Tap the drive housing (40) with a plastic spring (51).
hammer to help dislodge it from the gear case
(28). 19. Remove the two clutch jaws (52).
Warning : FaiIure to follow this procedure could 20. Remove the front drive gear bearing (30),
result in injury to personnel. drive gear cup (36), drive gear lock washer (35),
drive gear screw ring (37) and drive gear screw
9. Place the drive housing (40) in an arbor (34).
press, piston end up. Apply a load to the piston
(54) using the arbor press to compress the 21. Remove the large drive shaft bearing
piston return spring (59) before removing the retainer (53) using a screwdriver.
bulkhead retainer (45). Do not use compressed
air to load the piston. 22. Press the rear drive shaft bearing and drive
shaft (57) out of the piston. If the rear drive shaft
10. Remove the bulkhead retainer (45). Using a bearing needs to be replaced, proceed as
screwdriver and the arbor press. follows :
Caution : Make sure the tension of the spring a. Cut and remove the small drive shaft
pushes the bulkhead out of the drive housing bearing retained in the drive shaft, using a small
before removing the drive housing from the chisel.
arbor press. b. Press the rear drive shaft bearing (58) off
the drive shaft.
11. Remove the bulkhead (46) from the piston
(54). 23. Place the gear case (25) on a workbench
12. Remove the outer bulkhead ring (47) and 24. Remove the drive gear bearing retainer
the inner bulkhead ring (48). (32), using retaining ring pliers and working
08031-0D/H5250/94.09.07
through the access holes in the gear web, See

13. Slide the drive shaft (57) from the drive fig 5.
housing (40).
25. Pull the drive gear (29) out of the gear case.
14. Pull the piston return spring (59) off the drive
shaft. Note : Do not disassemble the drive gear and
clutch parts of the turbine powered starters. If
Note : Do not remove the front drive shaft the drive shaft is defective, install a new or
bearing (42) or the drive housing seal (43) factory-rebuilt unit.
unless replacement is necessary and new parts
are available. The bearing and/or the seal will 26. Remove the drive gear shaft bearing
always be damaged when removed from the retainer (33), using retaining ring pliers.
drive housing.
94.34-ES0S-G
Working Card
L+V28/32H
3. Seat the rear drive gear bearing into the

gear case by tapping the opposite end of the
drive gear, using a plastic hammer.
4. Install the drive gear shaft bearing retainer

5. Install the drive gear bearing retainer, using

retaining ring pliers and working through the
access holes in the gear web.
6. Lubricated the drive gear with approxi-

mately 240 ml of Ingersoll-Rand No.28 lubricant.
7. Press the rear drive shaft bearing (58) onto

the drive shaft.
Fig 5.
8. Slide the small bearing retainer convex side
first, onto the drive shaft. Press it into position in
27. Remove the rear drive gear bearing (31) accordance with the instructions packaged with
from the drive gear. the new retainer.
9. Assemble the drive gear Schrew (34), drive

Assembly of the Starter gear lock washer (35), drive gear cup (36) and
drive gear screw o-ring (37).
1. Always press on the inner ring of a ball
bearing when installing the bearing on a shaft. 10. Grasp the drive shaft (57) in a vise, external
splined end down. Place assembled drive shaft
2. Always press on the outer ring of a ball screw Unit into the drive shaft, screwhead down.
bearing when pressing the bearing in a bearing Lubricate the inside diameter of the drive shaft
recess. with Ingersoll-Rand No. 28 lubricant.
3. Whenever grasping a part in a vise, always 11. Slide the drive gear bearing (30) into the
use leather-covered, copper-covered vise jaws drive shaft.
to protect the surface of the part and help
prevent distortion. This is particularly true of 12. Lubricate with Ingersoll-Rand No.28
threaded members. lubricant and install the driving clutch jaw teeth
facing up and driven clutch jaw teeth facing
4. Always clean every part, and wipe every down into the drive shaft.
part with a thin film of oil before installation.
13. Insert the clutch spring (51) into the drive
shaft.
Gear Case
08028-0D/H5250/94.08.12
14. Insert the clutch spring cup (50) into the

1. Place the drive gear bearing retainer over drive shaft.
the rear end of the drive gear.
15. Press the inserted parts into the drive shaft,
2. Press the rear drive gear bearing (31) onto and install the clutch spring cup retainer (49).
the rear end of the drive gear, using an arbor
press.
94.34-ES0S-G
L+V28/32H
Note : If it is necessary to replace the drive Note : Feel the underside of the drive housing to
housing (40) and drive components, make sure make sure the drive shaft passes through the
that the piston seal has been removed from the bearing.
rear of the new piston (54).The piston seal must
be removed to prevent pressure build-up which 26. Install the bulkhead retainer (45), using a
will cause movement of the planet gear frame screwdriver.
shaft seal (16). If this conditions occurs, the
piston cannot retract and the drive pinion (63) Warning : Make sure the bulkhead retainer is
will remain in engagement with the flywheel, properly seated in the motor housing groove
causing damage to the starter drive train and/or before easing off the arbor press. Failure to do
starter motor. To remove the piston seal, insert a so will allow improperly retained parts to
screwdriver inside the lip of the seal and pry it separate when removed from the arbor press
loose from the piston. resuming in injury to personnel.
16. Install the piston (54) onto the drive shaft 27. Remove the drive housing from the arbor
until the rear drive shaft bearing seats into the press.
piston.
28. Lubricate and install the drive housing o-ring
17. Coil the large drive shaft bearing retainer (41) in the groove of the drive housing.
(53) into the groove of the piston to retain the
outer race of the drive shaft bearing, using a thin 29. Position the assembled gear case on a
flat blade screwdriver to assist in this operation. workbench. The assembled unit must be upright
to accept the drive housing
18. Lubricate the piston o-ring (55) and install it Carefully position the assembled drive housing
in the groove of the piston. (40) onto the gear case so as not to damage the
piston seal. Align the punch marks of the gear
19. Position the drive housing in an arbor press, case and drive housing.
pinion-end down and install the drive housing
seal (43) into the drive housing. Using a 30. Install the drive housing cap screw lock
pressing sleeve of the proper size, press the washers (39) and the drive housing cap screws
seal into the drive housing so that the lip of the (38) and tighten to 28 Nm torque.
seal faces away from the drive pinion.
31. Tighten the drive gear screw (34) 77.3 Nm
20. Press the bearing into the drive housing torque, using an impact wrench with a 8 mm
until it seats, using a sleeve that contacts the x203 mm long hex inserted into the end of drive
outer race of the front drive shaft bearing (42). shaft.
Drop the piston return spring seat (60) on top of
front drive shaft bearing. 32. Grease and slide the pinion spring (65) and
the pinion spring sleeve (64) over the pinion end
21. Slide the piston return spring (59) onto the of the drive shaft.
drive shaft and snap it into the front of the piston
so that it is against the large drive shaft bearing 33. Grease the pinion end of the drive shaft and
retainer (53). install the drive pinion (63).
08031-0D/H5250/94.09.07
22. Lubricate and insert the assembled drive 34. Grasp the drive pinion in acopper-covered
shaft into the drive housing. vise with the starter supported on a workbench.
23. Lubricate and install the outer bulkhead o- 35. Place the drive pinion washer (62) onto
ring (47) and the Inner bulkhead o-ring (48) on drive pinion retaining screw (61).
the bulkhead (46).
Note : The thread on the drive pinion retaining
24. Slide the bulkhead onto the piston. screw is right-hand thread.
25. With the drive housing in the arbor press, 36. Install the drive pinion retaining screw into
press down on the rear face of the piston. the end of the drive shaft and tighten it to 108.5
Nm torque.
94.34-ES0S-G
Working Card
L+V28/32H
Intermediate Gear Case, Motor Housing, 6. Install the other planet gear shaft retaining
Motor Assembly and Housing Exhaust Cover washer over the shaft at the rear of the planet
gear.
1. Press the front gear frame bearing (17) into
the rear of the intermediate gear case (13), 7. Press the rear gear frame bearing (24) on
using a bearing pressing tool of the proper size. the shaft at the rear of the planet gear frame,
using the proper size bearing inserting tool.
2. Press the planet gear frame shaft seal (16)
into the rear of the intermediate gear case over 8. Slide the planet gear frame assembly,
the front gear frame bearing, using a sleeve coupling end first, into the rear of the
which contacts the outer ring of the seal. intermediate gear case (13), making sure that
the planet gears mesh with the ring gear. Use
Note : Make sure the flat side of the seal is care so as to not damage the seal.
installed against the bearing.
9. Install the intermediate pinion (26), making
3. Install the rear gear case o-ring (14) in the sure that the notches at the rear of the pinion
groove at the rear of the intermediated gear align with the notches and tangs in the shaft of
case and the front gear case o-ring (15) in the the planet gear frame.
groove at the front of the intermediate gear
case. coat both o-rings. 10. Clean the threads of the intermediate pinion
retaining screw (27) and apply 2-3 drops of
4. Install one gear shaft retaining washer (23) Permabond HM 118 to the threads approxi-
on the front of the planet gear frame (18). Press mately 3 mm from the end of the screw. Install
the front bearing spacer (25) on the front shaft of screw and tighten enough to hold assembly
the planet gear frame to hold the gear shaft together.
retaining washer snugly in position.
11. For final tightening, position the intermediate
Note : Coat the front bearing spacer with gear gear case so the intermediate pinion is secured
Lube before installing it. Be careful not to gouge in the jaws of the copperfaced vise. Tighten the
or scratch the front bearing spacer during intermediate pinion retaining screw to 122 Nm
installation as this could result in leakage torque.
between the planet gear frame and gear case.
12. Remove the intermediate gear case from
5. Place planet gear frame on a bench, shaft the vise and set it on a bench.
side down. Place the planet gear bearing (20)
inside of planet gear (19). Place bearing spacers Note : The intermediate gear case will work in
(21) on top and bottom of bearing and gear. only one orientation.
Slide the components into the slots in the side of
the planet gear frame. Align holes in spacers Align the punch marks on the intermediate gear
and bearing with holes in planet gear frame and case and gear case and tap the intermediate
insert planet gear shaft (22), integral keyed end gear case with a plastic hammer until it seats in
down, through the spacers and bearing so that the rear of the gear case. Make sure the
the larger portion of the keyed end of the shaft intermediate pinion meshes with the drive gear.
08028-0D/H5250/94.08.12
contacts the planet gear shaft retaining washer

(23). Repeat the procedure for the two Coat the o-rings on the motor assembly and the
remaining planet gears and components. inside of the cylinder before installing the motor
assembly.
Note : Do not move or turn over the planet gear
frame until step 6 and 7 have been completed. 13. Install the motor assembly through the rear
Movement of the planet gear frame assembly of the motor housing with the geared end of the
could dislodge assembled components, making rotor toward the front.
it necessary to repeat step 5.
Note : Turn the intermediate pinion so that the
gear on the rotor meshes with the planet gears.
Make sure that the rear of the motor assembly is
installed flush with the rear of the cylinder.
94.34-ES0S-G
L+V28/32H
Fig 6. Turbine Starter.
14. Align the punch marks on the motor housing 18. Install the housing exhaust cover on the rear
with the punch marks on the intermediate gear of the motor housing using the starter assembly
case and tap the motor housing with a plastic cap screws (6) and cap screw washers (7). Use
hammer until it seats on the rear of the an 8 mm hex-head wrench to tighten each a little
intermediate gear case. at a time to a final torque of 61 to 68 Nm
increments.
15. Install the splash deflector (3), deflector
retaining spring (4) and deflector retaining screw 19. Mount the exhaust cover (68) on the
(5) in the rear of the housing exhaust cover. housing exhaust cover (1).
Note : Coat the threads of the deflector retaining Note: Use Intersoll-Rand SMB-441 pipe sealant
screw with Ingersoll-Rand SMB-441 sealant. on all plugs.
16. Coat the exhaust cover seal (2) and install it 20. Install the bottom housing plug (10) and the
in the groove on the housing exhaust cover. housing plug inlet boss (11). Put the starter on
08031-0D/H5250/94.09.07
its side with the side plug hole upward. Add 175
17. Align the punch marks on the housing ml automatic transmission fluid through the side
exhaust cover with the punch marks on the plug hole.
motor housing and tap the housing exhaust
cover with a plastic hammer until it seats. Caution : Do not overfill.
Install the side housing plug (10) and tighten all
plugs to 6.8 to 13.6 Nm torque.
94.34-ES0S-G
Working Card
L+V28/32H
Test and Inspection Procedure 4. Motor Action: Secure starter in a vise and
apply 90 psig (6.2 bar/620 kPa) pressure using a
1. Clutch Ratcheting: Turn the drive shaft 3/8" (9 mm) supply liner to the inlet of the motor.
pinion (63) by hand in the direction of the starter starter should run smoothly.
rotation. The clutch should rachet smoothly with
a slight clicking action. 5. Motor Seals : Plug the exhaust and slowly
apply 20 psig (1.35 bar/138 kPa) pressure to the
2. Motor and Gearing Freeness : Turn the inlet of the motor. Immerse the starter for 30
drive shaft pinion (63) opposite the direction of seconds in o non-flammable, bubble-producing
the starter rotation. The drive shaft pinion should liquid. If the starter is property sealed, no
turn by hand. bobbles will appear.
Note : Inadvertent application of air pressure to 6. Gear Case Seals : Plug the exhaust and
the "OUT" port will result in drive malfunction slowly apply 20 psig (1.38bar/138 kPa) pressure
(pinion will fail to retract). If this condition occurs, to the inlet of the motor. Immerse the starter for
loosen the drive housing cap screws (38) to vent 30 seconds in o non-flammable, bubble-
gear case (28). Also, loosen housing plugs (10) producing liquid.
and (11) to vent motor.
There should be no leakage in the housing joints
3. Pinion Engagement : Apply 50 psig (3.4 in the gear case area or in the shaft seal in the
bar/ 345 kPa) pressure to the engagement "IN" intermediate gear system. If the starter is
port. drive shaft pinion (63) should move properly sealed, no bubbles will appear.
outward and air should escape from the "OUT"
port. 7. Confirm Drive Rotation : Apply low
pressure to the motor and observe rotation. drive
Plug the "OUT" port and apply 150 psig (10.3 pinion (63) must rotate in the direction stamped
bar/1034 kPa) pressure to the "IN" port. Check on the nameplate. Chamfer on pinion teeth
and make sure that no air is escaping. should be on the trailing edge of the gear tooth.
Measure the dimension from the face of the

drive shaft pinion (63) to the face of the
mounting range. It should be 69.0+2.0 mm).
Remove the pressure from the "IN" port.

Measure the distance form the face of the drive
shaft pinion the face of the mounting flange. It
should be 45.0+2.0 mm.
08028-0D/H5250/94.08.12
94.34-ES0S-G
Working Card
Main Starting Valve 613-01.40
L+V28/32H

Shut-off fuel oil
Description:
Lubricating, disassembly and reassembly of main

starting valve in starting system. Hand tools:
Soft hammer.
Locking ring plier.
Allen key, 1/4".
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
61310 02 1/eng.
Data: 61310 03 1/eng.
61310 04 1/eng.
Data for pressure and tolerance (Page 600.35) 61310 07 1/eng.
91.08 - ES0S-G
613-01.40 Main Starting Valve Working Card
L+V28/32H
Warning: Disassembly:
Do not attempt any maintenance on the main start- 4) Clamp the main starting valve, in a vice with
ing valve before the starting air system has been the locking ring (9) end up.
bled off.
5) Carefully remove the locking ring (9). The end
plug (3) should spring out. If it does not, tap the valve
Important: housing (1) lightly with a soft hammer until it does.
The main starting valve should be periodically lubri- 6) Remove the end plug (3), spring (8) and piston
cated as follows: (2) assembly.
1) Blend off the air pressure. 7) Remove and discard all used o-rings, o-rings
retainer (5), bumper (7) and spring (8).
2) Remove the plug screw (A) , see fig. 1. and
squirt about 30 g of 10 w oil into the valve through the 8) Wash all other parts in a clean, nonflammable
plug opening. solvent.
3) Reinstall the plug.

Reassembly:
9) Using o-ring lubricant, lubricate and install the

new piston o-ring (4) and the new upper piston o-ring
B (6) on the piston (2).
6
Note: The upper piston o-ring (6) is slightly larger in
1 diameter than the end plug o-ring (11).
2 C 10) Turn the piston over and insert the new bum-
ber (7).
4
D 11) Using o-ring lubricant, lubricate and install the

7 5 new end plug seal o-ring (10) and the new end plug
8 o-ring (11) on the end plug (3).
11
A
12) Lubricate the lower small bore of the valve
9 housing (1) with o-ring lubricant.
10
3
13) Insert the piston assembly into the valve hous-
ing. Push on the piston until the piston o-ring seats
against the bevelied face.
08028-0D/H5250/94.08.12
A Plug screw B Pilot air

C Starting air outlet D Starting air inlet
14) Install the new o-ring retainer (5) with the large
1 Valve housing 2 Piston opening over the piston o-ring.
3 End plug 4 Piston o-ring
5 O-ring retainer 6 Piston o-ring
7 Bumper 8 Spring 15) Place the new piston spring (8) on the piston.
9 Retaining ring 10 O-ring
11 O-ring 16) Place the end plug assembly on the piston
spring.
17) Using a press to hold down the end plug

Fig. 1. Main starting valve.
assembly, install the end plug locking ring (9).
91.08 - ES0S-G
Working Card
Check of Compressed Air Piping System 613-01.90
L+V28/32H

Shut-off fuel oil
Description:
Check of compressed oil piping system.

Hand tools:
Screwdriver.
Starting position:
Compressed air connected to the engine.
Related procedure:
08028-0D/H5250/94.08.12
Working time: ½ hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

94.21 - ES0U-G
613-01.90 Check of Compressed Air Piping System Working Card
L+V28/32H
With air connected. With air disconnected and stopped engine.
1) Examine the piping system for leaks. 6) Move all valves and cocks in the piping system.
Lubricate valve spindles with graphite or similar.
2) Retighten all bolts and nuts in the piping system.
7) Connect the air supply and make a function test
3) Drain the system for condensed water. - This of the emergency valve. See description 613.01.
should be based on observations.
4) Check flexible connections for leaks and damages.
5) Check manometers.
08028-0D/H5250/94.08.12
94.21 - ES0U-G
Plate
Page 1 (3) Turbine Starter 61309-05H
L+V28/32H
96.26- ES0S-G
Plate
61309-05H Turbine Starter Page 2 (3)
L+V28/32H
Item Item
1 1/S Housing exhaust Hus for udstøds- 23 2/S Gear shaft retainer Spænderingsskive for
cover. dæksel. washer. gearaksel.
2 1/S Exhaust cover seal. Tætningsring for 24 1/S Rear gear frame Bagerste gearstelleje.
udstødsdæksel. bearing.
3 1/S Splash deflector. Stænk deflektor. 25 1/S Front bearing Forreste gearstelleje.
spacer.
4 1/S Deflector return Returfjeder for
spring. deflektor. 26 1/S Intermediate pinion. Mellemtandhjul.
5 !/S Deflector retaining Spændeskive for 27 1/S Intermediate pinion Spændeskrue for
screw. deflektor. retaining screw. mellemtandhjul.
6 4/S Starter assembly cap Dækselskrue for 28 1/S Gear case. Gearkasse.
screw. montage af starter.
29 1/S Drive gear. Drivgear.
7 4/S Cap screw washer. Skive for dækselskrue.
30 1/S Front drive gear Forreste drivgearleje.
8 1/S Motor housing. Motorhus. bearing.
10 1/S Housing plug. Prop til motorhus. 31 1/S Rear drive gear Bagerste drivgearleje.
bearing.
11 1/S Housing plug inlet Tilgangsknast for prop
boss. til motorhus. 32 1/S Drive gear bearing Spændskrue for
retainer. drivgearleje.
12 1/S Motor assembly. Motor samling.
33 1/S Drive gear shaft Spændskrue for
12A 2/S Cylinder o-ring seal. O-ringstætning for bearing retainer. drivgearakselleje.
cylinder.
34 1/S Drive gear screw. Drivgearskrue.
12B 2/S Housing o-ring seal. O-ringstætning for
motorhus. 35 1/S Drive gear lock Skive for drivgear.
washer.
13 1/S Intermediate gear Mellem gearkasse.
case. 36 1/S Drive gear cup. Dæksel for drivgear.
14 1/S Rear gear case o- Bagerste gearkasse o- 37 1/S Drive gear screw o- O-ring for drivgearskrue.
ring. ring. ring.
15 1/S Front gear case o- Forreste gearkasse o- 38 8/S Drive housing cap Dækselskrue for
ring. ring. screw. drivgear.
16 1/S Planet gear frame Tætningsring for 39 8/S Drive housing cap Skive for dækselskrue til
shaft seal. planetgearakselstel. screw lock washer. drivgearhus.
16A 1/S Spacer ring. Afstandsring. 40 1/S Drive housing kit. Drivgearhus.
17 1/S Front gear frame Forreste gearstelleje. 41 1/S Drive housing o-ring O-ring for drivgearhus.
bearing.
42 1/S Front shaft bearing. Forreste akselleje.
18 1/S Planet gear frame. Planetgearstel.
43 1/S Drive housing seal. Tætningsring for
19 1/S Planet gear. Planetgear. drivgearhus.
20 1/S Planet gear needle Nålevalse for planet- 44 1/S Drive housing vent Afluftningsprop for
roller. gear. plug. drivgearhus.
21 1/S Bearing spacer. Ligemellemstykke. 45 1/S Bulkhead retainer. Skotholder
22 1/S Planet gear shaft. Planetgearaksel. 46 1/S Bulkhead kit. Skotsæt
Qty.//E = Qty./Engine Qty./E = Qty./Motor
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter
96.26 - ES0S-G
Plate
Page 3 (3) Turbine Starter 61309-05H
L+V28/32H
Item Item
47 1/S Outer bulkhead o- Ydre skot o-ring.

ring.
48 1/S Inner bulkhead o- Indre skot o-ring.

ring.
49 1/S Clutch spring cup Fjedertallerken holder.

retainer.
50 1/S Clutch spring cup. Fjedertallerken.
51 1/S Clutch spring. Koblingsfjeder.
52 1/S Clutch jaw kit. Koblingssæt.
53 1/S Large drive shaft Stor lejespændering for

bearing retainer. drivaksel.
54 1/S Piston kit. Stempelsæt.
55 1/S Piston o-ring. Stempel o-ring.
57 1/S Drive shaft kit. Drivakselsæt.
58 1/S Rear drive shaft Bagerste drivakselleje.

bearing.
59 1/S Piston return spring. Stempel returfjeder.
60 1/S Seat. Sædering.
61 1/S Drive pinion retain- Tandhjulsspænde-

ing screw. skrue.
62 1/S Drive pinion washer. Tandhjulsskive.
63 1/S Drive pinion. L28/32H Tandhjul. L28/32H.
63A 1/S Drive pinion. V28/32H Tandhjul. V28/32H.
64 1/S Pinion spring sleeve. Tandhjulsbøsning.
65 1/S Pinion spring. Tandhjulsfjeder.
66 1/S Inlet flange kit. Tilgangsflangesæt.
67 3/S Cover Dæksel
68 1/S Self drilling screws Selvborende skruer
69 1/E Turbine starter, Turbinestarter,

complete. L28/32H komplet. L28/32H.
69A 2/E Turbine starter, Turbinestarter,

complete. V28/32H. komplet. V28/32H.
70 Spare parts kit, incl. Reservedelssæt incl.

item 2, 12A, 12B, 14, item 2, 12A, 12B, 14,
15, 16, 16A, 17, 21, 15, 16, 16A, 17, 21, 23,
23, 24, 25, 41, 45, 47, 24, 25, 41, 45, 47, 48,
48, 55, 61 and 62. 55, 61 og 62.
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter
96.26 - ES0S-G
Plate
Page 1 (2) Starting Valve 61310-03S
L+V28/32H
08028-0D/H5250/94.08.12
91.40-ES0S-G
Plate
61310-03S Starting Valve Page 2 (2)
L+V28/32H
Item Item
No. No.
1 1/V Body
7 1/V Solenoid
11 1/V Solenoid fixture
21 1/V Pilot valve
31 2/V Bolt
38 1/V Spool assy
50 1/E Main starting valve, complete
08031-0D/H5250/94.09.07

Qty./E= Qty./Engine
Qty./V = Qty./Valve
91.40-ES0S-G
Plate
Page 1 (2) Starting Valve 61314-03H
L+V28/32H
37
01
33*
34
30*
35
32*
31*
01.28 - ES0
Plate
61314-03H Starting Valve Page 2 (2)
L+V28/32H
Item Item
01 1/E Starting valve, Starteventil,

complete komplet
30* 1/V Armature, complete Anker, komplet
31* 1/V Spring Fjeder
32* 1/V Gasket Pakning
33* 1/V Gude pipe, complete Styrerør, komplet
34 1/V Solenoid Spole
35 1/V Gasket Pakning
37 1/V Nut Møtrik
38* 1/V Repair kit, consisting Reservedelssæt, be-

of item 30, 31, and 32 stående af item 30, 31,
and 32
39 1/V Repair kit, consisting Reservedelssæt, be-

of item 33 and 38 stående af item 33 og
38
Qty./V = Qty./Valve Antal/V = Antal/Ventil
01.28 - ES0
Plate
Page 1 (2) Main Stop Valve 61315-03H
L+V28/32H
92.14 - ES0S-G
Plate
61315-03H Main Stop Valve Page 2 (2)
L+V28/32H
Item Item
05 1/V Gland flange Ters
10 1/V Stem with disc Spindel med skive
18 1/V Gasket Pakning
19 1/E Stop valve, complete Stopventil, komplet

(straight way) (ligeløb)
20 1/E Stop valve, complete Stopventil, komplet

(angel way) (vinkelløb)
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./C = Qty./Valve. Antal/V = Antal/Ventil.
92.14 - ES0S-G
Plate
Page 1 (2) Air Strainer 61316-03H
L+V28/32H
08028-0D/H5250/94.08.12
94.20 - ES0S-G
Plate
61316-03H Air Strainer Page 2 (2)
L+V28/32H
Item Item
01 1/F Housing Hus
02 1/F Cover Dæksel
03 1/F Filter Filter indsats
04 4/F Stud Tap
05 4/F Nut Møtrik
06 1/E Air strainer, Filter, komplet

complete
08 1/F Gasket Pakning
09 1/F Plug screw Propskrue
08028-0D/H5250/94.08.12
Qty./F = Qty./Filter. Antal/F = Antal/Filter.
94.20 - ES0S-G
Plate
Page 1 (2) Safety Valve 61319-01H
L28/32H
01
02
04
03
08028-0D/H5250/94.08.12
92.04 - ES0S
Plate
61319-01H Safety Valve Page 2 (2)
L28/32H
Item Item
01 1/E Safety valve, Sikkerhedsventil,

(10 bar) (10 bar)
02 1/E Safety valve, Sikkerhedsventil,

(15 bar) (15 bar)
03 1/E Protective device Beskyttelseshætte
04 3/E Screw Skrue
08028-0D/H5250/94.08.12
92.04 - ES0S
Plate
Page 1 (2) ON-OFF Valve for Jet System 61320-02H
L+V28/32H
01
02
03
04
05
06
07
08028-0D/H5250/94.08.12
92.14 - ES0S-G
Plate
61320-02H ON-OFF Valve for Jet System Page 2 (2)
L+V28/32H
Item Item
01 1/V Coil Spole
02 1/V Housing Hus
03 1/E Valve, complete ¾" Ventil, komplet ¾"

connecting branch tilslutningsstuds
04 1/E Valve, complete 1" Ventil, komplet 1"

Connecting branch Tilslutningsstuds
05 1/E Valve, complete 1 ¼" Ventil, komplet 1 ¼"

06 1/E Valve, complete 1 ½" Ventil, komplet 1 ½"

07 1/E Valve, complete 2" Ventil, komplet 2"

08028-0D/H5250/94.08.12
Qty./V = Qty./Valve. Antal/V = Antal/Ventil.
92.14 - ES0SG
Plate
Page 1 (2) Air Filter 61321-03H
General
02.46 - ES0
Plate
61321-03H Air Filter Page 2 (2)
General
Item Item
10 1/E Filter complete Filter komplet
11 1/F Repair kit Reparationssæt

(filter and O-ring) (filter og O-ring)
02.46 - ES0
Plate
Page 1 (2) Pressure Reduction Valve 61322-03H
L+V28/32H
08028-0D/H5250/94.08.12
98.49 - ES0-G
Plate
61322-03H Pressure Reduction Valve Page 2 (2)
L+V28/32H
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse
01 1/V Cover Dæksel
02 10/V Screw Skrue
03* 2/V Filter Filter
04 1/V Tube incl. o-ring Rør, inkl. o-ring
05* 1/V O-ring O-ring
06* 1/V Diaphragh Membran
09 1/V Valve, complete Ventil, komplet
11* 1/V Valve spring Ventilfjeder
14 1/V Bottom plug, incl. Bundprop, inkl.

o-ring o-ring
16 2/V Pipe plug Rørprop
18 1/V Repair kit, incl. item Reparationssæt, inkl.

03, 05, 06, 07, 08, 10, item 03, 05, 06, 07, 08,
11, 12, 13, and 17 10, 11, 12, 13 og 17
19 1/E Reduction valve, Reduktionsventil,

complete komplet
20 1/E Pilot valve, complete Styreventil, komplet
21 1/V Repair kit Reparationssæt

for item 20 for item 20
22 2/V Screw Skrue
23 1/V Manometer Manometer

0-25 bar - PI 70 0-25 bar - PI 70
24 1/E Pressure reduction Trykreduktionsventil,

08028-0D/H5250/94.08.12
valve, complete as komplet som plate

plate 61322 61322
25 1/V Repair kit for item 19 Repair kit for item 19
Qty/E = Qty/Engine Antal/E = Antal/Motor
Qty/V = Qty/Valve Antal/V = Antal/Ventil
98.49 - ES0-G
Plate
Page 1 (2) Turning Gear 61325-07H
L28/32H
08028-0D/H5250/94.08.12
02.12 - EO0
Plate
61325-07H Turning Gear Page 2 (2)
L28/32H
Item Item
011 1/E Steel pipe Stålrør 322 2/E Bulkhead coupling Forskruning
023 1/E Stud coupling Kobling 334 1/E Lubricator Smøreapparat
035 3/E Silencer Lyddæmper 346 1/E House for air motor Hus for luftmotor
047 1/E Reducing adaptor Reduktionsstykke 358 1/E Shaft Aksel
059 1/E Solenoid valve Magnetventil 371 2/E Retaining ring Låsering
060 2/E Stud coupling Forskruning 383 1/E Screwed connection Forskruning
072 1/E Steel pipe Stålrør 395 1/E Bracket Konsol
084 4/E Screw Skrue 405 1/E Handle Håndtag
096 4/E Washer Skive 417 1/E Shaft Aksel
106 1/E Cable Kabel 429 2/E Retaining ring Låsering
118 1/E Terminal box Klemkasse 430 1/E Flange Flange
131 2/E Cable union Kabelunion 442 1/E Gear wheel Tandhjul
143 4/E Screw Skrue 454 6/E Screw Skrue
155 2/E Screw Skrue 466 1/E Air motor Luftmotor
167 1/E Position switch Switch
179 2/E Nut Møtrik
180 2/E Screw Skrue
192 6/E Screw Skrue
202 1/E Handle Håndtag
214 2/E Pin Stift
226 1/E Screw Skrue
238 1/E Linkage Lænkeled
251 1/E Linkage Lænkeled
263 1/E Snap coupling Lynkobling
275 1/E Snap coupling Lynkobling
287 2/E Flexible hose Fleksibel slange
299 1/E Plate Plade

08028-0D/H5250/94.08.12
309 1/E Bulkhead coupling Forskruning
310 3/E Stud coupling Forskruning
02.12 - EO0
Index
Page 1 (1) Fuel Oil System 614S
L28/32H
Description
Internal Fuel Oil System ............................................................................................ 614.01(15H)

Fuel Injection System – NICO ................................................................................... 614.01(21H)
Working Card
Fuel Injection Pump and Fuel Injection Pipe ........................................................ 614-01.05(02H)

Fuel Injection Pump and Fuel Injection Pipe (NICO) ........................................... 614-01.05(04H)
Fuel Injection Valve .............................................................................................. 614-01.10(02H)
Fuel Injection Valve-NICO .................................................................................... 614-01.10(04H)
Fuel Oil Split Filter ................................................................................................ 614-01.15(01H)
Check of Fuel Oil Piping System .......................................................................... 614-01.90(01H)
Adjustment of The Maximum Combustion Pressure ............................................ 614-05.01(02H)
Fuel Oil Feed Pump ............................................................................................. 614-10.00(01H)
Plates
Fuel Injection Pump ...................................................................................................... 61401-03H

Fuel Injection Pump(NICO) .......................................................................................... 61401-09H
Fuel Injection Valve ...................................................................................................... 61402-04H
Fuel Injection Valve(NICO) ........................................................................................... 61402-06H
Fuel Oil Split Filter ........................................................................................................ 61403-09H
Fuel Injection Pipe ........................................................................................................ 61404-06H
Fuel Oil Feed pump ...................................................................................................... 61410-15H
Technical Information
Expension Loop for Fuel oil in/outlet .................................................................................. 614-S3

08028-0D/H5250/94.08.12
94.47-ES0U
Description 614.01
Page 1 (3) Internal Fuel Oil System Edition 15H
L28/32H
Flywheel end
Cyl. 1 Leak from

Fuel oil fuel valve
feed
pump
Fuel oil
return
Waste tray
Fuel oil
Drain High pump
from cyl. pressure
head pipe Fuel oil
inlet
Fuel leakage alarm Leak from

Fuel oil fuel pump
filter
A3 A2 A1
Fig. 1. Diagram for Fuel Oil System
General
The internal built-on fuel oil system consists of the The safety filter is a duplex filter of the split type with
following parts: a filter fineness of 50 my. The filter is equipped with
a common three-way cock for manual change of
- the fuel oil feed system both the inlet and outlet side.
- the high-pressure injection equipment,
comprising fuel oil injection pumps, fuel oil During normal operation both filters should be in
injection valve and fuel oil high pressure operation. Single operation only to be used when
pipe dismantling one of the filters for manual cleaning or
- the waste oil system inspection.
08028-0D/H5250/94.08.12
The feed pump (if part of the delivery,) which is of the

Internal Fuel Oil Feed System gear wheel type, is equipped with a spring-loaded
adjustable by-pass valve.
The fuel oil is led to the injection pumps through a
safety filter by means of the engine driven feed pump The outlet pressure of the feed pump can be ad-
(if part of the delivery). justed by means of an adjusting screw in the by-pass
valve assembly.
94.11 - ES2S
614.01 Description
Edition 15H
Internal Fuel Oil System Page 2 (3)
L28/32H
For circulation of fuel during stand-still of the engine, The injection valve is for "deep" building-in to the
a by-pass line is mounted with a non-return valve centre of the cylinder head.
parallel to the feed pump.
Fuel Oil Injection Valve

Fuel Injection Equipment
The fuel oil injection valve consists of a nozzle holder
Each cylinder unit has its own set of injection equip- and a nozzle connected by a union nut. The nozzle
ment, comprising injection pump, high-pressure pipe holder includes a threaded pipe stub for mounting
and injection valve. the high-pressure pipe. It is led through a boring in
the cylinder head, together with an adjusting screw,
The injection equipment and the distribution supply a spring and spring spindle for the initial tensioning
pipes are housed in a fully enclosed compartment of the nozzle needle.
thus minimizing heat losses from the preheated fuel.
The initial tension of the spring, which determines
This arrangement reduces external surface tempe- the opening pressure of the nozzle, can be adjusted
ratures and the risk of fire caused by fuel leakage. by means of the centrally-mounted adjusting screw.
On the uppermost thick part of the holder, there are

Fuel Oil Injection Pump three sealing O-rings.
The fuel oil injection pump is installed on the roller Between the two lowest O-rings, the leak oil from the
guide housing directly above the camshaft, and it is nozzle needle is led out into the space between the
activated by the cam on the camshaft through roller high-pressure pipe and the protection tube.
guides fitted in the roller guide housing.
The nozzle and needle are lapped together as a pair,
The injection amount of the pump is regulated by and cannot be replaced individually. The nozzle is
transversal displacement of a toothed rack in the controlled by two pins attached to the bottom of the
side of the pump housing. holder.
By means of a gear ring, the pump plunger with the The joint surface between the nozzle and holder is
two helical millings, the cutting-off edges, is turned. machine-lapped to make it oil-tight.
Hereby the length of the pump stroke is reckoned The fuel injector is mounted in the cylinder head by
from when the plunger closes the inlet holes until the means of the integral flange in the holder and two
cutting-off edges again uncover the holes. studs with distance pieces and nuts.
The release of high pressure through the cutting-off A bore in the cylinder head vents the space below the
edges presses the oil with great force against the bottom rubber sealing ring on the injection valve,
wall of the pump housing. At the spot, two exchange- thus preventing any pressure build-up due to gas
08028-0D/H5250/94.08.12
able plug screws are mounted. leakage, but also unveiling any malfunction of the
bottom rubber sealing ring for leak oil.
The amount of fuel injected into each cylinder unit is
adjusted by means of the governor.
Fuel Oil High Pressure Pipe
It maintains the engine speed at the preset value by
a continuous positioning of the fuel pump racks, via The high-pressure pipe between fuel injection pump
a common regulating shaft and spring-loaded link- and fuel injector is a shielded pipe with coned pipe
ages for each pump. ends for attachment by means of a union nut, and a
nipple nut, respectively.
94.11 - ES2S
Description 614.01
Page 3 (3) Internal Fuel Oil System Edition 15H
L28/32H
The high-pressure pipe is led through a bore in the Waste Oil System
cylinder head, in which it is surrounded by a shielding
tube, also acting as union nut for attachment of the Waste leak oil from the compartment, fuel valve and
pipe end to the fuel injector. engine feed pump is led to a fuel leakage alarm unit.
The shielding tube has two holes in order to ensure The alarm unit consists of a box with a float switch for
that any leakage will be drained off to the cylinder level monitoring. In case of a larger leakage than
head bore. The bore is equipped with drain channel normal leakage, the float switch will initiate alarm.
and pipe. The supply fuel oil to the engine is led through the unit
in order to keep this heated up, thereby ensuring free
The shielding tube is supported by a sleeve, moun- drainage passage even for high-viscous waste/leak
ted in the bore with screws. oil.
The sleeve is equipped with O-rings in order to seal

the cylinder head bore.
08028-0D/H5250/94.08.12
94.11 - ES2S
Working Card
Fuel Injection Pump and Fuel Injection Pipe (NICO) 614-01.05
L+V28/32H

62014 01
Stopped lub. oil circul. 62006 26 20-120 Nm
62006 28 140-760 Nm
Description:
Dismounting, inspection/overhaul and mounting

of fuel injection pump. Inspection of fuel Hand tools:
injection pipe.
Starting position: Ring and open end spanner 19 mm
Allen key 8 mm, 10 mm
Cover in front of fuel injection pump has been Plier for lock ring.
removed. Tools for cleaning.
Clean kerosene or gas oil.
Cleanlubricating oil.
Anti seize product (Copaslip, Molykote GN Plus
Related procedure: or similar).
Inspection of roller guide for fuel injection pump

608-01.05.
Spare and wearing parts:

Man power:
08028-0D/H5250/94.08.12

Working time : 4 Hour
Capacity : 1 Man 61401 07 1/pump
61401 10 1/pump
61401 08 1/pump
61401 06 1/pump
Data: 61401 05 1/pump
61401 09 1/pump
94.47-ES0U
614-01.05 Fuel Injection Pump and Fuel Injection Pipe (NICO) Working Card
L+V28/32H
Dismounting of fuel injection pump 7. Press the guide : plunger (N) fig. 2
down wards and remove the snap ring (P).
1. Dismount the fuel injection pipe pos. 1 Remove the guide plunger (N) with lower
fig. 1 and the fuel inlet pipe pos. spring seat (O) and plunger (M).
Be sure not to damage the plunger.
2. Separate the spring loaded lever from
the control rack on the fuel injection pump.
Fig. 1 View from Control Side
3. Remove the pipe for lub. oil and drain.
4. Remove the screw in the bottom flange

(4 pieces) and take the fuel injection pump
away.
Separation of fuel injection pump.

08031-0D/H5250/94.09.07
5. If necessary, clean the exterior of the

injection pump.
6. Mount the injection pump in the

clamping bracket PYO-W020 (see plate
62014 item 03), on the test pump.
Fig. 2 Cross Section of Fuel Injection Pump
94.47-ES0U
Working Card
Fuel Injection Pump and Fuel Injection Pipe (NICO) 614-01.05
L+V28/32H
8. Take out the plunger spring (L), upper 14. The axial clearance between lower
spring seat (K) and control sleeve (J). If spring seat and plunger foot must not exceed
necessary remove the snap ring (R) and rack 0.25 mm. The clearance between lower
stopper (I) and dismount the control rack (H) spring seat and plunger foot is 0.05 to 0.1 mm
as well as the plug in the opposite end of the when new. See fig. 3.
control rack (H).
15. Check the deflectors (G) for wear and
9. Unscrew the four bolts (A) and remove renew if necessary.
the case : delivery valve (B). Take out the
spring : delivery valve (D) and the delivery 16. Monoblock cylinder (E), plunger (M) and
valve (F). delivery valve (F) are manufactured to very
close tolerances. Any attempt to refinish these
10. Loosen and remove the four bolts (C) parts causes alterations of the tolerances and
and take out the monoblock cylinder (E). must therefore NOT be carried out.
If during the visual inspection of the parts,
11. Remove all the o-rings and back-up heavy abrasion symptoms or damage can be
rings from the injection pump. observed, the part in question must be
replaced.
12. All parts must be cleaned, using
kerosene or gas oil and a hand brush (not a
steel brush). Assembling of fuel injection pump :
Blow through the holes for sealing oil in the
pump houses and the monoblock cylinder (E). 17. When assembling the injection pump,
proceed in the reverse order to
disassembling. Pay attention to the following :
Inspection of fuel injection pump:
13. Insert plunger (M) and delivery valve (F)

into the monoblock cylinder (E) after wetting
with clean gas oil. Plunger and delivery valve
must slide into the monoblock cylinder by their
own weight.
08028-0D/H5250/94.08.12
Fig. 4 Mounting of Control Rack Mechanism
A. At initial tightening up of new parts the

following (C) for monoblock cylinder (E).
Fig. 3 Clearance between Lower Spring Seat and Plunger Tighten screws to 90 Nm, loosen and tighten
again to 90 Nm and then tighten to 90 Nm +
10 Nm.
Employ the same procedure when tightening
the other pump components for the first time.
94.47-ES0U
614-01.05 Fuel Injection Pump and Fuel Injection Pipe (NICO) Working Card
L+V28/32H
B. Renew all sealing and back-up rings. Mounting of fuel injection pump :
For placing of the rings, see fig. 1.
19. Before mounting the fuel injection
C. Coat all the threads with an anti seize pump, clean the roller guide spring and
product. washer for spring in the roller guide housing.
D. Wipe dry with paper plane sealing 20. Reconnect the control rack (H) to the
surface on monoblock cylinder (E) and case : spring loaded lever and all the pipes to the
delivery valve (B) . fuel pump.
E. Before inserting the control sleeve (J),

the easy motion of the plunger (M) in the Fuel injection pipe:
monoblock cylinder (E) must be checked.
By normal working conditions the fuel injection
F. When assembling the control sleeve (J), pipe require very little maintenance except
ascertain that the tooth (recognizable by the replacement of O-rings and gasket in
chamfer) will enter the space of the control connection with the normal overhaul of fuel
rack (H) marked by two sings, see fig. 4. injection equipment. (See also description of
fuel injection pipe page 614.10).
G. The marking on the guide cam of the
plunger (M), must be in line with the marking
in the slots of the control sleeve (J). (Not
shown on fig. 4).
18. After assembling, the easy motion of the

control rack(H), must be checked and the
plunger (M) must be moved from the no-load
stop to fuel-load stop.
08031-0D/H5250/94.09.07
94.47-ES0U
Working Card
Fuel Injection Valve - NICO 614-01.10
L+V28/32H

62006 26 20-120 Nm
62014 35
62014 40
Description:
Dismounting, overhaul pressure testing and

mounting of fuel injection valve. Hand tools:

Starting position: Ring and open end spanner 24 mm
Socket spanner 24 mm
Top cover on the cylinder head and front cover Socket spanner 30 mm
on the fuel injection pump have been Tools for cleaning.
dismounted. For dismounting of fuel injection Clean kerosene or gas oil.
pipe, see working card 614-01.05. Anti seize product.
(Copaslip, Molykote GN Plus or similar).
Related procedure:
Man power: Spare and wearing parts:

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

Capacity : 1 man 61402 02 2/C
61402 03 1/C
61402 10 1/C
Data:

98.28-EO0
614-01.10 Fuel Injection Valve - NICO Working Card
L+V28/32H
The fuel injection valve is the one component 3. Clean the lower part of the atomizer
that has the greatest influence on the diesel complete (J) of carbonized oil deposits before
engine condition. dismantling the nozzle nut (H).
Various operation forms the fuel oil and Attention !

quality affect the overhaul intervals. In some
cases it may be necessary to shorten the Do not damage the lapped surfaces, when
prescribed overhaul intervals. removing the nozzle nut (H) and the atomizer
complete (J).
Dismounting and cleaning :
1. Dismount the fuel injection valve from

the cylinder head by means of the special tool
as shown in fig 1.
Fig 2 Fuel injection valve
4. The spring (F) and the spindle (G) are

to be taken out by unscrewing the adjusting
screw (D) completely.
Fig 1 Dismounting of fuel injection valve from cylinder 5. Clean all parts with kerosene or gas oil
and with a hard brush (not a steel brush).
08031-0D/H5250/94.09.07
head.
2. Mount the fuel injection valve into the 6. Clean the nozzle holes of charred coke
clamping bracket VTO-W022 (see plate by means of the supplied special drill with
62014, item 02) on the pressure testing pump, holder.
and loosen the nut (B) fig 2.
7. Clean the cooling chamber and the
Unstress the spring by turning the adjusting cooling ducts in the nozzle body and injector
screw (D). body.
Place them in a cleaning liquid and then blow

through the parts with working air.
98.28-EO0
Working Card
Fuel Injection Valve - NICO 614-01.10
L+V28/32H
Inspection of the parts: 12. Lubricate the shoulder of the atomizer

complete which is in contact with the nozzle nut
The nozzle body and needle are matched by with an antiseize product.
lapping and are therefore only interchange -able
as units. 13. Wipe the plane sealing surface of body
and nozzle dry with paper.
8. Insert the nozzle needle with gas oil in the
nozzle body. It must be controlled whether the 14. Renew the o-rings (C) and (E).
nozzle needle slides down by its dead weight on
its seat. Tightening torque for nozzle nut, see page
600.40
9. Check if the holes in the nozzle are worn
oval.
Pressure testing of fuel injection valve:
This is done by means of a magnifying glass.
The most effective checking of the fuel valves is
WHEN the nozzle holes.. THEN obtained through pressure testing, preferably
carried out after each overhaul and also in case
are worn oval Scrap the atomizer of irregularities in operation.
complete
are not worn oval Re-use the The pressure testing is carried out in the
atomizer complete following way by means of the pressure testing
apparatus supplied.
The beat way, however, to check if the holes are
15. Mount the fuel injection valve in the
worn out is to control the flow rate of the
bracket VTO-W022. The bracket must be in
atomizer complete which, in general, only can
such a position that the nozzle of the injector is
be made by MAN B&W Holeby.
pointing downwards.
10. Replace parts with heavy abrasion
16. Mount the test pipe VWM-W007 (see
symptoms, respectively damages, which were
plate 62014, item 05) on to the bracket for test of
observed at the visual inspection of the parts.
the cooling oil system.
Every effort to refinish will result in alterations of
To increase the pressure, use the lever on the
these values and malfunction of the nozzle.
test pump.
If heavy abrasion symptoms, respectively
17. Apply pressure to the cooling oil system,
damages are observed at the visual inspection
(see data page 600.35) after venting.
of the parts, the parts in question must be
replaced.
18. Check the sealing tightness of the
O-rings.
Reassembling:
19. Mount the test pipe VTO-W023 (see plate
When all parts have been carefully cleaned,
08028-0D/H5250/94.08.12
62014, item 04) for test of the injection pressure

inspected and overhauled and found in good
and atomizing.
order, then assemble the fuel injection valve.
20. Adjust the opening pressure to 320 bar by
When assembling the injection valve, proceed in
means of the adjusting screw (D), see fig 2, then
the opposite order compared to the
tighten the lock nut (B).
disassembly.
21. Check opening pressure again.
Pay attention to the following :
Do not expect chattering, but make sure that the
11. Lubricate the threads on the adjusting
nozzle spray from all holes is in the same angle.
screw (D) with lub. oil, and the threads of the
The nozzle might chatter if the lever is worked
injector body for the nozzle nut.
very fast, actually by hitting it.
98.28-EO0
614-01.10 Fuel Injection Valve - NICO Working Card
L28/32H
Do not expect nozzle tip with more than 1000 24. Grind the seating face, if necessary,
running hours to perform like a new nozzle in with the grinding too (see fig 3).
the test pump.
25. Coat the O-ring and the lower part of
22. Increase the pressure to 300 bar and the valve with an anti seize product and place
keep the pressure by working the lever slowly the valve in the cylinder head, and press it
downwards. down to the seat.
When the pressure is kept at 300 bar, there 26. Mount the high pressure pipe before
should be no more than one drip from the tightening the nuts. Then it is easier to fit the
nozzle tip for approx. 3-5 sec. threads.
27. Put on the distance pieces, fit the nuts

WARNING and tighten up with a torque spanner (for
Keep out of the fuel jets as they will torque moment, see page 600.40).
penetrate the skin. Fuel which has
penetrated the skin can cause painful
inflammations (blood poisoning).
Mounting of the fuel injection valve in the

cylinder head :
23. Clean and inspect the valve bore in the

cylinder head before mounting the fuel valve.
Fig 4 Grinding tools for fuel injection valve (extra tools)

08031-0D/H5250/94.09.07
Fig 3 Grinding tools for seat for fuel and liner injection
valve.
98.28-EO0
Working Card
Fuel Oil Split Filter 614-01.15
General

Shut-off fuel oil
Description:
Disassembly, cleaning and assembly of fuel oil

split filter. Hand tools:

Kerosene, gas oil or similar.
Starting position:
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
Data:

91.08 - ES0S
614-01.15 Fuel Oil Split Filter Working Card
General
1) During normal operation both filters should be 3) Position of three way cock, see fig. 2.
in operation, single operation only to be used when
dismantling one of the filters for manual cleaning or
inspection.
2) Normally the filters are cleaned during opera-

4 5
tion by turning the handle, (1) see fig. 1, on the filter
housing top a couple of turns. (clockwise).
Simultaneously with turning of the handle, the drain

cock, (2) in bottom of the filter housing should be
opened in order to drain of the dirt being scraped of
the filter element, (3).
Left Filter Both filters in Right Filter

1 This position is operation. This position is
only for cleaning only for cleaning
of the right filter, of the left filter,
not for continu- not for continu-
ous operating. ous operating.
5
Fig. 2. Fuel oil split filter (top view).
3
Note: Shut-off fuel oil, before dismantling filter ele-
ment.
4) If no drainage occurs when the drain cock is

opened, the filter housing should be dismantled for
manual cleaning. Remove the nuts (5), and take out
the filter element (3).
2
5) Clean the filter element in kerosene gas oil or
similar and blow it dry with working air.
Fig. 1. Fuel oil split filter 6) Mount the filter element again.
08028-0D/H5250/94.08.12
7) The filter element itself should never be dis-

mantled, but has to be replaced if damage or mal
function is experienced.
91.08 - ES0S
Working Card
Check of Fuel Oil Piping System 614-01.90
General

Shut-off fuel oil
Description:
Check of fuel oil piping system.

Hand tools:
Starting position:
Engine is running.
Related procedure:
08028-0D/H5250/94.08.12
Working time: ½ hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

92.04 - ES0S
614-01.90 Check of Fuel Oil Piping System Working Card
General
Fuel Oil System. 4) Move all valves and cocks in the piping system.
1) Dismount the covers to the injection pumps. Blow-
through drain pipes. 5) Check flexible connections for leaks and damages.
2) Examine the piping system for leaks. 6) Check the condition of the lower O-ring for the fuel
injecting valves by means of the venting pipe.
3) Retighten all bolts and nuts in the piping system.
For fuel oil condition, see section 604.
Venting pipe
Fig. 1. Cross section of cylinder head

08028-0D/H5250/94.08.12
92.04 - ES0S
Working Card
Adjustment of The Maximum Combustion Pressure 614-05.01
General

Description:
Adjustment of the maximum combustion pressu-

re for the cylinders one by one and for all cylinders
in total.
Hand tools:
Starting position: Ring and open end spanner, 19 mm.

Camshaft mounted and adjusted in Depth gauge.
relation to the crankshaft (lead), 607-01.20 Plastic hammer.
Intermediate wheel mounted.
Related procedure:
08028-0D/H5250/94.08.12
Working time : 2-5 Hours Plate no. Item no. Qty. /

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

91.45 - ES0S
614-05.01 Adjustment of The Maximum Combustion Pressure Working Card
General
If fuel oil valve, piston, inlet and exhaust valves as Thinner and/or fewer shims (increase of the distance
well as turbocharger and charge air cooler are working “X”) results in a delayed injection timing and a lower
correct and the compression pressure Pcomp is nor- Pmax.
mal the maximum combustion pressure will indicate
the injection timing for the fuel oil pump. Thicker and/or more shims (reduction of the distance
“X”) results in an advanced injection timing and a
If Pmax is too low it indicates that the injection timing higher Pmax.
is delayed.
If the distance “X” is to be changed the trigger (1) is
If Pmax is too high it indicates that the injection timing used for dismantling of the thrust piece (2), whereaf-
is advanced. ter the thickness and/or the number of shims (3) can
be changed.
The injection timing can be altered by inserting or
removing shims under the thrust piece on the roller By changing “X” with 0.10 mm the maximum com-
guide, thus changing the measure “X”, see fig. 1. bustion pressure is changed with - see page 600.35.
After replacement of shims the thrust piece is re-

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

3 Shims 4 Roller guide
5 Soft hammer
Fig. 1.
Fig. 3.
08028-0D/H5250/94.08.12
Action Results
Total height Distance Injection Max. combustion

on roller guide "x" timing pressure
increased Reduced ¯ Advanced increased
Reduced ¯ increased Delayed ¯ Reduced ¯
Fig. 2.
91.45 - ES0S
Working Card
Adjustment of The Maximum Combustion Pressure 614-05.01
General
When changing “X” it must be ensured that the

distance between the upper edge of the roller guide
housing and the thrust piece on the roller guide is not
exceeded, when the roller is resting on the circular
part of the fuel cam, see page 600.35.
In all cases “X” must be checked and adjusted, if

necessary, when fuel oil pump, roller guide, roller
guide housing and/or camshaft section have been
replaced/dismantled.
Note: If several fuel oil pumps, roller guides, roller

guide housings and/or camshaft sections are dis-
mantled at the same time it is advisable to number
the parts in order to facilitate remounting and adjust-
ment.
If the maximum combustion pressure differs from the

test bed records after adjustment of each individual
pump the camshafts placement can be changed, as
the camshafts gear wheels are provided with
oblonged holes so that they can be turned in relation
to the hub. Fig. 4.
The gear wheel is provided with an engraved scale,

see fig. 4, and the hub of the cam shaft is provided If the crankshaft is turned in the engines normal
with a mark. direction of rotation the maximum combustion pres-
sure P-max. is reduced.
When the screws, which fasten the gear wheel, are
loosened the gear wheel is turned (by turning the If the crankshaft is turned against the engines nor-
crankshaft) in relation to the camshaft. By reading mal direction of rotation the maximum combustion
the angle in which the gear wheel is displaced in pressure P-max. is increased.
relation to the camshaft the altered Pmax can be
calculated. A line on the scale corresponds to: see After the adjustment the screws are fastened with a
page 600.35. torque wrench, see page 600.40, and secured.
08028-0D/H5250/94.08.12
91.45 - ES0S
Working Card
Fuel Oil Feed Pump 614-10.00
L/V28/32H

Shut-off fuel oil
Description:
Disassembly, overhaul and assembly of fuel oil

feed pump. Hand tools:
Adjustment of fuel oil pressure.
Allen key, 8 mm, 10 mm, 22 mm.
Starting position: Big screwdriver.
Adjustable spanner.
All pipe connections to the feed pump have been Puller.
reconnected, and the feed pump is removed from Hard brush.
the engine. Gas oil.
Related procedure:

08028-0D/H5250/94.08.12
Man power:
Working time : 4 Hours
Capacity : 1 man 61410 02 1/pump
61410 07 1/pump
Data: 61410 08 4/pump
61410 09 1/pump
Data for pressure and tolerance (Page 600.35) 61410 10 1/pump
Data for torque moment (Page 600.40) 61410 11 1/pump
Declaration of weight (Page 600.45) 61410 12 1/pump
91.45 - ES0S
614-10.00 Fuel Oil Feed Pump Working Card
L/V28/32H
Disassembly. 8) Renew the sealing ring and o-ring in cover

(11), and the rotating packing (9).
1) Remove the coupling part (14), see fig. 1, by
means of a puller. 9) Inspect all other parts for wear and damage,
and renew, if necessary.
2) Disconnect the drain pipe (30).
3) Remove screws (12) and dismount the cover Assembly:

(11) with locking ring, sealing ring, o-ring and rotating
packing (9). 10) Mount the gear wheel (5 and 7), coat the
sealing lip with silastene or similar and mount the
4) After removal of the screws (4) (6 pcs.) the cover (3).
cover (3) is dismantled and the gear wheels (5 and
7) are pulled out. 11) Mount the rotating packing (9) and the cover
(11) with sealing ring, o-ring and locking ring.
5) Dismounting of the spring loaded adjustable
by-pass valve. 12) Connect the drain pipe (30) and mount the
coupling part (14).
Remove the cap nut (21), nut (20), spring housing
(19), spring (18) and the cylinder (23). If the piston 13) Mount the spring loaded by-pass valve, nut
(17) cannot be pulled out from the same side the plug (20), gasket (16), cap nut (21) and plug screw (15).
screw (15) can be removed and the piston can be
pressed from this side with a screw driver or the like. 14) Mount the feed pump on the engine and con-
nect all the pipes.
Overhaul:
Adjusting of Fuel Oil Pressure.
6) Clean all the parts with gas oil and a hard
brush. 15) The outlet pressure of the feed pump, can be
adjusted by means of an adjusting screw in the by-
Warning: Never use a steel brush. pass valve.
The parts are blown clean with working air. Remove the cap nut (21) and loosen the nut (20).
7) If the bearing bush are to be removed the By turning the spring housing clockwise the pressure
existing bearing bush is plugged out, the bores are is raised and reverse the pressure is lowered by
cleaned and new bearing bush is mounted, see fig. turning the spring housing (19) anti-clockwise. When
2. the correct pressure is reached, see page 600.30,
the spring housing (19) is locked with nut (20) and
Before the gear wheels can be mounted the bearing finally the gasket (16) and cap nut (21) are mounted.
bush must be adjusted with a reamer or a bearing
08028-0D/H5250/94.08.12
scraper, so that the gear wheel can run easily when

the pump is assembled.
91.45 - ES0S
Working Card
Fuel Oil Feed Pump 614-10.00
L/V28/32H
5 9
11
4
12
3
14
30
7
Fig. 2. Mounting of bearing bush.
17
19
16
21
15
23
20
18
Fig. 1. Fuel oil feed pump.

08028-0D/H5250/94.08.12
91.45 - ES0S
Plate
Page 1 (2) Fuel Injection Pump - NICO 61401-09H
L+V28/32H
08028-0D/H5250/94.08.12
98.28-EO0
Plate
61401-09H Fuel Injection Pump - NICO Page 2 (2)
L+V28/32H
Item Item
No. No.
01 1/P Case : Delivery valve 29 1/P Snap ring
02 1/P Ring 30 1/P Plug
03 4/P Bolt 31 1/P Gasket
04 1/P Plunger, complete 32 1/P Control rack
05 1/P Back-up ring
06 1/P O-ring
07 1/P O-ring
08 1/P Back-up ring
09 1/P O-ring
10 1/P O-ring
11 1/P Housing, complete
12 2/P Deflector
13 2/P Gasket
14 1/P Bolt
15 1/P Gasket
16 1/P Washer
17 1/P Pointer
18 1/P Nut
19 4/P Bolt
20 1/P Spring : Delivery valve
21 1/P Plug
22 1/P Snap ring
23 1/P Rack stopper
24 1/P Control sleeve
25 4/P Spring seat
26 1/P Spring : Plunger
27 1/P Spring seat
28 1/P Guide : Plunger 08031-0D/H5250/94.09.07

Qty./P = Qty./Pump
98.28-EO0
Plate
Page 1 (2) Fuel Injection Valve - NICO 61402-06H
L+V28/32H
08028-0D/H5250/94.08.12
98.28-EO0
Plate
61402-06H Fuel Injection Valve - NICO Page 2 (2)
L+V28/32H
Item Item
No. No.
01 1/V Injector body
02 2/V O-ring
03 1/V O-ring
04 2/V Dowel pin
05 1/V Atomized, complete
06 1/V Nozzle nut
07 1V Cap nut
08 1/V Nut
09 1/V Adjusting screw
10 1/V O-ring
11 1/V Spring
12 1/V Spindle
08031-0D/H5250/94.09.07

Qty./V = Qty./Valve
98.28-EO0
Plate
Page 1 (2) Fuel Oil Filter Duplex 61403-14H
L+V28/32H
08028-0D/H5250/94.08.12
02.08 - ES0
Plate
61403-14H Fuel Oil Filter Duplex Page 2 (2)
L+V28/32H
Item Item
01 1/E Fuel oil filter duplex, Brændselsoliespalte-

complete filter, komplet
02 2/F Filter element, Filterelement, komplet

complete
03 8/F Nut Møtrik
04 2/F O-ring O-ring
06 2/F Plug screw Propskrue
08 2/F Drain cock, Aftapningshane,

complete komplet
10 1/F Fixing screw Fastspændingsskrue
11 2/F Disc Skive
13 2/F Counter nut Omløbsmøtrik
14 2/F Sealing screw Tætningsskrue
15 2/F Handle Håndtag
16 2/F Split pin Split
17 2/F Washer Skive
18 2/F Nut Møtrik
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine. Qty./E = Qty./Engine.
Qty./F = Qty./Filter Qty./F = Qty./Filter.
02.08 - ES0
Plate
Page 1 (2) Fuel Injection Pipe 61404-06H
L/V28/32H
01
02
03
04 07
05 03
06
08
09
10
11
05
06
91.40 - ES0S
Plate
61404-06H Fuel Injection Pipe Page 2 (2)
L/V28/32H
Item Item
01 1/C Fuel oil high- Højtryksrør,

pressure pipe, komplet
complete
02 1/H Screwed socket Gevinmuffe
03 2/H O-ring O-ring
05 2/H Sleeve devided Bøsning 2-delt
06 2/H Round wire exp. Låsefjeder

ring
07 1/H Sleeve Styrebøsning
09 2/H Screw Skrue
10 1/H Flange Flange
11 1/H Sealing ring Tætningsring
Item Nos. marked with * are only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./H = Qty./High pressure pipe. Qty./H = Qty./Højtryksrør.
Qty./C = Qty./Cylinder. Qty./C = Qty./Cylinder.
91.40 - ES0S
Plate
Page 1 (2) Fuel Oil Feed Pump 61410-15H
L28/32H
01 08
02 09
03 10
04 11
12
13
14
15
16
17
18
19
33
05 20
06 21
07
22
25
26
27
23 23
24
28
29
30
31
32
98.13 - ES0S
Plate
61410-15H Fuel Oil Feed Pump Page 2 (2)
L28/32H
Item Item
01 1/P Housing Hus 31 1/P Spring Fjeder
02 1/P Gear wheel Tandhjul 32 2/P Guide pin Styrestift
03 6/P Screw Skrue 33 1/P Washer Skive
04 1/P End cover Endedæksel
05 2/P Plug screw Propskrue
06 2/P Gasket Pakning
07 1/P Gear wheel Tandhjul
08 4/P Bush Foring
09 1/P Rotating sealing Roterende pakning
11 1/P O-ring O-ring
12 1/P Sealing ring Tætningsring
13 4/P Screw Skrue
14 1/P Circlip Sikringsring
15 1/P Key Feder
16 1/P Coupling, complete Kobling, komplet
17 1/P Cover Dæksel
18 1/P Union Forskruning
19 1/P Pipe Rør
20 1/P Union Forskruning
22 1/E Pump, complete Pumpe, komplet
25 1/P Plunger Stempel
26 6/P Screw for mounting Skrue for montering
27 1/P Spring housing Fjederhus
28 1/P Cap nut Kapselmøtrik
29 1/P Cylinder Cylinder
30 1/P Nut Møtrik
Qty./P = Qty./Pump. Qty./P = Qty./Pumpe.
Qty./E = Qty./Engine. Qty./E = Qty./Motor
98.13 - ES0S
Plate
Page 1 (2) Filter 61445-01H
L+V28/32H
95.03 - ES0S
Plate
61445-01H Filter Page 2 (2)
L+V28/32H
Item Item
01 1/E Filter, complete Filter, komplet
02 1/E Filter cartridge Filter element
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
95.03 - ES0S
Index
Page 1 (1) Lubricating Oil System 615S
L28/32H
Description
Internal Lubricating Oil System ................................................................................... 615.01(21H)

Lubricating Oil Cooler .................................................................................................. 615.06(02H)
Centrifugal By-Pass Filter ............................................................................................ 615.15(05H)
Working Card
Lubricating Oil Pump .............................................................................................. 615-01.00(01H)

Prelubricating Pump ............................................................................................... 615-01.05(02H)
Prelubrication Pump(Imo pimp) ............................................................................S615-01.05(02H)
Lubricating Oil Filter ............................................................................................... 615-01.10(01H)
Lubricating Oil, Thermostatic Valve ....................................................................... 615-01.20(01H)
Checking o Lubricating System .............................................................................. 615-01.90(01H)
Lub oil Cooler ......................................................................................................... 615-06.00(02H)
Centrifugal Bypass Filter ........................................................................................ 615-15.00(01H)
Plates
Lubricating Oil Pump(Gear driven) ................................................................................ 61501-11H

Lubricating Oil Pump(Central driven) ............................................................................ 61501-12H
Lubricating Oil Filter(Type A) ......................................................................................... 61502-11H
Lubricating Oil Filter(Type B) ......................................................................................... 61502-12H
Lubricating Oil Filter(Suppl.for Plate61502-11H/12H) ................................................... 61502-15H
Lubricating Oil Thermostatic Valve(Amot) ..................................................................... 61503-08H
Prelubricating Pump with EL-Motor ............................................................................... 61504-04H
Prelubricating Pump with EL-Motor(IMO) ................................................................... S61504-04H
Lubricating Oil Cooler .................................................................................................... 61506-02H
Lubricating Oil Cooler(combine) .................................................................................... 61506-03H
Centrifugal By-Pass Filter .............................................................................................. 61515-08H
Hand Wing Pump .......................................................................................................... 61525-02H
Lubricating Oil Separator ............................................................................................... 61530-01H
Lubricating Oil Pipes in Engine ..................................................................................... 61530-02H
08028-0D/H5250/94.08.12
94.47-ES0U
Description 615.01
Page 1 (3) Internal Lubricating Oil System Edition 21H
L28/32H
C16 C3
Pre. lub. oil

inlet TC
Filter
Oil vapour
Eng. driven lub. discharge
oil pump Magnetic To main C13
filter bearing Governor
To pump drive To piston drive
Cyl. 1 To camshaft
drive
Sealing
oil To rocker arms
Lub oil cooler
Boring in
camshaft
To roller guide
To camshaft bearing
El-driven
C4
pre.lub.
oil pump
Fig. 1. Diagram for Internal Lubricating Oil System
General
The lubricating oil system is based on wet sump 3 - Camshaft drive

lubrication. All moving parts of the engine are 4 - Governor drive
lubricated with oil circulating under pressure in a
closed built-on system. 5 - Rocker arms
6 - Camshaft
The lubricating oil is furthermore used for the pur-
pose of cooling the pistons.
ad 1) For priming and during operation, the turbo-
charger is connected to the lub. oil circuit of the
engine, the oil serves for bearing lubrication.
System Flow
The inlet line to the turbocharger is equipped with a
The lubricating oil pump draws oil from the oil sump
fixed throttle in order to adjust the oil flow and a non-
08028-0D/H5250/94.08.12
and presses the oil through the cooler and filter to the
return valve to prevent draining during stand-still.
main lubricating oil pipe, from where the oil is
distributed to the individual lubricating points. From
The non-return valve has back-pressure function
the lubricating points the oil returns by gravity to the
requiring a pressure slightly above the priming
oil sump.
pressure to open in normal flow direction. In this way
overflooding of the turbocharger is prevented during
The main groups of components to be lubricated are:
stand-still periods, where the prelubricating pump is
running.
1 - Turbocharger
2 - Main bearings, big-end bearing ect. ad 2) Lubricating oil for the main bearings is
supplied through holes drilled in the engine frame.
92.25 - ES2S
615.01 Internal Lubricating Oil System Description
Page 2 (3)
Edition 21H
L28/32H
From the main bearings it passes through bores in driven prelub. pump mounted parallel to the main
the crankshaft to the connecting rod big-end bea- pump. The pump must be arranged for automatic
rings. operation, ensuring stand-still of the prelubricating
pump when the engine is running, and running dur-
The connecting rods have bored channels for supply ing engine stand-still in stand-by position.
of oil from the big-end bearings to the small-end
bearings, which has an inner circumferential groove, Running period of the prelubricating pump is
and a pocket for distribution of oil in the bush itself preferably to be continuous. If intermittent running is
and for supply of oil to the pin bosses and the piston required for energy saving purpose, the timing
cooling through holes and channels in the piston pin. equipment should be set for shortest possible
intervals, say 2 minutes of running, 10 minures of
From the front main bearings channels are bored in stand-still, etc. Further, it is recommended that the
the crankshaft for lubricating of the pump drive. prelub. pump is led from the emergency switch board
thus securing that the engine is not started without
ad 3) The lubricating oil pipes, for the camshaft prelubrication.
drive gear wheels, are equipped with nozzles which
are adjusted to apply the oil at the points where the
gear wheels are in mesh. Lubricating Oil Filter
ad 4) The lubricating oil pipe, and the gear wheels The lubricating oil filter is a double filter which is
for the governor drive are adjusted to apply the oil at generally used with only one filter chamber being in
the points where the gear wheels are in mesh. operation, the other filter chamber being stand-by.
ad 5) The lubricating oil to the rocker arms is led If the filter chamber in operation needs to be serviced,
through pipes to each cylinder head. It continues the operation can be switched to the other filter
through bores in the cylinder head and rocker arm chamber without any interruption in lubricating oil
to the movable parts to be lubricated at rocker arms supply to the engine.
and valve bridge. Further, lub. oil is led to the
movable parts in need of lubrication. Servicing is generally restricted to replacing of the
paper cartridges, cleaning of the radial mesh insert
ad 6) Through a bore in the frame lub. oil is led to and inspection of sealings, the latter to be replaced
the first camshaft bearing and through bores in the if damages observed.
camshaft from where it is distributed to the other
camshaft bearings. Each filter chamber is equipped with 1 or 2 replaceable
paper cartridges of fineness 10-15 microns.
Lubricating Oil Pump In the centre of each filter chamber a filter basket
(central element) is situated. This filter basket is
The lubricating oil pump, which is of the gear wheel acting as a safety filter, having a fineness of about
type, is mounted on the front end of the engine and 60 microns.
08028-0D/H5250/94.08.12
is driven by means of the crankshaft through a

coupling or a gear wheel. During operation an increased pressure drop across
the filter will be observed as dirt particles will deposit
The pressure regulator forms part of the lubricating on the filtration surfaces of the paper cartridges and
oil pump. Adjustment of the oil pressure is done by thus increase the flow resistance through the filter.
removing the cap nut and turning the adjusting screw
until reading the pressure stated in section 600. If the pressure drop across the filter exceeds 2.0 bar,
a release valve will open and by-pass the 10-15
Operating of Pre-lubricating Pump
As standard the engine is equipped with an electric-
92.25 - ES2S
Description
Internal Lubricating Oil System 615.01
L28/32H
microns filter element, and the engine will run with the warming up period, the oil is by-passing the
only the 60 microns safety filter. cooler. When the oil from the engine reaches the
normal temperature (see section 600) a controlled
To ensure safe filtering of the lubricating oil, none of amount af oil passes through the cooler.
the by-pass valves must open during normal service
and the elements should be replaced at a pressure The thermostatic elements must be replaced if the
drop across the filter of 1.5 bar. temperature during normal operation deviates
essential from the one stated in the test report.
Servicing is essential the exchange of the paper
cartridges. The valve cannot be set or adjusted, and it requires
no maintenance.
When exchanging cartridges, it is advisable to
release any old oil remaining in the filter housing by
means of the drain plug provided for this purpose,
and to wipe out the housing with a cloth.
The filter chambers can be serviced successively

during operation or when the engine is at standstill.
A
It is essential to follow the instructions in work card

615-01.10 closely when replacing filter cartridges.
Filter cartridges must under no circumstances be

cleaned and used again.
Thermostatic Valve C B
The thermostatic valve is designed as a T-piece with

the inlet in the cover (A) under which the thermostatic
elements are located.
The outlet to the engine (by-passing cooler) is Fig. 1. Thermostatic Valve

marked (B) and outlet to the cooler is marked (C). In
08028-0D/H5250/94.08.12
92.25 - ES2S
Description
Lubricating Oil Cooler 615.06
Page 1 (1)
Edition 02H
General
Principle of the Plate Heat Exchanger Plates
The built-on lubricating oil cooler is a plate heat After clamping of the plate pack, the plates - which
exchanger. are fitted gaskets - ensure an effective seal between
fluids and atmosphere. In addition, intermixing of the
The plate heat exchanger consist of a number of cold fluids is eliminated by a double gasket seal around
pressed plates which are compressed between a the inlet ports.
fixed port (head) and the mobile part (follow) by
means of tie bolts. Every second plate is turned through 180°. This
means that the double gasket seal occurs around
The plates are made with special corrugations, every second inlet to the channels between the
which ensures turbolent flow and high heat transfer plates.
cofficients.
The plate pack now forms a series of parallel flow
channels in which the fluids flow in a counter current
regime.
08028-0D/H5250/94.08.12
91.14 - ES0U
Working Card
Lubricating Oil Pump, Engine Driven 615-01.00
L/V28/32H

Shut-off fuel oil
Description:
Disassembly, overhaul and assembly of lubrica-

ting oil pump, engine driven.
Adjusment of lub. oil pressure. Hand tools:

Starting position: Ring and open end spanner, 46 mm.
(Socket spanner, 46 mm).
All pipe connections to the lub. oil pump have Allen key, 8 mm, 4 mm.
been reconnected, and the lub. oil pump is re- Plier for locking ring.
moved from the engine. Soft hammer.
Big screw driver.
Adjustable spanner.
Puller.
Related procedure: Silastene or similar.
Hard brush.
Man power:
08028-0D/H5250/94.08.12
Working time : 6-8 Hours Replacement and wearing parts:

Capacity : 1 man
Data: 61501 04 1/pump

61501 06 5/pump
Data for pressure and tolerance (Page 600.35) 61501 32 1/pump
91.45 - ES0S
615-01.00 Lubricating Oil Pump, Engine Driven Working Card
L/V28/32H
Disassembly: Before the gear wheels (7 and 8) can be mounted the

bearing bush must be adjusted with a reamer or a
1) Remove the coupling part or gear wheel (1), bearing scraper, so that the gear wheel can run
see fig. 2, by means of a puller or a soft hammer. easily when the pump is assembled.
2) Remove screws (2) and dismount the cover 8) Inspect all other parts for wear and damage,
(3). and renew, if necessary.
3) Dismount the locking ring (4), screws (5) and

remove the cover (6) with the overspeed device.
4) Remove the gear wheel (7 and 8). 1
15 14
5) Dismounting of the spring loaded adjustable 12
by-pass valve. 13
Remove the cap nut (9), nut (10), spring housing 11

(11), spring (12) and the cylinder (13). If the piston 7 10
(14) cannot be pulled out from the same side, the
plug screw (15) can be removed and the piston can 9
be pressed out from this side with a screw driver or 8
the like.
6
5
4
3
2
Fig. 2.
Assembly:
9) Mount the gear wheel (7 and 8).
Coat the sealing lip with silastene or similar and

Fig. 1. mount the cover (6) with gear wheel and locking ring
(4).
08028-0D/H5250/94.08.12
Overhaul. 10) Mount the cover (3) with gasket.
6) Clean all the parts with gas oil and a hard 11) Mount the gear wheel or coupling part (1).
brush, (never use a steel brush). The parts are blown
clean with working air. For tightening the nut for gear wheel, see page
600.40.
7) If the bearing bush is to be removed the
existing bearing bush is plugged out by means of a 12) Mount the spring loaded by-pass valve, nut
mandrel, the bores are cleaned and new bearing (10) with gasket, cap nut (9) and plug screw (15).
bush is mounted, see fig. 1.
91.45 - ES0S
Working Card
Lubricating Oil Pump, Engine Driven 615-01.00
L/V28/32H
Adjusting of Lub. Oil Pressure. By turning the spring housing clockwise the pressure
is raised and reverse the pressure is lowered by
13) The outlet pressure of the lub. oil pump, can be turning the spring housing (11) anti-clockwise. When
adjusted by means of a adjusting screw in the by- the correct pressure is reached , see page 600.30,
pass valve. the spring housing (11) is locked with nut (10) and
finally the gasket and cap nut (9) are mounted.
Remove the cap nut (9) and loosen the nut (10).
08028-0D/H5250/94.08.12
91.45 - ESoS
Working Card
Prelubricating Pump 615-01.05
General

Shut-off cooling water Wheel puller for bearing bush.
Shut-off fuel oil Compressed pin.
Shut-off cooling oil Protection cover for shaft seal.
Stopped lub. oil circul. Compressed pin for shaft seal.
(The special tools must be ordered separately

from MAN B&W Diesel A/S, Holeby)
Description:
Dismounting, replacement of the rotary shaft

seal and assembly of prelubricating pump.
Hand tools:
Bench vice.
Spanner.
Starting position: Torque spanner.
Plier for lock ring.
Soft hammer.
Related procedure:
08028-0D/H5250/94.08.12
Man power:
Working time : 2-3 Hours
Capacity : 1 man Plate no. Item no. Qty. /
Data: See plate 61504.

92.26 - ES0S
615-01.05 Prelubricating Pump Working Card
General
Overhauls. We advise not to change the bearing bushes. In

connectin with damages on the bearings it is normal
Overhauls for the purpose of avoiding functional that also the shafts and the parts in the gear box will
trouble are not normally necessary for the prelubri- be damaged.
cating pumps, when properly used, there is very little
wear on the pump gear shaft. When ordering spare parts, do not forget to state the
factory no. of the pump.
Spare Parts.
Replacement of mechanical seal.
Before any overhaul is done, please note the following:
1) Disconnect the cable and pipe connection to
If a pump gets unusable by wear, it must be replaced. the pump.
Installation of spare parts cannot bring it back to
normal condition. 2) Remove the pump from the engine base frame.
It pays to keep extra pumps in stock or to have 3) Separate the pump and the el-motor.
repairs (overhauls) carried out at our repair shop.
4) Remove the coupling part and key (12), see
The shaft seal needs only to be replaced in case of fig. 1, from the driving gear shaft (4).
leakage or after dismounting of drive shaft. The
marks from the seal do not necessarily mean that the 5) Tighten the pump to the flange. Pressure
sealing is defective, but there is a risk of leakage control valve (3) upwards.
after replacement of sealing.
6) Loosen screws (9) and take off the pressure
control valve (3).
12 11 16 01 04 02 03 09
08028-0D/H5250/94.08.12
Fig. 1. Prelubricating Pump.
92.26 - ES0S
Working Card
General
7) Take off the gear box (2), if necessary use a Mounting.
soft hammer for separation.
13) The mounting process follows in reverse order,
8) Remove the gear wheels from the cover (1). it is stressed that an exact cleaning works is
Dismounting is only possible by disturbing the rotor necessary.
shaft seal and by breaking the bearing bush.
Especially the sealing faces must be clean.
9) Remove the security ring (11) and take off the
rotary shaft seal (16). Tightening of screw pos. (9):
10) Press out the driving gear shaft bearing bush, R25 10 Nm
pull out the running bearing bush with the inner wheel R35 50 Nm
puller.
In connection with the bearing bush, attention must
11) Gear box (2). Dismounting is only possible by be paid to the placement of the butt joint and the
damaging the shaft bush. Press out the shaft bushes. mounting depth.
12) Pressure control valve (3). The pressure control The new shaft seal cannot be pressed into the
valve can be dismounted also without dismounting protection cover before exact mounting of the pump.
the pump.
O-ring must be changed.
08028-0D/H5250/94.08.12
92.26 - ES0S
Working Card
General

Shut-off fuel oil
Press Blocking - Reset
Dismantling, replacement of the mechanical and Ring and open end spanner, 13 mm.
assembly of prelubricating pump. Ring and open end spanner, 15 mm.
Adjustable spanner.
Screw driver.
Starting position: Lubricating light oil and grease.
Vessels for cleaning.
Related procedure:

Man power:
08028-0D/H5250/94.08.12

Working time : 2-3 hours
Capacity : 1 man See plate 61504
Data:

98.47-ES0
General
Periodic Overhauls 2) Shut off the suction to the pump and block
the electric motor starting button.
Periodic overhauls for the purpose of avoiding
functional trouble are not normally necessary 3) Loosen the screws which hold the motor
for the prelubricating pumps. When properly and pump together and life away the
used, there is very little wear on the pump motor.
screws.
4) Remove the front end cover of the pump
If oils and other liquids with abrasive properties (1). Do not damage the joint (2) between
are pumped periodic overhauls may front end cover and pump body.
nevertheless be carried out so that won parts
can be replaced in good time. The intevals 5) Press the stationary seal with o-ring (27
between such overhauls are determined by and 23) see fig. 2, out of the front cover.
experience in each individual case.
Impurities in the pumped liquid or careless

handling during dismantling and reassembly
can result in damage to the lapped sealing
surfaces. Dismantling and reassembling the
seal should therefore be carried out in
conditions of scrupulous cleanliness and
carefulness and every effort must be made to
avoid touching the sealing surfaces with the
fingers. The carbon ring must be carefully
handled.
Warning : It must not get id torch with grease.
Dismantling
Fig 2. Shaft seal
1) Turn the motor, using the fan beneath the
fan casing, until the set screw (20) see
fig.1, which locks the pump shaft to the 6) Remove the power rotor (17) fig. 1, from
motor shaft is accessible in one of the the pump body. If only the seal is to be
inspection holes in the pump body back off replaced, the idlers can remain in the
the stop screw all the way. pump body.
7) Remove the rotary seal ring (24) fig.1.
8) Press the rotating seal (18) out of the

08031-0D/H5250/94.09.07
power rotor (17). Due to rubber bellows

(25) fig. 2, the necessary press-off power
may be comparatively big.
Fig 1. Prelubricatig pump.
98.47-ES0
Working Card
General
Reassembly
The fit of the rotary seal on the pump shaft is

rather hard. To prevent damage of the bellows
(25) it is advisable to clean the pump shaft
from possible coaling like particles of coke
from oil etc.
Polish the pump shaft by means of an emery

or cleaning cloth to get a smooth finish. This Fig 3.
preparation facilitates the mounting of the
rotary seal. 17) The power rotor shall be forced up on the
motor shaft by means of a screw drivel put
The reassembly will take place in reverse into the groove of the power rotor shaft,
order: see fig. 3. Thereafter screw the set screw
(20) firmly against the motor shaft. This is
9) After cleaning wipe the shaft over with light necessary to ensure a correct play of the
oil (not grease). Press the rotating seal idler rotors.
(18) with removed rotary seal ring (24)
onto the rotor shaft. 18) Check that the pump rotates freely when
the motor is rotated by hand.
10) Check that the bellows are pressed
against the locating ring of the spring. Open the valves in the pipe lines and
Keep the seal pressed in that position for re-establish the electric supply to the motor.
half a minute until the bellow stick. Proceed in accordance with the instructions
“Starting-up”.
11) Mount the rotary seal ring (24) with its
smaller surface turning upwards, taking Note: Do not jet the pump run for more than
care that the grooves in the seal ring are in one minute without working.
line with the dimples of the retaining
sleeve.
Maintenance
12) Insert the power rotor in the pump casing
(3). The seal is self-adjusting and requires no
subse-quent tightening.
13) Wipe over the outside of the stationary
seat with its o-ring gasket (27 and 23) with If copious leakage occurs, this is the usual sign
light oil and press the seat into the front of wear, which may be due to such causes as
cover. incautious starting, dirty oil, poor alignment or
running without oil.
14) Mount the front cover (1) to the pump
08028-0D/H5250/94.08.12
casing (3) making sure not to forget the

joint (2) which seal between the pump Starting
casing and the front cover.
Starting should always take place with fully
15) Screw the set screw (20) into the power open valves in the suction and delivery lines.
rotor far enough to be guided into the
keyway in the motor shaft. As the prelubricating pump is self-priming it
carries off the air in the suction line and the
16) Mount the electric motor on the pump so noise reveals when the pump begins to work. It
that the set screw (20) enters the is essential for the air to be led off without any
motor-shaftkeyway. Tighten the screws appreciable counter pressure in the delivery
joining pump and motor flanges. line.
98.47-ES0
General
As soon as the pump has started to work Direction rotation

normally, the by-pass valve must be set by
means of a pressure gauge at the required When the pump is ready to be started, check
pressure. that the dive motor rotates in the correct
direction as indicated on the pump by briefly
Set the by-pass valve, with the screw (10) fig switching it on and by watching the fan impeller
1, on the end cover of the pump body. Turning of the electric motor.
to the right increases the opening pressure. Do
not set the valve at pressures higher than Note: Do not check the direction of rotation
necessary. without prior filling the pump with oil.
This pressure setting should be maintained

while the pump is in operation.
If the pump refuses to work properly after

having been started, it must not be allowed to
run for more than about half a minute. Fresh
attempts to make the pump go may be made
at intervals of about a minute and in
conjunction with these attempts the bypass
valve tension should be increased slightly. If
thes does not help, something must be wrong
and the fault must be located and remedied
before the pump is put into operation.
08031-0D/H5250/94.09.07
98.47-ES0
Working Card
Lubricating Oil Filter 615-01.10
General

Shut-off fuel oil
Description:
Replacement of paper filter element(s).

Cleaning of safety filter and filter housing. Hand tools:

Starting position: Adjustable spanner.
Related procedure:
08028-0D/H5250/94.08.12

Capacity : 1 man
61502 01 See plate 61502
Data: 61502 28 1/Filter.

91.45 - ES0S
Edition 01H
Lubricating Oil Filter Page 2 (3)
General
The lubricating oil filter is dimensioned so that each
of the two filter parts has sufficent capacity to treat 4) Filter housing cap is dismantled.
the amount of lubricating oil delivered by the pump.
5) Remove the inner safety element. Clean the
The three-way valve positioned is determining element with detergent. Check that it is intact.
whether the left hand or the right hand filter chamber
is in operation, and also gives the possibility of 6) Remove the outer element(s). Filter element is
having both filter chambers in operation of disposable type. It change always to new original
simultaneously. filter.
The three-way valve is marked with flow directions 7) Clean the filter housing and the cap. Be careful
and the figure indicates the operation modes accor- of not to let the oil from the dirty side to go into the
ding to valve positions. clean oil channel in the middle of bottom.
Three-way valve positions 5 6 5
Left hand filter Right hand filter

camber in operation. camber in operation.
8 1 2 8
7
4
Both filter camber in 3

operation.
1 Left hand filter camber 2 Right hand filter chamber

Fig. 1. Three-way valve positions. 3 Inlet 4 Outlet
5 Vent screw 6 Three-way valve/
switch valve
7 Fill-up valve 8 Drain plug
08028-0D/H5250/94.08.12
Service Procedure.
1) Turn the three-way valve, see fig. 2, into the

Fig. 2.
position setting the stand-by filter chamber in opera-
tion and the filter chamber requiring service out of
operation.
2) Open the vent screw (5) on the top of the filter 8) Check the seal on the bottom of the filter
to get the pressure out of the filter half. housing and in the cap. Change if needed.
3) Open the drain plug (8) under the filter housing 9) Assemble the filter in opposite order.
and drain off oil.
91.45 - ES0S
Working Card
Lubricating Oil Filter 615-01.10
General
10) Let the air valve be open and fill the filter
Fill-up valve positions
housing with oil by means of the slow fill-up valve (7)
in position FILL, see fig. 3. This valve is inside the
Operation Changing over three-way valve and by using it, the filling can be
made so slowly that the pressure on the other part of
the filter does not drop too much.
11) Close the vent screw (5) after the housing is

filled up with oil.
Switch in normal Switch in fill 12) Open the three-way valve (6) and close the fill-
operation position position up valve (7) by turning it to position CLOSED, see fig.
3.
13) The filter just serviced is now ready to be set in

Fig. 3. Fill-up valve position. operation.
Inspect for oil leakages in order to ascertain all

sealings to be tight.
Check that pressure drop across filter is correct.
Clean the other side of the filter correspondingly.

08028-0D/H5250/94.08.12
91.45 - ES0S
Working Card
Lubricating Oil, Thermostatic Valve 615-01.20
General
Stopped engine Plate No. Item No. Note.

Shut-off fuel oil
Description:
Inspection of thermostatic valve and replacement

of elements. Hand tools:

Copaslip
Tools and cleaning preparation for cleaning.
Starting position:
Lubricating oil drained from engine (if necessary).
Related procedure:
Man power:
08028-0D/H5250/94.08.12

Capacity : 1 Man Replacement and wearing parts:
Data: Plate No. Item No. Qty./
Data for pressure and tolerance (Page 600.35) 61503 03 1/engine

Data for torque moment (Page 600.40) 61503 05 2 or 4/engine
Declaration of weight (Page 600.45) 61503 09 3/engine
92.05 - ES0S
615-01.20 Lubricating Oil, Thermostatic Valve Working Card
General
The thermostatic valve cannot be adjusted and Replacement of elements:

under normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements in the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part of the housing.
1 3) Remove the assembled elements (3) and the

2 elements O-ring sealing.
3
4) Remove the gaskets between the upper and
5 lower part of the housing.
4 5) The upper and lower part of the housing are

thoroughly cleaned inside and on the gasket surfaces.
6) The sealing rings (4) for the elements in the

housing are replaced and lubricated with a thin layer
of copaslip.
7) Remount the assembled elements in the

housing by wriggling these somewhat over side.
8) Upper and lower part of the housing are

assembled with a new gasket (5), the nuts (1) are
mounted and tightened "cross-wise".
1. Nut Note:
2. Washer
3. Element After inspection or replacement of the elements the
4. O-rings sealing lub. oil temperature is checked to ensure that the
5. Gasket elements are working correctly.
Fig. 1 Thermostatic valve

08028-0D/H5250/94.08.12
92.05 - ES0S
Working Card
Check of Lubricating Oil Piping System 615-01.90
General

Shut-off fuel oil
Description:
Check and examination of the lubricating oil

piping system. Hand tools:
Starting position:
Engine running.
Related procedure:
08028-0D/H5250/94.08.12
Working time : ½ hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

92.04 - ES0U
615-01.90 Check of Lubricating Oil Piping System Working Card
General
Checks to be carried out. 4) Blow-through drain pipes.
1) Examine the piping system for leaks. 5) Check flexible connections for leaks and damages.
2) Retighten all bolts and nuts in the piping system. 6) Check manometers and thermometers for
possible damages.
3) Move all valves and cocks in the piping system. For lubricating oil condition, see section 604.
08028-0D/H5250/94.08.12
92.04 - ES0U
Working Card
Lubricating Oil Cooler 615-06.00
L+V28/32H

Shut-off fuel oil
Description:
Separation, cleaning and assembling.

Replacement of plates and gaskets. Hand tools:

Starting position: Adjustable spanner
Cooling water and lub. oil have been drained from

cooler/engine. All pipes are disconnected.
Related procedure:
Manpower:
08028-0D/H5250/94.08.12
Working time : 4 hours Replacement and wearing parts:

Capacity : 1 man
Plate No Item No Qty./
Data:
61506 09 4/cooler
96.26 - ES0S
615-06.00 Lubricating Oil Cooler Working Card
L+V28/32H
Introduction
Manual Cleaning
Cleaning of the cooler has to take place, when the
pressure drop on the oil and water side is larger than Clean the plates with a soft brush and a suitable
allowable and/or if the oil cannot be sufficiently detergent. In case of dense coating of scale or
cooled. organic materials, the plates must be put in a bath of
detergent.
Separation Note: Never use a steel brush, metal scraper or the

like.
Cooling and Pressure Relief
A high-pressure cleaner can be used with care,
Before opening the plate heat exchanger, it has to be however, never with sand or other abrasives added.
cooled down to below 40o C and be without pressure!
The cooling must not exceed 10o C per minute. Detergents

The pressure drop must not exceed 10 bar per
minute. A detergent is suitable, if it will remove any coating
on the plates without causing any damage to plates
Note: If these norms are exceeded, the guarantee and gaskets.
will cease to be valid.
Note: It is of great importance that decomposition of
the protective film on the stainless steel does
Separation of Edge-clamped Frame not take place - the film preserves the corro-
sion resistancy of the steel.
Upon completion of the procedure “Cooling and
Pressure Relief”, separate the frame by retaining Do not use chlorine-containing agents such
two or four diagonally placed bolts. as hydrochloricacid (HCI)!
Note: Take care that the movable cover does not tilt! Oil and fats are removed by using a water emulsi-
fying oil solvent, e.g. BP-system cleaner.
Loosen all bolts uniformly and diagonally (max. 10
mm at a time), then push the movable cover towards Organic and greasy coatings are removed by using
the pillar. When the pressure plate is not tight any- sodium hydroxide (NaOH):
more, the plates can be removed.
- max. concentration 1.5%
Note: When using plate heat exchangers on board (1.5% concentration corresponds to 3.75 l
ships, the movable covers have to be secured 30% NaOH per 100 l water).
in order to avoid danger due to the move- - max. temperature 85o C.
ments of the ship.
08028-0D/H5250/94.08.12
Stone and lime/calcareous deposits are removed by

using nitric acid (HNO3):
Cleaning
- max. concentration 1.5%
The capacity and corrosion resistance of the plate (1.5% concentration corresponds to 1.75 l
heat exchangers depend on the purity of the plates. 62% HNO3 per 100 l water).
Any coating on the plates can be removed manually. - max. temperature 65o C.
Note: The nitric acid has an important constructive

effect on the protective film of stainless steel.
96.26 - ES0S
Working Card
Lubricating Oil Cooler 615-06.00
L+V28/32H
Control of Cleaning Fluid Concentrations Replacement of Glued Gaskets
Sodium hydroxide (NaOH) solution is tritrated with On Plate 61506 are stated gasket and glue quantity.
0.1 n hydro-chloric acid (HCI) with methyl orange or
methyl red as indicator. Please use a degreasing agent on the new gaskets.
Nitric acid (HNO3) solution is titrated with 0.1 n The first plate after the end cover and the connector
sodium hydroxide (NaOH) with phenolphtalin as grid must have gaskets in all grooves. The gaskets
indicator. are to be cut according to the existing gaskets.
The concentration of the cleaning fluid in % can be Loosen the glued gaskets by heating the plate in
calculated from the titration result by means of the water at 100o C. Clean the plates and remove the
following formula: coatings, if any.
Concentration = bxnxm %
a x 10 Cleaning of New Gaskets and Plates
a : ml cleaning fluid taken out for titration New gaskets and gasket grooves of the plates are
b : ml titration fluid used as cover cleaned with a cloth moistened with degreasing
n : the molecular concentration of titration fluid agent. The glue surfaces must be absolutely clean
m : The molecular weight of the cleaning fluid - without finger prints etc.
(NaOH) molecular weight 40, HNO3 molecu-
lar weight 63) Please use our cleaning fluid, which is according to
suppliers recommendations.
Replacement of Plates and Gaskets Alternatively, please use:
Marking - Trichloroethylene
- Chlorothene VG
The plates are marked with material codes and - Acetone
reference numbers at each end, plus codes for non- - Methyl ethyl ketone
glue gaskets, if any, and stamped with the letter V - Ethylacetat
and H at either end (Fig 1).
It is important that all degreasing agent has evapo-
Looking towards the gasket side, the plate is desig- rated, before the glue is applied. This will normally
nated as a left plate, when the letter V is turning take approx. 15 min. at 20o C.
upwards - and a right plate when the letter H is
turning upwards. Inlets and outlets of the V-plates Clean the new gaskets on the glue surfaces with
are taking place through the corner holes Nos 1 and fine-grain sandpaper instead of the degreasing agent
4. Inlets and outlets of the H-plates are taking place supplied.
08028-0D/H5250/94.08.12
through the corner holes Nos 2 and 3.
Gluing
Replacement of Plates
Pliobond 25, which is a nitrile rubber glue on solvent
Before mounting a spare plate in the plate stack, basis (25% solids). The glue is applied with a brush
please make sure that the spare plate is identical in a thin layer on the backs of the gaskets and the
with the defective plate. gaskets are to dry in a clean place free of dust.
Note: The same corner holes must be open and the Apply a thin layer of glue on the gasket grooves of the
letters V and H must be placed correctly. plates and press the gaskets down into the gasket
grooves.
96.26 - ES0S
615-06.00 Lubricating Oil Cooler Working Card
L+V28/32H
The insertion of gaskets starts at both ends of the The fixed cover has number 1 and the serial num-
plate - and continues with the straight sections along bers for the subsequent plates and intermediate
the edges. frames, if any, have the numbers 2, 3, 4, 5 etc.
The gluing process is most easily effected by placing The serial number are stamped in the right top corner
the gaskets and the plates on a table. After having of the plates. Further, please note that the gasket
pressed the gaskets into the grooves of a plate, it is side must face the fixed cover.
stacked.
The plates with the gaskets are now mounted in the Fastening
frame which is lightly clamped. In case of use of
rubber grooves, they are assembled to the minimum Fasten the plate heat exchanger until the movable
measure stated on the engine sign plus 0.2 mm per cover touches the duct spacers.
plate.
Heat up the plate heat exchanger to 90-100°C by

means of water or steam.
Please note:
- The temperature must be kept for 1½-2 hours.

- The liquid pressure must be kept as low as
possible.
If there is no possibility of heating the plate heat

exchanger, it must be placed in a spot as warm as
possible with dismounted connections.
The drying time will at 20°C be approx. 48 hours. At

for instance 40°C, the drying time is reduced to
approx. 24 hours.
Fig 1.
Assembling
If the plates have been dismounted, they have to be

correctly assembled according to the plate item
numbers.
08028-0D/H5250/94.08.12
96.26 - ES0S
Plate
Page 1 (2) Lubricating Oil Pump (Gear driven) 61501-22H
L28/32H
01
02
20 03
19
24
22
23
22
14
35
06
18
04
07 05
29
25
06
10
08028-0D/H5250/94.08.12
09
28
11
27
12
11
13 26
32 30
33 31
34
02.41 - ES0
Plate
61501-22H Lubricating Oil Pump (Gear driven) Page 2 (2)
L28/32H
Item Item
01 1/P Nut Møtrik 30 1/P Cog wheel Konisk tandhjul
02 1/P Gear wheel Tandhjul 31 1/P Circlip Sikringsring
03 1/P Key Feder 32 1/P Gasket Pakning
04 1/P Gasket Pakning 33 1/P Cover Dæksel
05 1/P Plug screw Propskrue 34 6/P Screw Skrue
06 5/P Bush Bøsning 35 1/E Lub. oil pump, Smøreoliepumpe,

complete komplet
07 1/P Shaft with gear Aksel med tand-
wheel, short hjul, kort
09 1/P Socket Muffe
10 1/P Pin Stift
11 2/P Ball bearing Kugleleje
12 1/P Circlip Sikringsring
13 1/P Cog wheel Konisk tandhjul
14 1/P Piston, Trykregulering -

complete stempel, komplet
15 1/P Piston Stempel
16 1/P Spring Fjeder
17 1/P Cylinder Cylinder
18 2/P Guide pin Styrestift
19 1/P Pump housing Pumpehus
20 6/P Screw Skrue
21 1/P Adjusting screw Justerskrue
23 1/P Nut Møtrik
24 1/P Cap nut Hættemøtrik
25 1/P Shaft with gear Aksel med tand-

08028-0D/H5250/94.08.12
wheel, long hjul, lang
27 10/P Screw Skrue
28 2/P Cylindrical pin Cylindrisk stift
29 1/P Key Feder
02.41 - ES0
Plate
Page 1 (2) Lubricating Oil Filter (Type B) 61502-12H
L+V28/32H
25
27
24
18
29
01 19 06
48
05 + 01 46 04 03 +
19 02
23 07 09 +
28 30 15
35
26
36
17
44
32
31
08028-0D/H5250/94.08.12
45
+ For detaljer se / for details see Plate 61502-15H
94.23 - ES0S
Plate
61502-12H Lubricating Oil Filter (Type B) Page 2 (2)
L+V28/32H
Item Item
01 4/F Paper element Papirelement 45 2/F Drain plug Drænskrue
02 2/F Safety element Sikkerhedselement 46 2/F Spacer ring, complete Afstandsring, komplet
incl. seal inkl. tætning
03 + 1/F Valve housing, incl. Ventilhus, inkl.
item 07 and 30 item 07 og 30 47 1/F Seal kit, not shown on Pakningssæt, ikke vist
the front side of the på forsiden af platen
04 2/F Housing, incl. O-ring Hus, inkl. O-ring plate
05 + 2/F Cap, complete, incl. Dæksel , komplet, inkl. 48 1/E Lub. oil filter, Smøreoliefilter, komplet
item 12, 13, 14, 19 and item 12, 13, 14, 19 og 20 complete
20
06 1/F Spindle, incl. item 8, Spindel, inkl. item 8, 18

18 and 37 og 37
07 2/F Thrust ring Trykring
09 + 2/F By-pass code, incl. By-passventil, inkl. item

item 10, 11, 16, 34 and 10, 11, 16, 34 og 49
49
15 2/F Plug to indicator hole, Propskrue til indikator

incl. O-rings hul, inkl. O-ringe
17 2/F Vent screw, incl. item Luftskrue, inkl. item 31

31 and 32 og 32
18 1/F Fill-up valve Opfyldningsventil
19 8/F Sealing ring Tætningsring
23 12/F Stud Støttetap
24 12/F Screw Skrue
25 4/F Screw Skrue
26 12/F Nut Møtrik
27 4/F Washer Skive
28 12/F Washer Skive
29 12/F Washer Skive
30 5/F Pin Tap
31 6/F Pin Tap

08028-0D/H5250/94.08.12
44 2/F Opening guard, incl. Åbningsbeskyttelses-

vent screw skærm, inkl. luftskrue
Qty./F = Qty./Filter Antal/F = Antal/Filter
94.23 - ES0S
Plate
Page 1 (2) Lubricating Oil Filter (Suppl. for Plate 61502-11H/12H) 61502-15H
L+V28/32H
08
37 61502/03 +
39
38
19
61502/05 +
12
13 16
21 10
31
14
11
20
61502/09 +
49 34
40
08028-0D/H5250/94.08.12
+ se/see Plate 61502-11H (Type A), Plate 61502-12H (Type B)
94.23 - ES0S
Plate
61502-15H Lubricating Oil Filter (Suppl. for Plate 61502-11H/12H) Page 2 (2)
L+V28/32H
Item Item
08 1/F Cap Dæksel
10 2/F By-pass valve seat By-passventilsæde
11 2/F By-pass valve spool By-passvnetilspindel
12 2/F Flange Flange
14 2/F Screw Skrue
16 2/F By-pass valve spring By-passventilfjeder
19 8/F Seal Tætningsring
20 2/F Spring Fjeder
21 2/F Spring Fjeder
31 6/F Pin Stift
08028-0D/H5250/94.08.12
94.23 - ES0S
Plate
Page 1 (2) Lubricating Oil Thermostatic Valve 61503-08H
L28/32H
01
03
04
Note: When ordering new elements, state opening 05

temperature.
Husk! Ved bestilling af nye elementer at angive 06

åbningstemperaturen.
11
07
08
09
10
94.05 - ES0S
Plate
61503-08H Lubricating Oil Thermostatic Valve Page 2 (2)
L28/32H
Item Item
01 4/T Screw Skrue
03 2/T O-ring O-ring
04 2/T Thermostatic Følerelement

element
06 2/T Sleeve Bøsning
07 4/T Washer Skive
08 16/T Nut Møtrik
09 3/T Gasket Pakning
10 12/T Screw Skrue
11 1/E Thermostatic Termostatventil,

valve, complete komplet
Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
94.05 - ES0S
Plate
Page 1 (2) Prelubricating Pump with El-Motor 61504-04H
L28/32H
12 11 16 01 10 05 04 02 20 15 03 09
24
29
26
29
23
30
25
31 21
22
27
28
34 33
94.23 - ES0S
Plate
61504-04H Prelubricating Pump with El-Motor Page 2 (2)
L28/32H
Item Item
01 1/P Driving cover Medbringerdæksel
02 1/P Gear casing Gearhus
03 1/P End cover, complete, Endedæksel, komplet

incl. item 21 to 29 inkl. item 21 til 29
04 1/P Driving gear shaft Drivende gear aksel
05 1/P Gear shaft Gear aksel
09 4/P Screw Skrue
10 2/P Parallel pin Styrestift
11 1/P Retaining ring Sikringsring
12 1/P Parallel key Not
15 2/P O-ring O-ring
16 1/P Rotary shaft seal Roterende aksel tætning
20 1/E Pumpe, complete Pumpe, komplet uden

without El-motor el-motor
22 1/P Piston Stempel
23 1/P Spindle Spindel
24 1/P Dome nut Lukkemøtrik
25 1/P Spring Fjeder
26 1/P Pipe nut Rørmøtrik
27 2/P Screwed plug Propskrue
30 1/P Coupling, complete Kobling, komplet
31 1/E El-motor, complete El-motor, komplet
32 1/E Pre.lub oil pump, Forsmørepumpe,

complete with el- komplet med el-motor
motor
33 1/E Ball bearing, rear Kugleleje, bagside
34 1/E Ball bearing, front Kugleleje, forside
94.23 - ES0S
Plate
Page 1 (2) Lubricating Oil Cooler 61506-02H
L+V28/32H
01
02
04
03
05
Note: When orde-

ring plates, please
state the serial
numbers of the
plates. The serial
numbers of the pla-
tes can be found in
the top right-hand
corner of the pla-
tes. (See Working 06
Card 615-06.00)
Husk! Ved bestil-

ling af plader angi-
ves serienumme-
ret på pladen.
07
Serienummeret er
stemplet i toppen
af pladen til højre. 08
(Se arbejdskort
615-06.00)
15
08028-0E/H5250/94.08.12
09
10
12
14
11
13
16
96.26 - ES0S
Plate
61506-02H Lubricating Oil Cooler Page 2 (2)
L+V28/32H
Item Item
01 4/K Hexagon screw Bolt
02 4/K Washer Skive
03 4/K Washer Skive
04 1/K Pressure plate Trykplade
05 /I Gasket Pakning
06 2/K Guide bar Styrepind
07 4/K Distance piece Afstandsstykke
08 1/K Frame plate Stativplade
09 4/K Gasket Pakning
10 2/K Screw Skrue
11 1/K Glue Lim
12 2/K Guide bar Styrepind

(for dismantling) (for demontering)
13 32/K Screw Skrue
14 1/E Lubricating oi cooler, Smøreoliekøler,

complete komplet
15 /I Plates Plader
16 /I Cleaning fluid Rensevæske
08028-0E/H5250/94.08.12
Qty./K = Qty./Cooler Antal/K = Antal/Køler
Qty./I = Qty./Individual Antal/I = Antal/Individuel
96.26 - ES0S
Plate
Page 1 (2) Lubricating Oil Separator 61530-01H
L28/32H
01
02
04
03
05 06
07
08
09
10
11
18
12
13
14
15
16
17 19
20
21
94.24 - ES0S
Plate
61530-01H Lubricating Oil Separator Page 2 (2)
L28/32H
Item Item
02 1/F Pipe with Rør med

flange flange
03 1/F Breather with Ånderør med

flange flange
05 4/F Screw Skrue
06 8/F Screw Skrue
07 1/F Cover Dæksel
09 1/F Insert for oil Indsats for

separator olieudskiller
10 1/F Housing for Hus for

oil separator olieudskiller
11 4/F Screw Skrue
13 1/F Bend Bøjning
14 4/F Nut Møtrik
15 1/F Oil trap Olielås
16 1/F Union Forskruning
18 1/F Union Forskruning
19 4/F Screw Skrue
20 1/E Oil separator, com- Olieseparator, komplet

plete, consisting of bestående af item 06,
item 06, 07, 08, 09, 07, 08, 09 og 10
and 10
94.24 - ES0S
Plate
Page 1 (2) Lubricating Oil Pipes on Engine 61530-02H
L28/32H
01 08
02 15
03
04
05
10
08
03
08
12
Lub. oil filter 14
03
16
08 02
17 03
05
Thermostatic 03
valve 10
06 08
07 13 A 21
02
08 18 22
06 23
24
21
03
14 04
19
04 08 The piping design may vary from
06 the shown example, but it is of no
14
importance when ordering.
26
Lub. oil cooler 06 27
28
92.04 - ES0S
Plate
61530-02H Lubricating Oil Pipes on Engine Page 2 (2)
L28/32H
Item Item
01 /I Lub. oil distributing Sm. oliefordelingsrør

pipe
02 /I Stud Bolt
03 /I Pakning Pakning
04 /I Lub. oil pipe outlet fil- Sm. olierør afgang filter

ter
05 /I Nut Møtrik
07 /I Lub. oil pipe inlet Sm. olierør tilgang køler

cooler
08 /I Screw Sekskantskrue
12 /I Outlet pump/Inlet Sm. olierør afgang pum-

therm. valve pe/tilgang term. ventil
13 /I Lub. oil pipe inlet filter Sm. olierør tilgang filter
14 /I Stud Bolt
16 /I Lub. oil pipe inlet Sm. olierør tilg. pumpe

pump
17 /I Sm. oliesugerør
Lub. oil suction pipe
18 /I Bolt
Stud
19 /I Sm. olierør afgang køler
Lub. oil pipe outlet
cooler
21 /I Pakning
Gasket
22 /I Kontraventil
Non-return valve
23 /I Rør
Pipe
24 /I Bolt
Stud
26 /I Kugleventil
Ball valve
27 /I Pakning
Gasket
28 /I Propskrue
Plug screw
92.04 - ES0S
Index
Page 1 (1) Cooling Water System 616S
L28/32H
Description
Cooling Water System ................................................................................................. 616.01(17H)

Cooling Water Thermostatic Valve .............................................................................. 616.04(15H)
Working Card
Checking of Cooling Water System ....................................................................... 616-01.90(01H)

Cooling Water, Thermostatic Valve ........................................................................ 616-04.00(01H)
Plates
Fresh Water Thermostatic Valve (Amot) ....................................................................... 61604-07H

High Temperature Fresh Water Pump .......................................................................... 61610-05H
Low Temperature Fresh Water Pump ........................................................................... 61610-07H
Sea Water Pump ........................................................................................................... 61615-04H
Pipe on Cylinder Head ................................................................................................ S61625-04H
Cooling Water Pipes on Engine .................................................................................... 61630-01H
Preheater – Fresh Water ................................................................................................61635-01S
08028-0D/H5250/94.08.12
94.47-ES0U
Description
Cooling Water System 616.01
Page 1 (1)
Edition 17H
General
Description High Temperature Circuit
The cooling water system consists of two separate The high temperature circuit is used for cooling of the
systems the low temperature (LT) and the high cylinder units.
temperature (HT) circuits.
Cooling water is led through a distributing pipe to the
bottom of the cooling water space between the liner
Low Temperature Circuit and the frame of each cylinder unit. The water is led
out through bores in the top of the frame via the
The low temperature circuit is used for cooling of the cooling water guide jacket to the bore.
charge air and the lubricating oil, and the alternator
if the latter is water cooled.
08028-0D/H5250/94.08.12
90.47 - ES0U
Description
Cooling Water Thermostatic Valve 616.04
General
Thermostatic Valve The thermostatic valve cannot be set or adjusted, and

requires no maintenance.
The thermostatic valve in the high temperature circuit
is mainly located imediately after the outlet of the In some plants a corresponding thermostatic valve is
engine, but alternatively in the external cooling sy- installed in the low temperature circuit. The ther-
stem near the fresh water cooler. mostatic elements of this valve have an other tem-
perature range.
The cooling water enters through the cover (A) under
which the thermostatic elements are located.
The number of elements depends on the size of the

A
valve.
The outlet to the suction side of the pump is marked

(B) and outlet to the cooler is marked (C).
In the warming-up period the cooling water is by-

passing the cooler. When the outlet water from the
cylinder heads reaches the normal temperature (75-
85° C) a controlled amount of water passes through C B
the cooler.
The thermostatic elements must be replaced if the

cooling water temperature during normal operation
deviates essentially from the one stated in the test
report. Fig. 1. Thermostatic Valve
91.16 - ES0S
Working Card
Check of Cooling Water System 616-01.90
General

Shut-off fuel oil
Description:
Check of cooling water system.

Hand tools:
Starting position:
Engine is running
Related procedure:
08028-0D/H5250/94.08.12
Working time : ½ hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

92.04 - ES0U
616-01.90 Check of Cooling Water System Working Card
General
Checks to be carried out. 5) Check manometers and thermometers for

possible damages.
1) Examine the piping system for leaks.
6) Check the condition of the uppermost of the two
2) Retighten all bolts and nuts in the piping system. O-rings (which makes up the tightening between the
jacket cooling water space in the frame and the
3) Move all valves and cocks in the piping system. crankcase) by means of the inspection holes in the
Lubricate valve spindles with graphite or similar. engine frame - see also Working Card 606-01.40.
4) Check flexible connections for leaks. For check of the fresh water condition, see section
604.
08028-0D/H5250/94.08.12
92.04 - ES0U
Working Card
Cooling Water, Thermostatic Valve 616-04.00
L+V28/32H

Shut-off fuel oil
Description:
Inspection of thermostatic valve and replacement

of elements. Hand tools:

Copaslip
Tools and cleaning preparation for cleaning.
Starting position:
Cooling water drained from engine (if necessary).
Related procedure:
Man power:

Capacity : 1 Man Replacement and wearing parts:
Data: Plate No. Item No. Qty./
Data for pressure and tolerance (Page 600.35) 61604 03 1/engine

Data for torque moment (Page 600.40) 61604 05 2 or 4/engine
Declaration of weight (Page 600.45) 61604 09 3/engine
94.29 - ES0S-G
616-04.00 Cooling Water, Thermostatic Valve Working Card
L+V28/32H
The thermostatic valve cannot be adjusted and Replacement of elements:

under normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements in the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part of the housing.
1 3) Remove the assembled elements (3) and the

2 elements O-ring sealing.
3
4) Remove the gaskets between the upper and
5 lower part of the housing.
4 5) The upper and lower part of the housing are

thoroughly cleaned inside and on the gasket surfaces.
6) The sealing rings (4) for the elements in the

housing are replaced and lubricated with a thin layer
of copaslip.
7) Remount the assembled elements in the

housing by wriggling these somewhat over side.
8) Upper and lower part of the housing are

assembled with a new gasket (5), the nuts (1) are
mounted and tightened "cross-wise".
1. Nut Note:
2. Washer
3. Element After inspection or replacement of the elements the
4. O-rings sealing cooling water temperature is checked to ensure that
5. Gasket the elements are working correctly.
Fig. 1 Thermostatic valve
94.29 - ES0S-G
Plate
Page 1 (2) Fresh Water Thermostatic Valve 61604-07H
L28/32H
01
03
04
05
Note: When ordering new elements, state opening
temperature.
06
Husk! Ved bestilling af nye elementer at angive
åbningstemperaturen.
11
07
08
09
10
94.06 - ES0S
Plate
61604-07H Fresh Water Thermostatic Valve Page 2 (2)
L28/32H
Item Item
01 4/T Screw Skrue
04 4/T Thermostatic Følerelement

element
06 4/T Sleeve Bøsning
07 4/T Washer Skive
08 28/T Nut Møtrik
09 3/T Gasket Pakning
10 24/T Screw Skrue
11 1/E Thermostatic Termostatventil,

valve, complete komplet
Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
94.06 - ES0S
Plate
Page 1 (2) High Temperature Fresh Water Pump 61610-05H
L28/32H
11
06
09
07
12
08
03
09
10
01
02
14
16
03
04
05
19
17 18
91.42 - ES0S
Plate
61610-05H High Temperature Fresh Water Pump Page 2 (2)
L28/32H
Item Item
01 1/P Ball cock Kugleventil
03 2/P Key Feder
04 1/P Self locking nut Selvlåsende møtrik
05 1/P Impeller Løbehjul
06 8/P Screw Skrue
07 1/P Rotating sealing Roterende pakdåse
10 1/P Bearing housing Lejehus
11 1/P Shaft Aksel
12 1/P Circlip Låsering
19 1/E Fresh water pump, Ferskvandspumpe,

complete komplet
91.42 - ES0S
Plate
Page 1 (2) Sea Water Pump 61615-04H
L28/32H
11
06
09
07
12
08
03
09
10
01
02
14
16
03
04
05
19
17 18
91.43 - ES0S
Plate
61615-04H Sea Water Pump Page 2 (2)
L28/32H
Item Item
01 1/P Ball cock Kugleventil
03 2/P Key Feder
05 1/P Impeller Løbehjul
06 8/P Screw Skrue
07 1/P Rotating sealing Roterende pakdåse
10 1/P Bearing housing Lejehus
11 1/P Shaft Aksel
12 1/P Circlip Låsering
19 1/E Sea water pump, Saltvandspumpe,

complete komplet
91.43 - ES0S
Plate
Page 1 (2) Pipes on Cylinder Head 61625-04H
L28/32H
01
06
04
08
09
10
02
11
03
01
05
08028-0D/H5250/94.08.12
Cylinder Head
Plate 60501, 60502,
60508, and 60510
94.44 - ES0S
Plate
61625-04H Pipes on Cylinder Head Page 2 (2)
L28/32H
Item Item
02 2/C Nut Møtrik
03 3/C Screw Skrue
04 1/E Branch for cooling Grenrør for

water outlet pipe kølevand
06 1/C Thermometer, Termometer,

TI-11 TI-11
09 1/C Cooling water Forbindelsessrør

connecting pipe for kølevand
10 2/C Screw Skrue
11 2/C Screw Skrue
08028-0D/H5250/94.08.12
94.44 - ES0S
Plate
Page 1 (2) Cooling Water Pipes on Engine 61630-01H
L28/32H
07
05
04 06
03 16 16
17 21 30
02 17
22
06 27
07
01
06
02 07
03
04 24
25 See plate 61625
15 02
03
04
T
IN 05
. OU26
HT. 06
07
H T
04
29
08
09
10
02
03
12
03
04 02
14 04
03 20
04 21 25
27
O UT03 28
The piping design may vary from
.
LT 09 22 the shown example, but it is of no
23 importance when ordering.
04
IN 09
LT. 03
97.11 - ES0S
Plate
61630-01H Cooling Water Pipes on Engine Page 2 (2)
L28/32H
Item Item
01 /I HT water pipe inlet HT. tilgangsrør GenSet

GenSet
02 /I Stud Bolt
04 /I Nut Møtrik
05 /I Ball valve Kugleventil
07 /I Plug screw Propskrue
10 /I LT pipe inlet/outlet LT. rør ind/ud ladeluft-

charge air cooler køler
12 /I Orifice Blænde
14 /I LT water pipe outlet LT. afgangsrør sm.køler

lub. oil cooler
15 /I HT water distributing HT. fordelingsrør tilgang

pipe inlet engine motor
16 /I Plug screw Propskrue
20 /I LT water inlet GenSet LT. tilgang GenSet
21 /I Nut Møtrik
23 /I Bracket Konsol
24 /I HT water outlet collec- HT. afgang samlerør

ting pipe
25 /I Clamp Bøjle
26 /I Bracket Konsol
28 /I LT water inlet lub. oil LT. tilgang sm.køler

cooler
30 /I HT water collecting HT. samlerør

pipe outlet engine
97.11 - ES0S
Plate
Page 1 (2) Preheater - Fresh Water 61635-01H
General
01
02
92.08 - EO0S
Plate
61635-01H Preheater - Fresh Water Page 2 (2)
General
Item Item
01 1/E Preheater Forvarmer
02 1/E Pipe for Preheater Rør for Forvarmer
92.08 - EO0S
Index
Page 1 (1) Specific Plant Information 619
L28/32H
Description
Resilient Mounting of Generating Sets ..................................................................... 619.03 (03H)

Resilient Mounting of Generating Sets ..................................................................... 619.03 (04H)
Working Card
Fitting Instructions for Resilient Mountings of GenSets ........................................ 619-03.00 (03H)

Resilient Mounting of Generating Sets .................................................................. 619-03.00 (06H)
Replacement of Conicals ...................................................................................... 619-03.05 (01H)
Maintenance of Conicals ....................................................................................... 619-03.10 (01H)
Plates
Flexible External Connections ....................................................................................... 61902-03H

Conical Element ............................................................................................................ 61903-04H
Spring Unit ..................................................................................................................... 61903-06H
Viscodamper .................................................................................................................. 61903-07H
08028-0D/H5250/94.08.12
94.47-ES0U
Description 619.03
Page 1 (1) Resilient Mounting of Generating Sets Edition 04H
L+V28/32H
Resilient Mounting of Generating Sets Resilient Support
On resiliently mounted generating sets, the diesel A resilient mounting of the generating set is made
engine and the alternator are placed on a common with a number of spring units. The number and the
rigid base frame mounted on spring units. distance between them depend on the size of the
plant.
The spring units are mounted on the machine hall's
foundation by means of resilient adhesive pads or
bolts. Maintenance
All connections from the generating set to the external The spring units do not need any maintenance, but
systems should be equipped with flexible connections make sure, that they are never exposed to water or
and flexible pipes. Gangway etc must not be welded other fluids, high humidity or dust.
to the external part of the installation.
Do not place units with viscoliquid in or near water or
other liquids, the ingress may destroy the damping
efficiency. The viscoliquid then will have to be
replaced.
Engine
Alternator
Base Frame
Foundation
Fig 1 Resilient Mounting of Generating Sets
94.41 - EO0S
Description
Resilient Mounting of Generating Sets 619.03
L28/32H
Resilient Mounting of Generating Sets The support of the individual conical mounting can be
made in one of the following three ways:
On resilient mounted generating sets, the diesel
engine and the generator are placed on a common 1) The support between the bottom flange and the
rigid base frame mounted on the ship's/erection hall's foundation of the conical mounting is made with
foundation by means of resilient supports, type Coni- a loose steel shim. This steel shim is adjusted
cal. to an exact measurement (min. 40 mm) for each
conical mounting.
All connections from the generating set to the external
systems should be equipped with flexible connec-
tions, and pipes, gangway etc. must not be welded to
the external part of the installation.
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 brackets
on the base frame (see fig 1).
The setting from unloaded to loaded condition is

normally between 5-11 mm for the conical mounting.
The exact setting can be found in the calculation of

the conical mountings for the plant in question.
08028-0D/H5250/94.08.12
Fig 1 Resilient mounting of generating sets.
Fig 2 Support of conicals.
02.23 - ES1
619.03 Resilient Mounting of Generating Sets Description
L28/32H
2) The support can also be made by means of two Base Frame

steel shims, at the top a loose shim of at least
40 mm and below a shim of approx. 10 mm The resilient mounted generating set is normally
which are adjusted for each conical mounting delivered from the factory with engine and generator
and then welded to the foundation. mounted on the common base frame. Eventhough
engine and generator have been adjusted in the
3) Finally, the support can be made by means of factory with the generator rotor correctly placed in the
chockfast. It is recommended to use two steel stator, and the crankshaft bend of the engine (autolog)
shims, the top shim should be loose and have within the prescribed tolerances, it is recommended
a minimum thickness of 40 mm, the bottom to make an autolog before starting up the plant.
shim should be cast in chockfast with a thick-
ness of at least 10 mm.
Irrespective of the method of support, it is recommen-

ded to use a loose steel shim to facilitate a possible
future replacement of the conical mountings.
Adjustment of Engine and Generator on
08028-0D/H5250/94.08.12
02.23 - ES1
Working Card
Resilient Mounting of Generating Sets 619-03.00
L28/32H

Shut-off fuel oil
Description:
Mounting and adjustment instruction for new

GenSet. Hand tools:
Ring and open end spanner.

Feeler gauge, 1-2 mm.
Hydraulic jack (if nessary).
Starting position:
The foundation should be welded and milled off.
Related procedure:
Check of crankshaft bend (autolog)

08028-0D/H5250/94.08.12
Manpower:
Working time : hours
Capacity : 2 man
Data:

94.49 - EO0S
619-03.00 Resilient Mounting of Generating Sets Working Card
L28/32H
Spring Units Type GS 2. Remove the oilpaper from the adhesive pads
just before installation.
The spring unit type GS can be delivered in three
different types; GS, GS-V and GS-S. 3. Position the bottom adhesive pad on the
foundation according to the drawing.
Type GS is the basic type. It consists of a number of
springs between two plates, see fig 1. 4. Place the bottom part of the spring unit on the
top of that adhesive pad with the nuts of the
prestressing bolts on the lower side.
5. Place the other adhesive pads on the top of the

Thread M 20 for transport bolts spring unit.
Note: GS-V must be covered to protect viscoliquid.
6. Lower the base frame on the top of the unit

according to the drawing.
Prestressing bolts
Adhesive resilient pad 7. Measure the spring units and align with steel
shims, if necessary.
Fig 1 Spring Units Type GS The steel shims can be placed between single layers
of the upper adhesive pad.
Type GS-V has the same design as type GS, but it

contains viscoliquid in the lower plate which give a If alignment is Then
damping effect.
necessary split the upper adhesive
Note: These spring units must stand up during pad in two or more parts
transportation and when stored. according to number of
shims required
Type GS-S has the same design as type GS, however
with sordino damping. It consists of a material around not necessary installation is finished
the springs which has a damping effect on the
movement of the springs.
Note: The prestressing bolts should not be used for
All three types of spring units are delivered ex works, alignment of the machine, but should be loose after
- being prestressed. the installation.
There should be at least 10 mm clearance between

nut and element.
08028-0D/H5250/94.08.12
Mounting of Spring Units Type GS/GS-V/GS-S
1. Make sure the foundation is clean, oil-free and

levelled horizontally.
94.49 - EO0S
Working card
Fitting Instructions for Resilient Mounting of GenSets 619-03.00
L28/32H

Shut-off fuel oil
Stopped lub. oil circulation
Description

GenSets, and adjustment instruction for existing
plants.
Hand tools
Ring and open end spanner, 22 mm

Starting position Ring and open end spanner, 30 mm
Allen key, 6 mm
The foundation should be welded and milled off Feeler gauge, 1-2 mm
on shim surfaces. Measurement tool
Hydraulic jack (if necessary)
Related procedure
Check of main beraings alignment

(autolog) 610-01.00
Replacement of conicals 619-03.00
Man power
Working hours : 2 Hours

Capacity : 2 Men
08028-0D/H5250/94.08.12
Spare and wearing parts

Data
Plate No. Item No. Qty./
Data for torque moment (Page 600.40) 61903 01 4/conical mount.
Declaration of weight (Page 600.45) 61903 02 4/conical mount.
61903 03 1/conical mount.
02.23 - ES0
619-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
L28/32H
Mounting and Adjustment Instructions for 7) Turn all the internal buffers (2), see fig 1, to
New Generating Sets (Method 1) check that they can move freely.
Make Ready for Adjustment of Conical Ele- If all internal buffers Then
ments
Can move freely Let conical elements set-
If the conical elements have not been mounted by tle for 48 hours.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been Cannot be moved Turn the four jacking bolts
mounted by the factory, please start with item number in the base casting clock-
2. wise or anticlockwise to
release the internal buffer.
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), Adjustment of Conical Elements after 48
see fig 1. Hours Settling
2) Remove fixing bolt (7), spring washer (8) and After the conical elements have been deflected
top lock ring (6) from the conical element, see under static load for 48 hours, the laden height (H1)
fig 1. see fig 2, should be measured and compared to the
recommended laden height.
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.
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 6
8 5
4
08028-0D/H5250/94.08.12
9 1
Fig 2 Conical mounting.

Fig 1 Conical element
02.23 - ES1
Working card
L28/32H
8) Care must be taken, during levelling of the 12) Lift the generating set with crane or hydraulic
installation, to ensure that individual mount- jack.
ings are not overloaded. The variation in laden
height should not exceed 2 mm and should 13) Remove all the jacking bolts.
ideally be less. The laden height can be meas-
ured between top and base casting at H, on 14) Position each completed steel shim.
two sides (see fig 1).
15) Lower the generating set until it rests com-
Example: pletely in itself.
H1 + H2 + H3 ----- HN
Average = Number of conical elements 16) Number each steel shim together with each
conical element.
If Then
Adjustment of Internal Buffer
Difference exceeds Level the conical element
2 mm. by adjusting the jacking 17) Turn the internal buffer clockwise until it makes
bolts - commencing with contact with the steel shim.
the conical element with
the largest deviation. 18) Turn the internal buffer anticlockwise until it
obtains contact with the base casting.
Difference does not ex- The height of the steel
ceed 2 mm shim can be measured. This must be four full turns.
19) Turn the internal buffer 1.5 turn clockwise and

The difference between the two sides of a conical check with a feeler gauge between the base
mounting should not be more than 0.6 mm. casting of the conical element and the steel
shim that the internal buffer (2), see fig 1, does
not touch the steel shim.
Measuring of Steel Shim
20) Lock the internal buffer by remounting the top
9) Measure the steel shim on several points to lock ring (6) and turn it to the nearest thread
obtain the highest possible accuracy during hole - then secure with fixing bolt (7) and spring
preparation. washer (8), see fig 1.
Fabricating Steel Shim Mounting of Conical Elements on the Foun-

dation
10) Make sure that the minimum height of the steel
shim is 40 mm to secure a future replacement 21) Drill four mounting holes in the foundation for
08028-0D/H5250/94.08.12
of the conical element. each conical element, either
Drill the mounting holes in the steel shim according a) Mark the positions of the mounting holes on
to the conical base casting dimensions. the foundation through the conical element
and the steel shim.
Mounting of the Completed Steel Shim (Re)move the set completely so that the mark-
ings can be reached by drilling with conven-
11) Turn the internal buffer anticlockwise until it tional tools.
contacts the base casting to secure the laden
height of each conical element.
02.23 - ES1
L28/32H
Place the set on its former position by aligning The drilling has to be done on beforehand and
it with the drilled holes. the set must be aligned with the foundation
holes before the work starts to avoid further
or removal of the set.
b) Drill the mounting holes in the foundation by 22) Fix all the conical elements and the steel shims
means of the drilling pattern from the installa- to the foundation with four bolts per conical.
tion drawing.
Note! After completion of all works the buffer clear-
ance must be checked, see points 17, 18, 19 and 20.
08028-0D/H5250/94.08.12
02.23 - ES1
Working card
L28/32H

Shut-off fuel oil
Description

plants.
Hand tools

Allen key, 6 mm
Related procedure

(autolog) 610-01.00
Man power

Capacity : 2 Men
08028-0D/H5250/94.08.12

Data
02.23 - ES0
L28/32H
Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 2) of minimum 10 mm, see fig 2.
Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests com-
ments pletely on the foundation.
If the conical elements have not been mounted by 7) Check that all jacking bolts have full contact
the factory, they must be mounted on the prepared with the foundation.
brackets on the base frame. In case they have been
mounted by the factory, please start with item number 8) Turn the internal buffer (2), see fig 1 to check
2. that it can be moved freely.
1) Fit the conical elements to the bracket of the

base frame by means of four bolts screwed If all internal buffers Then
into the tapped holes on the top casting (5),
see fig 1. Can move freely Let conical elements set-
tle for 48 hours.
A supporting steel shim with a minimum height of 40
mm, to secure a future replacement of the conical Cannot be moved Turn the three jacking
element, complete with tapped holes for three jack- freely bolts in the supporting
ing bolts and mounting holes drilled according to steel shim clockwise, or
conical base casting dimensions, is required. anticlockwise to release
the internal buffer.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.
3) Position the supporting steel shim as per fig 2

and locate the conical element by means of
dowel pins.
4) Position the three jacking bolts in the tapped

holes in the supporting steel shim as per fig 2.
7 6
8 5
08028-0D/H5250/94.08.12
9 1

02.23 - ES1
Working card
L28/32H
Adjustment of Conical Elements after 48 Drill the mounting holes in the steel shim according
Hours Settling to the mounting holes in the conical base casting and
the mounting holes in the supporting steel shim.
After the conical elements have been deflected
under static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the Mounting of the Completed Steel Shim
12) Lift the generating set 1 mm totally be means
9) Care must be taken, during levelling of the of the three jacking bolts.
installation, to ensure that individual mount-
ings are not overloaded. The variation in laden 13) Position each completed steel shim.
height should not exceed 2 mm and should
ideally be less. The laden height can be meas- 14) Re-lower the generating set by means of the
ured between top and base casting at H, on three jacking bolts until it rests completely in
two sides (see fig 1). itself.
Example:
Adjustment of Internal Buffer
H1 + H2 + H3 ----- HN
Average = 15) Turn the internal buffer clockwise until it ob-
Number of conical elements
tains contact with the supporting steel shim.
If Then 16) Turn the internal buffer anticlockwise until it

obtain contact with the base casting.
Difference exceeds Level the conical element
2 mm. by adjusting the jacking This must be four full turns.
bolts - commencing with
the conical element with 17) Turn the internal buffer 1.5 turn clockwise and
the largest deviation. check with a feeler gauge between the base
casting on the conical element and the sup-
Difference does not ex- The height of the steel porting steel shim that the internal buffer (2)
ceed 2 mm shim can be measured. see fig 1, does not touch the supporting steel
shim.
The difference between the two sides of a conical 18) Lock the internal buffer by remounting the top
mounting should not be more than 0.6 mm. lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
washer (8), see fig 1.
Measuring of Steel Shim
Mounting of Conical Elements on the Foun-

08028-0D/H5250/94.08.12
10) Measure the steel shim on several points to

obtain the highest possible accuracy during dation
preparation.
19) Remove the dowel pins.
Fabricating Steel Shim 20) Drill four mounting holes in the foundation for
each conical element, either
11) Make sure that the minimum height of the steel
shim is 10 mm. a) Mark the positions of the mounting holes on
the foundation through the conical element
and the steel shims.
02.23 - ES1
L28/32H
(Re)move the set completely so that the mark- The drilling has to be done on beforehand and
ings can be reached by drilling with conven- the set must be aligned with the foundation
tional tools. holes before the work starts to avoid further
removal of the set.
Place the set on its former position by aligning
it with the drilled holes. 21) Fix all the conical elements and the supporting
steel shims/steel shims to the foundation with
or four bolts per conical.
b) Drill the mounting holes in the foundation by 22) Weld the lowest steel shim of approx. 10 mm
means of the drilling pattern from the installa- height to the foundation.
tion drawing.
Note! After completion of all works, the buffer clear-
ance must be checked, see points 15, 16, 17 and 18.
08028-0D/H5250/94.08.12
02.23 - ES1
Working card
L28/32H

Shut-off fuel oil
Description

plants.
Hand tools

Allen key, 6 mm
Related procedure

(autolog) 610-01.00
Man power

Capacity : 2 Men
08028-0D/H5250/94.08.12

Data
02.23 - ES0
L28/32H
Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 3) of minimum 10 mm plus permitted thickness,
as specified from the chockfast supplier, see
Make Ready for Adjustment of Conical Ele- fig 2.
ments
6) Lowed the generating set until it rests com-
If the conical elements have not been mounted by pletely on the foundation.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been 7) Check that all jacking bolts have full contact
mounted by the factory, please start with item number with the foundation.
2.
8) Turn the internal buffer (2), see fig 1, to check
1) Fit the conical elements to the bracket of the that it can be moved freely.
base frame by means of four bolts screwed
into the tapped holes on the top casting (5) see If all internal buffers Then
fig 1.
Can move freely Let conical elements set-
A supporting steel shim with a minimum height of 40 tle for 48 hours.
mm, complete with tapped holes for three jacking
bolts, four mounting holes and four tapped holes, Cannot be moved Turn the three jacking
drilled according to the conical base casting dimen- freely bolts in the supporting
sion, is required see fig 2. steel shim clockwise, or
anticlockwise and slacken
2) Remove fixing bolt (7), spring washer (8) and the four hold-down bolts
top lock ring (6) from the conical element, see to release the internal
fig 1. buffer.
3) Position the supporting steel shim as per fig 2

and locate the conical element by means of
four hold-down bolts.
4) Position the three jacking bolts in the tapped

holes in the supporting steel shim as per fig 2.
7 6
8 5
08028-0D/H5250/94.08.12
9 1

02.23 - ES1
Working card
L28/32H
Adjustment of Conical Element after 48 Hours 11) Drill the mounting holes in the steel shim
Settling according to the mounting holes in the conical
base casting and in the supporting steel shim.
After the conical elements have been deflected
under static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the Adjustment of Internal Buffer
12) Turn the internal buffer clockwise until it ob-
9) Care must be taken, during levelling of the tains contact with the supporting steel shim.
installation, to ensure that individual mount-
ings are not overloaded. The variation in laden 13) Turn the internal buffer anticlockwise until it
height should not exceed 2 mm and should obtains contact with the base casting.
ideally be less. The laden height can be meas-
ured between top and base casting at H, on This must be four full turns.
two sides (see fig 1).
14) Turn the internal buffer 1.5 turn clockwise and
Example: check with a feeler gauge between the base
H1 + H2 + H3 ----- HN casting on the conical element and the sup-
Average = Number of conical elements porting steel shim that the internal buffer (2),
see fig 1, does not touch the supporting steel
shim.
If Then
15) Lock the internal buffer by remounting the top
Difference exceeds Level the conical element lock ring (6) and turn it to the nearest thread
2 mm. by adjusting the jacking hole - then secure with fixing bolt (7) and spring
bolts - commencing with washer (8), see fig 1.
the conical element with
the largest deviation.
Mounting of Conical Elements on the Foun-
Difference does not ex- The height of the steel dation
ceed 2 mm shim and the chockfast
can be measured. 16) Drill four mounting holes in the foundation for
each conical element according to the sup-
porting steel shim/steel shim, either
The difference between the two sides of a conical
mounting should not be more than 0.6 mm. a) Mark the positions of the mounting holes on
the foundation through the conical element
and the shims.
Measuring of Steel Shim and Chockfast
(Re)move the set completely so that the mark-
08028-0D/H5250/94.08.12
10) The steel shim should be at least 10 mm high. ings can be reached by drilling with conven-
tional tools.
Check the minimum permitted thickness of chockfast
for the load and surface of this application with Place the set on its former position by aligning
chockfast supplier. it with the drilled holes.
or
Fabricating Steel Shim
Make sure that the minimum height of the steel shim

is 10 mm.
02.23 - ES1
L28/32H
b) Drill the mounting holes in the foundation by Make sure that the mounting bolts are isolated from
means of the drilling pattern. the chockfast.
The drilling has to be done on beforehand and Note! After completion of all works, the buffer clear-
the set must be aligned with the foundation ance must be checked, see points 12, 13, 14 and 15.
holes before the work starts to avoid further
removal of the set.
08028-0D/H5250/94.08.12
02.23 - ES1
Working card
Replacement of Conicals 619-03.05
L+V28/32H

Shut-off fuel oil
Description:
Replacement of conicals
Hand tools:
Starting position: Ring and open end spanner, 22 mm

Safety precautions Hydraulic jack
Related procedure:
Fitting instructions for resilient mounting
Man power:
Working hours : xxx Hours

Capacity : 2 Men
Data: Spare and wearing parts:
Data for pressure and tolerance (Page 600.35) Plate No. Item No. Qty./
Declaratiom of weight (Page 600.45)
94.29 - EO0S-G
619-03.05 Replacement of Conicals Working card
L+V28/32H
Replacement of Conicals
1. Loosen all conicals in one side. 3. Lift the GenSet until the steel shim can be
removed. This will give enough space for removing
damaged conical.
2. Mount a jack under the base frame, see fig 1.
4. Mount the GenSet conical.
Note! Conicals should only be replaced in pairs, see

fig 2 and plate 61903.
5. Lower the GenSet again.
6. Repeat point 1-5 for the other side.
7. Adjust the conicals, see Working Card 619-

03.00 "Fitting Instructions for Resilient Mounting of
GenSet.
Fig 1 Removal of conicals
Fig 2 The conicals must be pairs
94.29 - ES0S-G
Working Card
Maintenance of Conicals 619-03.10
L+V28/32H

Shut-off fuel oil
Description:
Control and adjustment of conicals.

Hand tools:
Ring and open end spanner.

Feeler gauge, 1-2 mm.
Hexagon socket key 6 mm.
Starting position:
Related procedure:
Check of crankshaft bend (autolog)

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

Capacity : 1 man
Data:

97.25 - EO0S-G
619-03.10 Maintenance of Conicals Working Card
L+V28/32H
1. Visual Check 2.2. Result of clearance check.
If Then
1.1. What to check.
Everything is OK Check is completed
Check for oil deposits on the rubber element. Everything is not OK Adjust conicals which do not com-
Check for loose mounting bolts. ply with the clearance demands
Check for damage in the rubber element. acc. to item 2.3. Recheck all con-
cals acc. to item 2.1.
Everything is still not OK Replace conical acc. to

1.2. Result of visual check. Working Card 619-03.05
If Then
Everything is OK Continue to next conical 2.3. Adjustment of conicals.
Oil deposits on rubber Clean rubber element a. Remove protective cap (no 10).
element
Loose mounting bolts Fasten mounting bolts

b. Remove fixing bolt (no 9) and top locking ring
(no 7).
Damage in conicals Replace conical according to
Working Card 619-03.05 c. Turn buffer clockwise until it has contact with
the steel shim (no 2).
2. Clearance Check d. Turn buffer anticlockwise until it has contact

with the conical base casting (no 3). This must be
four full rotations.
2.1. What to check.
e. Turn buffer two full rotations clockwise. This
Check clearance on all conicals between steel shim will ensure full vertical movement for the buffer.
and internal buffer through the slot in the base
casting of the conical (see fig 1) with a feeler gauge f. Check all conicals again.
of app. 2 mm.
g. Replace top locking ring, fixing bolt and protec-
tive cap etc.
08028-0D/H5250/94.08.12
Fig 1 Conical
97.25 - EO0S-G
Plate
Page 1 (2) Flexible External Connections 61902-03H
L28/32H
Item
Fig. Designation Connection
No.
Waste oil, outlet A3 01
Nozzle cooling oil, inlet A7 02
Nozzle cooling oil, outlet A8 03
Lubricating oil from separator, C3 04

inlet
Lubricating oil to separator, C4 05

outlet
Back flush from full-flow filter, C9 06

inlet
Lub. oil from by pass filter, C11 07

inlet
Lub. oil to by pass filter, outlet C12 08
Lub. oil supply, inlet C16 09
Venting to expansion tank F3 10
HT freshwater from preheater, F5 11

inlet
HT freshwater to preheater, F6 12
outlet
Fresh water for filling/draining F7 13
Compressed air, inlet K1 14
Control air, inlet K2 15
Drain from charge air cooler, M6 16

outlet
Fuel oil, inlet A1 17
Fuel oil, outlet A2 18
94.41 - ES0S
Plate
61902-03H Flexible External Connections Page 2 (2)
L28/32H
Item
Fig. Designation Connection
No.
Oil vapour discharge, outlet C13 19
Lubricating oil from full-flow C7 20

filter, inlet
Lubricating oil to full-flow filter, C8 21

outlet
HT freshwater, inlet F1 22
HT freshwater, outlet F2 23
LT freshwater/raw water, G1 24
inlet
LT freshwater/raw water, G2 25
outlet
Sea water, Inlet G3 26
Sea water, outlet G4 27
94.41 - ES0S
Plate
Page 1 (2) Conical Element 61903-04H
L+V28/32H
05
06
07
01
02
03
04
08028-0D/H5250/94.08.12
Note! When ordering, be aware that conical ele- Bemærk! Ved bestilling af conicals elementer.
ments always should be replaced in pairs, state Conicals elementer udskiftes parvis, opgiv fabrika-
manufacturing no. of existing conical elements. tions nr. på eksisterende conicals elementer.
97.44 - EO0S-G
Plate
61903-04H Conical Element Page 2 (2)
L+V28/32H
Item Item
01 4/M Screw Skrue
02 4/M Washer Skive
03 1/M Conical element Konisk understøtning
04 4/M Adjusting screw Justerskrue
05 1/M Protecting cap Beskyttelseskapsel
06 1/M Fixing ring Fiksering ring
07 1/M O-ring O-ring
08028-0D/H5250/94.08.12
Qty./M = Qty./Conical mounting. Antal/M = Antal/Conical montering.
97.44 - EO0S-G
Index
Page 1 (1) Tools 620 S
L28/32H
Description
Introduction to Spare Part Plates for Tools .............................................................. 620.01 (01H)
Working Card
Application of Hydraulic Tools ............................................................................. 620-01.05 (01H)

Maintenance of Hydraulic Tools .......................................................................... 620-01.10 (01H)
Tightening with Torque Spanner ........................................................................... 620-01.15 (01H)
Max Pressure Indicator ......................................................................................... 620-01.25 (02S)
Plates
Tools for Cylinder Head ..................................................................................................62005-03S

Tools for Piston, Connecting Rod and Cylinder Liner ....................................................62006-02S
Tools for operating Gear for Inlet Valves, Exhaust Valves and Fuel Injection Pumps .. 62008-01H
Tools for Control and Safety Systems, Automatics and Instruments ............................ 62009-02H
Tools for Crankshaft and Main Bearing ..........................................................................62010-02S
Tools for Fuel Oil System and Injection Equipment .......................................................62014-02S
Tools for Lubricating Oil System ................................................................................... 62015-01H
Hydraulic Tools ...............................................................................................................62021-03S
08028-0D/H5250/94.08.12
94.47-ES0U
Description Introduction to Spare Part Plates for Tools 620.01
General
The contents of these spare part plates with tools are However, some tools, such as torque spanners,
a summary of STANDARD TOOLS for normal hydraulic tools etc., may also have other applications.
maintenance and EXTRA TOOLS for reconditioning, Information about the exact use of the tools appears
which can be supplied by MAN B&W Diesel A/S, from the relevant sections in the instruction book.
Holeby. Thus, the list comprises the total extent of
tools available for this engine type. Note: The table on the spare part plates is marked
with an S or an E. An S means that the tools are
For each specific plant, the amount of tools delivered supplied when ordering Standard tools and an E
depends of the contractual specifications. means that the tools are supplied when ordering
Extra tools, i.e. Tools for Reconditioning. (Extra
The tools listed are assembled in sections corres- tools are not standard delivery)
ponding to the chapters of the instruction book.
08028-0D/H5250/94.08.12
93.50 - ES0U
Page 1 (7) Function of the Hydraulic Tools Edition 03H
General

Shut-off fuel oil
Safety hints andd function of hydraulic tools.
Starting position
Application of hydraulic tools 620-01.06
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
Edition 03H Function of the Hydraulic Tools Page 2 (7)
General
Function of the Bolt Tensioning Device 8. The operation and handling of the device are to
be carried out by expert staff only.
In order to achieve an optimal result with one or
several devices, some rules have to be considered. 9. The given max. operation pressure is not to be
We expressly point out that a conscientious handling exceeded in any case and is to be watched at
of the device as well as the accessories is of highest the manometer of the pressure generator dur-
importance. To ignore these rules or separate hints ing the complete tensioning or loosening pro-
means danger to life or danger of injuries! See Safety cedure. When having achieved the given pres-
Hints. sure, stop the pressurization immediately.
10. During the pressurization when tensioning or

Safety Hints loosening the bolt connection, always watch
the admissible stroke of the device. Exceeding
Beside regarding the general accident-prevention this stroke is connected with insufficient gener-
rules, the safe handling of the device and the hydrau- ating of tensioning force because the device is
lic accessories demand especially the consideration tensioned in itselve or the hydraulic pressure is
of the following hints. When disregarding even single bleeded automaticly.
items, you can cause danger to life and/or danger of
injuries! 11. On principle, when connecting high-pressure
hoses it has to be taken care that the connec-
1. When leakages occur during the pressuriza- tions are correct (see also separate hints).
tion, bleed pressure immediately and seal the
leakage or replace defect parts. 12. The hydraulic hoses have to be installed in a
way that they are not run over by vehicles or
2. In case of repair, use exclusively original spare unnecessarily walked over by people. Never
parts. Inexpert substitution of damaged parts lay hoses across sharp objects (danger of
by non-original spare parts is prohibited. cuts) and never bend or jam them in.
3. All assembly parts are to be handled in corre- 13. Never hold or transport the device by using the
spondence to the working cards only. A change high-pressure hoses.
in the procedure or another operation of the
device is not allowed. 14. An incorrect working manometer that doesn´t
show the right pressure leads to overstressing
4. Make sure that the components to be tensioned of the parts and to an incorrect bolt connection.
do not exceed the admissible strain. Apart from damaged parts an incorrect bolt
connection can also cause conditions that are
5. In order to use the device, the thread has to be danger to life. Therefore take care that the
sufficiently exceeding in order to avoid that the manometer shows the right value or the
turn of a thread cracks, see item 4. tensioning force is checked in an other way (for
example by using a master manometer).
08028-0D/H5250/94.08.12
6. During the pressurization the people involved Tensioning forces can be checked for example
have to remain in an appropriate distance. by measuring the linear deformation. Dam-
Staying in direction towards the bolt axis is aged manometers have to be exchanged im-
forbidden. mediately.
7. Tensioning pressures or tensioning forces are

to be given or changed by authorized person-
nel only while considering the admissible com-
ponent loads, see item 4.
99.43 - ES0
General
Working Hints
In order to achieve a bolt connection of high preci-

sion, it is vital to consider the following working hints:
- Prior to setting the device, clean all threads

and remove possible damages in order to
avoide a “freeze on”.
- The base plate for the device must be plain and

free of dirt. Further check the squareness
towards the bolt axis in order to avoid that the
bolt has a bending stress during the pressuri-
zation (tensioning).
- The stroke of the device may not at any point

be exceeded.
- For transporting the device it is necessary to

uncouple all high-pressure hoses. Fig. 1. Turnable connection unit.
- After each pressurization, bring the device

back to zero, see also Piston Return Stroke. Exchange of the Seals
Should leakages show up at the connection unit, it

Turnable Connection Unit might be necessary to exchange the seals.
For doing so, loosen the securing ring and take the
In order to simplify the connection of the hydraulic disc off the bolt nipple. Having removed the seals,
hose, a turnable connection unit is mounted on some clean the components with fluff-free cleaning mate-
devices. rial. You can also apply compressed air. Having
The turnable connection unit consists of the follow- checked the components for damages and oiled
ing components: them slightly, apply new seals by help of the entry
guide and reassemble the turnable connection unit.
- bolt nipple
- disc Hint: - For the cleaning, never use aggressive
- seal cleaning liquids.
- securing ring - For oiling the parts, use exclusively hydrau-
lic oil.
Furthermore, an entry guide is available or con- - For replacements, use exclusively new
08028-0D/H5250/94.08.12
tained in the scope of supply, see fig.1. seals.
Coupling of the High-Pressure Hoses
- Only couple when the hydraulic system is in a

pressureless condition.
- To produce a high-pressure connection, put

one coupling and one nipple into each other
while the coupling socket is pulled back. When
letting the coupling socket go, there is a form
fit barring the connection.
99.43 - ES0
Edition 03H
Function of the Hydraulic Tools Page 4 (7)
General
- By drawing the hose with a manual force of If necessary, turn back the device, but make sure
about 100 N make sure that the connection is that the max. admissible stroke of the device is not
correctly barred. exceeded. Beside that, it has to be ensured that the
cylinder and the support sleeve remain centrically
- For decoupling the high-pressure hose in a towards each other (consider centering shoulder).
pressureless condition, first pull back the cou-
pling socket and then take off the hose. Having made all hydraulic connections correctly,
see fig. 2, start the pressurization for the tensioning
procedure. If the necessary pressure is achieved
stop pressurization. The inducted force causes the
bolt to extend or an edging of the components to be
tensioned so that the main nut is lifted from the
flange. Screw it back to the flange, see fig. 3. Check
by help of a feeler gauge leaf whether the main nut
really fits tight to the flange. After that, bleed hydrau-
lic pressure. Now the connection is tensioned.
Fig. 2. Coupling of the high-pressure hoses.
Having brought the piston to its zero position, see fig.
4, the hydraulic hoses can be decoupled. In order to
Hoses with fast-lock coupling sockets avoid, also prevent impurities, it is advisable to close coupling
when uncoupled, that oil runs out. When the hoses sockets and coupling nipples at once by protecting
get heated, there can be an inside pressure in the caps. The device can be unscrewed from the bolt.
uncoupled condition making a coupling impossible.
By loosening one screw connection (see fig. 2) the
pressure can be bleeded
Þ Always consider the safety and working
hints!
- To avoid a contamination use protecting caps

for the sockets. Loosening Procedure
In order to loosen an existing bolt connection, screw

Tensioning Procedure the device onto the bolt. First put the support sleeve
on the bolt and align it centrically to the bolt axis.
Prior to the tensioning procedure make sure that the When screwing on the device take care that the
components to be tensioned are correctly positioned support sleeve at the cylinder is correctly centered
towards each other. Then screw the device onto the (consider centering shoulder).
bolt.
The piston of the device must be at its zero position.
First put the support sleeve on the bolt and align it Having screwed the device down until the support
centrically to the bolt axis. When screwing on the sleeve or the support cylinder fits tight to the flange,
device take care that the support sleeve at the
08028-0D/H5250/94.08.12
turn back the device by at least the value (slit

cylinder is correctly centered (consider centering measure) which the bolt and the components spring
shoulder). back elastically during the loosening procedure.
Screw the device until the support sleeve or the Hint: The adjusted slit measure may never exceed
support cylinder fits exactly to the flange. The piston the admissible stroke of the device! Furthermore,
of the device must be at its zero position. Further- take care that the window for the adjusting rod are
more, take care that the hydraulic connector and the well accessible.
window for the adjusting rod is well accessible. Having made all hydraulic connections correctly,
see fig. 2, start the pressurization.
99.43 - ES0
General
During the pressurization, a slight turn-back momen- Hint:

tum is applied to the main nut with the adjusting rod.
At the moment, when the main nut can be loosened, a) Should it be impossible to unscrew the device
interrupt the pressurization. Should it not be possible after the depressurization, it has been turned
to loosen the main nut when achieving the original back by a too low measure prior to the pres-
tensioning pressure, interrupt the pressurization surization. Pressurize again until the original
immediately. Find the cause with expert staff. tensioning pressure is reached, turn the main
nut and bleed the pressure again (tensioning
Having achieved the loosening pressure, turn back procedure). Now you can turn back the device
the main nut by the value that the bolt and the further. (Attention: consider the admissible
components spring back during the loosening proce- stroke of the device!) Now repeat the loosen-
dure. The slit measure, however, must be lower than ing procedure explained above.
the slit measure adjusted at the device before, see
also hint b. b) Should it be impossible to loosen the main nut
after the depressurization, it has been turned
The main nut may never be turned back until it fits to back by a too low measure prior to the pres-
the piston or the cylinder since then the device can surization. Pressurize again and turn the main
be tensioned in itself. nut further back. Bleed the pressure again.
Having turned back the main nut, the pressure can Hint: Never screw the main nut back until it fits to the
be bled. The bolt connection is loosened. Before piston since the device can be tensioned in
unscrewing the device, bring the piston back to its itself.
zero position, see fig. 4. After that, the hydraulic
hoses can be decoupled. In order to prevent impuri-
ties, it is advisable to close coupling sockets and Adjustment and Turn Back of the Main Nut
coupling nipples at once by protecting caps. The
device can be unscrewed from the bolt. During the pressurization of the device, the bolt is
Þ
being extended by the tensioning force and the
Make sure that no operational forces (e.g. components are being edged. The result is that the
inner pressure) affect the components to be main nut does no longer fit to the flange.
loosened since only part of the bolts take over
these forces and thus the bolts, which are not Having achieved the necessary pressure, adjust the
yet loosened, might be overburdened. main nut - when tensioning - until it fits to the flange
Þ
again before bleeding the pressure, see Tensioning
The pressure when the main nut can be loos- Procedure. When loosening the bolts, turn back the
ened may never exceed the tensioning pres- main nut after the pressurization according to the
sure by help of which the connection was bolt and component deformations, (see Loosening
tensioned! Should it not be possible to loosen Procedure.
the main nut when reaching the original
tensioning pressure interrupt the pressuriza-
08028-0D/H5250/94.08.12
Hint: During the loosening procedure, never turn

tion immediately. Find the cause with expert back the main nut until it fits to the piston or the
staff. cylinder since the main nut sticks after the depressu-
Þ
rization.
Always consider the safety and working hints!
The main nut is equipped with several radial bores
where the adjusting rod can be put in. The main nut
is accessible through the window in the support
sleeve.
99.43 - ES0
620-01.05 Function of the Hydraulic Tools
Working Card
General
During the piston return stroke, considerable back-

pressures can occur in the piston area of the device
since quite large quantities of oil have to flow back
through the small cross sections of the high-pres-
sure connections.
In order not to unnecessarily increase the force for

the piston return stroke turn the piston slowly. On
principle the piston of the device has to be pushed
back until it fits to the cylinder again.
Exchange of the Seals

Fig. 3 Adjustment and turn back of the main nut.
Should leakages occur at the piston of the device, an
exchange of the seals might be necessary.
Piston Return Stroke Drive out the piston by carefully beating with a
hammer while using a plastic spacer in order to
After each pressurization it must be ensured that the protect the device from unnecessary damages. After
piston of the device is brought back to its zero removing the hydraulic connector, you can also
position. On principle, it has to be considered that carefully lead compressed air into the piston area.
hydraulic oil is being displaced from the piston area.
In order to enable the oil to flow back to the tank of Attention: Sudden input of compressed air can lead
the pressure generator, the corresponding hydraulic to the piston’s uncontrolled outlet.
connections must be done. After removal of the piston, the seals and the backup
rings can be removed from the piston and the cylin-
The piston return stroke is done by a screw-down at der.
the bolt itself before the device is taken off.
Carefully clean the components with fluff-free mate-
Hint: When using fast lock coupling elements, the rial and check them for damages. If necessary, use
oil’s running out and thus a piston return stroke in an compressed air for the cleaning, but never aggres-
uncoupled condition is impossible! sive cleaning liquids. After that, slightly oil these
components with hydraulic oil and assemble new
backup rings as well as new seals to the piston and
the cylinder according to the drawing.
08028-0D/H5250/94.08.12
Fig. 4. Piston return stroke.
Fig. 5. Exchange of the seals.
99.43 - ES0
General
As shown in the picture, first assemble the backup

ring, then put the seal onto the backup ring. Piston
and cylinder can now be assembled again by putting
the components together. By slightly hammering on
the piston (with plastic spacer), it can be driven in
until it fits tightly to the cylinder (piston in its zero
position). It is essential that the piston does not tilt
during being driven in since this might damage the
seals as well as the components. When assembling
the piston it has to be taken care that the air can
come out of the piston area.
Maintenance and Storage
Regular maintenance of the device is not necessary,

but you should consider the following points:
a) Storage
After each operation, repair possible damages and

clean the device in order for it to be ready for the next
operation immediately. In order to avoid a corrosion
it is advisable to oil the device and especially its
thread. All coupling nipples, coupling sockets and
also loosened screw connections are to be closed by
protecting caps.
In addition, check the components of the device and

its accessories for completion.
Keep the device in the tool box also offering protec-
tion from mechanical damages.
The temperature must be between -20 C and +70 C
in order to exclude a damage of the seals.
b) Start-up of the device
Prior to the device’s operation, repair possible dam-

ages and clean the device.
08028-0D/H5250/94.08.12
Check the components of the device and its acces-

sories for completion.
The operating manual has to be read by all users.
99.43 - ES0
Working Card
Application of Hydraulic Tools 620-01.06
L/V28/32H

Shut-off cooling water See page 2
Shut-off fuel oil
Application of hydraulic tools.
Starting position
Function of hydraulic tools 620-01.05
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.50 - ES0
620-01.06 Application of Hydraulic Tools Working Card
L/V28/32H
This working card gives the information for application

of hydraulic tools, to be used in connection with
working card 620-01.05.
Please note:
The numbers refer to the
plate items in section 620.
Fig 1 Hydraulic tools.

08028-0D/H5250/94.08.12
99.50 - ES0
Working Card
Hand Lever Pump 620-01.07
General

Shut-off fuel oil
Application of hydraulic tools.
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
620-01.07 Hand Lever Pump Working Card
General
Warning: The hand lever pump is not equipped with Initial Start-up and Venting
a pressure relief valve.
Never use the pump without a mounted manometer. In general and venting
Always pay attention to the given pressure of the
connected pressure consumers. Do never exceed Please make sure that all parts of the pump, especially
this pressure or the max. pressure of the hand lever the manometer and the pressure port, are in a
pump. perfect condition. Defect parts are to be exchanged
against new ones immediately.
Important: Except for hydraulic oil, never use different
liquids such as petrol, water, diesel oil, alcohol or Turn the carrying handle with counter-clockwise
brake liquid, since these can lead to damages or rotation out of his fixing. Then turn it into the hand
even to destruction of the pump and/or the parts lever of the pump against the stopping face.
connected with it. Choose a place of assembling and
operation where the pump can always stand safe Attention: If the carrying handle is not srewed-in into
and firm on a horizontal plain. There should always the hand lever, it can cause injuries while using the
be sufficient space for operating the pump. i pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the oil filler cap and check the oil level. If
pump to great heat, fire or extreme coldness, since neccessary, fill up the tank with hydraulic oil according
this leads to damages or even destruction. Protect to IS0 VG 32. Never overfill the tank. Close the oil
the pump from falling objects and avoid hard blows filler cap.
or pushes. Open the tank breather with the square wrench
(included in the scope of supply) by about one turn.
Attention - Danger to life Now loosen the breather screw at the pump (see
Check the manometer of the pump for the needed drawing) with an allen key SW 2,5 by about one turn.
hydraulic pressure, given by an authorized person, Close the depressurization valve tightly. Now pump
not to be exceeded. Make sure that the pressure you at the hand lever until oil flows out of the breather
want to generate is also admissible for all connection screw bladder-free. Only then are you allowed to
parts. close the breather screw. The pump is now vented
and ready for operation.
All pressure connections and connecting elements
have to be clean and undamaged. High-pressure After each operation and for the transport, close the
connections from the pump to the tools have to be tank breather in order to avoid the hydraulic oil’s
established correctly prior to any pressurization. running out.
Disregard leads to danger to life. Please see working
card 620-01.06.
Pressurization
Attention - Danger on injuries
Loads being lifted by the pump may never be held by - Open the tank breather with the square wrench
the pump valves alone. Use additional non-return
08028-0D/H5250/94.08.12
approx. one turn.

valves or safety relief valves and secure the load by
sufficient support against falling. Remark: The pump is only to be operated with open
tank breather.
- Close the depressurization valve at the pump

when turning clockwise by handoperation.
Remark: The depressurization valve is designed for

manual operation. The use of any tools at the
depressurization valve could cause damages of the
valve or the valve seat.
99.43 - ES0
Working Card
Hand Lever Pump 620-01.07
General
- Pump at the hand lever until the wanted pres- Attention: Inside of the adjusting screw is another
sure is achieved. Check the pressurization at grub screw with inner hexagon (wrench size 4 mm)
the manometer and take care of possible to limit the stroke of the change-over piston inside of
leakages. the pump block. It is absolutely necessary, to screw
out the grub screw approx. 2 times before turning the
Remark: The pump is with two stages. The change adjusting screw!
from the first stage to the second stage happens
automatical at a system pressure of about 30 bar. The regulation of the adjusting screw follows gradually
in approx. 10° - steps. After everv adjusting step the
Attention: The pump is not equipped with an internal grub screw is to screw in until it fits closely and
pressure relief valve. The use of a manometer and approx. a l/4 turn to loosen.
the control of the system pressure during
pressurization is indispensable. Check by carefully pumping if the change-over pres-
sure wanted has been reached. If necessary, repeat
Attention: Do not stand directly over the moving line the procedure as described above.
of the pump lever. Under arising circumstances the
lever can “hit back”. To avoid accidents stand
sideways the pump.
Attention - High-pressure hydraulic

On principle, tihen leakages occur during the
pressurization, immediately release the hydraulic
pressure and seal the leakage or renew defect parts.
Depressurization
- Open the depressurization valve slowly by a

turn to the left.
- Make sure that the hydraulic pressure at the

manometer has been completely released.
Consider the returning time of the hydraulic oil.
Adjustment of change-over pressure from

stage 1 to stage 2
In exeptional case, it can be useful to adjust the

08028-0D/H5250/94.08.12
change-over pressure from stage 1 to stage 2 (factory

adjusted at approx. 30 bar).
Below of the pressure relief valve is an adjusting

screw with inner hexagon (wrench size 10 mm).
Turning out counter-clockwisely the adjusting screw
minimizes the change-over pressure, turning in
clockwise maximizes the change-over pressure.
99.43 - ES0
620-01.07 Hand Lever Pump Working Card
General
Analysis and Correction of Malfunction Pressure Port
Correction of malfunctions The pressure port of the pump is produced according

to our customers’ wishes. In addition, there is a
In case of malfunctions at the pump, the following variety of possibilities to connect the pump with one
points are to help you with the analysis of the or more pressure consumers. A selection of pres-
problem and correcting it yourself. sure ports please find in the annex.
For this, uncouple or unscrew all consumer and high-
pressure hoses from the pump. Attention - Danger to life
Prior to the pump’ s start-up please make sure that,
no matter which pressure port you chose, all
connection elements are in a perfect condition.
Malfunction Correction
Convince yourself of the fact that these are correctly
No pressurization 1. Check the oil level and, if connected and suitable for the necessary pressure.
necessary, fill it up as
described in chapter
Attention - High-pressure hydraulic
maintenance and storage.
2. Close depressurization valve. On principle, when leakages occur during the
3. Visual inspection whether pressurization, immediately release the hydraulic
there are leakages. If so, pressure and seal the leakane or renew defect parts.
seal them.
4. Vent the pump as described
in chapter initial start-up and
venting. Maintenance and Storage
Insufficient pressurization 1. Check the oil level and, if
necessary, fill it up, as
The pump should be lubricated frequently at the
described in chapter movable parts. Protect it from contamination because
(prior to any corrections, mainteance and storage. dirt in the oil or in the pressure port can lead to the
open de-pressurization 2. Close depressurization valve. pump’ s failure. A dry storage avoids the steel parts’
valve and release hydraulic 3. Visual inspection whether ther
pressure completely) are leakages. If so, seal them.
getting rusty.
4. Vent the pump as described The storage and transport of the pump should always
in chapter initial start-up and be done in a horizontal position. Thus, you avoid a
venting. possibly necessary venting of the pump during its
Pressure drop 1. Visual inspection whether
start-up.
there are leakages. If so,
(prior to any corrections, seal them. For checking the oil level, please open the
open de-pressurization 2. Close depressurization valve. depressurization valve and let the oil completely flow
valve and release hydraulic
pressure completely).
back into the tank. Open the oil filler cap and fill up
hydraulic oil according to IS0 VG 32, if neccessary.
If the problem cannot be solved, please contact MAN Do not overcharge the tank. Close the oil filler
B&W Diesel Holeby. cap.
08028-0D/H5250/94.08.12
The use of the pump in a dirty area requires a regular

oil change. Fill the pump with clean hydraulic oil and
lubricate all moving parts (hinges) regulary.
99.43 - ES0
Working Card
Maintenance of Hydraulic Tools 620-01.10
General

Shut-off fuel oil
Description:
Maintenance of hydraulic tools and pressure

testing of hoses. Hand tools:
Allen key, 6 mm.

Clean lub. oil.
Starting position:
Related procedure:

08028-0D/H5250/94.08.12

Man power:
62021 43 Hydraulic tool.
Working time : 1/2 Hour 62021 44 Hydraulic tool.
Capacity : 1 man 62021 29 Hydraulic tool.
62021 30 Hydraulic tool.
Data:

91.46 - ES0S
620-01.10 Maintenance of Hydraulic Tools Working Card
General
1) The hydraulic jacks require no maintenance

except replacement of defective sealing rings, each
of which consists of an o-ring and a back-up ring
fitted in ring grooves in the piston and cylinder.
The piston and cylinder are easily separated by

taking out the bleed screw and pressing the parts
apart with the help of working air.
Work.
air
Compression tool
Fig. 2.
Fit the sealing rings and lubricate with clean lub. oil.
Fig. 1. The piston and cylinder are pressed together by
means of the tool supplied. See that the rings do not
get stuck between the piston and cylinder.
Make sure that there are no marks or scratches on
the sliding surfaces of the parts. The presence of
metal particles will damage the sealing rings. Pressure Testing of Hoses.
2) The sealing rings are to be fitted with the o- To avoid working accidents caused by emission of
rings nearest to the pressure chamber and with the pressure oil from the hydraulic hoses, they should
back-up rings away from the pressure chamber. be pressure tested at 1200 bar once a year.
Note: During the pressure testing the hoses must be

covered carefully.
08028-0D/H5250/94.08.12
91.46 - ES0S
Working Card
Tightening with Torque Spanner 620-01.15
General

Shut-off fuel oil
Description:
Hand tools:
Starting position:
Related procedure:

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

Capacity
Data:

91.16 - ES0S
620-01.15 Tightening with Torque Spanner Working Card
General
1) Before the nuts are screwed on, the threads 7) For setting the spanner at the torque required,
and the contact faces should be grease with copaslip there is a ball on a small arm at the end of the handle.
or similar, the tightening torques being based on a
coefficient of fiction in the threads. 8) When pulling the ball with the arm outwards, a
small crank handle is formed.
2) The nuts should fit easily on the thread, and it
should be checked that they bear on the entire A spring-loaded slide in the handle provided with a
contact face. mark which, when turning the crank handle, can be
set at the required torque on the scale.
3) In the case of new nuts and studs, tighten and
loosen the nuts 2 or 3 times so that the thread may The torque spanner functions as follows:
assume its difinite shape, thus obviating the risk of
loose nuts. 9) The above-mentioned spring activates a pawl
system in the handle, and when using the spanner,
4) Nuts secured with a split pin are tightened to this pawl system will be released when the pre-set
the stated torque and then to the next split-pin hole. torque has been reached, at which moment a small
jerk is felt in the spanner and a small click is heard.
5) The following instructions apply to the use and
maintenance of torque spanner. 10) The torque spanner must not be used for
torque higher than those stamped on it, and it must
not be damaged by hammering on it or the like.
Torque Spanner.
6) The handle of the torque spanner is provided

with a scale indicating the torque at which the
spanner can be set.
Scale for torque moment Key for adjusting

of torque moment
Fig. 1. Torque spanner.

08028-0D/H5250/94.08.12
91.16 - ES0S
Working Card Tool Combinations for Tightening 620-01.20
Page 1 (3) of Connecting Rod Screws Edition 01H
L28/32H

Shut-off fuel oil 62006 30 Ekstra tools.
Shut-off cooling oil 62006 32 Only for tightening
Stopped lub. oil circul. 62006 34 200 mm.
62006 37 32 mm.
62006 39 Ekstra tools.
62006 41 Ekstra tools.
Description:
Tool combinations for tightening and checking

connecting rod screws. Hand tools:
Starting position:
Related procedure:
Dismounting of piston and connecting

rod, 606-01.00
Tightening and check of connecting
rod screws, 606-01.25
In-situ inspection of connecting
rod big-end bearing, 606-01.30
08028-0D/H5250/94.08.12
Working time : Hours Plate no. Item no. Qty. /

Capacity : man
Data:

91.45 - ES0S
620-01.20 Tool Combinations for Tightening Working Card
Edition 01H of Connecting Rod Screws Page 2 (3)
L28/32H
The tightening procedure for connecting rod screws

can be executed with the tools originally delivered Tool combinations for tightening of lower screws,
with the GenSets. see fig. 2.
The enclosed pages illustrate different tool combina-

tions applicable to tightening of connecting rod
screws. 1. Torque spanner, 140 - 760 Nm.
2. Ratchet, (only for tightening).
The turning of the screws through a 60° angle, can 3. Socket, 32 mm.
be executed with less muscle power if a planet gear
spanner (extra tools) is used.
If tool combination with planet gear spanner is used

for check of the connecting rod screws tightening
condition, the gear ratio (1:4) has to be taken into
consideration when setting the torque spanner. For
prescribed test torque of 700 Nm, the torque span-
ner should be set at 175 Nm. (4 x 175 = 700).
It is also acceptable to execute the turning of the 3 2 1

screws through a 60° angle, by means of a pneuma-
tic impact spanner, if available are adequate power
and dimensions.
Tightening with torque spanner ratchet, extension

piece (only for upper screws) and socket.
Fig. 2. Tools combinations for tightening of lower screws.
Tool combinations for tightening of upper screws,

see fig. 1.
Tightening with torque spanner, ratchet, planet gear
spanner, extension piece (only for upper screws)
and socket.
1. Torque spanner, 140 - 760 Nm.
2. Ratchet, (only for tightening).
Tool combinations for tightening of upper screws,
3. Extension piece, (200 mm).
4. Socket, 32 mm. see fig. 3.
Tool combinations for tightening of lower screws,

see fig. 4.
Tightening with pneumatic spanner and special

08028-0D/H5250/94.08.12
socket. (extra tools).
The turning of the screws through a 60° angle, can

be executed with a pneumatic impact spanner.
4 3 2 1
The impact spanner must be of adequate dimen-
sions and capacity, with 1" quadrangular terminal
shaft.
The 32 mm socket to be used must be a socalled

specially designed for use with mechanical or pneu-
Fig. 1. Tools combinations for tightening of upper screws. matic impact tools.
91.45 - ES0S
Working Card Tool Combinations for Tightening 620-01.20
Page 3 (3) of Connecting Rod Screws Edition 01H
L28/32H
Compared to sockets for manually operated span- The connecting rod screws are situated very closely,
ner, the power top has increased dimensions. leaving only minor space between collars and hexa-
gonals of the screw heads.
Dependent of the manufactures, it can be necessary

1. Torque spanner, 140 - 760 Nm. to adapt the power top to the limited space conditions
1
2. Ratchet, (only for tightening). around the screws.
3. Planet gear spanner, (ratio 1:4).
4. Extension piece, (200 mm). In such case only the absolutely necessary machin-
5. Socket, 32 mm.
ing should be executed.
3
An external diameter of 51 mm, see fig. 5 in a length
of 21 mm at the hexagonal end of the power top is
sufficient for access to the screws.
Connecting rod screws

5 4 2
Connecting rod
Fig. 3. Tools combination for tightening of upper screws with

planet gear.
ø51 21 mm
1. Torque spanner, 140 - 760 Nm. 1 Special socket

2. Ratchet, (only for tightening). (power top)
3. Planet gear spanner, (ratio 1:4).
4. Socket, 32 mm.
3
Fig. 5. Special socet.
08028-0D/H5250/94.08.12
Machining beyond these dimensions should not take

place as it could influence the rigidity of the power
top.
4 2
Fig. 4. Tools combination for tightening of lower screws with

planet gear.
91.45 - ES0S
Working Card
Max Pressure Indicator 620-01.25
General

Shut-off cooling water 62005 10 Max pres. indicator
Shut-off fuel oil
Description:
Operation.
Overhaul intervals. Hand tools:
Dismantling, overhaul and assembly.
Allen key, 3 and 6 mm.
Starting position:
Related procedure:
08028-0D/H5250/94.08.12
Working time : 1/2 hour Plate no Item no Qty/

Capacity : 1 man
See Plate 62005
Data:
Data for pressure and tolerance

Data for torque moment
Declaration of weight
94.12 - ES0S
620-01.25 Max. Pressure Indicator Working Card
General
Operation:
1) Open the indicator valve and blow through 1

shortly.
2) Connect the max pressure indicator to the

indicator valve and open the valve.
3) After 3-5 seconds read the max pressure on 2

the gauge. 5
Attention: The indicator valve has to be open while

reading the max pressure on the gauge. The 4
measuring period should not exceed 30 seconds.
3
4) Close the indicator valve and open the valve
screw (5), fig 1.
1 Housing 2 Allen screw
5) Disconnect the max pressure indicator and
3 Sealing 4 Screw
close the valve screw (5), fig 1.
5 Valve screw
6) Measure the remaining cylinders by following Fig 1 Pressure Indicator.

step 1 to 5.
Overhaul Intervals. 3) Loosen the screws (2) (4 pieces) for separating

upper and lower part.
1) Dismount and clean the non-return valve after
200 measuring periods. If the pressure drop is more 4) After separation of the upper and lower part,
than 5 bar within 60 seconds (test pressure 100 bar) take off the non-return valve assembly.
it is recommended to relap the non-return valve.
5) Lap the valve and the valve seat.
2) Check the pressure gaugeafter 1.000
measuring periods or after 12 month use. 6) Renew the sealing ring (3) and screws (2), if
necessary.
Attention: Use only exhaust gas or nitrogen gas and 7) When mounting the upper and lower part, use
never oil for testing the pressure drop and the only original screws.
pressure gauge. By using oil carbon will deposit
08028-0D/H5250/94.08.12
inside the measuring instrument. 8) Coat the screws (2) with copaslip or similar
and tighten to 10 Nm.
Dismantling and Assembly: 9) After assembly the instrument can be used

without any new calibration.
1) Dismount the valve screw (5), fig 1.
2) Turn the screw (4) into the instrument to Check of the Pressure Gauge:
enable dismounting of the housing (1).
10) Testing of the instrument should only be made
by skilled specialists, and it is recommended to send
the instrument to MAN B&W Diesel A/S, Holeby for
calibration.
94.12- ESOS

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Instruction Book

Instruction book for:

STX-MAN B&W Diesel Identification No for Instruction Book.

Identification No for Working Cards: 000-00.00

Identification No for Plates: 00000-00 H

Section No and Function

For ordering of spare parts, see page 600.50

641-315 641-315 641-050 641-315

Tell: 82-55-280-0114 Tell: 82-55-280-0540 Tell: 82-55-280-0600 Tell: 82-55-280-550 ~558

2. Engine No. - -, built by

3. Illustration plate number (complete with Ed. figures)

5. Quantity required (and description)

Main Data for Engine Type ...................................................... L28/32H

Main Data for Alternator Make ..................................................... x

Main Data for Turbocharger Make ..................................................... MAN

Serial No. for engine No. ....................... ...................................

Main Data for Governor Make ..................................................... Woodward

The book is a basic instruction manual for the

The first five sections (600-604) of the book serve as

The engine is divided into a number of main compo-

Each of these sections starts with technical de-

In particular, welding or work which causes spread-

Fire The opening of cocks may cause discharge of hot

Feeling over Turning with air

Feel-over sequence Check and maintain

Engine Type Identification

MCR : Maximum continuous rating

Front End Flywheel end

Exhaust Side / Right Side

Control Side / Camshaft Side / Left Side

Temperature Alarm High

Specification of letter code for measuring devices

1 st letter Following letters

V Viscosity S Switching, Stop

Standard text for instruments

01 inlet to air cooler 05 outlet from alternator

Lubricating Oil System

20 inlet to cooler 25 prelubricating

Charging Air System

30 inlet to cooler 35 surplus air inlet

Fuel Oil System

Cooling Oil System

50 inlet to fuel valves 55

Exhaust Gas System

Compressed Air System

70 inlet to engine 75 micro switch for turning gear

80 85 micro switch for overload

91 Natural gas - inlet to engine 95 voltage

General 4. Related procedures - indicates other works,

Experience with the specific plant/crew is to be used

1. Safety regulations, which MUST be carried

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

Fig 1. Guidance instruction for working cards.

Normal Value at Full load Alarm Set point Autostop of engine

Lubricating Oil System

Fuel Oil System

Cooling Water System

Exhaust Gas and Charge Air

Compressed Air System

Speed Control System

Remarks to individual Parameters B. Cooling Water Pressure, Alarm Set Points.

As the system pressure in case of pump failure will

Normal Value at Full load Alarm Set point Autostop of engine