Professional Documents
Culture Documents
SHINA / UNICORN
(HNo.SAS-434)
6L23/30H
Function
Section No
Sub-function
Function
Section No
H for Holeby
Edition
Section No and Function
This book must not, either wholly or partly, be copied, reproduced, made public or in any other way made
available to any third party without the written consent to this effect from MAN B&W A/S, Holeby.
STX Engine
Index
Page 1(1) Engine Data 500
L23/30H
Description
Working Card
Plates
STX Engine
Description
Main Data for GenSets 500.00
Page 1(1)
6L23/30H
Number of cylinders 6
Cycle 4 stroke
Cylinder bore 225 mm
Stroke 300 mm
Engine speed 720 min-1
Engine outpur (on flywheel) 780 kW
Compression ratio 13 : 1
Max. combustion pressure 132.6 kg/cm2
Firing order 1-4-2-6-3-5
Rotation C.W view from flywheel
STX Engine
Description
Introduction 500.01
Page 1 (1)
Edition 01H
L23/30H
Description
This instruction book serves the purpose of providing 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.
96.02 - ES0S-G
Description
Safety 500.02
Page 1 (2)
Edition 01H
L23/30H
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 rou- preserved against corrosion and protected against
tine 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.
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.
96.02 - ES0U-G
500.02 Safety Description
Edition 01H Page 2 (2)
L23/30H
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 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 502.
08028-0D/H5250/94.08.12
96.02 - ES0U-G
Description
Cross Section 500.05
Page 1 (1) Edition 01H
L23/30H
08028-0D/H5250/94.08.12
91.34-ES1S
Description 500.10
Page 1 (1) Key for Engine Designation Edition 01H
L23/30H
The engine types of the MAN B&W Holeby programme are identified by the following figures:
6 L 23/30 H MCR
No of cylinders
5, 6, 7, 8, 9
12, 16, 18
Engine Type
L : In-line
V : V-built
Cyl. diam/stroke
23/30 : 225/300
28/32 : 280/320
Design Variant
Rating
90.38 - ES1U-G
Description 500.11
Page 1 (1) Designation of Cylinders Edition 01H
L23/30H
89.17 - ES1S-L
Description 500.12
Page 1 (1) Engine Rotation Clockwise Edition 01H
L23/30H
Engine
08028-0D/H5250/94.08.12
Alternator
91.49 - ES1S-G
Description
Code Identification for Instruments 500.20
Page 1 (3) Edition 01H
L23/30H
Symbol explanation:
Measuring device
TI
Local reading
40
Temperature Indicator
No 40 *
Measuring device
PI Sensor mounted on engine/unit
22 Reading/identification mounted in a panel on the engine/unit
Pressure Indicator
No 22 *
Measuring device
TAH Sensor mounted on engine/unit
12 Reading/identification outside the engine/unit
* Refer to standard location and text for instruments on the following pages.
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
X Sound T Transmitting
Z Position X Failure
96.02 - ES1U-G
500.20 Code Identification for Instruments Description
Edition 01H Page 2 (3)
L23/30H
Diesel engine/Alternator
LT Water System
HT Water System
96.02 - ES1U-G
Description
Code Identification for Instruments 500.20
Page 3 (3) Edition 01H
L23/30H
60 outlet cylinder 65
61 outlet turbocharger 66
62 inlet turbocharger 67
63 68
64 69
Load Speed
Miscellaneous
93 knocking sensor 97
94 cylinder lubricating 98
99
96.02 - ES1U-G
Description
Introduction to Planned Maintenance Programme 500.24
Page 1 (1)
Edition 02H
L23/30H
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 500.25, 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 the actual stated.
service results and thus the intervals between
necessary overhauls.
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
96.02 - ES0S-G
Description
Planned Maintenance Programme 500.25
Page 1 (4) Edition 01S
L23/30H
720/750 RPM
overhauled parts
Working
Observations
l = Overhaul to be carried out
Description
3rd month
Check new/
Monthly
Card
200
16000
32000
8000
Weekly
50
2000
after hours
n
Daily
= Check the condition
No
Operating of Engine:
Cylinder Head:
03.05-STX
500.25 Planned Maintenance Programme Description
Editiong 01S Page 2 (4)
L23/30H
720/750 RPM
overhauled parts
Working
Ovservations
Description l = Overhaul to be carried out
3rd month
Card
Check new/
50
2000
8000
200
32000
16000
Weekly
Monthy
after hours
n = Check the condition
Daily
No
03.05 - STX
Description
Planned Maintenance Programme 500.25
Page 3 (4) Edition 01S
L23/30H
720/750 RPM
overhauled parts
Working
Observations
l = Overhaul to be carried out
Description
3rd month
Check new/
50
2000
8000
Card
200
32000
16000
Weekly
Monthly
after hours
n
Daily
= Check the condition
No
Turbocharger System:
03.05-STX
500.25 Planned Maintenance Programme Description
Edition 01S Page 4 (4)
L23/30H
720/750 RPM
overhauled parts
Working
Observations
l = Overhaul to be carried out
Description
3rd month
Check new/
Card
Monthly
50
2000
8000
200
32000
16000
Weekly
after hours
n
Daily
= Check the condition
No
03.05-STX
Description
Operation Data & Set Points 500.30
Page 1 (2) Edition 35H
L23/30H
Pressure after filter (inlet eng) PI 22 3-4 bar PAL 22 3 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
Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar (C)
Temp. nozz. cool. oil, outlet eng. TI 51 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)
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.
* for 720/750 rpm ** for 900 rpm.
03.46 - ES1
500.30 Operation Data & Set Points Description
Edition 35H Page 2 (2)
L23/30H
08028-0D/H5250/94.08.12
03.46 - ES1
Description 500.35
Page 1 (1) Data for Pressure and Tolerance Edition 15H
L23/30H
506 Piston and piston ring grooves (see working card 506-01.10)
Clearance in big-end bearing 0.15-0.20 mm
Clearance between connecting rod bush and piston pin 0.15-0.25 mm.
Maximum ovalness in big-end bore (without bearing) 0.08 mm.
New cylinder liner, inside diameter 225,000-225,046 mm.
Maximum inside diameter cylinder liner, max. ovalness 0.1 mm 225.50 mm
508 Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.50 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.
Measurement "X" between thrust piece and roller guide housing 5.5 ± 2.5 mm
1.5 mm
For L23/30H 900 rpm version a pressure of 135 bar measured at the
indicator cock correspond to 130 bar in the combustion chamber
03.36 - ES0
Description 500.40
Page 1 (1) Data for Torque Moment Edition 09S
L23/30H
720/750 rpm
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
505 Cylinder cover stud (in frame) Stud M48 200 Copaslip
Nut for cylinder cover stud Nut M45 750 Copaslip
02.15 - ES0U
Description
Declaration of Weight 500.45
Page 1 (1) Edition 01H
L23/30H
97.06 - ES0U
Description
Ordering of Spare Parts 500.50
Page 1 (2)
Edition 01H
L23/30H
Whenever spare parts are ordered (or reference is These data are used by us to ensure supply of the
made in correspondence etc.) the following data must correct spare parts for the individual engines, even
be indicated for the particular engine: though the spare part illustrations contained in this
book may not always be in complete accordance with
1. Name of plant the individual components of a specific engine.
2. Engine type and engine No ----, built by
3. Illustration plate number (complete with ed. Note: For ordering of spare parts for governor,
figures) turbocharger and alternator, please see special in-
4. Item No struction book for these components.
5. Quantity required (and description)
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
08028-0D/H5250/94.08.12
609
06
610
611
13
612
07
3
61
4
91.4
61
6 - ES
0S
14
5
61
6
61
7
61
8
61
9
61
0
62
96.02 - ES2S-G
Description
Ordering of Spare Parts 500.50
Page 2 (2) Edition 01H
L23/30H
Name of Plant:
96.02 - ES2S-G
Description
Service Letters 500.55
Page 1 (1)
Edition 01H
L23/30H
Description
In order to ensure the most efficient, economical, and importance to the operation of the plant, we recommend
up-to-date operation of our engines, we regularly send that engine staff to file them to supple-ment the
out "Service Letters", containing first-hand informa- relevant chapters of this instruction book.
tion regarding accumulated service experience.
96.02 - ES0U-G
Description 500.60
Page 1 (3) Conversion Table Edition 01H
L23/30H
SI Base Units Length (m)
time minute min 1 min = 60 s Velocity, Speed (m/s) (3.6 km/h = 1 m/s)
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
92.16 - ES0U
500.60 Conversion Table Description
Edition 01H Page 2 (3)
L23/30H
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 lb/cub. ft 16.02 kg/m3 * 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name taken from the
Force (1 kg m/s2 = 1 N)
Energy, Work (1 Nm = 1 J, Wh)
1 kp (kilopound)* 9.807 N
* 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.
92.16 - ES0S
Description 500.60
Page 3 (3) Conversion Table Edition 01H
L23/30H
Reference conditions
Specific fuel oil consumption values refer to brake power, and the following
Heat conductance (W/(m K)) reference conditions:
92.16 - ES0U
Description
Basic Symbols for Piping 500.65
Page 1 (3) Edition 01H
L23/30H
1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint
1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere
1.6 High pressured pipe 3. VALVES, GATE VALVES, COCKS AND FLAPS
2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight
2.5 Expansion pipe (corrugated) general 3.8 Non-return valve (flap), angle, screw
96.02 - ES0S-G
500.65 Basic Symbols for Piping Description
Edition 01H Page 2 (3)
L23/30H
3.31 Cock with bottom connection 4.14 Solenoid and pilot directional valve
3.32 Cock, straight through, with bottom conn. 4.15 By plunger or tracer
L23/30H
5.17 Water trap with manual control 7. READING INSTR. WITH ORDINARY DESIGNATIONS
5.21 Single acting cylinder with spring returned 7.4 Distance level indicator
5.23 returned
Steam trap
96.02 - ES0S-G
Index
Page 1(1) Operation of Engine 501
L23/30H
Description
Working Card
Plates
STX Engine
Description
Operating 501.01
Page 1 (2)
Edition 01H
L23/30H
Preparations for Starting 4. Check the pressure in the starting air receiver(s)
and open the starting air supply (blow-off water, if any,
The following describes what to do before starting, and drain the starting air system before opening.
when the engine has been out of service for a longer
period of time, or if major overhauls have been made. 5. Regulating gear - please check:
1. Check the oil level in the base frame (or in the - that all fuel pumps are set at index "0" when the
lub. oil tank, if the engine is with dry sump), air regulating shaft are in STOP position.
lubricator and in the govenor.
- that each fuel pump can be pressed by hand to
Start-up the prelubricating pump. full index when the regulating shaft are in STOP
position, and that the pumps return automatically to
The engine shall be prelubricated at least 2 minutes the "0" index when the hand is removed.
prior to start.
- that the spring-loaded pull rod is working
Check oil pressures before and after the filter. correctly.
2. Open the cooling water supply, start separate - that the stop cylinder for regulating the shaft
cooling water pumps where installed, and check the works properly, both when stopping normally and at
cooling water pressure. overspeed and shut down.
Note: To avoid shock effects owing to large tempe- - that testing is made by simulating these
rature fluctuations just after the start, it is recom- situations.
mended:
6. Open the indicator valves and turn the engine
a) to preheat the engine. Cooling water of at least some few revolutions, check that no liquid is flowing
60 °C should be circulated through the frame and out from any of the indicator valves during the turning.
cylinder head for at least 2 hours before start:
Slow-turning must always be carried out, before the
- either by means of cooling water from engines engine is started after prolonged out of-service pe-
which are running or by means of a built-in preheater riods and after overhauls, which may involve a risk of
(if installed). liquid having collected in the cylinders.
b) When starting without preheated cooling water, 8. Disengage the turning gear, if fitted. Check that
the engine must only be started on MDO (Ma-rine it is locked in the "OUT" position.
Diesel Oil).
08028-0D/H5250/94.08.12
Note: When starting on HFO (Heavy Fuel Oil), only 2. Check the lubricating oil pressure, cooling water
item "a" applies. pressure, fuel oil feed pressure. Check that the
prelubricating oil pump is stopped.
3. Open the fuel oil supply to the feed pump.
3. Check that all alarms are connected.
Starting on HFO: circulate preheated fuel through the
pumps until correct working temperatures have been See also "checks after starting-up".
obtained. This normally takes 30-60 minutes.
96.02 - ES0U-G
501.01 Description
Edition 01H
Operating Page 2 (2)
L23/30H
Starting on MDO
7. Keep the charging air pressure and tempera-
ture under control. For normal values, see the test For starting on MDO there are no restrictions except
report from shop and sea trials. lubricating oil viscosity may not be higher than 1500
cSt (5° C SAE 30, or 10° C SAE 40).
8. Recharge the starting air receivers when the
pressure has dropped to about 20 bar. Stop rechar- Initial ignition may be difficult if the engine and
ging at 30 bar. ambient temperatures are lower than 5° C and 15° C
cooling water temperature.
96.02 - ES0U-G
Description
Out of Service 501.05
Page 1 (2) Edition 01H
L23/30H
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 me- replaced before start, after repair, or after excessive
dia cooling water and fuel oil should be continuously differential pressure. After removal, dirty elements
circulated at temperatures similar to the operation can be examined for particles of bearing metal at the
conditions. bottom of the paper lamella. (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.
During the lay-up period (and also when laying-up the The following should be made during 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. Work 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 el-driven prelub. pump, open up the
crankcase and camshaft housings and check that the 5.3. Remedy leakages of water and oil in the engine,
oil is flowing freely from all bearings. Also, take off the and blow through blocked-up drain pipes.
top covers on the cylinder heads and make sure that
oil is not supplied for lubrication of rocker arms, as 5.4. Drain starting air pipes of water.
non-return valves are fitted which do not open until the
oil pressure at the inlet to the rocker arms exceeds 1 5.5. Empty the oil sump of lubricating oil and remove
08028-0D/H5250/94.08.12
4.2. After stopping the prelub. pump, check the 6. Work after Repairs
bottom of the oil sump for fragments of babbitt from
bearings 6.1. If an opening-up of engine or lubricating oil
system may have caused ingress of impurities,
cleaning should be carried out very carefully before
starting the engine.
96.02 - ES0U-G
501.05 Description
Edition 01H
Out of Service Page 2 (2)
L23/30H
The differential pressure across the lub. oil filter must 6.7 b) Adjustment speed: Switch-in the alternator
be watched very carefully after cleaning and starting- on the switchboard and set the load to about 40%. On
up the engine. Be sure to replace filter cartridges in reaching normal oil temperatures in governor and
due time. engine, increase the load instantly to about 80% (by
starting the major pump or compressor). This must
6.2. After restoring normal lubricating oil circulation, not cause the frequency to fall by more than some
turn the engine at least two revolutions by means of 8%, and the engine must return to a constant no rpm
the turning rod to check the movability of the relevant after about 3 seconds (although this rpm will be a little
parts of the engine. lower than before owing to the speed droop of
the governor). If the engine is operated in parallel with
6.3. Close the drain cocks in the turbocharger (or in other engines, an even sharing of load shall be
the exhaust gas system, if mounted). established within about 3 seconds. If the governor
reacts too slowly, compensating adjustment is ef-
6.4. Lubricate thebearings and rod connections in fected as indicated in Woodward's instruction manual
the manoeuvring gear. Disconnect the governor and (Compensating Adjustment).
move the rod connections by hand to check that the
friction in bearings and fuel pumps is sufficiently low. Note: It is a condition for this test that the engine and
If repair of bearings or alignment of engine has been turbocharger are in perfect operating condition, so
made, check no 1, 2, and 5 should be repated. that possible sources of error immediately can be
eliminated
6.5. Checks to be made just before starting of the
engine are mentioned under 501.01. 6.7 c) Hunting: Run the engine at synchronous
rpm, and without load. Provided the governor oil is
6.6. Add cooling water and check the leakage pres- warm, the regulating lever must not perform any major
sure system on at the upper and lower cy-linder liner periodical movments, and neither must there be any
sealings and at cooling water connections. variation in the engine speed. If that is the case,
repeat the compensating adjustment according to
6.7. Check the governor as follows: Woodward's instruction manual.
Start up the engine and run it at the synchronous
number of revolutions. 6.7 d) Speed droop: in case of unsatisfactory load
sharing between two ore more engines this can be
6.7 a) Speed-setting: Before switching-in the al- rectified by increasing the speed droop of the engine
ternator on the switchboard please check that the that is subject to the greatest load (or by reducing the
servomotor adjusts the rpm with a suitable quickness setting of the other engines).
after actuation of the synchronizer knob on the switch-
board. The range from - 5% to + 5% from the syn- The setting should not normally be increased beyond
chronous rpm should be tested. 70 on the scale, and satisfactory parallel operation
can generally be obtained at settings between 40 and
60.
08028-0D/H5250/94.08.12
96.02 - ES0U-G
Description
Starting-up after Out of Service Periods 501.10
Page 1 (1)
Edition 01H
L23/30H
The following enumerate checks are to be made After the last feel-over, repeat check 4 page 501.05,
immediately after starting, during load increase, and see also Ignition in Crankcase page 503.04 in
during normal running. section 503.
In the following it is assumed that the engine has After repair or renewal of cylinder liners, piston rings
been out of service for some time, for instance due or bearings, allowance must be made for a running-
to repairs and that checks during out of service in period, i.e. the engine load should be increased
periods have been carried out as described in the gradually as indicated in the tables below. The
previous chapter. engine output is determined on the basis of the fuel
index and the load on the electric switchboard. The
When starting after such an out-of-service period, turbocharger speed gives some indication of the
the following checks must be made in the stated engine output, but is not directly proportional to the
order in addition to normal surveillance and recor- output throughout the service period.
ding.
Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for certain
1. To be Checked immediately after Starting: that there are no hot spots in the engine. Then,
increase the speed to the normal rpm and connect to
1.1. Check that the turbocharger is running. the switchboard and put on load.
1.2. Check that the lubricating oil pressure is in The load increase during the starting-up sequence
order. may, for instance, be:
1.3. Check that all cylinders are firing (see exhaust 25 % load for 2 hours
temperatures). 50 % load for 2 hours
75 % load for 2 hours
1.4. Check that everyting is normal for the engine 100 % load may be put on.
speed, fuel oil, cooling water and system oil.
The pump index indicated in the tables has been
1.5. Check by simulation of the overspeed shut- given as a percentage of the index at full load. To
down device that the engine stops. The overspeed enable the index to be read directly off the fuel
setting should be according to " Set Points and pumps, the following formula can be employed:
Operation Data " section 500.
I = I% x IF
100
2. To be Checked during Starting-up, but
only if Required after Repairs or Alterations: IF = Index at full load (from testbed table)
2.1. If the condition of the machinery is not well- I% = Index expressed as % of full load index
known, especially after repairs or alterations, the (stated in the preceding starting-up
08028-0D/H5250/94.08.12
Feel: Main, crankpin, (alternator), and camshaft After completing the starting-up sequence, make
bearings, piston pins, cylinder liners, roller guides sure that all fuel pumps are set at the same index and
and gear wheels. that the governor can cause all fuel pumps to move
to "0" index.
96.30 - ES0U-G
Description
Guidelines for Longterm Low-Load Operation on HFO 501.15
Page 1 (1) Edition 02H
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
00.11 - ES1
Index
Page 1(1) Engine Performance and Condition 502
L23/30H
Description
Working Card
Plates
STX Engine
Description Engine Performance and Condition 502.01
Page 1 (3) Edition 01H
L23/30H
Performance Data and Engine Condition An increase of charge air temperature involves a
corresponding increase of the exhaust gas temperature
During operation small alterations of the engine level in a ratio of about 1:1.5, i.e. 1°C higher charge air
condition continuously take place as a result of temperature causes about 1.5°C higher exhaust gas
combustion, including fouling of airways and gasways, temperature.
formation of deposits, wear, corrosion, etc. If
continuously recorded, these alterations of the Reduction of the charge air pressure results in a
condition can give valuable information about the corresponding reduction of the compression pressure
operational and maintenance condition of the engine. and max. combustion pressure. When checking the
Continual observations can contribute to forming a max. pressure adjustment of the engine, it is therefore
precise and valuable basis for evaluation of the to be ensured that the existing charge air pressure is
optimal operation and maintenance programmes for correct.
the individual plant.
The injected amount of fuel is equivalent to supplied
We recommend taking weekly records of the most energy and is thus an expression of the load and mean
important performance data of the engine plant. During pressure of the engine. The fuel pump index can
recording (working card 502-01.00 can be used), the therefore be assumed to be proportional to the mean
observations are to be continually compared in order pressure. Consequently, it can be assumed that the
to ascertain alterations at an early stage and before connected values of the pump index are proportional
these exert any appreciable influence on the operation to the load.
of the plant.
The specific fuel consumption, SFOC (measured by
As a reference condition for the performance data, the weight) will, on the whole, remain unaltered whether
testbed measurements of the engine or possibly the the engine is operating on HFO or on MDO, when
measurements taken during the sea trial at the delivery considering the difference in calorimetric combustion
of the ship can be used. If considerable deviations value. However, when operation on HFO, the
from the normal condition are observed, it will, in a combination of density and calorific value may result
majority of cases, be possible to diagnose the cause in an alteration of up to 6% in the volumetric
of such deviations by means of a total evaluation and consumption at a given load. This will result in a
a set of measurements, after which possible corresponding alteration in the fuel pump index, and
adjustment/overhauls can be decided and planned. regard should be paid to this when adjusting the
overload preventative device of the engine.
Evaluation of Performance Data Abrasive particles in the fuel oil result in wear of fuel
pumps and fuel valve nozzles. Effective treatment of
For example, fouling of the air side of the air cooler will the fuel oil in the purifier can limit the content of
manifest itself in an increasing pressure drop, lower abrasive particles to a minimum. Worn fuel pumps will
charge air pressure and an increased exhaust result in an increase of the index on account of an
temperature level (with consequential influence on increased loss in the pumps due to leakage.
08028-0D/H5250/94.08.12
96.20 - ES0U-G
502.01 Engine Performance and Condition Description
Edition 01H Page 2 (3)
L23/30H
The operational observations supplemented by the Normally, the fuel nozzle temperature will be higher
daily routine monitoring contribute to ensuring that than the approx. 180°C, at which cold corrosion starts
faulty adjustments and other deviations in the to occur.
performance of individual components are observed
in time to avoid operational disturbances and so that Abrasive particles in the fuel oil involve a heavier wear
normal routine overhauls can be carried out as of the fuel valve needle, seat, and fuel nozzle holes.
scheduled. Therefore, abrasive particles are, to the greatest
possible extent, to be removed at the purification.
If abnormal or incomprehensible deviations in the
operation are recorded, expert assistance for the
evaluation of these should be obtained. Exhaust Valves
The rate of fouling and thereby the influence on the Especially under favourable conditions, fuel qualities
operation of the engine is greatest for small with a high vanadium and sodium content will promote
turbochargers where the flow openings between the burning of the valve seats. Combinations of vanadium
guide vanes of the nozzle ring are relatively small. and sodium oxides with a corrosive effect will be
Deposits especially occur on the guide vanes of the formed during the combustion. This adhesive ash
nozzle ring and on the rotor blades. In the long run, may, especially in the case of increased valve
fouling will reduce the efficiency of the turbocharger temperatures, form deposits on the seats. An
and thereby also the quantity of air supplied for the increasing sodium content will reduce the melting
combustion of the engine. A reduced quantity of air point and thereby the adhesive temperature for the
will result in higher wall temperatures in the combustion ash, which will involve a greater risk for deposits. This
spaces of the engine. condition will be especially unfavourable when the
weight ratio Na increases beyond 1:3.
Detailed information and instructions regarding water Va
washing of the turbocharger are given in the section
512. The exhaust valve temperature depends on the actual
maintenance condition and the load of the engine.
With correct maintenance, the valve temperature is
Fuel Valves kept at a satisfactory low level at all loads. The air
supply to the engine (turbocharger/air cooler) and the
Assuming that the fuel oil is effectively purified and maximum pressure adjustment are key parameters in
that the engine is well maintained, the operational this connection.
08028-0D/H5250/94.08.12
96.20 - ES0U-G
Description Engine Performance and Condition 502.01
Page 3 (3) Edition 01H
L23/30H
Air Inlet Valves Engine Room Ventilation, Exhaust System
The operational conditions of the air inlet valves are Good ventilation of the engine room and a suitable
not substantially altered when using residual fuel. location of the fresh air intake on the deck are
important. Seawater in the intake air might involve
corrosive attack and influence the overhaul intervals
Fuel Pumps 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.
08028-0D/H5250/94.08.12
96.20 - ES0U-G
Description Evaluation of Readings Regarding 502.02
Page 1 (1) Combustion Condition Edition 01H
L23/30H
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.
92.03 - ES0S-G
Description
Condensate Amount 502.05
Page 1 (2) Edition 01H
L23/30H
10 20 30 40 50 60 70
0.10
0.08
r
ba
0
2.
0.06
r
Max. water content
ba
0
of atmosphere
3.
Ι %
%
0%
%
%
60
70
80
90
10
0.04
A B
in air tank
Pressure
0.02
ΙΙ
30 bar
ΙΙΙ
Relative 0
air humidity 30 40 50 60 70
96.02 - ES1S-G
502.05 Condensate Amount Description
Edition 01H Page 2 (2)
L23/30H
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 receiver.
Example:
= (l - ll) x le x P
= (0.033 - 0.021) x 8.2 x 780 = 76,8 kg/h 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
96.02 - ES1S-G
Working Card 502-01.00
Page 1 (4) Engine Performance Data Edition 01H
L23/30H
Starting position:
Engine is running.
Related procedure:
08028-0D/H5250/94.08.12
Data:
96.37 - ES0U-G
502-01.00 Engine Performance Data Working Card
Edition 01H Page 2 (4)
L23/30H
Engine Performance Data
M/V Engine Type Engine No Date/Year Hour Total Engine
1 2 3 4 5 6 Running Hours
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
20 Exhaust Temp. (° 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
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
Sign.
48 49 50
96.37 - ES0U-G
Working Card
Engine Performance Data 502-01.00
Page 3 (4) Edition 01H
L23/30H
Instruction for Filling in the Diagram "Engine 14. Cos j/kVAr - can be read on the switchboard.
Performance Data"
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.
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
500.00. the 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
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-G
502-01.00 Engine Performance Data Working Card
Edition 01H Page 4 (4)
L23/30H
28. Gas before temperature exhaust TC (°C) ture (sea, raw or fresh) at inlet lub. oil cooler (°C)
- thermometer TI 62. - thermometer TI 07.
29. Exhaust gas temperature after TC (°C) 41. Low temperature (LT) cooling water tempera-
- thermometer TI 61. ture (sea, raw or fresh) at outlet lub. oil cooler °C)
- thermometer TI 03.
30. Exhaust gas pressure after the TC (bar)
- pressure gauge PI 61. 42. Low temperature (LT) cooling water tempera-
ture (sea, raw or fresh) at inlet alternator (°C)
- thermometer TI 04.
Lubricating Oil System
43. Low temperature (LT) cooling water tempera-
31. Lub. oil inlet cooler temperature (°C) ture (sea, raw or fresh) at outlet alternator (°C)
- thermometer TI 20. - thermometer TI 05.
32. Lub. oil pressure before the filter (bar) 44. High temperature (HT) fresh water tempera-
- pressure gauge PI 21. ture (FW) at inlet engine (°C)
- thermometer TI 10.
33. Pressure of the lub. oil after the filter (bar)
- Pressure gauge PI 22. 45. High temperature (HT) fresh water tempera-
ture (FW) of outlet engine (°C)
The filter element should be replaced with a pressure - thermometer TI 10.
drop across the filter of 1.5 bar (see section 615).
34. Lub. oil inlet engine temperature (°C) Fuel Oil System
- thermometer TI 22.
46. Fuel oil temperature at inlet engine (°C)
35. Lub. oil pressure before the turbocharger - thermometer TI 40.
(bar).
- pressure gauge PI 23. 47. Fuel oil pressure before engine (bar)
- pressure gauge PI 40.
- thermometer TI 02.
96.37 - ES0U-G
Index
Page 1(1) Trouble Tracing 503
L23/30H
Description
Working Card
Plates
STX Engine
Description
Starting Failures 503.01
Page 1 (1) Edition 02H
General
Engine turns as soon as shut- Faults in electrical system. Check electrical parts.
off valve is opened, without
start button being activated.
Engine does not turn when start Air pressure in starting air re- Start compressors, re-charge
button is activated. ceiver too low. air receiver.
Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing or clutch jaws,
see Working Card 513-01.30.
Faults in electrical system. Check electrical parts.
Engine turns too slowly or Worn air motor parts. Remove and disassemble the
irregularly when start button is air motor. Examine all parts
depressed. and replace any that are worn
or damaged. Use the guide-
lines for determining unserv-
iceable parts, see Working
Card 513-01.30.
Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.
08028-0D/H5250/94.08.12
00.12 - ES0
Description
Faults in Fuel Oil System 503.02
Page 1 (3)
Edition 01H
L23/30H
Engine turns on starting air, but Sluggish movement of manoeuvering Lubricate and mobilize rod con-
ignition fails. Fuel pumps are not gear. nections in manoeuvering gear.
actuated.
Governor setting incorrect. Adjust governor, see special in-
struction manual.
Too low pressure before fuel injection Increase the fuel oil feed pump
pumps (3). pressure.
Cont.
96.37 - ES0U-G
503.02 Faults in Fuel Oil System Description
Edition 01H Page 2 (3)
L23/30H
First ignitions are too violent Slow turning with open indicator
(safety valves are opening). Oil has collected on piston crown (7). valves. To locate defective fuel
Engine runs erratically. val-ve, remove oil.
Remarks
1) If the shutdown function is due to overspeed, 4) If the fuel is forced into the cylinder through a
the shutdown impulse is cancelled by setting the defective fuel valve or through worn-out atomizer
overspeed governor and thus venting the stop cylin- holes, no or too sluggish atomization may prevent
der. ignition, possibly followed by too violent ignition.
2) Whenever air is present in the fuel oil system 5) To obtain ignition temperature in the cylinders,
repeat venting of fuel pumps. The cause may be that the compression pressure during starting should be
a fuel valve is kept in open position (spindle sticking normal, see the testbed report. This can be checked
or spring broken). Heating of fuel to a too high by measuring the compression pressure during
temperature may have a similar effect owing to starting. Cylinders having too low compression should
formation of gas in the fuel. If a sticking valve is be inspected.
08028-0D/H5250/94.08.12
96.37 - ES0U-G
Description
Faults in Fuel Oil System 503.02
Page 3 (3) Edition 01H
L23/30H
7) Oil on the piston crown will in most cases have If a repair cannot be made on the spot, it is decided
leaked down from a defective fuel valve. As these oil if running may continue, with or without the defective
accumulations are dangerous, the leakage should charger blanked off.
be found and remedied before the engine is started
again. When continuing the running with the turbocharger
out of operation, the engine output must be reduced.
The exhaust temperature must not exceed the nor-
Turbocharger Failure mal valve, for full load running with an intact turbo-
charger. For further details see the separate turbo-
If heavy vibrations, bearing failure or other trouble charger instr. manual.
arise in a turbocharger, the engine load must be
reduced until the vibrations cease. When possible,
the engine is stopped in order to locate and remedy
the fault (see turbocharger instr. manual).
08028-0D/H5250/94.08.12
96.27- ES0U-G
Description
Disturbances during Running 503.03
Page 1 (3)
Edition 01H
L23/30H
Exhaust temperature(s) (All cyls.) Increased charging air See Working Card 512-01.00.
increase(s) temperature due to ineffective air
coolers.
Reduce load and water-wash tur-
(All cyls.) Fouling or air and gas bine. Clean air filters and coolers.
passages.
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.
Engine RPM decreases Pressure before fuel pumps too Raise fuel oil feed pump pressure
low. to normal. Check filter.
Water in the fuel. Drain off water and vent the fuel
pumps.
96.37 - ES0U-G
503.03 Disturbances during Running Description
Page 2 (3)
Edition 01H
L23/30H
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.
Exhaust valve knocking. Adjusting 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. Stop the engine. For further details,
Filters/cooler fouled. see "Ignition in crankcase". See
also Working Card 515-01.00 for
lub. oil pump and Working Card
515-01.10 for the lub. oil filter
Remarks
08028-0D/H5250/94.08.12
1) This manifests itself by the exhaust 2) Blow-by means a serious danger of piston
temperature rising and falling of the compression seizure, and the engine must, if possible, be stopped
and maximum combustion pressure of the respective and the piston in question pulled. If this is not
cylinder dropping. 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.
96.37 - ES0U-G
Description
Disturbances during Running 503.03
Page 3 (3) Edition 01H
L23/30H
3) If this happens the fuel pump barrel and plunger 6) If the cooling water temperature for the entire
must be changed, and if, it is necessary to increase engine has risen to 90-100° C, it should be checked
the fuel pump index by more than 10 index degrees, whether steam has developed by opening the test
to obtain full load of the respective cylinder, the fuel cocks, if fitted on the discharge from cylinders. If this
pump is worn out in most cases. Usually this is is the case, there is no water on the cooling surfaces,
confirmed by inspection of the fuel pump plunger on which may therefore be heated unduly. To avoid
which the helical cut-off edge will show a pitted and heat stresses arising in cylinder liners and cylinder
corroded area where material is plucked out. In that heads, if the water returns too early, the engine
case the pump can be provided with a new barrel and should be stopped and left to cool, while the discharge
plunger. valve is closed. After 15 minutes it is opened a little
to allow the water to rise slowly in the cooling jackets.
Check filling at test cocks. Make crankcase inspection
4) The governor will not reduce the fuel pump to ascertain that internal water leakage has not
delivery to zero in case of, for instance, failure of the arisen. Remember slow turning with open indicator
governor oil pump, but the engine speed will start valves at subsequent starting-up.
fluctuating.
When the governor is defective the engine is pro- 7) If the lubricating oil pressure drops below the
tected against racing by the overspeed trip, i.e. the minimum mentioned in "Data" find the cause of the
engine is stopped automatically in case of excessive pressure drop and remedy the defect before re-
speed. It is therefore, essential, that the overspeed starting the engine. Feel over 5-15-30 minutes after
trip is kept in perfect order. Regarding governor starting, and again when full load is obtained. See
failure, see special instruction book. section 502.
96.37 - ES0U-G
Description
Disturbances during Running 503.03
Page 1 (3) Edition 01 H
L23/30H
Exhaust temperature(s) (All cyls.) Increased charging air See section 501; Operational Observat-
Increase (s) temperature due to ineffective air coolers. ions, item e.
(All cyls.) Fouling or air and gas passages. Reduce load and water-wash turbine.
Clean air filters and coolers.
(All cyls.) Insufficient cleaning of fuel oil or See section 501; Operational Observat-
changed combustion characteristics. ions, item c.
(All cyls.) Wrong position of camshaft Check Pmax. Check camshaft adjustment.
(maladjustment).
(single cyls.) Fuel valve or valve nozzle See section 501; Operational Observat-
defective. ions.
(Single cyls.) Leaky exhaust valves (1). Check the valve clearance. Replace cyl.
head with defective valve.
(Single cyls.) Damaged fuel pump cam. Replace the single camshaft section.
Exhaust temperature(s) (All cyls.) Decreased charging air Check that thermostatic valve (bypass
decrease(s) temperature. valve) in cold water system is working
properly and correctly set.
(Single cyls.) Air in fuel pump(s) and fuel Venting of fuel pump(s) until fuel without air
injection valve(s). bubbles appears.
Check feed pump pressure.
(Single cyls.) Spindle in fuel valve sticking Change and overhaul defective fuel valve.
(3).
(Single cyls.) Fuel pump plunger sticking or Change fuel pump plunger/barrel
leaking. assembly.
Engine RPM decreases Pressure before fuel pumps too low. Raise fuel oil feed pump pressure to
normal. Check filter.
Water in the fuel. Drain off water and vent the fuel pumps.
Cont
96.02-ES0U-G
503.03 Disturbances during Running Description
Page 2 (3)
Edition 01 H
L23/30H
Smoky exhaust. Turbine RPM lagging behind engine Reasonably smoke is normal when RPM
RPM. increases; no measures called for. If
smoky exhaust during normal running,
dean turbine(s) and check valves.
Air supply too low. Fouling of air and gas passages, see
section 501;Operational Observations.
Exhaust valve knocking. Adjusting screw for valve setting loose. Inspect and replace defective parts as
Push rod thrust disc damaged. necessary.
Rising cooling water Pump stopped. Increased friction (7). Stop the engine. Check the cooling water.
temperature. Find cause Of Increased friction and
remedy fault.
Lubricating oil pressure fails. Lubricating oil pump defective. (8) Stop the engine. For further details, see
Filters/cooler fouled. "Ignition in crankcase".
Remarks
1) This manifests itself by the exhaust 2) Blow-by means a serious danger of piston
temperature rising and falling of the compression seizure, and the engine must, if possible, be
and maximum combustion pressure of the stopped and the piston in question pulled. If this is
respective cylinder dropping. not possible, the fuel pump index must, as
described above, be moved to stop. Leaky piston
To limit the damage to the valves these should be rings will normally result in a heavy excess
changed immediately, if possible, or the fuel pump pressure in the crankcase.
of the cylinder concerned should be put out of
operation by moving the index to stop and locking
08028-0D/H5250/94.08.12
it in this position.
96.02-ES0U-G
Description
Disturbances during Running 503.03
Page 3 (3) Edition 01 H
L23/30H
3) If this happens the fuel pump barrel and 6) If the cooling water temperature for the entire
plunger must be changed, and if, it is necessary to engine has risen to 90-100° C, it should be
increase the fuel pump index by more than 10 checked whether steam has developed by opening
index degrees, to obtain full load of the respective the test cocks, if fitted on the discharge from
cylinder, the fuel pump is worn out in most cases. cylinders. If this is the case, there is no water on
Usually this is confirmed by inspection of the fuel the cooling surfaces, which may therefore be
pump plunger on which the helical cut-off edge will heated unduly. To avoid heat stresses arising in
show a pitted and corroded area where material is cylinder liners and cylinder heads, if the water
plucked out. In that case the pump can be returns too early, the engine should be stopped
provided with a new barrel and plunger. and left to cool, while the discharge valve is
closed. After 15 minutes it is opened a little to
allow the water to rise slowly in the cooling jackets.
4) The governor will not reduce the fuel pump Check filling attest cocks. Make crankcase
delivery to zero in case of, for instance, failure of inspection to ascertain that internal water leakage
the governor oil pump, but the engine speed will has not arisen. Remember slow turning with open
start fluctuating. indicator valves at subsequent starting-up.
96.02-ES0U-G
Description 503.04
Page 1 (1) Ignition in Crankcase Edition 01H
L23/30H
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, arise between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is transmitted otherwise to after stopping the engine. When opening up, keep
the crankcase, the heated surface will cause eva- clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed onto it. When do not smoke.
the oil vapours condense they form 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, forcing the relief roller guides, etc.).
valves to open. In a few cases, presumably when the
whole crankcase has been filled with oil mist, a Look for squeezed-out bearing metal and discolo-
subsequent explosion has thrown off crankcase ration by heat (blistered paint, burnt 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. Section 502, Check 1.
It is therefore important that the lubricating oil filtra-
tion equipment is in perfect condition. Filter cartrid- 7. Stop and feel over. Look out for oil mist.
ges must not be used again, if they have been
removed from the filter. Check of the oil condition by Especially the frictional surfaces that caused the
analysis is recommended. heating should be felt over (5-15-30 minutes after
starting, and again when full load is obtained). Sec-
tion 501.10, Point 2.
08028-0D/H5250/94.08.12
96.37 - ES0U-G
Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 01H
L23/30H
Oil leakage through cover nut. Missing or damaged O-ring (see Item Replace O-ring.
291, Plate 51515).
Dirt deposit not completely removed. Clean and bring to notice of main-
tenance staff.
96.30 - ES0U
Description 503.06
Page 1 (2) Trouble Shooting Guide for Turbine Starter Edition 01H
L23/30H
Motor will not run. No air supply. Check for blockage or damage to air
supply lines or tank.
Drive (57) will not engage. No pressure to drive housing port. Check air supply.
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 (63) or Inspect drive pinion and flywheel
flywheel. and replace, if necessary.
Cont. ....
96.38 - ES0U-G
503.06 Description
Edition 01H
Trouble Shooting Guide for Turbine Starter Page 2 (2)
L23/30H
Oil blowing out of exhaust. Oil in air supply line. Inspect air line and remove source
of oil.
Oil leaking from gear case (28). Worn or damaged O-rings. Replace O-rings.
Loose or leaking pipe plugs (10) or Tighten or replace pipe plugs using
(11). Ingersoll-Rand No SMB-441 pipe
sealant.
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
08028-0D/H5250/94.08.12
96.38 - ES0U-G
Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1)
Edition 01H
L23/30H
The pump does not work after Pump draws in air at suction side. Check packings and pipes for
start. tightness.
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.
96.02 - ES0U-G
Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01H
L23/30H
Trouble Shooting In case of fatigue fracture, this will normally
necessitate a replacement of all plates and gaskets
In case of damage to plates or gaskets, it will often as there may be a risk of fatigue fracture in all the
be necessary to replace these. material.
In case of corrosion, all plates must be examined
First examine the external conditions around the carefully!
plate heat exchanger in order to localize the cause of For work to be carried out see working card 515-
the damage! very carefully. 06.00.
Visible Leakage
Leakage. Too high pressure. Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operat-
ing Data & Set Points".
Leakage. Fouled or deformed plates. Separate the plate heat exchanger and
(Phase 2) Inelastic or deformed gaskets. check if the plates are deformed or fouled.
Check that the gaskets are elastic and
non-deformed, and that the faces of the
joints are clean.
Replace deformed plates and gaskets, if
any.
Before assembling clean all plates and
gaskets very carefully.
Assemble the plate heat exchanger and
start it up again.
Note! Even tiny impurities such as sand
grains may cause leakage.
96.30 - ESOU-G
503.10 Trouble Shooting for Lubricating Oil Cooler Description
Edition 01H Page 2 (2)
L23/30H
Non-Visible Leakage
Reduced heat transmission and/or in- Fouled plates or choked plate Separate the plate heat exchanger and
creasing pressure drop. channels. check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger and
start it up again.
96.30 - ES0U-G
Index Specification and Treatment
Page 1(1) 504
Lubricating Oil, Fuel Oil and Cooling Water
L23/30H
Description
Working Card
Plates
STX Engine
Description
Lubricating Oil Specification 504.01
Page 1 (1) Edition 05H
General
This document is valid for the following engine types: Based on typical load profile for marine GenSet (50-
L16/24, L21/31, L23/30H, L27/38, L28/32H, V28/ 60% of rated power)
32H, V28/32S
Oil type TBN TBN TBN
For the engines, a HD-lub. oil (heavy duty) corre- (initial) (equilibrium) (min. level)
sponding to at least type CD Comercial Class D after
API service system (meets MIL-L-2104 C and D) has Gas oil 8-12 6-8 6
to be used.
Marine diesel 10-15 8-10 8
The oil should be rust and oxidation inhibited. Heavy fuel (S<1.5) 10-15 8-10 8
When selecting a lubricating oil, attention must be Heavy fuel (1.5<S<2.5) 15-20 10-14 8
paid to the fuel oil sulphur content.
Heavy fuel (2.5<S<3.5) 20-25 10-14 8
Due to generating running mode for HOLEBY's Heavy fuel (3.5<S<4.5) 20-25 10-14 8
engines, where the lub. oil consumption depends on
running time and the fuel oil consumption and follow-
ing the sulphur input to the lub. oil depends on the Based on typical load profile for stationary GenSets
load, a lower TBN-value (Total Base Number) than (50-100% of rated power)
normal for main engines is needed.
Oil type TBN TBN TBN
(initial) (equilibrium) (min. level)
Viscosity
Gas oil 8-12 6-8 6
Marine
Marine diesel 10-15 8-10 8
L16/24, L21/31, L27/38 Based on typical load profile for variable speed
L23/30H, L+V28/32H, V28/32S engine, pumps (10-100% of rated power)
08028-0D/H5250/94.08.12
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
Maintenance of Lubricating Oil Condition 504.03
Page 1 (2)
Edition 01H
L23/30H
General of the rated flow of the separator.
During operation of trunk engines the lubricating oil In order to keep the amount of lubricating oil in the
will be contaminated slowly by small particles origi- engine in good condition, it is necessary to treat 0.27
nating from the combustion. l/kw per hour (0.20 l/BHP per hour).
The burning of heavy fuels will normally increase this A centrifuge for treating this amount of lubricating oil
contamination due to the increased content of carbon under the mentioned derated flow conditions should
residues and other impurities. have a rated capacity of 1.08-1.8 l/kw per hour (0.8-
1.3 l/BHP per hour), but in each case the separator
Contamination of lubricating oil with water, fresh or manufacturer's recommendations for capacity and
salt, can also take place. operation instructions should be followed.
A certain amount of contaminants can be kept For engines with cartridge-type oil filters (dept filters),
suspended in the lub. oil without affecting the lubri- continuous and efficient purification of the oil in the
cating properties. separator is essential to ensure long service life of the
cartridge filters.
But the condition of the lub. oil should be kept under
observation by analyzing oil samples. See also 504.04 For cleaning of the lubricating oil system after over-
"Criteria for Cleaning/Exchange of Lubricating Oil". hauls and inspection of the lub. oil piping system, see
section 515.
The engine bearings are protected by the full-flow lub.
oil filter built onto the engine, the filter cartridges
having a fineness of 15 micron and the safety filter a Deterioration of Oil
fineness of 60 micron.
Oil seldom loses its ability to lubricate, i.e. to form a
The condition of the lub. oil can be maintained/ friction-decreasing oil film, but it may become cor-
reestablished by exchanging the oil at fixed intervals rosive to the steel journals of the bearings in such a
or based on analysis results. way that the surface of these journals becomes too
rough and wipes the bearing surface.
Cleaning with Centrifugal Separators In that case not only the bearings must be renewed,
but the journals must be polished. Corrosiveness of
A more economical solution is to maintain the condi- the lubricating oil is due to either far advanced
tion by continuous treatment. Experience has proved oxidation of the oil itself (TAN) or to the presence of
that centrifuging is superior to other methods of inorganic acids (SAN). In both cases the presence of
cleaning lubricating oils. water will multiply the effect, especially an influx of
seawater as the chloride ions act as an inorganic acid.
The optimum cleaning effect is achieved by keeping
08028-0D/H5250/94.08.12
Low viscosity is obtained by preheating the lubrica- At normal service temperature the rate of oxidation is
ting oil to a temperature of 85 °C - 95 °C. insignificant, but the following factors will accelerate
the process:
Slow passage of the lubricating oil through the centri-
fugal separator is obtained by using reduced flow rate
and by operating the separator 24 hours a day, only High Temperature
stopping when cleaning of the bowl is necessary.
The temperature level will generally rise if the coolers
When treating detergent type lubricating oil, the flow
rate is usually recommended to be reduced to 15-25%
96.02 - ES0U-G
504.03 Maintenance of Lubricating Oil Condition Description
Edition 01H Page 2 (2)
L23/30H
are ineffective.
Oxidation of the oil will be considerably accelerated if Water washing of HD-oils must not be carried out.
catalytic particles are present in the oil. Wear partic-
les of copper are especially harmful, but also ferrous
particles and rust are active. Furthermore, the lacquer Water in the Oil
and varnish-like oxidation products of the oil itself
have an accelerating effect. Continuous cleaning of If the TAN is low, a minor increase in the fresh water
the oil is therefore important to keep the sludge content of the oil is not immediately detrimental whi-
content low. le the engine is running. Naturally, it should be brought
down again as quickly as possible (below 0,2% water
content, which is permissible). If the engine is stopped
Signs of Deterioration when corrosion conditions are unsatisfactory, it should
be turned just over 1/2 revolution once every hour (i.e.
If circulating oil of inferior quality is used and the stop in different positions) while the oil circulation and
oxidative influence becomes grave, prompt action is purifying at a high preheating temperature continue to
necessary as the last stages in the deterioration may remove water. Water in the oil may be noted by steam
develop surprisingly quickly, i.e. within one or two formation on the sight glasses, by appearance, or
weeks. Even if this seldom happens, it is wise to be ascertained by immersing a piece of glass or a
acquainted with the signs of deterioration. These may soldering iron heated to 200-300°C in an oil sample. If
be some or all of the following: there is a hissing sound, water is present. If a large
quantity of water has entered the oil system, it may be
- Sludge precipitation in purifier multiplies. profitable to suck up sedimented water from the
bottom of the tank. Taste the water for salt. If salty,
- Smell of oil becomes acrid or pungent. an oil sample should be analysed immediately for
chloride ions.
- Machined surfaces in crankcase become cof-
fee brown by a thin layer of lacquer.
96.02 - ES0U-G
Description
Criteria for Cleaning/Exchange of Lubricating Oil 504.04
Page 1 (2) Edition 03H
General
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.
Possible test
method : ASTM D-445 (modified) The TBN is normally reduced gradually with the
time of operation. The influential elements are the
sulphur content in the fuel oil, the lubricating oil
2. Flash Point amount and the amount of re-filling due to normal
consumption. After a certain time of ope-ration,
Limit value : > 185° C the TBN will stabilize at a lower value, the TBN
equilibrium.
Possible test
method : Setaflash tests (cut of point cor
relates with 204° C i ASTM D-92
(coc)
96.44 - ES1
504.04 Criteria for Cleaning/Exchange of Lubricating Oil Description
Edition 03H Page 2 (2)
General
6. The Total Contamination (insolubles Con- Also infra red test can be used.
tent) Heptane insolubles
08028-0D/H5250/94.08.12
96.44 - ES1
Description 504.05
Page 1 (1) Lubricating Points Edition 01H
L23/30H
Lubricating Oil Types Used in the Engine.
Engine system lubricating oil SAE 30 oil according to lubricating oil specification on page 504.01.
Hydraulic tools Hydraulic oil or turbine oil (with a viscocity of about SAE 20).
08028-0D/H5250/94.08.12
96.02 - ES0U-G
Description
Lubricating Oil in Base Frame 504.06
Page 1 (1) Edition 01H
L23/30H
94.20 - ES1S
Description
Specific Lube Oil Consumption SLOC 504.07
Page 1 (2) Edition 01H
General
In order to determine the engine condition, the lube In order to evaluate the correct engine SLOC, the
oil consumption needs to be recorded. To secure a following circumstances must be noticed and
uniform method to evaluate the SLOC, the following subtracted from the engine SLOC:
method should be used as guidance:
A1) Desludging interval and sludge amount from
During the routinely engine inspections the lube oil the lube oil separator (or automatic lube oil filters).
level in the base frame must be observed. The The expected lube oil content of the sludge amount
engine must be in operation or the pre-lubricating is 30%.
pump must be running during this inspection!
The following does also have an influence on the
The lube oil volume between maximum and minimum SLOC and must be considered in the SLOC
level at the dipstick is described in the Instruction evaluation:
Manual or in the Product Manual. If the lube oil level
is at the minimum, lube oil is added until the max level A2)
is reached at the dipstick. Lube oil evaporation
Lube oil leakages
The lube oil volume added, the lube oil temperature Lube oil losses at lube oil filter exchange
and the engine running hours are recorded and the
readings could be filled in the attached data sheet.
The engine maximum continuous rating (PMCR) must
The lube oil density, ρ @ 15°C must be known in always be used in order to be able to compare the
order to convert ρ to the present lube oil temperature individual measurements, and the running hours
in the base frame. The following formula is used to since the last lube oil adding must be used in the
calculate ρ: calculation. Due to inaccuracy *) at adding lube oil,
the SLOC can only be evaluated after 1,000 running
ρlube oil [kg/m3] = hours or more, where only the average values of a
number of lube oil addings are representative.
ρlube oil @15°C [kg/m3] – 0,64 * (tlube oil [°C] – 15)
If the SLOC deviates from the nominal value stated
in the Instruction Manual or in the Product Manual,
The following formula is used to calculate the SLOC: the engine cylinder condition should be inspected.
SLOC [g/kWh] =
03.14 - ES0
Description
Specific Lube Oil Consumption SLOC 504.07
Page 2 (2) Edition 01H
General
Plant / Ship
Lube oil consumption
Engine type:___________________ Engine # :__________________
03.14 - ES0
Description
Fuel Oil Specification 504.20
Page 1 (3) Edition 04H
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.
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
01.34 - ES1
504.20 Fuel Oil Specification Description
Edition 04H Page 2 (3)
General
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.
Solid
particles ppm (mg/kg) max. 20
08028-0D/H5250/94.08.12
01.34 - ES1
Description
Fuel Oil Specification 504.20
Page 3 (3) Edition 04H
General
Approx. viscosity
after preheater
Temperature sec.
cSt
after preheater °C Rw.
7 43
170
160 10 52
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
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 504.25
Page 1 (2) Edition 02H
General
The quality of a fuel oil is stated, in analysis data, in Combustion quality is the ability of the fuel oil to ignite
terms of physical and chemical properties, which are and burn in a proper way. The ignition quality,
decisive to the suitability of the fuel oil for different combustion intensity, and length and completeness
applications. For diesel engine fuels the combustion of combustion are properties influenced by the
quality, the content of impurities and the handling chemical combustion and structure of the fuel oil.
properties are the main quality criteria.
Ignition quality relates to ignition delay, i.e. the time
Since residual fuels are traded and designated elapsed between the start of injection and the start of
according to viscosity, it has become common combustion.
practice to associate viscosity with quality. This
practice can be very misleading, especially with Ignition quality is expressed by the cetane number,
modern residual fuels, as a fuel oil of low viscosity diesel index or cetane index. In all cases the higher
can often be just as bad, or even worse, than other the value, the better the ignition quality. For diesel oil
fuel oils of very high viscosity. the ignition quality is expressed by the cetane number
determined by a specified method in a standard
The quality of refinery residues is dependent on the engine running under standard conditions.
origin of the crude oil, the grade of utilization when
refining the crude oil, and the refinery technique For residual fuels the ignition quality can be expressed
used. by the diesel index or cetane index, both to be
calculated from physical properties such as the
Some of the residues used in fuel oil production are aniline point, specific gravity and mid-distillation
of a viscosity requiring visbreaking, a process which temperature. The cetane number, diesel index or
will reduce the viscosity without improving the quality cetane index of a certain fuel oil will show reasonable
at all. correlation between the numerical values.
When producing residual fuels from visbreaked, A FIA cetane number test is also good for evaluation
cracked residues and from "straight run" residues, of the combustion quality.
the final adjustment of viscosity to fulfil the
requirements of the different grades of intermediate The combustion condition of the fuel oils is normally
fuels is achieved by adding gas oil. evaluated from Conradson Carbon residue and the
asphaltene contents.
However, it must be noted that considerable reduction
of the viscosity is achieved by adding a relatively
small amount of gas oil, which will give only a minor Content of Impurities
improvement of the quality of the blend. This means
that the quality to a major extent depends on residues The content of impurities of diesel engine fuels
present in the blend. Therefore the quality also should be kept as low as possible, and harmful and
depends on the density, see 504.26. unwanted impurities should, to the greatest possible
08028-0D/H5250/94.08.12
02.16 - ESO - G
504.25 Fuel Oil Quality Description
Edition 02H Page 2 (2)
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
02.16 - ES0 - G
Description
Nomogram for Determination of CCAI 504.26
Page 1 (2) Edition 02H
General
08028-0D/H5250/94.08.12
01.34 - ES1
504.26 Nomogram for Determination of CCAI Description
Edition 02H Page 2 (2)
General
08028-0D/H5250/94.08.12
01.34 - ES1
Description
Analysis Data 504.27
Page 1 (4) Edition 02H
General
Comments on Analysis Data for Fuel Oils Asphaltenes also influences the lubricating proper-
ties of the fuel oil and, in extreme cases, high
Carbon Residue asphalteness content may lead to fuel injection
pump sticking.
The carbon residue of a fuel oil indicates its coke-
forming tendency and can be used to determine the Fuel oils with a high asphalteness content will have
tendency to form deposits in the combustion cham- a tendency to form sludge, especially if the water
ber and gasways. The higher the carbon residue content is also high. The asphaltenes content of a
value, the higher the fouling tendency. fuel oil is influenced by pre-treatment. The heaviest
semi-solid asphaltenes, and asphaltenes bound to
Some changes in the combustion process, requiring water as sludge, can be separated by centrifuging.
adjustment of the maximum pressure, may also be
attributed to a high carbon residue content. The
value is measured by standardized tests, such as Diesel Index
the Conradson or Ramsbottom tests which give
similar results. Diesel index is a calculated value to determine the
ignition quality of a fuel oil. The ignition quality is
The non-vaporized residue from the carbonizing test related to the hydrocarbon composition, paraffin
consists of carbonaceous material and inorganic being of high quality, n-heptanes of moderate quality
impurities and is expressed as percentage weight of and aromatics of low quality.
the fuel sample tested. Carbon residue and
asphaltenes content generally move in parallel, both With certain exceptions the properties of the aniline
in relation to the carbon-to-hydrogen ratio, with in- point and the specific gravity reflect the hydrocarbon
creasing values for a higher ratio. composition of a fuel oil, and are therefore used in
the following simple formula as an expression of
The carbon-to-hydrogen ratio and thus also the ignition quality:
carbon residue depends on the source of the crude
oil and the type of refinery processing used. Diesel index = (aniline point °F x API gravity) x 0.01.
The effect of carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment of the fuel oil, as centrifuging equal volumes of the fuel and aniline become just
only influences solid inorganic contaminants and miscible. The test relies on the fact that aromatic
hard asphalts, which are only small amounts of the hydrocarbons mix completely with aniline at com-
percentage weight called carbon residue. paratively low temperatures, whereas paraffins re-
quire considerably higher temperatures before they
are completely miscible.
Asphaltenes
A high aniline point thus indicates a highly paraffinic
Asphaltenes is defined as the part of a fuel oil sample fuel, and consequently a fuel oil of good ignition
which is insoluble in heptane. The content of quality. Similarly, a high API gravity number denotes
08028-0D/H5250/94.08.12
asphalteness is expressed as percentage weight of a low specific gravity and high paraffinicity, and
the fuel oil sample tested. again a good ignition quality.
Asphaltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea of the
solid hydrocarbon compounds dispersed in the fuel ignition quality, but generally gives figures slightly
oil, has a similar effect on the combustion process to above the cetane number.
the carbon residue, the main impact being fouling of
gasways. The stability of the fuel oil is related to the Fuel oils with poor ignition quality and a low diesel
asphaltenes content. index might in particular cause problems in starting
diesel engines and running at low load.
02.16 - ES0 - G
504.27 Analysis Data Description
Edition 02H Page 2 (4)
General
In addition to starting difficulties, a prolonged ignition Especially if the weight ratio of sodium to vanadium
delay may give rise to alternations in the maximum exceeds 1:3, ash with a very low melting point and
pressure, leading to increased mechanical or ther- stiction temperature is formed, giving rise to high
mal load. temperature corrosion of exhaust valves and de-
posit formation in turbochargers.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling It is possible to reduce the tendency for formation of
of gasways. detrimental vanadium-sodium ash by effective cen-
trifuging, which will remove sodium salts together
with water. If a very low content of sodium is ensured,
Sulphur a relatively high vanadium content might be accept-
able.
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free Water
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low The water content of fuel oil is measured by a
temperature corrosion. During combustion, sulphur standardized distillation test and is expressed as
oxides are produced in the form of gases. Since percentage volume of the sample tested. Water in
humidity is also present sulphur and sulphuric acid the fuel oil may lead to several detrimental effects on
may be formed on components in the combustion the fuel oil system, and corrosion and cavitation of
chamber and in the gasways, where the temperature fuel injection pumps and fuel valves, and cause
is below that of the dew point for sulphuric acid. fouling of exhaust systems and turbochargers.
The detrimental effect of sulphur in fuel oil is counter- Due to its content of sodium, salt water in combina-
acted by maintaining an adequate temperature of tion with vanadium contributes to the formation of
the combustion chamber components and by using low-melting corrosive ash, which attacks exhaust
alkaline lubricating oil to neutralize the sulphuric acid valves and turbochargers. When it disturbs the fuel
produced during combustion. atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
It is possible to reduce the water content of a fuel oil
Vanadium and sodium are constituents of the ash primarily by centrifuging, and this should be done to
content. The amounts of these are measured by the widest possible extent in order to avoid the
analyzing the residue from the combustion test used detrimental effects of water in the fuel oil.
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil Ash
sample being tested for ash content. Vanadium
08028-0D/H5250/94.08.12
derives from the crude oil itself and, being oil soluble, Ash content is a measure of the non-combustible
cannot be removed from the fuel oil by conventional material present in the fuel oil. The ash content is
pre-treatment. Sodium derives from the crude oil, determined by a combustion test and it is expressed
and also from contamination with salt water during as a percentage weight residue from complete com-
storage and transport of the fuel oil. Sodium is water- bustion of the oil sample tested.
soluble and, regardless of derivation, tends to com-
bine with the water present in the fuel oil. Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
Owing to its water solubility, it is possible to remove contamination of the fuel oil.
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.
02.16 - ES0 - G
Description
Analysis Data 504.27
Page 3 (4) Edition 02H
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.
dimensioning the centrifuge size are based on the As the formula indicates, the API gravity is in inverse
fact that approx. 1/3 of the catalyst particles in terms proportion to density and specific gravity.
of weight is removed.
Density is an important parameter in the centrifuging
process, where separating water and water-dis-
Viscosity solved impurities from the fuel oil is based on the
difference in densities. If the density of the fuel oil
Basically viscosity is a measure of the internal fric- approaches that of water, centrifuging thus becomes
tion or resistance of a liquid to flow. less effective, necessitating a reduced flow rate and
therefore increased centrifuge capacity.
02.16 - ES0 - G
504.27 Analysis Data Description
Edition 02H Page 4 (4)
General
08028-0D/H5250/94.08.12
02.16- ES0 - G
Description
Fuel Oil Cleaning 504.30
Page 1 (2) Edition 01H
L23/30H
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 seat 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 HFO by Centrifuging
96.02 - ES0S-G
504.30 Fuel Oil Cleaning Description
Edition 01H Page 2 (2)
L23/30H
Separation Temperature
˚F ˚C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
100
15 25 45 75 130 cSt/80˚C
08028-0D/H5250/94.08.12
96.02 - ES0S-G
Description
Freshwater System Treatment 504.40
Page 1 (5) Edition 02H
General
Protection against Corrosion in Freshwater Cleaning agents emulsified in water as well as
Cooling System slightly alkaline cleaning agents can be used for the
degreasing process, whereas ready-mixed cleaning
The engine fresh water must be carefully treated, agents which involve the risk of fire must obviously
maintained and monitored so as to avoid corrosion not be used. For descaling with acid, especially
or the formation of deposits which can result in products based on amino-sulphonic acid, citric acid,
insufficient heat transfer, it is necessary to treat the and tartaric acid are recommendable, as these acids
cooling water. MAN B&W recommend that this treat- are usually obtainable as solid substances, easily
ment is carried out according to the following proce- soluble in water, and do not emit poisonous vapours.
dure:
The cleaning agents should not be directly admixed,
but should be dissolved in water and then added to
– Clean the cooling water system. the cooling water system.
– Fill up with deionized or distilled cooling water Normally, cleaning can be executed without any
(for example from the freshwater generator) dismantling of the engine. We point out that the water
with corrosion inhibitor added. should be circulated in the engine to achieve the best
possible result.
– Carry out regular checks of the cooling water
system and the condition of the cooling water. As cleaning can cause leaks to become apparent in
poorly assembled joints or partly defective gaskets,
inspection should be carried out during the cleaning
Observance of these precautions, and correct ven- process. The acid content of the system oil should
ting of the system, will reduce service difficulties also be checked immediately after cleaning, and 24
caused by the cooling water to a minimum. hours afterwards.
Before starting the inhibition process, any existing The filling-up with cooling water and the admixture of
deposits of lime or rust, or any oil sludge, should be the inhibitor is to be carried out directly after the
removed in order to improve the heat transfer and to cleaning in order to prevent formation of rust on the
ensure uniform protection of the surface by means of cleaned surfaces.
the inhibitor.
Raw Water
The cleaning should comprise degreasing to remove
oil sludge, and descaling with acid afterwards to The formation of lime stone on cylinder liners and in
remove rust and lime deposits. cylinder heads may reduce the heat transfer, which
will result in unacceptably high temperatures in the
Ready-mixed cleaning agents, specially made for material.
08028-0D/H5250/94.08.12
00.11- ES1
504.40 Freshwater System Treatment Description
Edition 02H Page 2 (5)
General
If deionized or distilled water cannot be obtained, Checking of the Cooling Water System and
normal drinking water can be used in exceptional the Sooling Water during Service
cases. If so, the total hardness of the water must not
exceed 9° dH (German hardness degrees). The If the cooling water is contaminated during service,
chloride, chlorine, sulphate, and silicate contents are sludge or deposits may form. The condition of the
also to be checked. These contents should not cooling water system should therefore be regularly
exceed the following values: checked, especially if deionized or distilled water is
not used. If deposits are found in the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces or, if necessary, the entire system
Chlorine 10 ppm (10 mg/litre) should be cleaned.
Sulphate 100 ppm (100 mg/litre)
Silicate 150 ppm (150 mg/litre) According to experience, a zinc galvanized coating
in the freshwater cooling system is often very sus-
There should be no sulphide and ammonia content. ceptible to corrosion, which results in heavy for-
Rain water must not be used, as it may be heavily mation of sludge, even if the cooling water is cor-
contaminated. rectly inhibited. The initial descaling with acid will, to
a great extent, remove the galvanized coating. Gen-
It should be noted that softening of water does not erally, therefore, we advise against the use of galva-
reduce its sulphate and chloride contents. nized piping in the freshwater cooling system.
00.11- ES1
Description
Freshwater System Treatment 504.40
Page 3 (5) Edition 02H
General
A chloride content in the cooling water higher than The cooling water system must not be kept
the 50 ppm specified might, in exceptional cases be under pressure.
tolerated. However, in that case the upper limit
specified by the individual inhibitor supplier must not Check, and repair any leaks.
be exceed.
Drain the system and fill up completely with clean tap
A clear record of all measuring results should be water, in order to flush out any oil or grease from the
kept, so that the actual condition and trend of the tank.
system may be currently ascertained and evaluated.
Circulate the water for 2 hours, and drain again.
A sudden or gradual degrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased Descaling with Acid Solution
by adding inhibtor; however, if major quantities are
necessary, the water should be replaced. Fill up with clean tap water and heat to 70-75° C.
Every third month a cooling water sample should be Dissolve the necessary dosage of acid compound in
sent ashore for laboratory analysis, in particular to a clean iron drum with hot water.
ascertain the contents of inhibtor, sulphate, and iron,
as well as the total salinity of the water. Fill the drum half up with water and slowly add the
acid compound, while stirring vigorously. Then fill
the drum up completely with hot water while conti-
Cleaning and Inhibiting Procedure nuing to stir (e.g. using a steam hose).
The engine must not be running during the cleaning Be careful - use protective spectacles and gloves.
procedure, as this may involve the risk of overhea-
ting when draining. For engines which have been treated before the trial
trip, the lowest concentration recommended by the
supplier will normally be sufficient.
Degreasing
For untreated engines, a higher concentration -
Use clean tap water for filling-up. The cooling water depending on the condition of the cooling system -
in the system can be used, if it does not contain will normally be necessary.
inhibitors.
Drain some water from the system and add the acid
Heat the water to 60° C and circulate the water solution via the expansion tank.
continuously.
The cooling water system must not be put under
Drain to lowest water level in expansion tank. pressure.
08028-0D/H5250/94.08.12
Add the amount of degreasing chemical specified by Keep the temperature of the water between 70° C
the supplier, preferably from the suction side of the and 75° C, and circulate it constantly. The duration
freshwater pump. of the treatment will depend on the degree of fouling.
Normally, the shortest time recommended by the
Drain to lowest water level in the expansion tank supplier will be sufficient for engines which are
directly afterwards. treated before the trial trip. For untreated engines, a
longer time must be reckoned with. Check every
Circulate the cleaning chemical for the period speci- hour, for example with pH-paper, that the acid in the
fied by the supplier. solution has not been used up.
00.11- ES1
504.40 Freshwater System Treatment Description
Edition 02H Page 4 (5)
General
The solubility of acids in water is often limited. Weight out the quantity of inhibitors specified by the
Therefore if, in exceptional cases, a large amount is supplier and dissolve in a clean iron drum with hot
required, descaling can be carried out in two stages water from the evaporator.
with a new solution of compound and clean water.
Normally the supplier will specify the maximum Add the solution via the expansion tank to the
solubility. system. Then fill up to normal water level with water
from the evaporator.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized Allow the engine to run for not less than 24 hours to
with clean tap water containing 10 kg soda per ton of ensure that a stable protection of the cooling surfa-
water. Circulate the mixture for 30 minutes, then ces is formed.
drain and flush the system.
Subsequently, test the cooling water with a test kit
The cooling water system must not be put under (available from the inhibitor supplier) to ensure that
pressure. an adequate inhibitor concentration has been obtai-
ned.
Continue to flush until water used is neutral (pH
approx. 7). This should be checked every week.
08028-0D/H5250/94.08.12
00.11- ES1
Description
Freshwater System Treatment 504.40
Page 5 (5) Edition 02H
General
Maker's minimum
Company Name of Inhibitor Delivery Form Recommended
Dosage*
The list is for guidance only and must not be The suppliers are listed in alpabetical order.
08028-0D/H5250/94.08.12
00.11- ES1
Index
Page 1(1) Cylinder Head 505
L23/30H
Description
Working Card
Plates
STX Engine
Description
Cylinder Head 505.01
Page 1 (1)
Edition 01H
L23/30H
The individual cast-iron cylinder heads, one for each The inlet and exhaust valve spindles are identical and
cylinder unit, are equipped with a centrally situated therefore interchangeable.
fuel injection valve, two inlet valves, two exhaust
valves and one indicator cock. The valve spindles are made of heat-resistant material.
Hard metal is welded on to the valve spindle seats.
The head has a thick, bore-cooled flame plate for
satisfactory control of mechanical and thermal loads The valve spindles are fitted with valve rotators which
and stress. turn the spindles a little each time the valves open.
The cylinder head is attached by means of 4 nuts and The cylinder head is equipped with replaceable seat
4 studs screwed into deep bosses in the engine frame rings for inlet and exhaust valves.
top plate. The nuts are tightened by means of hydraulic
tools. The seating surfaces are hardened in order to minimize
wear and prevent dent marks, on the inlet seat by
induction hardening, on the exhaust seat by hard
metal armouring.
08028-0D/H5250/94.08.12
95.50 - ES0U-G
Working Card
Dismantling of Cylinder Head 505-01.00
Page 1 (2) Edition 01H
L23/30H
Hand tools:
Related procedure:
Manpower:
Replacement and wearing parts:
08028-0D/H5250/94.08.12
Data:
95.50 - ES0S
505-01.00 Working Card
Edition 01H
Dismantling of Cylinder Head Page 2 (2)
L23/30H
8) Remove the cylinder head nuts, see Fig 1, Mounting of Lifting Tool with the Fuel Injection
by means of hydraulic jacks. See working card 520- Valve is Removed from the Cylinder Head.
01.05.
12)Mount the two-distance pieces to the studs.
Fig 1
08028-0D/H5250/94.08.12
95.50 - ES0S
Working Card 505-01.05
Page 1 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 01H
L23/30H
Description:
Related procedure:
95.50 - ES0S
505-01.05 Inspection of Inlet Valve, Exhaust Valve and Valve Guide Working Card
Edition 01H Page 2 (3)
L23/30H
Or as an Alternative:
Or as an alternative:
Fig 2.
Place wooden blocks under the valve spindle heads.
table and take out the valve spindle.
3) Turn back the rocker arm and remove the
spring-loaded valve bridge over the valve spindles. 11) Repeat point 4 - 10 to remove the two other
valve spindles.
Fig 1.
95.50 - ES0S
Working Card
Page 3 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide 505-01.05
Edition 01H
L23/30H
95.50 - ES0S
Working Card Reconditioning of Valve Spindle Seat 505-01.10
Page 1 (3)
and Valve Seat Ring Edition 01H
L23/30H
Description:
Related procedure:
Data:
95.50 - ES0S
505-01.10 Reconditioning of Valve Spindle Seat Working Card
Edition 01H and Valve Seat Ring Page 2 (3)
L23/30H
Reconditioning of Valve Seat Ring However, when the seat "S" has been ground to such
an extent that the recess "R" disappears, see fig 1,
Reconditioning of valve seat rings by machining is the valve seat ring has to be scrapped and a new one
carried out by means of a grinding machine, the pilot must be installed, see working card 505-01.35
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
"H"1
Scrapping of Valve Seat Rings
0
"A" 30° ± 0,25°
Normally, the valve seat ring can be reconditioned
several times.
95.50 - ES0S
Working Card Reconditioning of Valve Spindle Seat 505-01.10
Page 3 (3)
and Valve Seat Ring Edition 01H
L23/30H
"H"2
Fig 3.
08028-0D/H5250/94.08.12
95.50 - ES0S
Working Card
Valve Rotator 505-01.15
Page 1 (2) Edition 01H
L23/30H
Description:
Small screwdriver.
Ring and open-end spanner 24 mm.
Starting position:
Related procedure:
Data:
95.50 - ES0S
5 05-01.15 Valve Rotator Working Card
Edition 01H Page 2 (2)
L23/30H
Dismantling of Rotocap
1) Clean the valve rotator. See working card 505-01.05, point 3 to 9, opposite
direction.
2) Inspect for wear and ball impressions.
95.50 - ESOS
Working Card
Replacement of Valve Guide 505-01.20
Page 1 (2) Edition 01H
L23/30H
Description:
Hammer.
Nitrogen (N2), or similar.
Mandrel for knocking out the valve guide.
Starting position:
Related procedure:
95.50 - ES0S
505-01.20 Replacement of Valve Guide
Working Card
Edition 05H Page 2 (2)
L23/30H
When to Replace the Valve Guide 4) Before mounting - cool down the new valve
guide to approx. -70°C with nitrogen or similar.
If the clearance exceeds the max. limit, see page
500.35, the valve guide must be replaced. 5) Insert the valve guide into the bore.
Mandrel
Fig 2.
2) Clean the bore of the cylinder head carefully. Screw-drivers or other sharp tools should never be
used for this purpose.
3) Inspect for marks that can prevent mounting
of new valve guide. 8) For mounting of valve spindle, see working
card 505-01.05.
95.50 - ESOS
Working Card
Indicator Valve 505-01.26
Page 1 (2) Edition 01H
L23/30H
Starting position:
Related procedure:
Data:
95.50 - ES0S-G
505-01.26 Indicator Valve Working Card
Edition 01H Page 2 (2)
L23/30H
Maintenance
95.50 - ES0S-G
Working Card
Replacement of Sleeve for Fuel Injector 505-01.30
Page 1 (2) Edition 01H
L23/30H
Description:
Brass mandrel.
Hammer.
Lub. oil.
Starting position: Two small screw-drivers.
Loctite 572.
The cylinder head has been dis-
mounted from engine 505-01.00
The fuel injector has been removed 514-01.10
Related procedure:
96.19 - ES0S
505-01.30 Replacement of Sleeve for Fuel Injector Working Card
Edition 01H Page 2 (2)
L23/30H
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.
Brass mandrel
Fig 2.
96.19 - ES0S
Working Card
Replacement of Valve Seat Ring 505-01.35
Page 1 (4) Edition 01H
L23/30H
Description:
Starting position:
96.26 - ES0S
505-01.35 Replacement of Valve Seat Ring Working Card
Edition 01H Page 2 (4)
L23/30H
Dismounting of Valve Seat Rings Dismounting of a Valve Seat Ring is Carried out
According to the 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) 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 pin (7) until the
Dismounting of a valve seat ring is carried out by latter is guided by the valve seat ring. The stud (1) is
means of a special extractor tool set comprising the then screwed in until it rests in the valve guide.
components, see fig 1.
08028-0D/H5250/94.08.12
96.26 - ESOS
Working Card
Replacement of Valve Seat Ring 505-01.35
Page 3 (4) Edition 01H
L23/30H
3) By pumping up the pack, see working card 3) To facilitate mounting the valve seat ring is it
520-01.05 for the use of hydraulic tools, the valve cooled down, however, a min. of -25°C otherwise,
seat is pressed out max. 6 mm, and the pressure is the o-ring can be damaged.
released again. The collar nut hexagon is tightened
and the operation is continued until the valve seat 4) Place the o-ring on the valve seat ring and coat
ring can be removed. with oil/loctite as shown in fig 4, just before positioning
it in the bore.
Fig 4.
2
08028-0D/H5250/94.08.12
1 Handle 2 Stud
Fig 3. Fig 5.
96.26 - ES0S
505-01.35 Replacement of Valve Seat Ring Working Card
Edition 01H Page 4 (4)
L23/30H
08028-0D/H5250/94.08.12
96.26 - ESOS
Working Card
Mounting of Cylinder Head 505-01.40
Page 1 (2) Edition 01H
L23/30H
Description:
Hand tools:
Related procedure:
95.50 - ES0S
505-01.40 Mounting of Cylinder Head Working Card
Edition 01H Page 2 (2)
L23/30H
Check to be Done before Lifting Place the spacer ring around the nuts with the slot in
such a position that the tommy bar can be used.
1) Check the jointing surfaces of the cylinder
head/cylinder liner to see that they are clean and Tighten the hydraulic jacks and make sure that the
without damage marks, see working card 506-01.45. cylinder of the jacks bears firmly against the spacer
Fit new O-rings on the water passage, lubricate the O- ring. Tighten up all the nuts, see page 500.40. For
rings with a little oil. using the hydraulic tools, see working card 520-01.05.
2) Check all contact faces on the cylinder head 7) If new studs or nuts have been fitted, the nuts
and nuts, including threads, and make sure that these
are level and smooth and absolutely free from foreign
particles.
Fig 2.
Tightening of Cylinder Head Nuts 9) Fit the pipes for fuel oil, lub. oil, cooling water
and the flange for exhaust pipe.
08028-0D/H5250/94.08.12
5) Coat threads and contact faces with copaslip 10) Prior to starting up check for leakages. After
before fitting the nuts. starting up check for leakages and oil flow.
6) Screw nuts onto the studs and tighten lightly 11) Mount the cover for rocker arm and the front
with the tommy bar. cover for fuel pump.
95.50 - ES0S
Working Card
Inspection of Cylinder Head Cooling Water Space 505-01.45
Page 1 (2) Edition 01H
L23/30H
Description:
Steel brush
Starting position:
Related procedure:
Data:
95.50 - ES0S
505-01.45 Inspection of Cylinder Head Cooling Water Space
Working Card
Edition 01H Page 2 (2)
L23/30H
95.50 - ES0S
Plate
Page 1 (2) Cylinder Head 50501-01H
L23/30H
302
363
255 052
218
243 039 279
292
280
135
147
015
159
111
123 351
351
076
064
338
08028-0D/H5250/94.08.12
160
172
184
196
184
98.34 - ES0S
Plate
50501-01H Cylinder Head Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
98.34 - ES0S
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-01H
L23/30H
573
249 237 095
286 262
See plate
50501
453
178 441
490 490
See plate
50501
524/536
548
08028-0D/H5250/94.08.12
585
512
512
98.34 - ES0S
Plate
50502-01H Valve Spindles and Valve Gear Page 2 (2)
L23/30H
Item Item
no. Qty. Designation Benævnelse no. Qty. Designation Benævnelse
010 2/C Valve bridge, compl. Ventilbro, komplet 490 4/C Outer spring Udvendig fjeder
incl. item 022, 034, 046, inkl. item 022, 034, 046,
071, 083, 095, 105, 117, 071, 083, 095, 105, 117, 512 4/C Valve spindle, inlet Ventilspindel, inds.
129 and 130 129 og 130 and outlet og uds.
046 2/C Ball guide Kuglestyr 548 4/C Spring washer Fjederskive
071 2/C Thrust piece Trykstykke 573 2/C Bearing bush Lejebøsning
083 2/C Thrust screw Trykskrue 585 4/C Retainer ring Låsering
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./ = Qty./Individual Antal/I = Antal/Individuelt
98.34 - ES0S
Plate
Page 1 (2) Indicator Valve 50508-01H
L23/30H
049
037
013
025
08028-0D/H5250/94.08.12
95.50 - ES0S
Plate
50508-01H Indicator Valve Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
95.50 - ES0S
Plate
Page 1 (2) Cylinder Head, Top Cover 50510-01H
L23/30H
087
099
063
075 110
051
038
122
014
026
08028-0D/H5250/94.08.12
94.22 - ES0S
Plate
50510-01H Cylinder Head, Top Cover Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
94.22 - ES0S
Index
Page 1(1) Piston, Connecting Rod and Cylinder Liner 506
L23/30H
Description
Working Card
Plates
STX Engine
Description
Piston, Connecting Rod and Cylinder Liner 506.01
Page 1 (1)
Edition 01H
L23/30H
The piston, which is oil-cooled and of the monobloc The connecting rod is die-forged. The big-end has an
type made of nodular cast iron, is equipped with 3 inclined joint in order to facilitate the piston and
compression rings and 1 scraper ring. connecting rod assembly to be withdrawn up through
the cylinder liner. The joint faces on the connecting
By use of a combination of compression rings with rod and the bearing cap are serrated to ensure precise
different barrel-shaped profiles and chrome-plated location and to prevent relative movement of the
running surface on all rings, the piston ring pack is parts.
optimized for maximum sealing effect and minimum
wear rate. The big-end bearing is of the trimetal type, i.e. steel
shells lined with tin-aluminium or lead-bronze coated
The piston has a cooling oil space close to the piston with a running layer. Designed as plain type or
crown and the piston ring zone. The heat transport, rillentype. The bearing shells are of the precision type
and thus the cooling effect are based on the shaker and are therefore to be fitted without scraping or any
effect arising during the piston movement. Oil from other kind of adaption.
the engine's lubricating oil system is used as cooling
oil. The small-end bearing is of the trimetal type and is
pressed into the connecting rod.
The piston is provided with a turned edge at the top
due to the flame ring mounted in the cylinder liner.
Cylinder Liner
96.19 - ES0U
Working Card
Dismounting of Piston and Connecting Rod 506-01.00
Page 1 (3) Edition 01H
L23/30H
Data:
96.20 - ES0S
506-01.00 Dismounting of Piston and Connecting Rod Working Card
Edition 01H Page 2 (3)
L23/30H
08028-0D/H5250/94.08.12
96.20 - ES0S
Working Card
Dismounting of Piston and Connecting Rod 506-01.00
Page 3 (3) Edition 01H
L23/30H
4.
96.20 - ES0S
Working Card
Separation of Piston and Connecting Rod 506-01.05
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
Data:
95.50 - ES0S
506-01.05 Separation of Piston and Connecting Rod Working Card
Edition 01H Page 2 (2)
L23/30H
95.50 - ES0S
Working Card
Piston 506-01.10
Page 1 (4) Edition 01H
L23/30H
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:
Related procedure:
Data:
95.50 - ES0S
506-01.10 Piston
Working Card
Edition 01H Page 2 (4)
L23/30H
Removal of Piston Ring Inspection of Piston
For removal of piston rings, which are to be used 1) Remove the piston and scraper rings.
again, and for all mounting of rings, only the special
ring opener which prevents local over stressing of 2) Clean and examine the piston rings to determine
the rings should be used. if reuse is acceptable, see page 3.
Straps to expand the ring gap or tools working on the 3) Clean the piston on the outside and on the
same principle must not be used, as this would result inside.
in permanent deformation which might cause blow-
by or broken rings. 4) Inspect the piston ring and scraper ring grooves
for wear, see page 3.
08028-0d/H5250/94.08.12
95.50 - ES0S
Working Card
Piston 506-01.10
Page 3 (4) Edition 01H
L23/30H
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 +0.14
4.0 mm 4.43 mm
1 4.0 mm +0.12
or
Piston ring New +0.11
B) The clearance between the new piston/scraper 4.0 mm 4.43 mm
2 4.0 mm +0.09
ring and ring groove is exceeded, see fig 1B.
Piston ring New +0.11
4.0 mm 4.43 mm
3 4.0 mm +0.09
Note! At each piston overhaul:
- The piston and scraper ring must be New +0.10
Scraper ring 7.0 mm 7.43 mm
exchanged. 7.0 mm +0.08
- The cylinder liner must be honed according Table 1. Nominal size, new ring groove tolerance and wear
to the instructions. limit for ring grooves.
0.45 mm
95.50 - ES0S
506-01.10 Working Card
Edition 01H
Piston Page 4 (4)
L23/30H
Piston Ring No 1:
marked with ident.
No "top 881500-3"
or "0946".
Piston Ring No 2:
marked with ident.
No "top 881502-7"
or "0947".
Piston Ring No 3:
marked with ident.
No "top 881501-5"
or "0945".
Scraper ring:
marked with ident.
No "top 881503-9"
or "0120".
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.
95.50 - ES0S
Working Card
Connecting Rod 506-01.15
Page 1 (4) Edition 01H
L23/30H
Description:
Hand tools:
Related procedure:
Data:
95.50 - ES0S
506-01.15 Connecting Rod Working Card
Edition 01H Page 2 (4)
L23/30H
1. Clean all machined surfaces on the connecting For check of ovalness the bearing cap has to be
rod. mounted onto the big-end bore without bearing shells.
2. Degrease the serrated joint faces, tapped holes Note !! The ident. No on the connecting rod and the
and connecting rod screws with a volatile solvent and bearing cap must always be the same, see fig 3.
blow dry with working air.
8. Mount the bearing cap onto the connecting rod
have seizures in Renew the screws 13. Check if maximum ovalness is exceeded, see
threads or pittings on page 500.35.
contact surface
95.50 - ES0S
Working Card
Connecting Rod 506-01.15
Page 3 (4) Edition 01H
L23/30H
maximum ovalness is Reuse the connecting rod 1. Inspect the surface of the piston pin and the
not exceeded connecting rod bush.
Serration
Impact mark Impact mark Impact mark
A B
C
Connecting rod
Ident no.
Connecting rod
specified maximum ovalness is exceeded, contact Ident No
MAN B&W Diesel A/S, Holeby for overhaul).
95.50 - ES0S
506-01.15 Connecting Rod Working Card
Edition 01H Page 4 (4)
L23/30H
08028-0D/H5250/94.08.12
95.50 - ES0S
Working Card
Mounting of Piston and Connecting Rod 506-01.20
Page 1 (4) Edition 01H
L23/30H
Description:
Related procedure:
95.50 - ES0S
506-01.20 Mounting of Piston and Connecting Rod Working Card
Edition 01H Page 2 (4)
L23/30H
2) Lift up the piston and connecting rod and mount Mounting of Big-end Bearing
the piston and scraper rings, see point 14, and
working card 506-01.10. 6) Lower the piston further down, lubricate the
ends of the bearing shells (as in fig. 2) with copaslip,
3) Remove the backstop for cylinder liner and molycote pasta or similar and mount the upper shell
place the piston guide ring on top of the cylinder liner, of the big-end bearing.
see fig 1.
Fig 1.
Fig 2.
95.50 - ES0S
Working Card 506-01.20
Page 3 (4) Mounting of Piston and Connecting Rod Edition 01H
L23/30H
Fig 3.
Fig 5.
card 506-01.25.
Fig 4.
95.50 - ES0S
506-01.20 Working Card
Edition 01H
Mounting of Piston and Connecting Rod Page 4 (4)
L23/30H
If the rings are opened further than necessary there is Before fitting the coil spring loaded scraper ring, the
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 to the joint pin. The coil spring is placed and assembled
the inner running surface of the cylinder. 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, see working card 506- Ascertain correct assembling by checking the back
01.10 "Piston". clearance.The back clearance is sufficient when the
face of the ring is below the groove edge when the ring
is pressed against the bottom of the groove.
08028-0D/H5250/94.08.12
95.50 - ES0S
Working Card
Hydraulic Tightening of Connecting Rod Screws 506-01.25
Page 1 (2) Edition 04H
L23/30H
Description:
Starting Position:
Related Procedure:
Data:
00.28 -ES0
506-01.25 Hydraulic Tightening of Connecting Rod Screws Working Card
Edition 04H Edition 2 (2)
L23/30H
00.28 - ES0
Working Card
In-situ Inspection of Connecting Rod Big-end Bearing 506-01.30
Page 1 (3) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Data:
96.30 - ES0S
506-01.30 In-situ Inspection of Connecting Rod Big-end Bearing Working Card
Edition 01H Page 2 (3)
L23/30H
Fig 1. Fig 2.
Dismounting of Bearing Cap 7) Lift the piston/connecting rod from the bearing
journal.
3) Remove the fuel injector.
Note: the piston/connecting rod should be lifted
4) Insert the long-eye bolt and screw it into the further then, just to allow dismounting of the upper
thread hole in the piston, see fig 2. bearing shell, see fig 2.
08028-0D/H5250/94.08.12
96.30 - ES0S
Working Card
In-situ Inspection of Connecting Rod Big-end Bearing 506-01.30
Page 3 (3) Edition 01H
L23/30H
9) Clean all components, see working card 506- Tightening of Connecting Rod Screws
01.20.
18) Tighten the screws according to "Tightening
Procedure for Connecting Rod Screw", see working
Mounting of Upper Bearing Shells card 506-01.25.
96.30 - ES0S
Working Card
Inspection and Honing of Cylinder Liner 506-01.35
Page 1 (4) Edition 01H
L23/30H
Description:
Related procedure:
Data:
96.04 - ES0S
506-01.35 Inspection and Honing of Cylinder Liner Working Card
Edition 01H Page 2 (4)
L23/30H
Measurement of Cylinder Diameter Prior to honing, deposits of coke and possible wear
edges in the top of the liner must be removed by
While the piston is removed from the cylinder, the 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 uppermost ring has to be cleaned in water. Subsequently, the
piston ring, halfway down and at the bottom of the flame ring is remounted in the cylinder before carrying
cylinder liner, see fig 1 and page 4. out the honing process.
80-160 rpm.
Fig 1.
Fig 2.
Honing the Cylinder Liner
The renovation can be made either with dismantled The honing is made by means of a flex-honer with
liner in the workshop or with liner mounted in the fineness grains 80-120. A revolution speed between
engine frame and by the use of the belonging funnel. 80 and 160 rpm is chosen.
96.04 - ES0S
Working Card
Inspection and Honing of Cylinder Liner 506-01.35
page 3 (4) Edition 01H
L23/30H
After the honing, the liner is carefully cleaned with gas Fig 3.
oil. Make sure that all abrasive particles have been
removed.
08028-0D/H5250/94.08.12
96.04 - ES0S
08028-0D/H5250/94.08.12
96.04 - ES0S
Working Card
Page 4 (4)
L A
e
n B
g
t C
h
63
w
A i
s
194
e
C A
r
362
B
B o
s C
s
w
i
s
e
C Liner
temp.
˚C
Remarks...
506-01.35
L23/30H
Edition 01H
Working Card
Replacement of Cylinder Liner 506-01.40
Page 1 (2) Edition 01H
L23/30H
Description:
Adjustable spanner.
Starting position:
Related procedure:
Manpower:
Replacement and wearing parts:
Working time : 11/2 hours
08028-0D/H5250/94.08.12
96.27 - ES0S
506-01.40 Replacement of Cylinder Liner Working Card
Edition 01H Page 2 (2)
L23/30H
Fig 2.
96.27 - ES0S
Working Card Grinding of Seal Face on 506-01.45
Page 1 (2) Cylinder Liner and Cylinder Head Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
95.50 - ES0S-G
506-01.45 Grinding of Seal Face on Working Card
Edition 01H Cylinder Liner and Cylinder Head Page 2 (2)
L23/30H
Fig 3.
Fig 1.
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, i.e. the difference
2) Face-grind the sealing grooves in the cylinder between measurements y and z must not be less than
liner flange, see Fig 2, and the sealing surface on the 0.5 mm, see Fig 4.
cylinder head, see Fig 3, with the use of grinding pasta
and the grinding tool.
y - z = min. 0.5 mm
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.
95.50 - ES0S-G
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2)
at Low Overhaul Heights Edition 01H
L23/30H
Cylinder head has been dismounting from the Inside micrometer (195 mm).
engine. Feeler gauge 0.15 - 0.20 mm.
Crankcase open.
Related procedure:
Data:
95.50 - ES0S-G
506-01.50 Dismantling of Piston and Cylinder Liner Working Card
Edition 01H at Low Overhaul Heights Page 2 (2)
L23/30H
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 liner. 1) Mount the normal lifting tool for cylinder liners.
2) Mount the collar on the connecting rod, see 2) Carefully pull the cylinder liner half-way out of
plate 52050, item no 045. the frame.
3) Place the piston with the collar on the cylinder 3) Mount a special lifting tool for cylinder liners at
liner. low overhaul heights, see plate 52050, item no 033.
4) Mount pull-lifts on the collar. 4) Attach pull-lifts on the lifting tool for the cylinder
liner, see plate 52050, item no 033.
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.
08028-0D/H5250/94.08.12
95.50 - ES0S-G
Plate
Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 50601-05H
L23/30H
720/750 RPM
08028-0D/H5250/94.08.12
00.27 - ES0
Plate
50601-05H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)
L23/30H
720/750 RPM
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
00.27 - ES0
Plate
Page 1 (2) Cylinder Liner 50610-01H
L23/30H
720/750 RPM
08028-0D/H5250/94.08.12
97.05 - ES0S
Plate
50610-01H Cylinder Liner Page 2 (2)
L23/30H
720/750 RPM
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
97.05 - ES0S
Index
Page 1(1) Camshaft and Camshaft Drive 507
L23/30H
Description
Working Card
Plates
STX Engine
Description
Camshaft and Camshaft Drive 507.01
Page 1 (1)
Edition 01H
L23/30H
General The lubricating oil pipes for the gear wheels are
equipped with nozzles which are adjusted to apply the
The camshaft which controls the actuation of inlet oil at the points where the gear wheels are in mesh.
valves, exhaust valves and fuel injection pumps is The position of the nozzles is determined by direction
driven by a gear wheel on the crankshaft through an 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 located in a high level housing in the Engine seen from aft - fly wheel end
engine frame.
The camshaft runs in replaceable, identical, steel-
backed bronze bushings fitted into borings of the
transverse girders in the housing.
94.26 - ES0S
Working Card
Check of Camshaft and Camshaft Drive 507-01.00
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
97.06 - ES0U-G
507-01.00 Check of Camshaft and Camshaft Drive Working Card
Edition 01H Page 2 (2)
L23/30H
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.
08028-0D/H5250/94.08.12
97.06 - ES0U-G
Working Card
Inspection and Replacement of Camshaft Bearing 507-01.05
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
95.02 - ES0S-G
507-01.05 Inspection and Replacement of Camshaft Bearing Working Card
Edition 01H Page 2 (2)
L23/30H
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 clean lubricating oil and push the camshaft into
508-01.00 and 508-01.05. position, making sure that the marks on the flanges
coincide.
Pull the disconnected sections of the camshaft so far
a head that the bearing which is to be replaced is free. Assemble the sections and fit the bolts (coated with
08028-0D/H5250/94.08.12
copaslip or similar).
Take out the locating screw of the camshaft bearing
concerned and push the bearing out of the bore in the Tighten the nuts with a torque spanner, see data sheet
engine frame, see fig 1. 500.40.
Check the lubricating oil ducts to the bearing for free Mount all roller guides as well as the fuel oil feed
flow. pump.
95.02 - ES0S-G
Working Card
Adjustment of Camshaft 507-01.20
Page 1 (2) Edition 01H
L23/30H
Description:
Depth gauge.
Starting position:
Related procedure:
Data:
96.30 - ES0S-L
507-01.20 Adjustment of Camshaft Working Card
Edition 01H Page 2 (2)
L23/30H
Roller guide
Cam for
exhaust valve
Cam for fuel Fig 2.
oil pump
96.30 - ES0S-L
Plate
Page 1 (2) Intermediate Wheel 50701-01H
L23/30H
288
073+
181
144
048
168
132
264
227
024
120 215
193 203
239
156
240
119
215
08028-0D/H5250/94.08.12
276
252
061+
193
94.22 - ES0S
Plate
50701-01H Intermediate Wheel Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
94.22 - ES0S
Plate
Page 1 (2) Camshaft and Camshaft Bearing 50705-07H
L23/30H
08028-0D/H5250/94.08.12
99.41 - ES0
Plate
50705-07H Camshaft and Camshaft Bearing Page 2 (2)
L23/30H
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse
026 4/E Camshaft , aft/inter- Styreaksel agter/mel- 230 1/E Camshaft "aft" Styreaksel, agter
mediate, 5 cyl. engine lem, 5 cyl. motor 7 cyl. engine 7 cyl. motor
038 1/E Camshaft "fore" Styreaksel "for" 242 1/E Camshaft "aft" Styreaksel, agter
5 cyl. engine 5 cyl. motor 8 cyl. engine 8 cyl. motor
051 1/E Camshaft bearing Styreakselleje 254 4/E Camshaft , intermed- Styreaksel mellem
iate, 6 cyl. engine 6 cyl. motor
063 Camshaft bearing Styreakselleje
5/E 5 cyl. engine 5 cyl. motor 266 5/E Camshaft , intermed- Styreaksel mellem
6/E 6 cyl. engine 6 cyl. motor iate, 7 cyl. engine 7 cyl. motor
7/E 7 cyl. engine 7 cyl. motor
8/E 8 cyl. engine 8 cyl. motor 278 6/E Camshaft , intermed- Styreaksel mellem
iate, 8 cyl. engine 8 cyl. motor
075 1/E Gear wheel Tandhjul
291 1/E Camshaft "fore" Styreaksel "for"
087 10/E Screw Skrue 6 cyl. engine 6 cyl. motor
099 10/E Spring washer Fjederskive 301 1/E Camshaft "fore" Styreaksel "for"
7 cyl. engine 7 cyl. motor
109 10/E Screw Skrue
313 1/E Camshaft "fore" Styreaksel "for"
110 Self locking nut Selvlåsende møtrik 8 cyl. engine 8 cyl. motor
50/E 5 cyl. engine 5 cyl. motor
40/E 6 cyl. engine 6 cyl. motor 325 1/E Camshaft complete, Styreaksel komplet,
52/E 7 cyl. engine 7 cyl. motor 6 cyl. eng. incl. item 6 cyl. motor inkl. item
66/E 8 cyl. engine 8 cyl. motor 109, 110, 122, 134, 146, 109, 110, 122, 134, 146,
158, 171, 183, 195, 205, 158, 171, 183, 195, 205,
122 1/E Hub Nav 229, 254, 291, 374 229, 254, 291, 374
134 6/E Screw Skrue 337 1/E Camshaft complete, Styreaksel komplet,
7 cyl. eng. incl. item 7 cyl. motor inkl. item
146 6/E Disc spring Fjederskive 109, 110, 122, 134, 146, 109, 110, 122, 134, 146,
158, 171, 183, 195, 205, 158, 171, 183, 195, 205,
158 1/E Guide ring Sikringsring 230, 266, 301, 374 230, 266, 301, 374
217 1/E Camshaft, complete Styreaksel komplet, 362 Packing ring Pakningsring
for 5 cyl. engine, incl. 5 cyl. motor, inkl. item 6/E 5 cyl. engine 5 cyl. motor
08028-0D/H5250/94.08.12
item 026, 038, 109, 110, 026, 038, 109, 110, 122, 7/E 6 cyl. engine 6 cyl. motor
122, 134, 146, 158, 171, 134, 146, 158, 171, 183, 8/E 7 cyl. engine 7 cyl. motor
183, 195, 205, 374 195, 205, 374 9/E 8 cyl. engine 8 cyl. motor
229 1/E Camshaft "aft" Styreaksel, agter 374 1/E Shaft Aksel
6 cyl. engine 6 cyl. motor
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
99.41 - ES0S
Index Operating Gear for Inlet Valves,
Page 1(1) 508
Exhaust Valves and Fuel Injection Pumps
L23/30H
Description
Operating gear for valves and fuel injection pumps ------------------------------------ 508. 01 (01H)
Working Card
Plates
STX Engine
Description
Operating Gear for Valve and Fuel Injection Pumps 508.01
Page 1(1)
Edition 01H
L23/30H
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 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 seats. 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.
96.03 - ES0S
Working Card
Inspection of Valve Roller Guides 508-01.00
Page 1 (3) Edition 01S
L23/30H
Dismounting. inspection and/or overhaul, and Ring and open end spanner, 19mm.
mounting of valve roller guides. Ring and open end spanner, 24mm.
Inspection of roller guide housing. Socket spanner, 19 mm.
Socket spanner, 10 mm.
Allen key, 3 mm.
Allen key, 10 mm.
Starting position: Ratchet spanner.
Hammer.
Top cover for cylinder head and cover for fuel in- Drift.
jection pump removed.
Related procedure:
96.03-ES0S
508-01.00 Inspection of Valve Roller Guides Working Card
Edition 01S Page 2 (3)
L23/30H
Dismounting of Roller Guide. 5) Dismount the screws (3) which secure the
roller guide top cover, take off the cover, the
1) Turn the engine so that the roller, rests on the spring (7) and lift out the roller guide (5).
circular part of the cam.
Disconnect any pipes that may be in the way (lub.
2) Unscrew the nuts which secure the rocket arm oil and fuel oil pipes).
brackets, and lift off the rocker arm with brack-
ets. 6) If the roller guide housing is to be dismantled,
the fuel injection pump and the fuel injection
3) Remove the push rods (1), see fig 1. pump roller guide are to be dismounted, see
working card 514-01.05 and a number af lubri-
cating oil and fuel oil pipes are also to be dis-
connected.
4) Loosen the lock screw for the push rod pro- lubricating grooves.
tecting tube, see plate 50801, item 207, on the
roller guide top cover and lift up and remove Mounting of Roller Guide.
the protecting tube (2).
11) When assembling the parts, which is carried
out in the reverse order to the above care
must be exercised not to damage the o-rings
when mounting the protecting tube.
96.03-ES0S
Working Card
Inspection of Valve Roller Guides 508-01.00
Page 3 (3) Edition 01S
L23/30H
96.03-ES0S
1999.11.16-S.H.B(No. 13) note to be added by S S H1
Working Card
Inspection of Fuel Injection Pump Roller Guide 508-01.05
Page 1 (2) Edition 01S
L23/30H
Description:
Related procedure:
Data:
96.03-ES0S
508-01.05 Inspection of Fuel Injection Pump Roller Guide Working Card
Edition 01S Page 2 (2)
L23/30H
96.03-ES0S
1999.11.16-S.H.B(No. 8) note to be added by S S H1
Working Card
Control and Adjusting of Valve Clearance 508-01.10
Page 1 (3) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Data:
Data for pressure and tolerance (Page 500.35) See also plate 50502.
Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
96.38 - ES0S
508-01.10 Control and Adjusting of Valve Clearance Working Card
Edition 01H Page 2 (3)
L23/30H
Fig 2.
96.38 - ES0S
Working Card
Control and Adjusting of Valve Clearance 508-01.10
Page 3 (3) Edition 01H
L23/30H
Fig 3.
08028-0D/H5250/94.08.12
96.38 - ES0S
Plate
Page 1 (2) Roller Guide and Push Rods 50801-01H
L23/30H
268
293 303
268
185
173
185
090
219
112
197
124
207
089
148
100
281
028
077
077
041
053
220
041
053
065 065
08028-0D/H5250/94.08.12
256 244
161 016+
136 232
94.32 - ES0S
Plate
50801-01H Roller Guide and Push Rods Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
016+ 1/C Housing for Hus for 315 1/C Valve gear complete, Ventilbevægelse
roller guides rullestyr as shown on plate komplet, som vist på
50801 except item 303 plate 50801 undtagen
028 1/C Roller guide for Rullestyr for pumpe item 303
pump
041 3/C Pin Foring + Item No. 016 require + Item nr. 016 kræver
an individual match- en individuel tilpasning
053 3/C Bush Tap ing before mounting, før montering, kontakt
con-tact MAN B&W, MAN B&W, Holeby
065 3/C Roller Rulle Holeby
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
94.32 - ES0S
Index Control and Safety Systems
Page 1(1) 509
Automatics and Instruments
L23/30H
Description
Working Card
Functional test and adjustment of safety, alarm and monitoring equipment ----- 509- 01 .00 (01H)
Function test and adjustment of overspeed trip ----------------------------------------- 509- 01 .05 (01H)
Adjustment and test of ON/OFF pressostate ---------------------------------------------509- 05 .00 (01S)
Adjustment and test of ON/OFF thermostate -------------------------------------------- 509- 05 .01 (01S)
Function and test of level switch (LAL 25) ------------------------------------------------ 509- 05 .02 (01H)
Adjustment and test of analogous pressure transmitter ------------------------------- 509- 05 .03 (01S)
Adjustment and test of analogous temperature transmitter ---------------------------509- 05 .04 (01H)
Adjustment of lambda controller ------------------------------------------------------------- 509- 10 .00 (08H)
Plates
Pressostate, thermostate, difference pressostate and pressure transmitter ------------ 50907- 01S
Thermometer -------------------------------------------------------------------------------------------- 50907- 02S
Pick-up ---------------------------------------------------------------------------------------------------- 50908- 01H
Temperature Transmitter ----------------------------------------------------------------------------- 50908- 03H
Lambda controller -------------------------------------------------------------------------------------- 50910- 02H
Starting box ---------------------------------------------------------------------------------------------- 50935- 01H
STX Engine
Description 509.01
Page 1 (2) Control and Safety Systems Edition 01H
L23/30H
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 512. this pump.
The spring-loaded pull rod permits the governor to At the same time the arm (2) presses down the
08028-0D/H5250/94.08.12
give full deflection even if the stop cylinder of the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keeps the fuel pump regulating whereby compressed air will be led to the Lambda
shaft at "no fuel" position. cylinder, see description 509.10, in which the piston
is pressed forward and, through the arm, turns the
Each fuel pump is connected to the common, lon- fuel pump regulating rod to STOP position, thereby
gitudinal regulating shaft by means of a two-piece, the engine stops, the spring-loaded pull rod
spring-loaded arm. connection to the governor being compressed.
96.38 - ES0S-G
509.01 Description
Edition 01H
Control and Safety Systems Page 2 (2)
L23/30H
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
96.38 - ES0S-G
Description 509.05
Page 1 (3) Instruments and Automatics Edition 01H
L23/30H
As standard the engine is equipped with an instrument The instrument panel is mounted flexibly on rubber
panel, comprising instruments for visual indication of elements and all manometer connections are connec-
the most essential pressures. ted to the panel by means of flexible hoses, as shown
Illustrated on fig. 1. on fig. 2.
Flexible hose
Rubber element
Valves
Push button
The following incorporating pressure gauges for the most Fig. 2. Cross section of instrument panel
essential pressures.
08028-0D/H5250/94.08.12
96.03 - ES0S
509.05 Description
Edition 01H
Instruments and Automatics Page 2 (3)
L23/30H
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 60 Exhaust gas - outlet each cylinder leakage alarm unit.
Thermometer TI 61 Exhaust gas - outlet turbocharger
96.03 - ES0S
Description 509.05
Page 3 (3) Instruments and Automatics Edition 01H
L23/30H
The alarm unit consists 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 comparement, this When the mechanical overspeed is activated, see
will be led out through the bore "A" in the pipe "B" as 509.01 fig. 2, a micro-switch will release the alarm for
illustrated. overspeed (SAH 81) and activate the shut-down
solenoid in the governor.
In case of a larger than normal leakage, the level in the
box will rise and the level switch "C" will be activated. The latter function is a back-up for the mechanical
The larger amount of leak oil will be lead out through overspeed.
the top of the pipe "B".
08028-0D/H5250/94.08.12
96.03 - ES0S
Description
Lambda Controller 509.10
Page 1 (1) Edition 02H
L23/30H
00.11 - ES0-G
Description 509.35
Page 1 (1) Starting Box Edition 01H
L23/30H
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.
Remote Start
"Remote" is activated.
Manual Stop
Blocking
94.26 - ES2S-G
Description 509.40
Page 1 (1) Converter for Engine- and Turbocharger RPM Signal Edition 01H
L23/30H
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
Engine run
96.30 - ES2S-G
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2) Alarm and Monitoring Equipment Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Data:
96.03 - ES0U-G
509-01.00 Functional Test and Adjustment of Safety, Working Card
Edition 01H Alarm and Monitoring Equipment Page 2 (2)
L23/30H
Maintenance of monitoring and safety systems. It is recommended that all functions are tested every
three months 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
96.03 - ES0U-G
Working Card
Functional Test and Adjustment of Overspeed Trip 509-01.05
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Data:
96.03 - ES0S-G
509-01.05 Functional Test and Adjustment of Overspeed Trip Working Card
Edition 01H Page 2 (2)
L23/30H
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 the
tachometer. lock screw and turn the adjusting screw, using the
tubular pin spanner supplied, see fig 2.
On reaching the revolution number indicated on page
500.30 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.
Fig 2.
96.03 - ES0S-G
Working Card
Adjustment and Test of On/Off Pressostate 509-05.00
Page 1 (2) Edition 01S
L23/30H
08028-0D/H5250/94.08.12
91.45-ES0S-G
509-05.00 Adjustment and Test of On/Off Pressostate Working Card
Edition 01S Page 2 (2)
L23/30H
08028-0D/H5250/94.08.12
91.45-ES0S-G
Working Card
Adjustment and Test of On/Off Thermostate 509-05.01
Page 1 (2) Edition 01S
L23/30H
08028-0D/H5250/94.08.12
96.26-ES0S-G
509-05.01 Adjustment and Test of On/Off Thermostate Working Card
Edition 01S Page 2 (2)
L23/30H
08028-0D/H5250/94.08.12
96.26-ES0S-G
Working Card
Function and Test of Level Switch (LAL 25) 509-05.02
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Data:
91.03 - ES0S-G
509-05.02 Function and Test of Level Switch (LAL 25) Working Card
Edition 01H Page 2 (2)
L23/30H
Function.
Test:
08028-0D/H5250/94.08.12
91.03 - ES0S-G
Working Card Adjustment and Test of Analogous Pressure 509-05.03
Page 1 (2)
Transmitter Edition 01S
L23/30H
08028-0D/H5250/94.08.12
91.45-ES0S-G
509-05.03 Adjustment and Test of Analogous Pressure Working Card
Page 2 (2)
Edition 01S Transmitter
L23/30H
08028-0D/H5250/94.08.12
91.45-ES0S-G
Working Card Adjustment and Test of 509-05.04
Page 1 (2) Analogous Temperature Transmitter Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Data:
96.26 - ES0S-G
509-05.04 Adjustment and Test of Working Card
Edition 01H Analogous Temperature Transmitter Page 2 (2)
L23/30H
The PT 100 sensor consists of a resistance wire Otherwise the test can be carried out by watching if
which changes resistance depending on the tempe- the alarm plant gives any alarm, when the alarm limit
rature. which is stated on page 500.30 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:
Test:
08028-0D/H5250/94.08.12
96.26 - ES0S-G
Working Card
Lambda Controller 509-10.00
Page 1 (2)
Edition 08H
L23/30H
Starting position
Related procedure
Data
99.28 - ES0
509-10.00 Working Card
Edition 08H
Lambda Controller Page 2 (2)
L23/30H
Lambda Controller
1. Band steel
Fig 3.
1 2. Pick-up
3. Regulating arm
3
3. Fit the adjustment screw (4), fig 2, until the
2 piston has contact with the spring without com-
pressing the spring.
Fig 1.
4. Fasten the adjustment screw.
5. Adjustment finished.
9. Adjustment finished.
Fig 2.
99.28 - ES0
Plate
Page 1 (2) Governor and Governor Drive 50901-01H
L23/30H
08028-0D/H5250/94.08.12
91.43 - ES0S-L
Plate
50901-01H Governor and Governor Drive Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
045 1/E Gasket Pakning + Item No. 212 require + Item nr. 212 kræver en
an individual matching individual tilpasning
057 4/E Nut Møtrik (by shims) before (med shims) før monte-
mounting, contact, ring, kontakt MAN B&W,
069 2/E Stud Tap MAN B&W, Holeby Holeby.
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
91.43 - ES0S-L
Plate
Page 1 (2) Regulating Device 50902-01H
L23/30H
08028-0D/H5250/94.08.12
94.46 - ES0S
Plate
50902-01H Regulating Device Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
040 2/R Split pin Split 375 1/C Split pin Split
052 2/R Self locking nut Selvlåsende møtrik 387 1/C Pin Stift
064 2/R Screw for ball head Skrue for kuglehoved 399 1/C Pin Stift
076 1/R Spring loaded pull rod, Fjederbelastet træk- 409 1/C Spring arm Fjederarm
complete stang, komplet
410 1/C Spring Fjeder
088 2/R Pull rod head Trækstangshoved
422 3/C Spring pin Fjederstift
111 1/R Split pin Split
434 1/C Armholder Armholder
123 1/R Pull rod end Trækstangsende
446 1/C Screw Skrue
135 1/R Cylindrical pin Cylindrisk stift
458 1/C Bushing Bøsning
147 1/R Spring housing Fjederhus
471 1/C Bearing bracket Lejeblik
159 1/R Pointed screw Pinolskrue
483 2/C Spring pin Fjederstift
160 1/R Spring Fjeder
495 2/C Screw Skrue
172 1/R Cylindrical pin Cylindrisk stift
505 1/R Screw Skrue
184 1/R Guide ring Styrering
517 1/R Guide pin Styrestift
196 1/R Guide ring Styrering
529 1/R Stop arm Stoparm
206 1/R Pull rod Trækstang
530 2/E Screw Skrue
218 1/R Nut Møtrik
542 2/E Screw Skrue
231 1/R Locking plate Låseblik
554 2/E Washer Skive
243 1/R Arm Arm
566 2/E Nut Møtrik
255 1/R Spring pin Fjederstift
578 1/E Bracket Konsol
267 1/R Screw Skrue
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare part kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./R = Qty./Regulating device Antal/R = Antal/Reguleringsmekanisme
94.46 - ES0S
Plate
Page 1 (2) Overspeed Device 50903-01H
L23/30H
08028-0D/H5250/94.08.12
94.01 - ES0S-V
Plate
50903-01H Overspeed Device Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
046 1/E Spring Fjeder 382 1/E Spring (left) Fjeder (venstre)
105 1/E Spring pin Fjederstift 441 1/E Elastic coupling Elastisk kobling
117 1/E Cylindrical pin Cylindrisk stift 453 1/E Spring (right) Fjeder (højre)
142 1/E Flyweight housing Hus for svingvægt 489 1/E Pneumatic valve Pneumatisk ventil
166 1/E Spring Fjeder 500 1/E Overspeed device, Overspeed anordning,
complete komplet
178 1/E Circlip Sikringsring
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
94.01 - ES0S-V
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50905-02H
L23/30H
08028-0D/H5250/94.08.12
98.35 - ES0S
Plate
50905-02H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Qty./E = Antal/Motor
98.35 - ES0S
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50905-02H
L23/30H
08028-0D/H5250/94.08.12
93.29-ES0S
Plate
50905-02H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L23/30H
Item Item
Qty. Designation Qty. Designation
No. No.
011 1/E Cable union
023 1/E Plug screw
035 1/E Packing ring
047 1/E Level switch
059 1/E Plug screw
060 1/E Packing ring
08028-0D/H5250/94.08.12
93.29-ES0S
Plate
Page 1 (2) Prelubricating Oil Alarm (LAL 25) 50905-03H
L23/30H
08028-0D/H5250/94.08.12
98.35 - ES0S-G
Plate
50905-03H Prelubricating Oil Alarm (LAL 25) Page 2 (2)
L23/30H
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Qty./E = Antal/Motor
98.35 - ES0S-G
Plate
Page 1 (2) Instrument Panel 50905-04H
L23/30H
322
310
309
299
287
08028-0D/H5250/94.08.12
93.04 - ES0S-L
Plate
50905-04H Instrument Panel Page 2 (2)
L23/30H
143 1/E Housing for instru- Hus for instrument 405 4/E Nut Møtrik
ment panel panel
417 1/E Instrument panel, Instrument panel,
155 1/E Bracket for instru- Konsol for instrument complete, L23/30H komplet, L23/30H
ment panel , L23/30H panel, L23/30H
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Qty./E = Antal/Motor
93.04 - ES0S-L
Plate Pressostate, Thermostate
Page 1 (2) 50907-01S
Difference Pressostate and Pressure Transmitter
L23/30H
08028-0D/H5250/94.08.12
91.44-ES0S-G
Pressostate, Thermostate Plate
50907-01S Page 2(2)
Difference Pressostate and Pressure Transmitter
L23/30H
08028-0D/H5250/94.08.12
91.44-ES0S-G
Plate
Page 1 (1) Pick-up 50908-01H
L23/30H
95.28 - ES0S
Plate
Page 1 (2) Temperature Transmitter 50908-03H
L23/30H
08028-0D/H5250/94.08.12
91.44-ES0S-G
Plate
50908-03H Temperature Transmitter Page 1 (2)
L23/30H
08028-0D/H5250/94.08.12
91.44-ES0S-G
Plate
Page 1 (2) Lambda Controller 50910-02H
L23/30H
08028-0D/H5250/94.08.12
97.14 - ES0S
Plate
50910-02H Lambda Controller Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
97.14 - ES0S
Plate
Page 1 (2) Starting Box 50935-01H
L23/30H
017
029
030
94.36 - ES0S-G
Plate
50935-01H Starting Box Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Enigne. Qty./E = Qty./Motor
94.36 - ES0S-G
Index
Page 1(1) Crankshaft and Main Bearings 510
L23/30H
Description
Working Card
Plates
STX Engine
Description
Crankshaft and Main Bearings 510.01
Page 1 (1)
Edition 01H
L23/30H
The crankshaft, which is a one-piece forging with In special cases a vibration damper is mounted on the
ground main bearing and crankpin journals, is sus- crankshaft to limit torsional vibrations. The damper
pended in inderslung bearings. The main bearings are consists essentially of a heavy flywheel totally en-
equipped with insertion-type shells, which are coated closed in a light casing. A small clearance is allowed
with a wearing surface. To attain a suitable bearing between the casing and the flywheel, and this space
pressure the crankshaft is provided with is filled with a highly viscous fluid. The casing is rigidly
counterweights, which are attached to the crankshaft connected to the front end of the engine crankshaft
by means of two screws. and the only connection between the crankshaft and
the damper flywheel is through the fluid. Under condit-
At the flywheel end the crankshaft is fitted with a gear ions of no vibration, the casing and damper flywheel
wheel which through an intermediate wheel drives the tend to rotate as one unit, since the force required to
camshaft. Also fitted here is the flywheel and a shear the viscous film is consi-derable. As the torsional
coupling flange for connection of a reduction gear or vibration amplitudes increase, the casing follows the
an alternator. At the opposite end there is a claw-type movement of the crankshaft but the flywheel tends to
coupling for the lub. oil pump or a flexible gear wheel rotate uniformly by virtue of its inertia, and relative
connection for lub. oil and water pumps. motion occurs 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
96.03 - ES0U
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 1 (7)
(Hydraulic Tightened Connecting Rod) Edition 04H
L23/30H
Starting position:
Related procedure:
Data:
00.27 - ES0
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 04H (Hydraulic Tightened Connecting Rod) Page 2 (7)
L23/30H
Alignment of Main Bearings. As the crankshafts of medium speed engines are very
stiff, any great deviations in the alignment will result
The lower main bearing shells should be positioned in clearance at the bottom shell of the bearings.
so that they keep the main bearing journals of the
crankshaft centered in a straight (ashore horizontal) The cause of incorrect main bearing position may be
line. Deviations from this centre line cause the wear of the bearings or misalignmnet of the engine.
crankshaft to bend and increase the load on some
main bearings.
Effecting The Deflection Measurement.
If two adjacent main bearings are placed too low, the
crankshaft centre line will in this place be lowered to The deflection measurement is effected by placing a
form an arc, causing the intermediate crank throw to springloaded dial gauge in the centre punch marks
bend in such a way that it "closes" when turned into provided for this purpose, see fig. 1.
bottom position and "opens" in top position.
"Closing" of the throw in top dead centre is regarded
As the magnitude of such axial lengthening and as negative, (compression of the gauge).
shortening during the turning of the throw increases in
proportion to the difference in the height of the In the example, page 3, the deflection reading is
bearing, it is measured as a check on the alignment therefore negative.
and condition of the bearing.
08028-0D/H5250/94.08.12
00.27 - ES0
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 3 (7)
(Hydraulic Tightened Connecting Rod) Edition 04H
L23/30H
As during the turning of the throw, the gauge and the The total deflection ("opening-closing") of the throw
connecting rod will meet near the bottom position of during the turning from bottom to top position is
the throw, the measurement for the bottom position is entered in fig. 4.
to be replaced by the average of the two near by
positions on either side. These figures are due to vertical misalignment of the
main bearings.
The dial gauge is set to zero, when the crank throw is
in the near-bottom (x in fig. 8) and during the turning Similarly, horizontal misalignment procedures the
the throw is stopped in the position horizontal-top- figures in the table fig. 5.
horizontal-near bottom (P-T-S-Y in fig. 8) for reading
of the gauge. Besides misalignment of the bearings, the readings
can be influenced by ovality or eccentricity of the
journals.
Checking The Deflection Measurement.
The reading is entered in the table page 6, see Engines Equipped with Turning Gear.
example in fig. 2 - 6.
When taking these deflection readings for the three
As "bottom" reading is used the mean value of the two aftmost cylinders, the turning gear should at each
"near bottom" readings X and Y, fig. 3. stoppage be turned a little backwards to ease off the
tangential pressure on the teeth of the turning wheel
as this pressure may otherwise falsify the readings.
08028-0D/H5250/94.08.12
00.27 - ES0
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 04H (Hydraulic Tightened Connecting Rod) Page 4 (7)
L23/30H
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Fig. 2. Fig. 5.
Fig. 6.
S P
Y X
08028-0D/H5250/94.08.12
Fig. 7. Fig. 8.
00.27 - ES0
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 5 (7)
(Hydraulic Tightened Connecting Rod) Edition 04H
L23/30H
00.27 - ES0
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
(Hydraulic Tightened Connecting Rod) Page 6 (7)
Edition 04H
L23/30H
Instruction/Instruktion
Top
1/100 mm
Bottom end/ Bottom start/
Bund slut Bund start
Cyl. no 1 2 3 Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
08028-0D/H5250/94.08.12
00.27 - ES0
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 7 (7)
(Hydraulic Tightened Connecting Rod) Edition 04H
L23/30H
Engine no.:
Motornr.:
Cyl. no. 1 2 3 4 5 6 7 8 9
Bottom X 0 0 0 0 0 0 0 0 0
Left side P
Top T
Right side S
Bottom Y
Bottom
(0.5xY)=B
Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V
Deflection from
horizontal mis-
alignment.
Left side - Right
side or P - S = H
08028-0D/H5250/94.08.12
Check on gauge
readings.
T+B= C
P+S= D
00.27 - ES0
Working Card
Inspection of Main Bearing Shells 510-01.05
Page 1 (3) Edition 01H
L23/30H
Related procedure:
Data:
96.30 - ES0S-G
510-01.05 Inspection of Main Bearing Shells Working Card
Edition 01H Page 2 (3)
L23/30H
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.
96.30 - ES0S-G
Working Card
Inspection of Main Bearing Shells 510.01-05
Page 3 (3) Edition 01H
L23/30H
Cleaning
16) Lubricate the end of the bearing shells with
12) Clean all machined surfaces, on frame, bearing molycote pasta or similar.
cap, stud, nuts and bearing shells.
17) Insert the lower bearing shell in the bearing cap
and mount the locking piece.
Inspection of Main Bearing Shells
Lubricate the bearing shell and journal with clean
13) Inspect the main bearing shells according to lubricating oil.
working card 506-01.16.
Note: The bearing is marked according to size and Mounting of the Main Bearing Cap
when replaced it must be by a new bearing of the
same size. 18) Raise the bearing cap into position, dismount
the guide tubes, coat the bearing studs with molycote
pasta or similar and fit the bearing stud nuts.
Mounting of the Main Bearing Shells
Make sure that the bearing cap and bearing shell are
14) Push the upper bearing shell as far into posi- in their correct position.
tion as possible.
19) Dismantle the wire straps.
15) Fit the tool for upper main bearing in the
lubricating hole in the crankshaft and turn in the 20) Mount the hydraulic tools, see working card
upper bearing shell by turning the crankshaft. 520-01.05, and tighten the nuts as prescribed on
page 500-40.
Make sure that the shell enters its correct position
then remove the tool for upper main bearing. 21) Coat the back side of the bracing screws' (side
screws') hexagonal head with a thin coat of silastene
or similar.
96.30 - ES0S-G
Working Card
Inspection of Guide Bearing Shells 510-01.10
Page 1 (3) Edition 01H
L23/30H
Hand tools:
Starting position:
Allen key, 12 mm.
Socket spanner, 36 mm.
Lead hammer.
Silastene.
Copaslip.
Related procedure:
Manpower:
Replacement and wearing parts:
08028-0D/H5250/94.08.12
Data:
96.20 - ES0S
510-01.10 Inspection of Guide Bearing Shells
Working Card
Edition 01H Page 2 (3)
L23/30H
96.20 - ES0S
Working Card 510-01.10
Page 3 (3) Inspection of Guide Bearing Shells Edition 01H
L23/30H
The bearing shells of the guide bearing, which are Make sure that the thrust washers, bearing shell and
identical to those of the main bearings, are narrower bearing cap are in their correct position.
than the bore for the guide bearing and it is therefore
essential that the shells are positioned perfectly 20) Dismantle the wire straps.
correct in the bore.
08028-0D/H5250/94.08.12
96.20 - ES0S
Plate
Page 1 (2) Crankshaft 51001-04H
L23/30H
08028-0D/H5250/94.08.12
98.34 - ES0S
Plate
51001-04H Crankshaft Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./W = Qty./Counterweight Antal/W= Antal/Kontravægt
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
98.34 - ES0S
Plate
Page 1 (2) Resilient Gear Wheel 51002-02H
L23/30H
243
135
123
111
206
088
135
052
160
196
218 147
172 111
111 159
08028-0D/H5250/94.08.12
231
172
040 184
111 064
172 076
94.24 - ES0S
Plate
51002-02H Resilient Gear Wheel Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
94.24 - ES0S
Plate
Page 1 (2) Flywheel with Gear Rim 51003-02H
L23/30H
105
046+
058
Crankshaft
(Plate 51001)
034
010
022
08028-0D/H5250/94.08.12
96.03 - ES0S
Plate
51003-02H Flywheel with Gear Rim Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Antal/Motor
96.03 - ES0S
Index
Page 1(1) Engine Frame and Base Frame 511
L23/30H
Description
Working Card
Plates
STX Engine
Description
Engine Frame and Base Frame 511.01
Page 1 (1)
Edition 01H
L23/30H
Frame
On the sides of the frame there are covers for acces
The engine frame is made of cast iron, and is attached to the camshaft, the charge air receiver and crank-
to the top of the base frame by means of bolts. The case. Some of the covers are fitted with relief valves
cross girders of the frame are provided with bores for which will act, should oil vapours in the crankcase be
the main bearings in which the crankshaft is underslung, ignited, for instance in the event of a hot bearing.
i.e. it is carried by the main bearing caps.
The charge air cooler housing is a integrated part of
The main bearing caps are attached by means of the frame.
studs and nuts, which are loosened and tightened with
the aid of hydraulic tools. After mounting, the main
bearing caps are further secured by means of bracing Base Frame
screws, which are screwed horizontally into the sides
of the caps and tightened against the sides of the Engine and alternator (gear, pump) are mounted on a
engine frame. The main bearings are equipped with common base frame which is in welded design.
replaceable shells which are fitted without scraping.
The base frame is used as lubricating oil reservoir
The crankshaft guide bearing is located at the fly- "wet sump".
wheel end of the engine.
94.26 - ES0U
Working Card
Functional Test of Crankcase Safety Relief Valves 511-01.00
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
97.06 - ES0S-G
511-01.00 Functional Test of Crankcase Safety Relief Valves Working Card
Edition 01H Page 2 (2)
L23/30H
08028-0D/H5250/94.08.12
97.06 - ES0S-G
Plate
Page 1 (2)
Frame with Main Bearings 51101-02H
L23/30H
08028-0D/H5250/94.08.12
96.51 - ES0S
Plate
51101-02H Frame with Main Bearings Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
025 5/E Bracing bolt Sideskrue 385 1/B Packing ring Pakningsring
049 4/C Nut for cylinder Møtrik for cylinder- 397 1/E Frame complete, incl. Stativ komplet, inkl.
head stud dækseltap item 049, 062, 108, 133, item 049, 062, 108, 133,
145, 169, 170, 216, 241, 145, 169, 170, 216, 241,
050 4/C Protective cap Beskyttelseshætte 290, 300, 324, 348, 361, 290, 300, 324, 348, 361,
373, 385, plate 50701 373, 385, plate 50701
062 4/C Stud for cylinder head Tap for cylinderdæksel item 048, 061, 073, 276 item 048, 061, 073, 276
086 1/E Coupling Kobling + Item No 108, 300 + Item nr. 108, 300 kræ-
require an individual ver en individuel
098 2/E Plug Prop matching before tilpasning før montering,
mounting, contact kontakt MAN B&W,
108+ 1/C Main bearing cap Hovedlejedæksel MAN B&W, Holeby Holeby
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
Qty./B = Qty./Bearing Antal/B = Antal/Leje
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
96.51 - ES0S
Plate
Page 1 (2) Mounting of Pumps 51102-02H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S
Plate
51102-02H Mounting of Pumps Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
94.23 - ES0S
Plate
Page 1 (2) Covers on Frame 51106-02H
L23/30H
08028-0D/H5250/94.08.12
96.51 - ES0S
Plate
51106-02H Covers on Frame Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
96.51 - ES0S
Pate
Page 1 (3) Covers on Frame 51106-03S
L23/30H
08028-0D/H5250/94.08.12
96.51-ES0S
Pate
51106-03S Covers on Frame Page 2 (3)
L23/30H
ltem ltem
Qty Designation Qty Designation
No No
058 2/C O-ring 298 Handle
071 4/D Washer 22/E 5cyl.engine
083 4/D Self locking nut 26/E 6cyl.engine
095 1/D Housing for safety valve 30/E 7cyl.engine
129 8/C Screw 34/E 8cyl.engine
154 28/E Screw 308 Washer
166 2/E Cover 24/E 5cyl.engine
178 2/E Gasket 28/E 6cyl.engine
191 2/C Stud 32/E 7cyl.engine
201 2/E Stud 36/E 8cyl.engine
213 4/C Screw 321 Guard intermediate
225 1/C Cover of camshaft housing 4/E 5cyl.engine
237 1/C O-ring 5/E 6cyl.engine
249 5/E Screw 6/E 7cyl.engine
250 5/E Washer 7/E 8cyl.engine
262 1/E Guard end aft 333 2/C Stud
274 1/E Guard end aft 345 1/E Guard end fore
286 Spring pin 357 1/E Guard end fore
22/E 5cyl.engine 369 1/E Guard
26/E 6cyl.engine 370 6/E Screw
30/E 7cyl.engine 382 1/E Guard end fore
34/E 8cyl.engine 394 6/C Screw only for 900rpm
404 2/E Screw
416 Cover for drankcase
6/E 5cyl.engine
7/E 6cyl.engine
9/E 7cyl.engine
10/E 8cyl.engine
428 4/E Screw
441 2/E Tapered dowel
453 2/E Washer
465 2/E Nut
08028-0D/H5250/94.08.12
96.51-ES0S
Pate
Page 3 (3) Covers on Frame 51106-03S
L23/30H
ltem ltem
Qty. Designaion Qty. Designaion
No. No.
490 Cover with safety valve, complete incl.
item 010, 022, 034, 046, 071, 083, 095,
105, 117
4/E 5cyl.engine
5/E 6cyl.engine
6/E 7cyl.engine
7/E 8cyl.engine
500 Guard intermediate complete incl Item
191, 286, 308, 321, 333
4/E 5cyl.engine
5/E 6cyl.engine
6/E 7cyl.engine
7/E 8cyl.engine
693 /l Packing silicone paste
703 1/E Cover
715 6/E Screw
08028-0D/H5250/94.08.12
96.51-ES0S
Pate
Page 1 (3) Covers on Frame 51106-03S
L23/30H
08028-0D/H5250/94.08.12
96.51-ES0S
Pate
51106-03S Covers on Frame Page 2 (3)
L23/30H
ltem ltem
Qty Designation Qty Designation
No No
058 2/C O-ring 298 Handle
071 4/D Washer 22/E 5cyl.engine
083 4/D Self locking nut 26/E 6cyl.engine
095 1/D Housing for safety valve 30/E 7cyl.engine
129 8/C Screw 34/E 8cyl.engine
154 28/E Screw 308 Washer
166 2/E Cover 24/E 5cyl.engine
178 2/E Gasket 28/E 6cyl.engine
191 2/C Stud 32/E 7cyl.engine
201 2/E Stud 36/E 8cyl.engine
213 4/C Screw 321 Guard intermediate
225 1/C Cover of camshaft housing 4/E 5cyl.engine
237 1/C O-ring 5/E 6cyl.engine
249 5/E Screw 6/E 7cyl.engine
250 5/E Washer 7/E 8cyl.engine
262 1/E Guard end aft 333 2/C Stud
274 1/E Guard end aft 345 1/E Guard end fore
286 Spring pin 357 1/E Guard end fore
22/E 5cyl.engine 369 1/E Guard
26/E 6cyl.engine 370 6/E Screw
30/E 7cyl.engine 382 1/E Guard end fore
34/E 8cyl.engine 394 6/C Screw only for 900rpm
404 2/E Screw
416 Cover for drankcase
6/E 5cyl.engine
7/E 6cyl.engine
9/E 7cyl.engine
10/E 8cyl.engine
428 4/E Screw
441 2/E Tapered dowel
453 2/E Washer
465 2/E Nut
08028-0D/H5250/94.08.12
96.51-ES0S
Pate
Page 3 (3) Covers on Frame 51106-03S
L23/30H
ltem ltem
Qty. Designaion Qty. Designaion
No. No.
490 Cover with safety valve, complete incl.
item 010, 022, 034, 046, 071, 083, 095,
105, 117
4/E 5cyl.engine
5/E 6cyl.engine
6/E 7cyl.engine
7/E 8cyl.engine
500 Guard intermediate complete incl Item
191, 286, 308, 321, 333
4/E 5cyl.engine
5/E 6cyl.engine
6/E 7cyl.engine
7/E 8cyl.engine
693 /l Packing silicone paste
703 1/E Cover
715 6/E Screw
08028-0D/H5250/94.08.12
96.51-ES0S
Pate
Page 1 (2) Covers on Frame 51107-03S
L23/30H
08028-0D/H5250/94.08.12
Pate
51107-03S Covers on Frame Page 2 (2)
L23/30H
ltem ltem
Qty Designation Qty Designation
No No
1 1/D Seat
2 1/D Disc
3 1/D Cover
4 1/D Stem
5 1/D Spring seat
6 3/D Pipe
7 1/D Spring
8 1/D O-ring
9 1/D O-ring
10 1/D O-ring
11 3/D Bolt
12 3/D Gasket
13 3/D Nut
14 3/D Spring washer
15 3/D Bolt
16 3/D Gasket
17 3/D Nut
18 3/D Spring washer
08028-0D/H5250/94.08.12
L23/30H
Description
Working Card
Plates
STX Engine
Description
Turbocharger System 512.01
Page 1 (2) Edition 01H
L23/30H
Water washing, turbine side, inlet P7 Exhaust gas, outlet P2 M1 Charge air, inlet
P8 Water washing,
compressor side with
quick coupling, inlet
Exhaust gas to TC
The turbocharger pumps the air through the charging The exhaust gas receiver is made of pipe sections,
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.
95.26 - ES0S
512.01 Turbocharger System Description
Edition 01H Page 2 (2)
L23/30H
In the cooled intermediate piece a thermometer for To avoid excessive thermal loss and to ensure a
reading the exhaust gas temperature is fitted and reasonably low surface temperature the exhaust gas
there is also possibility of fitting a sensor for remote receiver is insulated.
reading.
95.26 - ES0S
Description Cleaning the Turbocharger In Service 512.05
Page 1 (1) Water Washing of Compressor Edition 01H
L23/30H
Fouling of air filter, compressor or charging air cooler The intervals between cleaning by injection of water
may be observed as changes in performance para- should be adjusted after assessing the degree and
meters: rate of fouling in the particular plant, i.e. based on
observations and experience.
- Decreasing charging air pressure.
- Decreasing turbocharger rotor speed.
- Increasing exhaust gas temperature.
- Severe fouling of airways may even result in
compressor surge.
94.26 - ES0U-G
Description Cleaning the Turbocharger in Service 512.15
Page 1 (1) Water Washing - Turbine Side Edition 01H
L23/30H
Description
The tendency to fouling on the gas side of turbo- Heavily contaminated turbines, which where not
chargers depends on the combustion conditions, cleaned periodically from the very beginning or after
which are a result of the load on and the maintenance an overhaul, cannot be cleaned by this method.
condition of the engine as well as the quality of the
fuel oil used. If vibration in the turbocharger occur after water-
washing has been carried out, the washing should be
Fouling of the gas ways will cause higher exhaust repeated. If unbalance still exists, this is presumably
gas temperatures and higher surface temperatures due to heavy fouling, and the engine must be stopped
of the combustion chamber components and will and the turbocharger dismantled and manually
also lead to a lower performance. cleaned.
Tests and practical experience have shown that The washing water should be taken from the fresh
radial-flow turbines can be successfully cleaned by water system and not from the fresh cooling water
injection water into the inlet pipe of the turbine. The system or salt water system. No cleaning agents and
cleaning effect is based on the water solubility of the solvents need to be added to the water.
deposits and on the mechanical action of the im-
pinging water droplets and the water flow rate. To avoid corrosion during standstill, the engine
must, upon completing of water washing run for at
The necessary water flow is dependent on the gas least 1 hour before stop so that all parts are dry.
flow and the gas temperature. Enough water must
be injected per time unit so that, not the entire flow
will evaporate, but about 0.25 l/min. will flow off Water Washing System
through the drainage opening in the gas outlet. Thus
ensuring that sufficient water has been injected. The water washing system consists of a pipe system
equipped with a regulating valve, a manoeuvring
Service experience has shown that the above valve, a 3-way cock and a drain pipe with a drain
mentioned water flow gives the optimal cleaning valve from the gas outlet, see illustration on working
effect. If the water flow is reduced the cleaning effect card 512-15.00.
will be reduced or disappear. If the recommended
water flow is exceed, there is a certain risk of a The water for washing the turbine, is supplied from
accumulation of water in the turbine casing, which the external fresh water system through a flexible
can result in damage on the turbocharger. hose with couplings. The flexible hose must be
disconnected after water washing.
The best cleaning effect is obtained by cleaning at
low engine load approx. 20% MCR. Cleaning at low By activating the manoeuvring valve and the regu-
load will also reduce temperature shocks. lating valve, water is led through the 3-way cock to
the exhaust pipe intermediate flange, equipped with
Experience has shown, that washing at regular a channel to lead the water to the gas inlet of the
intervals is essential to successful cleaning, as turbocharger.
excessive fouling is thus avoided. Washing at inter-
vals of 100 hours is therefore recommended. De- The water which is not evaporated, is led out through
pending on the fuel quality these intervals can be the drain pipe in the gas outlet.
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.
96.39 - ES0U-G
Working Card
Overhaul of Charging Air Cooler 512-01.00
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
96.20 - ES0S
512-01.00 Overhaul of Charging Air Cooler Working Card
Edition 01H Page 2 (2)
L23/30H
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-
502. mendation must be followed.
96.20 - ES0S
Working Card Water Washing of Compressor Side 512-05.05
Page 1 (2) Turbocharger Type NR15/R Edition 01H
5, 6L23/30H
Description:
Starting position:
Related procedure:
Manpower:
Replacement and wearing parts:
08028-0D/H5250/94.08.12
91.45 - ES0S
512-05.05 Water Washing of Compressor side Working Card
Edition 01H Turbocharger Type NR15/R Page 2 (2)
5, 6L23/30H
91.45 - ES0S
Working Card
Water Washing of Turbine Side 512-15.00
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
91.04 - ES0S
512-15.00 Water Washing of Turbine Side Working Card
Edition 01H Page 2 (2)
L23/30H
Fig 1. Arrangement for water washing. Note: The regulating valve has to be opened slowly.
91.04 - ES0S
Plate
Page 1 (2) Charging Air Cooler - Freshwater 51201-04H
5L23/30H-720/750 RPM
6L23/30H-720/750 RPM
08028-0D/H5250/94.08.12
97.06 - ES0S
Plate
51201-04H Charging Air Cooler - Freshwater Page 2 (2)
5L23/30H-720/750 RPM
6L23/30H-720/750 RPM
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
017, 029, 030, 042, 054, 042, 054, 066, 078, 091,
066, 078, 091, 101, 113, 101, 113, 125, 137, 149,
125, 137, 149, 150, 174, 150, 174, 186, 198, 208,
186, 198, 208, 221, 233, 221, 233, 269, 270 og
269, 270 and 294 294
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor
Qty./K = Cooler Antal/K = Køler
97.06 - ES0S
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-01S
5L23/30H
6L23/30H-720/750 RPM
08028-0D/H5250/94.08.12
94.22-ES0S
Plate
51202-01S Exhaust Pipe Arrangement Page 2 (2)
5L23/30H
6L23/30H-720/750 RPM
Item Item
Qty. Designation Qty. Designation
No. No.
012 1/C Intermediate piece, complete, incl. 193 3/C Plug screw
item 181, 193, 203, 215 and 227 203 3/C Gasket
024 2/C Gasket 215 1/C Plug screw
036 4/C Screw 227 1/C Sealing ring
041 1/E Exhaust pipe 239 4/C Screw
051 Exhaust pipe 240 1/C Screw
3/E 5 cyl. engine 252 1/C Cooling water nipple
4/E 6 cyl. engine 264 2/C O-ring
061 1/E Exhaust pipe for cyl. 1
073 1/E Flange
081 Compensator
4/E 5 cyl. engine
5/E 6 cyl. engine
097 1/E Compensator
101 Gasket
8/E 5 cyl. engine
10/E 6 cyl. engine
111 3/E Gasket
121 Nut
96/E 5 cyl. engine
120/E 6 cyl. engine
131 Screw
96/E 5 cyl. engine
120/E 6 cyl. engine
144 8/E Screw
156 16/E Nut
168 8/E Screw
171 8/E Screw
181 1/C Intermediate piece
191 1/E End cover, aft
08028-0D/H5250/94.08.12
94.22-ES0S
Plate
Page 1 (2) Turbocharging Arrangement 51203-03H
5L23/30H-720/750/900 RPM
6L23/30H-720/750 RPM
08028-0D/H5250/94.08.12
96.51 - ES0S
Plate
51203-03H Turbocharging Arrangement Page 2 (2)
5L23/30H-720/750/900 RPM
6L23/30H-720/750 RPM
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
043 1/E Bracket for Konsol for 413 2/E Support Holder
tubocharger turbolader
425 2/E Support Holder
055 6/E Screw Skrue
437 4/E Screw Skrue
067 6/E Spring lock Låseskive
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/E = Antal/Cylinder
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
96.51 - ES0S
Index
Page 1(1) Compressed Air System 513
L23/30H
Description
Working Card
Plates
STX Engine
Description
Compressed Air System 513.01
Page 1 (2) Edition 01S
L23/30H
The compressed air system on the engine con- The engine is started by means of a built-on air
tains a starting system, starting control system and starter, which is of the turbine starter motor type
safety system. Further, the system supplies air to with gear box, safety clutch and drive shaft with
the lambda system. pinion. Further, the starting system consists of a
08028-0D/H5250/94.08.12
L23/30H
08028-0D/H5250/94.08.12
air will be supplied to the fuel limitating cylinder,
thus limiting the fuel supply during the start se-
quence.
General
Starting position
Related procedure
08028-0D/H5250/94.08.12
Data
02.46 - ES0
513-01.21 Air Filter Working Card
Edition 01H Page 2 (2)
General
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
02.46 - ES0
Working Card
Overhaul, Test and Inspection of Turbine Starter 513-01.30
Page 1 (9) Edition 01H
L23/30H
Description:
96.38 - ES0S-G
513-01.30 Overhaul, Test and Inspection of Turbine Starter
Working Card
Edition 01H Page 2 (9)
L23/30H
General Information
4) When grasping a part in a vice, always use 5) Remove the deflector retaining screw (5),
copper-covered vice jaws to protect the surface of deflector retaining 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
larly true of threaded members. 2.
96.38 - ES0S-G
Working Card
Overhaul, Test and Inspection of Turbine Starter 513-01.30
Page 3 (9) Edition 01H
L23/30H
gear case (13), See fig 3.
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 vice 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 vice 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
gear case.
Fig 4.
Drive Housing
Fig 3.
1) Grasp the drive pinion (63) in a copper-faced
96.38 - ES0S-G
513-01.30 Overhaul, Test and Inspection of Turbine Starter Working Card
Edition 01H Page 4 (9)
L23/30H
vice with the starter supported on the workbench. Note: Do not remove the front drive shaft bearing
(42) or the drive housing seal (43) unless replace-
2) Remove the drive pinion retaining screw (61) ment is necessary and new parts are available. The
which has a right-hand thread. bearing and/or the seal will always be damaged
when removed from the drive housing.
3) Remove the starter from the vice.
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
hammer 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.
08028-0D/H5250/94.08.12
12) Remove the outer bulkhead ring (47) and the Note: Do not disassemble the drive gear and clutch
inner bulkhead ring (48). parts of the turbine powered starters. If the drive
shaft is defective, install a new or factory-rebuilt
13) Slide the drive shaft (57) from the drive hous- unit.
ing (40).
25) Remove the drive gear shaft bearing retainer
14) Pull the piston return spring (59) off the drive (33), using retaining ring pliers.
shaft.
26) Remove the rear drive gear bearing (31) from
the drive gear.
96.38 - ES0S-G
Working Card
Overhaul, Test and Inspection of Turbine Starter 513-01.30
Page 5 (9) Edition 01H
L23/30H
Assembly of the Starter 10) Grasp the drive shaft (57) in a vice, external
splined end down. Place assembled drive shaft
1) Always press on the inner ring of a ball bearing screw Unit into the drive shaft, screwhead down.
when installing the bearing on a shaft. Lubricate the inside diameter of the drive shaft with
Ingersoll-Rand No. 28 lubricant.
2) Always press on the outer ring of a ball bearing
when pressing the bearing in a bearing recess. 11) Slide the drive gear bearing (30) into the drive
shaft.
3) Whenever grasping a part in a vice, always
use leather-covered, copper-covered vice jaws to 12) Lubricate with Ingersoll-Rand No. 28 lubricant
protect the surface of the part and help prevent and install the driving clutch jaw teeth facing up and
distortion. This is particularly true of threaded mem- driven clutch jaw teeth facing down into the drive
bers. shaft.
4) Always clean every part, and wipe every part 13) Insert the clutch spring (51) into the drive
with a thin film of oil before installation. shaft.
14) Insert the clutch spring cup (50) into the drive
Gear Case shaft.
1) Place the drive gear bearing retainer over the 15) Press the inserted parts into the drive shaft,
rear end of the drive gear. and install the clutch spring cup retainer (49).
08028-0D/H5250/94.08.12
96.38 - ES0S-G
513-01.30 Overhaul, Test and Inspection of Turbine Starter Working Card
Edition 01H Page 6 (9)
L23/30H
Note: If it is necessary to replace the drive housing 25) With the drive housing in the arbor press,
(40) and drive components, make sure that the press down on the rear face of the piston.
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
24) Slide the bulkhead onto the piston. 35) Place the drive pinion washer (62) onto drive
pinion retaining screw (61).
96.38 - ES0S-G
Working Card
Overhaul, Test and Inspection of Turbine Starter 513-01.30
Page 7 (9) Edition 01H
L23/30H
Note: The thread on the drive pinion retaining screw Note: Do not move or turn over the planet gear
is right-hand thread. frame until step 6 and 7 have been completed.
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 vice. 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 vice 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
two remaining planet gears and components.
96.38 - ES0S-G
513-01.30 Overhaul, Test and Inspection of Turbine Starter
Working Card
Edition 01H Page 8 (9)
L23/30H
13) Install the motor assembly through the rear of 16) Coat the exhaust cover seal (2) and install it in
the motor housing with the geared end of the rotor the groove on the housing exhaust cover.
toward the front.
17) Align the punch marks on the housing exhaust
Note: Turn the intermediate pinion so that the gear cover with the punch marks on the motor housing
on the rotor meshes with the planet gears. Make and tap the housing exhaust cover with a plastic
sure that the rear of the motor assembly is installed hammer until it seats.
flush with the rear of the cylinder.
18) Install the housing exhaust cover on the rear
14) Align the punch marks on the motor housing of the motor housing using the starter assembly cap
with the punch marks on the intermediate gear case screws (6) and cap screw washers (7). Use an 8 mm
and tap the motor housing with a plastic hammer hex-head wrench to tighten each a little at a time to
until it seats on the rear of the intermediate gear a final torque of 61 to 68 Nm increments.
08028-0D/H5250/94.08.12
case.
19) Mount the exhaust cover (68) on the housing
15) Install the splash deflector (3), deflector re- exhaust cover (1).
taining spring (4) and deflector retaining screw (5) in
the rear of the housing exhaust cover. Note: Use Intersoll-Rand SMB-441 pipe sealant on
all plugs.
Note: Coat the threads of the deflector retaining
screw with Ingersoll-Rand SMB-441 sealant.
96.38 - ES0S-G
Working Card
Overhaul, Test and Inspection of Turbine Starter 513-01.30
Page 9 (9)
Edition 01H
L23/30H
20) Install the bottom housing plug (10) and the Measure the dimension from the face of the drive
housing plug inlet boss (11). Put the starter on its shaft pinion (63) to the face of the mounting flange.
side with the side plug hole upward. Add 175 ml It should be 69.0 +2.0 mm).
automatic transmission fluid through the side plug
hole. Remove the pressure from the “IN” port. Measure
the distance form the face of the drive shaft pinion
Caution: Do not overfill. to the the face of the mounting flange. It should be
Install the side housing plug (10) and tighten all 45.0 +2.0 mm.
plugs to 6.8 to 13.6 Nm torque.
4) Motor Action: Secure starter in a vise and
apply 90 psig (6.2 bar/620 kPa) pressure using a 3/
Test and Inspection Procedure 8" (9 mm) supply line to the inlet of the motor. starter
should run smoothly.
1) Clutch Ratcheting: Turn the drive shaft pin-
ion (63) by hand in the direction of the starter 5) Motor Seals: Plug the exhaust and slowly
rotation. The clutch should rachet smoothly with a apply 20 psig (1.38 bar/138 kPa) pressure to the
slight clicking action. inlet of the motor. Immerse the starter for 30 sec-
onds in o non-flammable, bubble-producing liquid. If
2) Motor and Gearing Freeness: Turn the drive the starter is properly sealed, no bobbles will ap-
shaft pinion (63) opposite the direction of the starter pear.
rotation. The drive shaft pinion should turn by hand.
6) Gear Case Seals: Plug the exhaust and slowly
Note: Inadvertent application of air pressure to the apply 20 psig (1.38 bar/138 kPa) pressure to the
“OUT” port will result in drive malfunction (pinion will inlet of the motor. Immerse the starter for 30 sec-
fail to retract). If this condition occurs, loosen the onds in o non-flammable, bubble-producing liquid.
drive housing cap screws (38) to vent gear case
(28). Also, loosen housing plugs (10) and (11) to There should be no leakage in the housing joints in
vent motor. the gear case area or in the shaft seal in the
intermediate gear system. If the starter is properly
3) Pinion Engagement: Apply 50 psig (3.4 bar/ sealed, no bubbles will appear.
345 kPa) pressure to the engagement “IN” port.
drive shaft pinion (63) should move outward and air 7) Confirm Drive Rotation: Apply low pressure
should escape from the “OUT” port. to the motor and observe rotation. Drive pinion (63)
must rotate in the direction stamped on the name-
Plug the “OUT” port and apply 150 psig (10.3 bar/ plate. Chamfer on pinion teeth should be on the
1034 kPa) pressure to the “IN” port. Check and trailing edge of the gear tooth.
make sure that no air is escaping.
08028-0D/H5250/94.08.12
96.38 - ES0S-G
Working Card
Main Starting Valve 513-01.40
Page 1 (2) Edition 01H
L23/30H
Description:
Soft hammer.
Locking ring plier.
Allen key, 1/4".
Starting position:
Related procedure:
94.22 - ES0S-G
513-01.40 Main Starting Valve Working Card
Page 2 (2)
Edition 01H
L23/30H
Warning:
4) Clamp the main starting valve, in a vice with the
Do not attempt any maintenance on the main starting locking ring (9) end up.
valve before the starting air system has been 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 plug 8) Wash all other parts in a clean, nonflammable
opening. solvent.
10) Turn the piston over and insert the new bumber
2 C
(7).
4
11)Using O-ring lubricant, lubricate and install the new
D end plug seal O-ring (10) and the new end plug O-ring
7 5 (11) on the end plug (3).
8
11
12) Lubricate the lower small bore of the valve
A
housing (1) with O-ring lubricant.
9
10 13) Insert the piston assembly into the valve hous-
3
ing. Push on the piston until the piston O-ring seats
against the bevelied face.
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
08028-0D/H5250/94.08.12
94.22 - ES0S-G
Working Card
Check of Compressed Air Piping System 513-01.90
Page 1 (2) Edition 01H
L23/30H
Starting position:
Related procedure:
Data:
94.21 - ES0U-G
513-01.90 Check of Compressed Air Piping System Working Card
Edition 01H Page 2 (2)
L23/30H
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 of
3) Drain the system for condensed water. - This the emergency valve. See description 513.01.
should be based on observations.
5) Check manometers.
08028-0D/H5250/94.08.12
94.21 - ES0U-G
Plate
Page 1 (3) Turbine Starter 51309-01H
L23/30H
08028-0D/H5250/94.08.12
96.26 - ES0S-G
Plate
51309-01H Turbine Starter Page 2 (3)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
014 1/S Housing exhaust Hus for udstøds- 254 1/S Bearing spacer Ligemellemstykke
cover dæksel
266 1/S Planet gear shaft Planetgearaksel
026 1/S Exhaust cover seal Tætningsring for
udstødsdæksel 278 2/S Gear shaft retainer Spænderingsskive for
washer gearaksel
038 1/S Splash deflector Stænk deflektor
291 1/S Rear gear frame Bagerste gearstelleje
051 1/S Deflector return Returfjeder for deflektor bearing
spring
301 1/S Front bearing spacer Forreste gearstelleje
063 1/S Deflector retaining Spændeskive for
screw deflektor 313 1/S Intermediate pinion Mellemtandhjul
075 4/S Starter assembly cap Dækselskrue for 325 1/S Intermediate pinion Spændeskrue for
screw montage af starter retaining screw mellemtandhjul
087 4/S Cap screw washer Skive for dækselskrue 337 1/S Gear case Gearkasse
099 1/S Motor housing Motorhus 349 1/S Drive gear Drivgear
109 1/S Housing plug Prop til motorhus 350 1/S Front drive gear Forreste drivgearleje
bearing
110 1/S Housing plug inlet Tilgangsknast for prop
boss til motorhus 362 1/S Rear drive gear Bagerste drivgearleje
bearing
122 1/S Motor assembly Motor samling
374 1/S Drive gear bearing Spændskrue for
134 2/S Cylinder o-ring seal. O-ringstætning for retainer drivgearleje
cylinder
386 1/S Drive gear shaft Spændskrue for
146 2/S Housing o-ring seal. O-ringstætning for bearing retainer drivgearakselleje
motorhus
398 1/S Drive gear screw Drivgearskrue
158 1/S Intermediate gear Mellem gearkasse
case 408 1/S Drive gear lock Skive for drivgear
washer
171 1/S Rear gear case o-ring Bagerste gearkasse o-
ring 421 1/S Drive gear cup Dæksel for drivgear
183 1/S Front gear case o- Forreste gearkasse o- 433 1/S Drive gear screw o- O-ring for drivgearskrue
ring ring ring
195 1/S Planet gear frame Tætningsring for 445 8/S Drive housing cap Dækselskrue for
shaft seal. planetgearakselstel screw drivgear
205 1/S Spacer ring Afstandsring 457 8/S Drive housing cap Skive for dækselskrue til
screw lock washer drivgearhus
217 1/S Front gear frame Forreste gearstelleje
bearing 469 1/S Drive housing kit Drivgearhus
229 1/S Planet gear frame Planetgearstel 470 1/S Drive housing o-ring O-ring for drivgearhus
08028-0D/H5250/94.08.12
230 1/S Planet gear Planetgear 482 1/S Front shaft bearing Forreste akselleje
242 1/S Planet gear needle Nålevalse for planet- 494 1/S Drive housing seal. Tætningsring for
roller gear drivgearhus
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty.//E = Qty./Engine Qty./E = Qty./Motor
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter
96.26 - ES0S-G
Plate
Page 3 (3) Turbine Starter 51309-01H
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
504 1/S Drive housing vent Afluftningsprop for 768 Spare parts kit, incl. Reservedelssæt inkl.
plug drivgearhus item 026, 134, 146, item 026, 134, 146, 171,
171, 183, 195, 205, 183, 195, 205, 217, 254,
516 1/S Bulkhead retainer Skotholder 217, 254, 278, 291, 278, 291, 301, 470, 516,
301, 470, 516, 541, 541, 553, 624, 685 og
528 1/S Bulkhead kit Skotsæt 553, 624, 685 and 697 697
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Motor Qty./E = Qty./Motor
Qty./S = Qty./Turbine Starter Qty./S = Qty./Turbinestarter
96.26 - ES0S-G
Plate
Page 1 (2) Main Starting Valve 51310-01H
L23/30H
045*
021*
057* 033*
069*
082*
094
070*
08028-0D/H5250/94.08.12
94.22 - ES0S-G
Plate
51310-01H Main Starting Valve Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./V = Qty./Valve Antal/V = Antal/Ventil
94.22 - ES0S-G
Plate
Page 1 (2) Starting Valve 51314-01S
L23/30H
08028-0D/H5250/94.08.12
91.40-ES0S-G
Plate
51314-01S Starting Valve Page 2(2)
L23/30H
Item Item
Qty Designation Qty Designation
No. No.
1 1/V Body
7 1/V Solenoid
11 1/V Solenoid fixture
21 1/V Pilot valve
31 1/V Bolt
38 2/V Spool assy
50 1/E Main starting valve, complete
08028-0D/H5250/94.08.12
91.40-ES0S-G
Plate
Page 1 (2) Main Stop Valve 51315-03H
L23/30H
08028-0D/H5250/94.08.12
94.22-ES0S-G
Plate
51315-03H Main Stop Valve Page 2 (2)
L23/30H
Item Item
Qty. Designation Qty. Designation
No. No.
1 1/V Body
2 1/V Bonnet
3 1/V Disc
4 1/V Valve disc nut
5 1/V Packing gland
6 1/V Gland nut
7 1/V Stem
8 1/V Cross recessed pan head machine
screw
9 1/V Hand wheel
10 1/V Hexagon nut
11 1/V Split pin
12 1/V Lock plate
13 1/V Disc lock washer
14 1/V Packing gland
15 1/V Name plate
16 1/V Seat ring
17 1/V Stop valve complete
08028-0D/H5250/94.08.12
94.22-ES0S-G
Plate
Page 1 (2) Air Strainer 51316-03H
L23/30H
08028-0D/H5250/94.08.12
94.22-ES0S-G
Plate
51316-03H Air Strainer Page 2 (2)
L23/30H
Item Item
Qty. Designation Qty. Designation
No. No.
01 1/F Body
02 1/F Bonnet
03 1/F Strainer wire gauze
04 4/F Stud
05 4/F Hexagon nut
06 1/F Plug
07 1/F Gasket
08 1/F Gasket
09 1/E Air strainer, complete
08028-0D/H5250/94.08.12
94.22-ES0S-G
Plate
Page 1 (2) Safety Valve 51319-02H
L23/30H
08028-0D/H5250/94.08.12
94.20-ES0S-G
Plate
51319-02H Safety Valve Page 2 (2)
L23/30H
Item Item
Qty. Designation Qty. Designation
No. No.
01 1/E Safety valve. (1 Mpa)
03 1/E Protective device
04 3/E Screw
08028-0D/H5250/94.08.12
94.20-ES0S-G
Plate
Page 1 (2) ON-OFF Valve for Jet System 51320-01H
L23/30H
08028-0D/H5250/94.08.12
94.22 - ES0S-G
Plate
51320-01H ON-OFF Valve for Jet System Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./V = Qty./Valve. Antal/V = Antal/Ventil.
94.22 - ES0S-G
Plate
Page 1 (2) Air Filter 51321-01H
L23/30H
08028-0D/H5250/94.08.12
95.03 - ES0S-G
Plate
51321-01H Air Filter Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
96.03 - ES0S-G
Plate
Page 1 (2) Pressure Reduction Valve 51322-03H
L23/30H
08028-0D/H5250/94.08.12
94.22-ES0S-G
Plate
51322-03H Pressure Reduction Valve Page 2 (2)
L23/30H
Item Item
Qty. Designation Qty. Designation
No. No.
01 1/V Body
02 1/V Bonnet
03 1/V Seat
04* 1/V Stem Guide nut
05* 1/V Disc Holder
06* 1/V Disk Lock cover
07* 1/V Disc gland
08* 1/V Stem
09* 2/V O-ring
10 1/V Cap
11* 1/V Diaphragm seat
12* 1/V Spring
13* 1/V Spring
14* 1/V Bearing
15* 1/V Spring seat
16* 1/V Diaphragm washer
17* 1/V Adjust screw
18* 1/V Lock nut
19* 1/V Handle
20 1/V Name plate
21 1/V Nylon nut
22 8/V Stud bolt
23 8/V Nut
24 8/V Spring washer
25 1/V Nylon nut
26 2/V Stem lock nut
27 * 1/V Gasket
28 1/V Name plate
29 * 1/V Diaphragm
30 * 1/V Disc
31 1/E Pressure reduction valve complete
32 1/V Manometer
08028-0D/H5250/94.08.12
94.22-ES0S-G
Index
Page 1(1) Fuel Oil System 514
L23/30H
Description
Working Card
Fuel injection pump and fuel injection pump -----------------------------------------------514- 01 .05 (01H)
Fuel injection valve ------------------------------------------------------------------------------514- 01 .10 (02H)
Fuel oil split filter ---------------------------------------------------------------------------------514- 01 .15 (01H)
Check of fuel oil piping system ---------------------------------------------------------------514- 01 .90 (01H)
Adjustment of the maximim combustion pressure -------------------------------------- 514- 05 .01 (01H)
Plates
STX Engine
Description 514.01
Page 1 (3) Internal Fuel Oil System Edition 01H
L23/30H
Flywheel end
Fuel oil
return
Waste tray
Fuel oil
Drain High pump
from cyl. pressure
head pipe Fuel oil
inlet
A3 A2 A1
Waste oil, Fuel oil, Fuel oil,
inlet outlet inlet
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.
94.26 - ES0S
514.01 Description
Edition 01H
Internal Fuel Oil System Page 2 (3)
L23/30H
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.
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
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.
94.26 - ES0S
Description 514.01
Page 3 (3) Internal Fuel Oil System Edition 01H
L23/30H
The connection between injection pump and fuel Waste leak oil from the compartment, fuel valve and
injector is a shielded high pressure pipe. The high engine feed pump is led to a fuel leakage alarm unit.
pressure pipe is equipped with connection tapers
matching to simiular taper facings on the threaded The alarm unit consists of a box with a float switch for
connectors on the injection pump and the fuel injec- level monitoring. In case of a larger leakage than
tor. normal leakage, the float switch will initiate alarm.
The supply fuel oil to the engine is led through the
unit in order to keep this heated up, thereby ensuring
free drainage passage even for high-viscous waste/
leak oil.
94.26 - ES0S
Working Card
Fuel Injection Pump and Fuel Injection Pipe 514-01.05
Page 1 (4) Edition 01H
L23/30H
Description:
Hand tools:
Starting position:
Ring and open end spanner 13 mm
Cover in front of fuel injection pump has been Ring and open end spanner 14 mm
removed. Ring and open end spanner 17 mm
Ring and open end spanner 19 mm
Allen key 8 mm, 10 mm
Plier for lock ring.
Tools for cleaning.
Related procedure: Clean kerosene or gas oil.
Clean lubricating oil.
Inspection of roller guide for Anti seize product (Copaslip, Molykote GN Plus
fuel injection pump, 508-01.05 or similar).
Capacity : 1 Man
51401 189 1/pump
51401 190 1/pump
51401 236 1/pump
Data: 51401 248 1/pump
96.30 - ES0S
514-01.05 Fuel Injection Pump and Fuel Injection Pipe Working Card
Edition 01H Page 2 (4)
L23/30H
Dismounting of fuel injection pump 7. Press the thrust cap (N) fig. 2 downwards and
remove the securing ring (P). Remove the thrust cap
1. Dismount the fuel injection pipe pos. 1 fig 1 and (N) with lower spring plate (O) and plunger (M). Be
the fuel inlet pipe pos 2. sure not to damage the plunger.
D
A
C
1 2
B
F
E
1
2
G
G
4
5
J 6
R
K
H
3. Remove the pipe for lub.oil and drain. M
O
Separation of fuel injection pump.
P
08028-0D/H5250/94.08.12
96.30 - ES0S
Working Card
Fuel Injection Pump and Fuel Injection Pipe 514-01.05
Page 3 (4) Edition 01H
L23/30H
8. Take out the plunger spring (L), upper spring 14. The axial clearance between lower spring plate
plate (K) and pinion (J). If necessary remove the lock and plunger foot must not exceed 0.25 mm. The
ring (R) and guide pin (I) and dismount the regulating clearance between lower spring plate and plunger
rod (H) as well as the cap screw in the opposite end foot is 0.05 to 0.1 mm when new. See fig 3.
of the regulating rod (H).
15. Check the cavitation plugs (G) for wear and
9. Unscrew the four screws (A) and remove the renew if necessary.
connecting piece (B). Take out the valve spring (D)
and the non-return valve (F). 16. Barrel (E), plunger (M) and non-return valve
(F) are manufactured to very close tolerances.
10. Loosen and remove the four screws (C) and Any attempt to refinish these parts causes alterat-
take out the barrel (E). ions of the tolerances and must therefore NOT be
carried out.
11. Remove all the O-rings and back-up rings from If during the visual inspection of the parts, heavy
the injection pump. abrasion symptoms or damage can be 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).
Blow through the holes for sealing oil in the pump Assembling of fuel injection pump:
houses and the barrel (E).
17. When assembling the injection pump, proceed
in the reverse order to disassembling. Pay attention
Inspection of fuel injection pump: to the following:
Plunger (M)
Marking on
regulating rod
Tooth with chamfer
Max. 0.25 mm
Marking on pinion
Spring (L)
Lower spring
Plate (O)
08028-0D/H5250/94.08.12
96.30 - ES0S
514-01.05 Working Card
Edition 01H Fuel Injection Pump and Fuel Injection Pipe Page 4 (4)
L23/30H
B. Renew all sealing and back-up rings. For Mounting of fuel injection pump:
placing of the rings, see fig 1.
19. Before mounting the fuel injection pump, clean
C. Coat all the threads with an anti seize product. the roller guide spring and washer for spring in the
roller guide housing.
D. Wipe dry with paper plane sealing surface on
barrel (E) and connecting piece (B). 20. Reconnect the regulating rod (H) to the spring
loaded lever and all the pipes to the fuel pump.
E. Before inserting the pinion (J), the easy motion
of the plunger (M) in the barrel (E) must be checked.
Fuel injection pipe:
F. When assembling the pinion (J), ascertain that
the tooth (recognizable by the chamfer) will enter the By normal working conditions the fuel injection pipe
space of the regulating rod (H) marked by two sings, require very little maintenance except replacement
see fig 4. of O-rings and gasket in connection with the normal
overhaul of fuel injection equipment.
G. The marking on the guide cam of the plunger
(M), must be in line with the marking in the slots of the
pinion (J). (Not shown on fig 4).
08028-0D/H5250/94.08.12
96.30 - ES0S
Working Card
Fuel Injection Valve 514-01.10
Page 1 (4)
Edition 02H
L23/30H
Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump has been dismounted. Ring and open end spanner 24 mm
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).
Related procedure:
95.50 - ES0S
514-01.10 Fuel Injection Valve
Working Card
Page 2 (4)
Edition 02H
L23/30H
The fuel injection valve is the single component that 3. Clean the lower part of the nozzle (J) from
has the greatest influence on the diesel engine carbonized oil deposits before dismantling the nozzle
condition. Various forms of operation and quality of nut (H). Remove the nozzle nut (H) and the nozzle
fuel oil affect the overhaul intervals. In some cases (J).
it may be necessary to shorten the prescribed
intervals.
D
Dismounting and cleaning:
B
1. Dismount the fuel injection valve from the
cylinder head by means of the special tool as shown
in fig. 1.
E
B. Lock nut F
C. Sealing ring
D. Adjusting screw G
E. Sealing ring
F. Nozzle spring H
G. Spring spindle
J
H. Nozzle nut
J. Nozzle
Attention!
Do not damage the lapped surface.
95.50 - ES0S
Working Card
Fuel Injection Valve 514-01.10
Page 3 (4) Edition 02H
L23/30H
Inspection of the parts: Pressure testing of fuel injection valve:
8. Nozzles are matched by lapping and are 14. The most effective checking of the fuel valves
therefore only interchangeable as units. Insert nozzle is obtained through pressure testing, preferably
needle with gas oil in the needle guide. It must be carried out after each overhaul and also in case of
controlled whether the nozzle needle slides down by irregularities in operation. The pressure testing is
its dead weight on its seat. carried out in the following way by means of the
pressure testing apparatus supplied.
9. If the holes are oval worn, which is checked
with of a magnifying glass, the nozzle must be 15. Mount the fuel injection valve in the bracket
scrapped. VTO-W020 (see plate 52014 item no. 25) again. The
bracket to be in such a position that the nozzle of the
10. The best way, however, to check if the holes injector is pointing downwards.
are worn out is to control the flow rate of the nozzle
which, in general, only can be made at the 16. For test of the injection pressure and atomizing
manufacturer's works on a special test stand. mount the test pipe VTO-W021 (see plate 52014
item 049), increase pressure by means of the lever
11. Every effort to refinish will result in alterations on the test pump, and adjust the opening pressure to
of these values and malfunction of the nozzle. If 320 bar, by the adjusting screw (D), see fig 2, then
heavy abrasion symptoms, respectively damages tighten lock nut (B) and check opening pressure
are observed at the visual inspection of the parts, the again.
parts in question must be replaced. Do not expect chattering, but make sure that the
nozzle spray from all holes in the same angle. The
nozzle might chatter if the lever is worked very fast,
Reassembling: actually by hitting it.
Do not expect a nozzle tip with more than 1000
12. When all parts have been overhauled, found in running hours to perform like a new nozzle in the test
good order and carefully cleaned, assemble the fuel pump.
injection valve again. Then increase the pressure to 300 bar and keep the
pressure by working the lever slowly downwards.
13. When assembling the injection valve, proceed When the pressure is kept at 300 bar, there should
in the opposite order compared to the disassembly. be no more than one drip from the nozzle tip for
Pay attention to the following: approx. 3-5 sec.
A. Lubricate the threads on the adjusting screw WARNING: Keep out of the fuel jets as they will
(D) with lub. oil, and the threads of the nozzle holder penetrate the skin. Fuel which has penetrated
for the nozzle nut. The shoulder of the nozzle which the skin can cause painful inflammations (blood
is in contact with the nozzle nut, must be lubricated poisoning).
with an antiseizure product.
95.50 - ES0S
514-01.10 Fuel Injection Valve Working Card
Page 4 (4)
Edition 02H
L23/30H
Mounting of the fuel injection valve in cylinder 19. Mount the high pressure pipe before tightening
head: the nuts then it is easier to fit the threads.
Fig 3 Grinding tools for seat and liner for fuel injection valve.
08028-0D/H5250/94.08.12
95.50 - ES0S
Working Card
Fuel Oil Split Filter 514-01.15
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
Data:
91.08 - ES0S-G
514-01.15 Fuel Oil Split Filter Working Card
Edition 01H Page 2 (2)
L23/30H
1) During normal operation both filters should be in 3) Position of three way cock, see fig 2.
operation, single operation only to be used when
dismantling one of the filters for manual cleaning or
inspection.
3
Note: Shut-off fuel oil, before dismantling filter ele-
ment.
Fig 1 Fuel oil split filter 6) Mount the filter element again.
function is experienced.
91.08 - ES0S-G
Working Card
Check of Fuel Oil Piping System 514-01.90
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Engine is running.
Related procedure:
Data:
92.04 - ES0S-G
514-01.90 Check of Fuel Oil Piping System Working Card
Edition 01H Page 2 (2)
L23/30H
Fuel Oil System. 4) Move all valves and cocks in the piping system.
Lubricate valve spindles with graphite or similar.
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 504.
Venting pipe
92.04 - ES0S-G
Working Card
Adjustment of The Maximum Combustion Pressure 514-05.01
Page 1 (3) Edition 01H
L23/30H
Description:
Hand tools:
Related procedure:
91.45 - ES0S-G
514-05.01 Adjustment of The Maximum Combustion Pressure Working Card
Edition 01H Page 2 (3)
L23/30H
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 normal Pmax.
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), whereafter
is advanced. 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 combus-
guide, thus changing the measure “X”, see fig 1. tion pressure is changed with - see page 500.35.
1 5
1
2 2
3 2
Total height 3
3
4
4 4
Fig 1
Fig 3
08028-0D/H5250/94.08.12
Action Results
Fig 2
91.45 - ES0S-G
Working Card
Adjustment of The Maximum Combustion Pressure 514-05.01
Page 3 (3) Edition 01H
L23/30H
When the screws, which fasten the gear wheel, are If the crankshaft is turned against the engines normal
loosened the gear wheel is turned (by turning the direction of rotation the maximum combustion pres-
crankshaft) in relation to the camshaft. By reading the sure P-max. is increased.
angle in which the gear wheel is displaced in relation
to the camshaft the altered Pmax can be calculated. A After the adjustment the screws are fastened with a
line on the scale corresponds to: see page 500.35. torque wrench, see page 500.40, and secured.
91.45 - ES0S-G
Plate
Page 1 (2) Fuel Injection Pump 51401-01H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S
Plate
51401-01H Fuel Injection Pump Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
021 1/P Pump housing Pumpehus 307 1/P Securing ring Beskyttelsesring
045 2/P Packing ring Pakningsring 320 1/P Plunger and barrel Stempel og cylinder
incl. non-return valve inkl. kontraventil
057 1/C Fuel injection pump, Fuel indsprøjtnings- for L23/30H, 900 rpm for L23/30H, 900 rpm
complete for L23/30H, pumpe, komplet for
720/750 rpm L23/30H, 720/750 rpm 344+ 1/P Screw Skrue
069 1/P Plunger and barrel Stempel og cylinder 356+ 1/P Packing ring Pakningsring
incl. non-return valve inkl. kontraventil for
for L23/30H, L23/30H, 720/750 rpm 368 2/P Screw Skrue
720/750 rpm
381 1/C Fuel injection pump, Fuel indsprøjtnings-
070 1/P Joint washer Pakning complete for pumpe, komplet for
L23/30H, 900 rpm L23/30H, 900 rpm
082 2/P Washer Skive
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
94.23 - ES0S
Plate
Page 1 (2) Fuel Injection Valve 51402-01H
L23/30H
141
153
189
165
104
189
021
094
177
116
045
082
033
08028-0D/H5250/94.08.12
069
057
96.39 - ES0S
Plate
51402-01H Fuel Injection Valve Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./V = Qty./Valve Qty./V = Qty./Ventil
Qty./C = Qty./Cylinder. Qty./C = Qty./Cylinder.
96.39 - ES0S
Plate
Page 1 (2) Fuel Oil Filter Duplex 51403-01H
L23/30H
08028-0D/H5250/94.08.12
95.28 - ES0S-G
Plate
51403-01H Fuel Oil Filter Duplex Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine. Qty./E = Qty./Engine.
Qty./F = Qty./Filter Qty./F = Qty./Filter.
95.28 - ES0S-G
Plate
Page 1 (2) Fuel Injection Pipe 51404-01H
L23/30H
130
237
010
178 250
262
142
130
178
166
154 262
142
154
166
095
08028-0D/H5250/94.08.12
201
213
225
94.22 - ES0S
Plate
51404-01H Fuel Injection Pipe Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder. Qty./C = Qty./Cylinder.
94.22 - ES0S
Index
Page 1(1) Lubricating Oil System 515
L23/30H
Description
Working Card
Plates
STX Engine
Description 515.01
Page 1 (3) Internal Lubricating Oil System Edition 01H
L23/30H
C3
Filter
Pre. lub.
Pre.lub. oil oil pump
inlet TC
Oil vapour
Lub. oil cooler PI discharge
23
To main bearing
C13
To camshaft
Cyl. 1
To pump To
drive piston
drive
TI Governor
20
drive
To rocker arms
Forced oil
Boring in camshaft
Eng. driven
lub. oil pump
To camshaft bearing PI
21-22
C4
General
The lubricating oil system is based on wet sump 2 - Main bearings, big-end bearing ect.
lubrication. All moving parts of the engine are 3 - Camshaft drive
lubricated with oil circulating under pressure in a
closed built-on system. 4 - Governor drive
5 - Rocker arms
The lubricating oil is furthermore used for the pur-
pose of cooling the pistons. 6 - Camshaft
96.30 - ES0S
515.01 Internal Lubricating Oil System Description
Page 2 (3)
Edition 01H
L23/30H
96.30 - ES0S
Description
Internal Lubricating Oil System 515.01
Page 3 (3) Edition 01H
L23/30H
If the pressure drop across the filter exceeds 2.0 bar, The outlet to the engine (by-passing cooler) is mar-
a release valve will open and by-pass the 10-15 ked (B) and outlet to the cooler is marked (C). In the
microns filter element, and the engine will run with warming up period, the oil is by-passing the cooler.
only the 60 microns safety filter. When the oil from the engine reaches the normal
temperature (see section 500, data 500.30) a
To ensure safe filtering of the lubricating oil, none of controlled 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.
A
The filter chambers can be serviced successively
during operation or when the engine is at standstill.
Thermostatic Valve
96.30 - ES0S
Description
Lubricating Oil Cooler 515.06
Page 1 (1)
Edition 01H
L23/30H
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.
frame plate (head) and the pressure plate (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.
96.26 - ES0U-G
Description
Centrifugal By-Pass Filter 515.15
Page 1 (1)
Edition 01H
L23/30H
Description
Principle of Operation
D
Oil enters the base of the filter and depresses the cut-
B
off valve (A) which has a pre-set pressure valve. The
cut-off valve is fitted to ensure that at low pressure E
and flow conditions the entire oil pump output is
C
supplied to the engine working parts. Having depressed
the cut-off valve the oil travels up the centre of the
spindle. Through holes at the top (B) and enters the
rotor (C) at the maximum height above the stand tube.
F
The oil completely fills the cleaning chamber (D) and
travels through the strainer (E) into the drive chamber
(F), leaving under pressure via diametrically opposed A
tangential nozzles in the bottom of the rotor.
The centrifugal force field within the spinning rotor Fig. 1. Diagram showing Principle of Operation.
forces the contaminants to travel to the inner wall of
the rotor, where they form a dense rubber-like sludge
which is easily removed.
96.03 - ES0S-G
Working Card
Lubricating Oil Pump, Engine Driven 515-01.00
Page 1 (3) Edition 01H
L23/30H
Description:
96.26 - ES0S-G
515-01.00 Lubricating Oil Pump, Engine Driven Working Card
Edition 01H Page 2 (3)
L23/30H
2) Remove screws (2) and dismount the cover 8) Inspect all other parts for wear and damage,
(3). and renew, if necessary.
Fig. 2.
Assembly:
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
500.40.
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.
96.26 - ES0S-G
Working Card
Lubricating Oil Pump, Engine Driven 515-01.00
Page 3 (3) Edition 01H
L23/30H
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 500.30,
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
96.26 - ES0S-G
Working Card
Lubricating Oil Filter 515-01.10
Page 1 (3) Edition 01H
L23/30H
Description:
Related procedure:
08028-0D/H5250/94.08.12
91.45 - ES0S-G
515-01.10 Working Card
Edition 01H
Lubricating Oil Filter Page 2 (3)
L23/30H
The lubricating oil filter is dimensioned so that each of
the two filter parts has sufficent capacity to treat the 5) Remove the inner safety element. Clean the
amount of lubricating oil delivered by the pump. element with detergent. Check that it is intact.
The three-way valve positioned is determining whether 6) Remove the outer element(s). Filter element is
the left hand or the right hand filter chamber is in of disposable type. It change always to new original
operation, and also gives the possibility of having filter.
both filter chambers in operation simultaneously.
7) Clean the filter housing and the cap. Be careful
The three-way valve is marked with flow directions of not to let the oil from the dirty side to go into the
and the figure indicates the operation modes accor- clean oil channel in the middle of bottom.
ding to valve positions.
8) Check the seal on the bottom of the filter
7
4
2) Open the vent screw (5) on the top of the filter housing and in the cap. Change if needed.
to get the pressure out of the filter half.
9) Assemble the filter in opposite order.
3) Open the drain plug (8) under the filter housing
and drain off oil. 10) Let the air valve be open and fill the filter
L23/30H
housing with oil by means of the slow fill-up valve (7)
in position FILL, see fig 3. This valve is inside the
Fill-up valve positions
three-way valve and by using it, the filling can be
made so slowly that the pressure on the other part of
Operation Changing over the filter does not drop too much.
12) Open the three-way valve (6) and close the fill-
up valve (7) by turning it to position CLOSED, see fig.
Switch in normal Switch in fill 3.
operation position position
13) The filter just serviced is now ready to be set in
operation.
Fig 3. Fill-up valve position. Inspect for oil leakages in order to ascertain all
sealings to be tight.
91.45 - ES0S-G
Working Card
Lubricating Oil, Thermostatic Valve 515-01.20
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Manpower:
08028-0D/H5250/94.08.12
Data for pressure and tolerance (Page 500.35) 51503 020 2/engine
Data for torque moment (Page 500.40) 51503 044 2 /engine
Declaration of weight (Page 500.45) 51503 093 3/engine
92.05 - ES0S-G
515-01.20 Lubricating Oil, Thermostatic Valve Working Card
Edition 01H Page 2 (2)
L23/30H
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.
92.05 - ES0S-G
Working Card
Check of Lubricating Oil Piping System 515-01.90
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Engine running.
Related procedure:
08028-0D/H5250/94.08.12
Data:
92.04 - ES0U-G
515-01.90 Check of Lubricating Oil Piping System Working Card
Edition 01H Page 2 (2)
L23/30H
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 504.
Lubricate valve spindles with graphite or similar.
08028-0D/H5250/94.08.12
92.04 - ES0U-G
Working Card
Lubricating Oil Cooler 515-06.00
Page 1 (4) Edition 02H
L23/30H
Description:
Related procedure:
Manpower:
08028-0D/H5250/94.08.12
96.39 - ES0S
515-06.00 Lubricating Oil Cooler Working Card
Edition 02H Page 2 (4)
L23/30H
Cleaning of the cooler has to take place, when the Clean the plates with a soft brush and a suitable
pressure drop on the oil and water side is larger than detergent. In case of dense coating of scale or
allowable and/or if the oil cannot be sufficiently organic materials, the plates must be put in a bath of
cooled. detergent.
Cooling and Pressure Relief A high-pressure cleaner can be used with care,
however, never with sand or other abrasives added.
Before opening the plate heat exchanger, it has to be
cooled down to below 40o C and be without pressure!
Detergents
The cooling must not exceed 10o C per minute.
The pressure drop must not exceed 10 bar per A detergent is suitable, if it will remove any coating
minute. on the plates without causing any damage to plates
and gaskets.
Note: If these norms are exceeded, the guarantee
will cease to be valid. Note: It is of great importance that decomposition of
the protective film on the stainless steel does
not take place - the film preserves the corrosion
Separation of Edge-clamped Frame resistancy of the steel.
Upon completion of the procedure “Cooling and Do not use chlorine-containing agents such
Pressure Relief”, separate the frame by retaining as hydrochloricacid (HCI)!
two or four diagonally placed bolts.
Oil and fats are removed by using a water
Note: Take care that the pressure plate does not tilt! emulsifying oil solvent, e.g. BP-system cleaner.
Loosen the bolts uniformly and diagonally (max. 10 Organic and greasy coatings are removed by using
mm at a time), then push the pressure plate towards sodium hydroxide (NaOH):
the end support. When the pressure plate is not tight
anymore, the plates can be removed. - max. concentration 1.5%
(1.5% concentration corresponds to 3.75 l
Note: When using plate heat exchangers on board 30% NaOH per 100 l water).
ships, the pressure plate have to be secured - max. temperature 85o C.
in order to avoid danger due to the movements
of the ship. Stone and lime/calcareous deposits are removed by
08028-0D/H5250/94.08.12
96.39 - ES0S
Working Card
Lubricating Oil Cooler 515-06.00
Page 3 (4) Edition 02H
L23/30H
Sodium hydroxide (NaOH) solution is tritrated with On Plate 51506 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 molecular
weight 63) Please use our cleaning fluid, which is according to
suppliers recommendations.
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
Looking towards the gasket side, the plate is evaporated, before the glue is applied. This will
designated as a left plate, when the letter V is turning normally 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
Replacement of Plates
96.39 - ES0S
515-06.00 Lubricating Oil Cooler Working Card
Edition 02H Page 4 (4)
L23/30H
Gluing Assembling
Pliobond 25, which is a nitrile rubber glue on solvent If the plates have been dismounted, they have to be
basis (25% solids). The glue is applied with a brush correctly assembled according to the plate item
in a thin layer on the backs of the gaskets and the numbers.
gaskets are to dry in a clean place free of dust.
The fixed cover has number 1 and the serial numbers
Apply a thin layer of glue on the gasket grooves of the for the subsequent plates and intermediate frames,
plates and press the gaskets down into the gasket if any, have the numbers 2, 3, 4, 5 etc.
grooves.
The serial number are stamped in the right top corner
The insertion of gaskets starts at both ends of the of the plates. Further, please note that the gasket
plate - and continues with the straight sections along side must face the fixed cover.
the edges.
96.39 - ES0S
Working Card
Centrifugal Bypass Filter 515-15.00
Page 1 (3) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
08028-0D/H5250/94.08.12
Manpower:
Data for pressure and tolerance (Page 500.35) 51515 398 1/Filter
Data for torque moment (Page 500.40) 51515 408 1/Filter
Declaration of weight (Page 500.45) 51515 421 1/Filter
96.03 - ES0S
515-15.00 Centrifugal Bypass Filter Working Card
Edition 01H Page 2 (3 )
L23/30H
Cleaning Procedure, see Plate 51515 Note: Failure to do so could cause an out-of-
balance condition which will accelerate bearing
and spindle wear.
1) Isolate the filter by closing the valve for
lubricating oil inlet to the filter. 7) Clean nozzle with brass wire. Examine top and
bottom bearings in tube assembly. If damaged or
2) Slacken cover clamp ring (266). Unscrew co- worn - replace tube assembly complete. Examine O-
ver fixing nut and lift off cover. ring (063) and renew if damaged.
3) Lift off rotor assembly having allowed oil to 8) Reassemble rotor complete and tighten top
drain from nozzles. The rotor should be removed and nut.
replaced on the spindle with extreme care in order to
ensure that the bearings are not damaged. 9) Examine spindle journals. If damaged or worn
- replace with body assembly complete.
4) Unscrew rotor cover nut (026) and separate
cover (038) from body. 10) Reassemble filter complete checking that ro-
tor revolves freely. Then replace filter body cover.
Tighten cover nut and secure safety clamp. The
clamp ring should be securely fitted at all times and
026 the filter should not be run without the clamp ring
fitted.
038
11) Open for lubricating oil.
075
Maintenance - Bearings and Spindle
96.03 - ES0S
Working Card 515-15.00
Page 3 (3 ) Centrifugal Bypass Filter Edition 01H
L23/30H
To Check Bearing Clearances The maximum clearances when new are 0,08 mm at
top and 0,06 mm at bottom bearing. If the clearance
This is most easily done by applying a dial gauge to exceeds 0,25 mm top or 0,2 mm bottom then check
the outside of the rotor opposite each bearing in turn the sizes of the individual components and replace
and measuring the total play thus: as necessary.
1) Apply dial gauge and measure play. Spindle top journal diameter 14,98 mm Min.
Spindle bottom journal diameter 21,63 mm Min.
2) Turn rotor 90° and repeat measurement. Top bearing bore diameter 15,06 mm Max.
Bottom bearing bore diameter 21,69 mm Max.
3) Re-apply dial gauge at 90° to previous position
and repeat. The spindle and body assembly and the rotor bearing
tube assembly are factory assembled items and
4) Turn rotor 90° and repeat. should only be replaced with complete assemblies.
96.03 - ES0S
Plate
Page 1 (2) Lubricating Oil Pump (Gear driven) 51501-03H
5-6L23/30H-720/750 RPM
L23/30H-900 RPM
08028-0D/H5250/94.08.12
01.37 - ES0S
Plate
51501-03H Lubricating Oil Pump (Gear driven) Page 2 (2)
5-6L23/30H-720/750 RPM
L23/30H-900 RPM
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
031 1/P Shaft with gear Aksel med tand- 329 2/P Nut Møtrik
wheel, long hjul, lang
330 1/E Lub. oil pump, Smøreoliepumpe,
043 1/P Shaft with gear Aksel med tand- complete komplet
wheel, short hjul, kort
342 1/P End cover Endedæksel
055 5/P Bush Bøsning
354 1/P Cover Dæksel
067 1/P Gear wheel Tandhjul
366 1/P Key Feder
079 1/P Nut Møtrik
391 1/P Gasket Pakning
080 1/P Cog wheel Konisk tandhjul
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
01.37 - ES0S
Plate
Page 1 (2) Lubricating Oil Filter (Type A) 51502-01H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S-G
Plate
51502-01H Lubricating Oil Filter (Type A) Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
013 2/F Paper element Papirelement 289 2/F Drain plug Drænskrue
025 2/F Safety element Sikkerhedselement 290 1/F Seal kit, not shown on Pakningssæt, ikke vist
the front side of the på forsiden af platen
037+ 1/F Valve housing, incl. Ventilhus, inkl. plate
item 074 and 216 item 074 og 216
300 1/E Lub. oil filter, Smøreoliefilter, komplet
049 2/F Housing, incl. O-ring Hus, inkl. O-ring complete
062 1/F Spindle, incl. item 121, Spindel, inkl. item 121,
312 and 444 312 og 444
108 2/F Vent screw, incl. item Luftskrue, inkl. item 228
228 and 241 og 241
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./F = Qty./Filter Antal/F = Antal/Filter
94.23 - ES0S-G
Plate
Page 1 (2) Lubricating Oil Filter (Suppl. for Plate 51502-01H) 51502-02H
L23/30H
312
444 51502/037+
468
456
397
51502/050+
348
361 385
419 324
420
373
336
407
51502/086+
493 432
481
08028-0D/H5250/94.08.12
94.23 - ES0S-G
Plate
51502-02H Lubricating Oil Filter (Suppl. for Plate 51502-01H) Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./F = Qty./Filter Antal/F = Antal/Filter
94.23 - ES0S-G
Plate
Page 1 (2) Lubricating Oil Thermostatic Valve 51503-01H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S-L
Plate
51503-01H Lubricating Oil Thermostatic Valve Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
94.23 - ES0S-L
Plate
Page 1 (2) Prelubricating Pump 51504-01H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S-L
Plate
51504-01H Prelubricating Pump Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
94.23 - ES0S-L
Plate
Page 1 (2) Lubricating Oil Cooler 51506-01H
L23/30H
027 015
040
039
088
172 111
123
08028-0D/H5250/94.08.12
160 147
159
135
351
00.37 - ES0S-G
Plate
51506-01H Lubricating Oil Cooler Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./K = Qty./Cooler Antal/K = Antal/Køler
Qty./I = Qty./Individual Antal/I = Antal/Individuel
00.37 - ES0S-G
Plate
Page 1 (2) Centrifugal By-Pass Filter 51515-01H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S
Plate
51515-01H Centrifugal By-Pass Filter Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
014 1/F Rotor, complete incl. Rotor, komplet inkl. item 301 1/F Circlip Låsering
item 026, 038, 063, 075, 026, 038, 063, 075, 109,
109, 110, 171, 195 and 110, 171, 195 og 205 313 1/F Cover Dæksel
205
325 1/F Body cover, complete Dæksel, komplet inkl.
026 1/F Cover nut Dækselmøtrik incl. item 087, 266, 278, item 087, 266, 278, 291,
291, 301 and 313 301 and 313
038 1/F Rotor cover Rotordæksel
337 Centrifugal by-pass Centrifugal by-pass
051 1/F Body Sokkel filter, complete filter, komplet
1/E 5-6 cyl. 5-6 cyl.
063 1/F O-ring O-ring 2/E 7-8 cyl. 7-8 cyl.
099 1/F Paper insert Papirindsats 362 1/F Bracket for mounting Konsol for montering
122 1/F Plug (cut off valve) Prop (modtryksventil) 398 1/F Spare parts kit, incl. Reservedelssæt, inkl.
item 087, 278, 291 and item 087, 278, 291 og
134 1/F Spring (cut off valve) Feder (modtryksventil) 301 301
146 1/F Gasket (cut Pakning (modtryks-ven- 408 1/F Spare parts kit, incl. Reservedelssæt, inkl.
off valve) til) item 122, 134, 146 and item 122, 134, 146 og
158 158
158 1/F Shuttle (cut Ventilkegle (modtryks-
off valve) ventil) 421 1/F Spare parts kit, incl. Reservedelssæt, inkl.
item 063, 146, 229, 230 item 063, 146, 229, 230
171 1/F Bearing, complete Lejemontering, komplet and 291 og 291
incl. item 195 and 205 inkl. item 195 og 205
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./F = Qty./Filter Antal/F = Antal/Filter
94.23 - ES0S
Plate
Page 1 (2) Hand Wing Pump 51525-01H
L23/30H
019
08028-0E/H5250/94.08.12
94.20 - ES0S-G
Plate
51525-01H Hand Wing Pump Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0E/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor
94.20 - ES0S-G
Plate
Page 1 (2) Lubricating Oil Separator 51530-01H
L23/30H
08028-0D/H5250/94.08.12
94.24 - ES0S-L
Plate
51530-01H Lubricating Oil Separator Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./F = Qty./Filter Antal/F = Antal/Filter
94.24 - ES0S-L
Index
Page 1(1) Cooling Water System 516
L23/30H
Description
Working Card
Plates
STX Engine
Description 516.01
Page 1 (1) Cooling Water System Edition 01H
L23/30H
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.
96.03 - ES0U-G
Description
Cooling Water Thermostatic Valve 516.04
Page 1 (1) Edition 01H
L23/30H
94.26 - ES0S-G
Working Card
Check of Cooling Water System 516-01.90
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Engine is running
Related procedure:
08028-0D/H5250/94.08.12
Data:
92.04 - ES0U-G
516-01.90 Check of Cooling Water System Working Card
Edition 01H Page 2 (2)
L23/30H
4) Check flexible connections for leaks. For check of the fresh water condition, see section
504.
08028-0D/H5250/94.08.12
92.04 - ES0U-G
Working Card
Cooling Water, Thermostatic Valve 516-04.00
Page 1 (2) Edition 01H
L23/30H
Description:
Starting position:
Related procedure:
Manpower:
08028-0D/H5250/94.08.12
Data for pressure and tolerance (Page 500.35) 51604 031 1/engine
Data for torque moment (Page 500.40) 51604 055 2 or 4/engine
Declaration of weight (Page 500.45) 51604 092 3/engine
94.29 - ES0S-G
516-04.00 Cooling Water, Thermostatic Valve Working Card
Edition 01H Page 2 (2)
L23/30H
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.
94.29 - ES0S-G
Plate
Page 1 (2) Cooling Water Thermostatic Valve 51604-01H
L23/30H
08028-0D/H5250/94.08.12
94.23 - ES0S
Plate
51604-01H Cooling Water Thermostatic Valve Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
94.23 - ES0S
Plate
Page 1 (2) High Temperature Fresh Water Pump 51610-01H
L23/30H
720/750 RPM
08028-0D/H5250/94.08.12
01.36 - ES0S
Plate
51610-01H High Temperature Fresh Water Pump Page 2 (2)
L23/30H
720/750 RPM
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
01.36 - ES0S
Plate
Page 1 (2)
Pipes on Cylinder Head 51625-01H
L23/30H
08028-0D/H5250/94.08.12
94.25 - ES0S
Plate
51625-01H Pipes on Cylinder Head Page 2 (2)
L23/30H
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Qty./E = Qty./Motor
Qty./E = Qty./Cylinder Qty./C = Qty./Cylinder
94.25 - ES0S
Plate
Page 1 (2) Preheater - Fresh Water 51635-04H
L23/30H
V28/32S
08028-0D/H5250/94.08.12
03.04 - ES0
Plate
51635-04H Preheater - Fresh Water Page 2 (2)
L23/30H
V28/32S
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
03.04 - ES0
Index
Page 1(1) Special Equipment 517
L23/30H
Description
Working Card
Plates
STX Engine
Index
Page 1(1) Driven Machinery 518
L23/30H
Description
Generator ------------------------------------------------------------------------------------------518. 01
Working Card
Plates
STX Engine
Index
Page 1(1) Specific Plant Information 519
L23/30H
Description
Working Card
Plates
STX Engine
Description
Resilient Mounting of Generating Sets 519.03
Page 1 (2) Edition 01S
L23/30H
Resilient Mounting of Generating Sets 1. The support between the bottom flange of the
conical mounting and the foundation is made
On resiliently mounted generating sets the diesel with a loose steel shim. This steel shim is ad-
engine and the alternator are placed on a common justed to an exact measurement (min. 75 mm)
rigid base frame mounted on the vessel's/engine for each conical mounting.
room's foundation by means of resilient supports,
type conical. 2. The support can also be made by means of
two steel shims, at the top a loose steel shim
All connections from the generating set to the ex- of at least 75 mm and below a steel shim of at
ternal systems should be equipped with flexible least 10 mm which are adjusted for each coni-
connections and pipes. Gangway etc. must not be cal mounting and then welded to the founda-
welded to the external part of the installation. tion.
Resilient Support
96.03-ES0S-G
519.03 Resilient Mounting of Generating Sets Description
Edition 01S Page 2 (2)
L23/30H
3. Finally, the support can be made by means of Adjustment of Engine and Alternator on Base
chockfast. It is necessary to use two steels Frame
shims, the top steel shim should be loose and
have a minimum thickness of 75 mm and the The resiliently mounted generating set is normally
bottom steel shim should be cast in chockfast delivered from the factory with engine and alterna-
with a thickness of at least 10 mm. tor mourned on the common base frame.
Eventhough, engine and alternator have been ad-
justed by the factory with the alternator rotor
Irrespective of the method of support, the 75 mm placed correctly in the stator, and the crankshaft
steel shim is necessary to facilitate a possible fu- bend of the engine within the prescribed toler-
ture replacement of the conical mountings, which ances, it is recommended to check the crankshaft
are always replaced in pairs. deflection before starting up the plant.
08028-0D/H5250/94.08.12
96.06-ES0S-G
Working card
Page 1 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 01S
L23/30H
Mounting and adjustment instruction for new Ring and open-end spanner, 22mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 30mm
plants. Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Starting position:
Related procedure:
Man power:
Plate no Item no Qty/
Working time : hour
Capacity : 2 men
Data:
96.03-ES0S-G
519-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 01S Page 2 (3)
L23/30H
Mounting and Adjustment Instructions for New If all internal buffers Then
Generating Sets (Method 1) move freely let conical element set-
tle for 48 hours.
Preparations for Adjustment of Conical Elements
cannot be moved freely turn the jacking bolts
If the conical elements have not been mounted by clockwise to release the
the factory, they must be mounted on the prepared internal buffer.
brackets on the base frame. In case they have
been mounted by the factory, please start with
item no 2. Adjustment of Conical elements after 48 Hours
Settling
1) Fit the conical elements to the bracket of the
suspended equipment by means of the nut in After the conical elements have been deflected
the top (7), see fig 1. under static load for 48 hours, the laden
height(H1) should be measured and compared to
2) Position the four jacking bolts in the tapped the recommended laden height, see fig 2.
holes (8), in the bottom flange, see fig 1.
08028-0D/H5250/94.08.12
Fig.2
96.06-ES0S-G
Working card
Page 3 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 01S
L23/30H
8) Check the laden height by measuring the 12) Lift the generating sets by means of a crane or
height of the individual conical element with a hydraulic jack.
gauge block micrometer at two positions.
13) Remove all jacking bolts.
The difference between the individual conical ele-
ments should be as little as possible and not ex- 14) Position each complete steel shim.
ceed ± 2 mm in order to secure the overall level
and load distribution. 15) Lower the generating set until it rests com-
pletely in is itself.
Example:
H1+ H2+ H3 ---- HN 16) Number each steel shim together with each
Average = No of conicals element conical element.
If Then
Adjustment of Internal buffer
the difference exceeds level the conical ele-
± 2 mm. ment by adjusting the 17) Turn the internal buffer clockwise until it
jacking bolts commenc- makes contact with the steel shim.
ing with the conical
element with the largest 18) Turn the internal buffer anti-clockwise until it
deviation. makes contact with the base casting.
the difference does not the height of the steel This must be done in four full turns.
exceed ± 2 mm shim can be measured.
19) Turn the internal buffer 1½ turn clockwise and
Note: The internal buffer must be abel to move check with a feeler gauge between the bottom
freely during the entire adjustment procedure. flange on the conical element and the steel
shim that the internal buffer (2), see fig 1,
Measuring of Steel Shim does not touch the steel shim.
9) Measure the steel shim on several points to 20) Mount the nut (1). Then block the internal
obtain the highest possible accuracy during buffer (2) with a spanner and at the same time
preparation. tighten the nut (1) according to page 500.40.
Drill the mounting holes in the steel shim accord- 22) Fix the conical element and the steel shim to
08028-0D/H5250/94.08.12
ing to the conical base casting dimensions. the foundation with four bolts.
Mounting of Complete Steel Shim Note: After completion of the above the buffer
clearance must be checked, see items 17,18,19
11) Turn the internal buffer anti-clockwise until it and 20.
contacts the base casting to secure the load
height of each conical element.
96.03-ES0S-G
Working card
Page 1 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 02S
L23/30H
Description:
Hand tools:
Starting position:
Ring and open-end spanner, 22mm
The foundation should be welded and milled off Ring and open-end spanner, 30mm
on shim surfaces. Measurement tool
Hydraulic jack (if necessary)
Related procedure:
Man power:
Plate no Item no Qty/
Working time : hour
Capacity : 2 men
Data:
98.08-ES0
519-03.00 Fitting Instructions for Resilient Mounting of GenSets Working card
Edition 02S Page 2 (3)
L23/30H
Mounting and Adjustment Instructions for New 6) Check that all jacking bolts have full contact
Generating Sets (Method 2) with the foundation.
Preparations for Adjustment of Conical 7) Remove the nut (1) form the conical element,
Elements see fig 1.
If the conical elements have not been mounted by 8) Turn the internal buffer (2) to check that it can
the factory, they must be mounted on the prepared be moved freely, see fig 1.
brackets on the base frame. In case they have
been mounted by the factory, please start with
item No 2. If all internal buffers Then
1) Fit the conical elements to the bracket of the move freely let conical element set-
suspended equipment by means of the nut in tle for 48 hours.
the top (7), see fig 1.
cannot be moved freely turn the three jacking
A75 mm supporting steel shim, complete with bolts in the supporting
tapped holes for three jacking bolts and mounting steel shim clockwise, or
holes drilled according to conical base casting di- anticlockwise to release
mensions, is required. the internal buffer.
98.08-ES0
Working card
Page 3 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 02S
L23/30H
The difference between the individual conical ele- Adjustment of Internal buffer
ments should be as little as possible and not ex-
ceed ± 2 mm in order to secure the overall level 15) Turn the internal buffer clockwise until it
and load distribution. makes contact with the supporting steel
shim.
Example:
H1+ H2+ H3 ---- HN 16) Turn the internal buffer anti-clockwise until it
Average = No of conicals element makes contact with the base casting.
the difference exceeds level the conical ele- 17) Turn the internal buffer 1½ turn clockwise
± 2 mm. ment by adjusting the and check with a feeler gauge between the
jacking bolts commenc- bottom flange on the conical element and the
ing with the conical supporting steel shim that the internal buffer
element with the largest (2), see fig 1, does not touch the supporting
deviation. steel shim.
the difference does not the height of the steel 18) Mount the nut (1). Then block the internal
exceed ± 2 mm shim can be measured. buffer (2) with a spanner and at the same
time tighten the nut (1) according to page
500.40.
11) Make sure that the minimum height of the 21) Fix the conical element and the supporting
steel shim is 10mm in order to secure a future steel /shim to the foundation with four bolts.
replacement of the conical mounting.
22) Weld the lowest steel shim to the foundation.
Drill the mounting holes in the steel shim accord-
ing to the conical base casting dimensions. Note: After completion of the above, the buffer
clearance must be checked, see items 15,16,17
and 18.
98.08-ES0
Description
Page 1 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 03S
L23/30H
Description:
Hand tools:
Starting position:
Ring and open-end spanner, 22mm
The foundation should be welded and milled off Ring and open-end spanner, 30mm
on shim surfaces. Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Related procedure:
Man power:
Plate no Item no Qty/
Working time : hour
Capacity : 2 men
Data:
96.03-EO1S-G
519-03.00 Fitting Instructions for Resilient Mounting of GenSets Description
Edition 03S Page 2 (3)
L23/30H
Mounting and Adjustment Instructions for New 6) Check that all jacking bolts have full contact
Generating Sets (Method 3) with the foundation.
Preparations for Adjustment of Conical 7) Remove the nut (1) form the conical element,
Elements see fig 1.
If the conical elements have not been mounted by 8) Turn the internal buffer (2) to check that it can
the factory, they must be mounted on the prepared be moved freely.
brackets on the base frame. In case they have
been mounted by the factory please start with item If all internal buffers Then
No 2.
move freely let conical element set-
1) Fit the conical elements to the bracket of the tle for 48 hours.
suspended equipment by means of the nut in
the top , see fig 1. cannot be moved freely turn the three jacking
bolts in the supporting
A75 mm supporting steel shim, complete with steel shim clockwise,
tapped holes for three jacking bolts, four mounting and slack back the four
holes and four tapped holes, drilled according to hold-down bolts to re-
conical base casting dimensions, is required, see lease the internal
fig 2. buffer.
96.03-EO1S-G
Description
Page 3 (3) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 03S
L23/30H
fast for the load and surface of this application with Note: After completion of the above, the buffer
chockfast supplier. clearance must be checked, see items 12,13,14
and 15.
96.03-EO1S-G
Working Card
Replacement of Conicals 519-03.05
Page 1 (2) Edition 01S
L23/30H
Description:
Replacement of conicals.
Related procedure:
Data:
96.03-EO0S-G
519-03.05 Replacement of Conicals Working Card
Edition 01S Page 2 (2)
L23/30H
Replacement of Conicals 3. Lift the GenSet until the steel shim can be
removed. This will give enough space for
1. Loosen all conicals in one side. removing damaged conical.
2. Mount a jack under the base frame, see fig 1. 4. Mount the GenSet conical.
08028-0D/H5250/94.08.12
96.03-EO0S-G
Working Card
Replacement of Conicals 519-03.10
Page 1 (2) Edition 01S
L23/30H
Description:
Hand tools:
Starting position:
Ring and open-end spanner.
Feeler gauge, 1-2 mm.
Related procedure:
Man power:
Plate no Item no Qty/
Working time : 2 hour
Capacity : 1 man
Data:
96.27-EO0S-G
519-03.10 Replacement of Conicals Working Card
Edition 01S Page 2 (2)
L23/30H
loose mounting bolts fasten mounting bolts 5. Remove protective cap by loosen the nut (1).
damage to conicals is replace conical accord- 6. Turn internal buffer (2) clockwise until it makes
observed ing to Working Card contact with the steel Shim (4).
519-03.05
7. Turn internal buffer (2) anti-clockwise until it
makes contact with the conical base casting
(3). This must be done in four full rotations.
Clearance Check
8. Turn internal buffer (2) two full rotations clock-
What to Check wise. This will ensure full vertical movement
for the buffer.
4. Check clearance on all conicals between steel
shim and internal buffer through the slot in the 9. Check all conicals again.
base casting of the conical (see fig 1) with a
feeler gauge of approx. 2mm. 10. Tighten the nut (1), see page 500.40 and at
the same time block the internal buffer (2) with
a spanner.
08028-0D/H5250/94.08.12
Fig 1 Conical
96.27-EO0S-G
Plate
Page 1 (2) Flexible External Connections 51902-01H
L23/30H
Item
Figure Designation Connection
No
96.03 - ES0S-G
Plate
51902-01H Flexible External Connections Page 2 (2)
L23/30H
Item
Figure Designation Connection
No
96.03 - ES0S-G
Plate
Page 1 (2) Conical Element 51903-01H
L23/30H
08028-0D/H5250/94.08.12
Note! When ordering be aware that conical ele- Bemærk! Ved bestilling af conicals elementer skal
ments always should be replaced in pairs. State conicals elementer altid udskiftes parvis. Opgiv
manufacturing No of existing conical elements. fabrikationsnr. på eksisterende conicals elementer.
96.03 - EO0S-G
Plate
51903-01H Conical Element Page 2 (2)
L23/30H
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/M = Qty/Conical mounting. Antal/M = Antal/Conical montering.
96.03 - EO0S-G
Index
Page 1(1) Tools 520
L23/30H
Description
Working Card
Plates
STX Engine
Working Card 520-01.05
Page 1 (7) Function of the Hydraulic Tools Edition 02H
General
Starting position
Related procedure
Data
99.43 - ES0
520-01.05 Working Card
Edition 02H Function of the Hydraulic Tools Page 2 (7)
General
Function of the Bolt Tensioning Device 8. The operation and handling of the device are to
be carried out by expert staff only.
In order to achieve an optimal result with one or
several devices, some rules have to be considered. 9. The given max. operation pressure is not to be
We expressly point out that a conscientious handling exceeded in any case and is to be watched at
of the device as well as the accessories is of highest the manometer of the pressure generator dur-
importance. To ignore these rules or separate hints ing the complete tensioning or loosening pro-
means danger to life or danger of injuries! See Safety cedure. When having achieved the given pres-
Hints. sure, stop the pressurization immediately.
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.
99.43 - ES0
Working Card 520-01.05
Page 3 (7) Function of the Hydraulic Tools Edition 02H
General
Working Hints
99.43 - ES0
520-01.05 Working Card
Edition 02H
Function of the Hydraulic Tools Page 4 (7)
General
- By drawing the hose with a manual force of If necessary, turn back the device, but make sure
about 100 N make sure that the connection is that the max. admissible stroke of the device is not
correctly barred. exceeded. Beside that, it has to be ensured that the
cylinder and the support sleeve remain centrically
- For decoupling the high-pressure hose in a towards each other (consider centering shoulder).
pressureless condition, first pull back the cou-
pling socket and then take off the hose. Having made all hydraulic connections correctly,
see fig. 2, start the pressurization for the tensioning
procedure. If the necessary pressure is achieved
stop pressurization. The inducted force causes the
bolt to extend or an edging of the components to be
tensioned so that the main nut is lifted from the
flange. Screw it back to the flange, see fig. 3. Check
by help of a feeler gauge leaf whether the main nut
really fits tight to the flange. After that, bleed hydrau-
lic pressure. Now the connection is tensioned.
Fig. 2. Coupling of the high-pressure hoses.
Having brought the piston to its zero position, see fig.
4, the hydraulic hoses can be decoupled. In order to
Hoses with fast-lock coupling sockets avoid, also prevent impurities, it is advisable to close coupling
when uncoupled, that oil runs out. When the hoses sockets and coupling nipples at once by protecting
get heated, there can be an inside pressure in the caps. The device can be unscrewed from the bolt.
uncoupled condition making a coupling impossible.
By loosening one screw connection (see fig. 2) the
pressure can be bleeded
Þ Always consider the safety and working
hints!
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
Working Card 520-01.05
Page 5 (7) Function of the Hydraulic Tools Edition 02H
General
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
Þ
rization.
Always consider the safety and working hints!
The main nut is equipped with several radial bores
where the adjusting rod can be put in. The main nut
is accessible through the window in the support
sleeve.
99.43 - ES0
520-01.05 Function of the Hydraulic Tools
Working Card
Edition 02H Page 6 (7)
General
99.43 - ES0
Working Card 520-01.05
Page 7 (7) Function of the Hydraulic Tools Edition 02H
General
a) Storage
99.43 - ES0
Working Card
Application of Hydraulic Tools for Connecting Rod 520-01.06
Page 1 (2) Edition 03H
L23/30H
Starting position
Related procedure
Data
00.20 - ES0
520-01.06 Application of Hydraulic Tools for Connecting Rod Working Card
Edition 03H Page 2 (2)
L23/30H
08028-0D/H5250/94.08.12
00.20 - ES0
Working Card Application of Hydraulic Tools 520-01.06
Page 1 (2) for Cylinder Head and Main Bearing Edition 04H
L23/30H
Starting position
Related procedure
Data
00.20 - ES0
520-01.06 Application of Hydraulic Tools Working Card
Edition 04H for Cylinder Head and Main Bearing Page 2 (2)
L23/30H
Please note:
The numbers refer to the
plate items in section 520.
08028-0D/H5250/94.08.12
00.20 - ES0
Working Card
Hand Lever Pump 520-01.07
Page 1 (4) Edition 01H
General
Starting position
Related procedure
Data
99.43 - ES0
520-01.07 Hand Lever Pump Working Card
Edition 01H Page 2 (4)
General
Warning: The hand lever pump is not equipped with Initial Start-up and Venting
a pressure relief valve.
Never use the pump without a mounted manometer. In general and venting
Always pay attention to the given pressure of the
connected pressure consumers. Do never exceed Please make sure that all parts of the pump, especially
this pressure or the max. pressure of the hand lever the manometer and the pressure port, are in a
pump. perfect condition. Defect parts are to be exchanged
against new ones immediately.
Important: Except for hydraulic oil, never use different
liquids such as petrol, water, diesel oil, alcohol or Turn the carrying handle with counter-clockwise
brake liquid, since these can lead to damages or rotation out of his fixing. Then turn it into the hand
even to destruction of the pump and/or the parts lever of the pump against the stopping face.
connected with it. Choose a place of assembling and
operation where the pump can always stand safe Attention: If the carrying handle is not srewed-in into
and firm on a horizontal plain. There should always the hand lever, it can cause injuries while using the
be sufficient space for operating the pump. i pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the oil filler cap and check the oil level. If
pump to great heat, fire or extreme coldness, since neccessary, fill up the tank with hydraulic oil according
this leads to damages or even destruction. Protect to IS0 VG 32. Never overfill the tank. Close the oil
the pump from falling objects and avoid hard blows filler cap.
or pushes. Open the tank breather with the square wrench
(included in the scope of supply) by about one turn.
Attention - Danger to life Now loosen the breather screw at the pump (see
Check the manometer of the pump for the needed drawing) with an allen key SW 2,5 by about one turn.
hydraulic pressure, given by an authorized person, Close the depressurization valve tightly. Now pump
not to be exceeded. Make sure that the pressure you at the hand lever until oil flows out of the breather
want to generate is also admissible for all connection screw bladder-free. Only then are you allowed to
parts. close the breather screw. The pump is now vented
and ready for operation.
All pressure connections and connecting elements
have to be clean and undamaged. High-pressure After each operation and for the transport, close the
connections from the pump to the tools have to be tank breather in order to avoid the hydraulic oil’s
established correctly prior to any pressurization. running out.
Disregard leads to danger to life. Please see working
card 520-01.06.
Pressurization
Attention - Danger on injuries
Loads being lifted by the pump may never be held by - Open the tank breather with the square wrench
the pump valves alone. Use additional non-return
08028-0D/H5250/94.08.12
99.43 - ES0
Working Card
Hand Lever Pump 520-01.07
Page 3 (4) Edition 01H
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.
Depressurization
99.43 - ES0
520-01.07 Hand Lever Pump Working Card
Edition 01H Page 4 (4)
General
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Working Card
Maintenance of Hydraulic Tools 520-01.10
Page 1 (2) Edition 01H
L23/30H
Description:
Related procedure:
Man power:
52021 430 Hydraulic tool.
Working time : 1/2 hour 52021 442 Hydraulic tool.
Capacity : 1 man 52021 299 Hydraulic tool.
52021 309 Hydraulic tool.
Data:
96.03 - ES0S-G
520-01.10 Working Card
Edition 01H Maintenance of Hydraulic Tools Page 2 (2)
L23/30H
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.
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-rings To avoid working accidents caused by emission of
nearest to the pressure chamber and with the back-up pressure oil from the hydraulic hoses, the hoses
rings away from the pressure chamber. should be pressure tested at 1200 bar once a year.
96.03 - ES0S-G
Working Card 520-01.15
Page 1 (2) Tightening with Torque Spanner Edition 01H
L23/30H
Description:
Hand tools:
Starting position:
Related procedure:
Data:
96.03 - ES0S-G
520-01.15 Working Card
Edition 01H
Tightening with Torque Spanner Page 2 (2)
L23/30H
1) Before the nuts are screwed on, the threads and 7) For setting the spanner at the torque required,
the contact faces should be greased with copaslip or there is a ball on a small arm at the end of the handle.
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 contact A spring-loaded slide in the handle provided with a
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 are 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 the this pawl system will be released when the pre-set
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 the 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
96.03 - ES0S-G