Beruflich Dokumente
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Maintenance
DOOSAN - Diesel
5 23/30 720 RPM
Hull 3071
Engine Type 5 L23/30 720 RPM
Project Name: SETA3071-1,2&3
Project . DMM1-5182/5183/5184
NICE Service
Necessary /nformation for Customers' Expectation
Access NICE Service via website, by e-mail
http://nice.doosanengine.com
e-mail: nice.service@doosan.com
DOOSAN ENGINE CO" LTD, 69-3, Sinchon-dong, Seongsan-gu Technical Serice : +82 55 260 6996
CUSOMER SASFAC ON Changwon-si, Gyeongnam, Korea 642-370 Parts Sales : +82552606260
T e l e f a x : +82552606772
Doosan Engine
"ti'f= Doosan Engine 23/30 Vol. 1
CHAPTERI IL__~
T1~TL~E~______________________________~
511
512
513
514
Engine Frame and Base Frame
Turbocharger System
Compressed
Internal Fuel
l
System
System
515 Internal Lubricating l System
516 Cooling Water System
519 Spec. plant
520 Tools
'.
Section 500
Main Data for Engine
cription
(? 5
,
(;r fo r Engine Designation 500.10
t'e~jgn~tion of CyIinders 500.11
:J in e Rotation CIockwise 500.12
~"'~ Iclentification for Instruments 500.20
(;0 odJction to PIanned Maintenance Programme 500.24
r
I",t ned Maintenance Programme 500.25
f'1~;ration Data & Set Points 500.30
" ee n Passport" 500.33
.or ta fo r Pressure and Tolerance 500.35
:J~ ta for Tghtening Torque 500.40
:J~ Iar~tion of Weight 500.45
t'1e C
v dering of Spare Parts 500.50
Or r ice Letters 500.55
f;e "5n Table 500.60
(;0 'c 5ymboIs for Piping 500.65
13~5
Dcscrition
Page 1 (1) Warnlng 500
General
Warning!
08.16-ESO
',M$%','MAN DieSeII
Description
Page 1 (1) Main Data for Engine 500.00
Edition 11
23J30
Cycle 4-stroke
Configuration -
Speed 720501900
Bore 225mm
Slroke 300mm
----_._-
Power lay-out MCR version
*For l23/30H-900 rpm V a pressure of 135 bar reasured at the indicator cock correspond 10
130 bar the combustion chamber.
05.17 - ES1
MiMMAN DieS~
Description
Introduction 500.01
Page 1 (1)
Edition 02
General
Descrip!ion
This instructio book serves the purpose provide Reliable and economical operation the plant iS
general information operation and maintenance, conditional its correct operation and mainte-
and describe the design. can also be used as nance accordance with & Diesel /
a reference when ordering spare parts. instructions. Emissions related maintenance the
diesel engine shall be performed as specified
& W Diesel A/S' instruclions and any additional
instruclions 10 that effect included the Technical
File. Consequently, is essential that the engine
room personnel are l acquainted with the con-
tents this book and, respect instructions
emissions related maintenance the diesel engine,
also the additional instructions that effect set
Secion 505-519
Spare parts plates the Technical File.
03.36 - ESO
DescripHon
Safety 500.02
PageI (2)
Edition 02
General
GeneraI Spares
Proper maintenance, which iS the aim this bool<, Large spare parts should, as lar as possible, be placed
iS a crucial aspect achieving optimum salety well slrapped Ihe area use and should be
the engine room. The general measures mentioned accessible by crane. The spare parls sl10uld be well-
here should, therelore, be a natural routine lor the preserved against corrosion and protecled against
entire engine room staft. mechanical damage. Slock Sl10Uld be checl<ed at
intervals and replenished in time.
CIeanliness
Lgh!
The engine room should be kept clean above and
below the Iloor plates. 1I grit or sand blows the Ample working lighl should be permanently installed
engine room while the ship iS in port, the ventilation appropriate places tl,e engine room, and
should be stopped and ventilating ducts, skylights, able working light explosion-prool fittings should
and doors the engine room should be closed. be available everywhere.
01.32 ESO
I+llMMAN DieseII
500.02 Description
Safety Page 2 (2)
Edition 02
General
Whenever repairs alterations l,aVe been made After prolonged out-of-service periods overhaul
the running gear, apply the "feel-over sequence" worl< which may l a risk accumulation of liquid
il ! iS ensured that there iS undue heating, oil- the combustion spaces, turning should always be
mist formation, blow-by, failure ! cooling water effected through at least w complete revolutions.
lubricating l systems.
Check and
FeeI-over 8eqlence
Lubricating l condition, l elements and meas-
Feel over after 5-15 and 30 minutes' idle running and uring equipment, see "Planned Maintenance Pro-
finally when the engine is running at ll load. 8ee gramme".
also ''Operation'' the section 501.
01.32 - ESO
Description
Page 1 (1) Cross Section 500.05
Edition 06
23/30
99.40 - ES1
4 DieS1
DescripIion
Cross Section 500.05
Poge 1 (1) Edition 06
23/30
99.40 - ES1
'!,'.( DieseI[
Description 500.10
Page 1 (1) Key for Engine Designation Edilion 03
General
The engine types the Diesel programme are identilied by the lollowing ligures:
cylnders
5, 6, 7, 8, 9
t2, 16, 18
EngineType
l-l
V : V-built
CyI. diam/stroke
16/24: 160/240
21/31: 210/310
23/30: 225/300
27/38: 270/380
28/32: 280/320
32/40: 320/400
Design Variant
CR
Raling
08.16 - ES1
ill$MIMAN DieseII
Description
Designation Cylinders
500. i 1
Page 1 (1)
Edition 03
General
Service side Fuel Pump side Left side
98.19 - ES1
', .lf DieseII
Description
Engine Rotation Clockwise 500.12
Page1 (1)
EcItion 02
Generai
..
[
-~
.. _-
'---"
/ Engine
(
Alternator
,,,' DieseI!
Description
Code !dentification for Instrument 500.20
Page 1 (2) EdJtion 03
General
Exp/ana!ion of Symbo/s
Iemperature )ndicator
. 40 '
"'r= Measuring device
.... . ~...... Sensor mounted engine/unit
22 Readinglidentification mounted a panel the engine/unit
f'ressure indicator
. 22 '
Measuring device
Sensor mounted engine/unit
Reading/identification outside the engine/unit
~
.. Measureing device
..- Sensor mounted engine/unit
22 Reading/identification a panel the engine/unit and reading/indication outside
the engine/unit
Pressure Transmitting
.22'
04.36' ES1
500.20 Code Identification for Instruments
Description
Edition 03 Page 2 (2)
Genera\
Standard Text for Instruments
Diesel EllgineJAlternator
LTWater System
l 10 cooler 04 l 10 alternaor 07 l lub. l cooler
02 outlet from air cooler 05 outlet from alternato. 08 inlel 10 fresh water cooler (SW)
03 out!et from lub. ! cooler 06 outlet from fresh water cooler (SW) 09
Water SysteIn
1 l 10 engine 14 l 10 cQoler 17 ou!let from fresh waler cooler
1 FW l 10 engine 14 FW jnlel 10 cooler 18 ll 10 fresh waler cooler
11 outlet from each cylinder 148 FW from cooler 19 prehealer
12 outlet from engine 15 l from sysem 19 l 10 prechaJnber
13 l \0 pump 16 ll from tl!rbocharger 198 l fronl precllamber
Lubricating i Systenl
20 inlet 10 cooler 24 sealing l - l engine 28 level base frame
21 autlet from coolcl' / l 10 fiJter 25 prelubricating 29 main bearings
22 outlet froln filter l 10 engine 26 ll rocker arms and roller guides
23 ll 10 trbocharger 27 intermecliate bearing J allernator bearing
Compressed System
70 l 10 engine 74 l 10 reducion valve 78 l 10 sealing l syslem
71 10 slop cylindel' 75 microswilch for 1urning gear 79
72 l 10 balance arm l 76 jnlet tl!rning gear
73 control 77 wasle gate pressure
Load Speed
80 overspeed 84 engine stop 88 index - fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocllarger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine slart 87 ready 10 slarl
Miscellaneous
91 natural gas - l! 10 engine 94 cylinder lubricaling 97 remote
92 mist detector 95 vollage 98 alternator winding
93 knocking sensor 96 switCll for operating location 99 common alarm
04.36 - ES1
', DieseII
Descriton
Introduction to Planned Maintenance Programme 500.24
Pago 1 (2)
Editlon 03
General
The overhaul intervals are based on operation 1) Salety regulations, which MUST be carried !
a specilied l l quality at normal service output, belore the maintenance worl< can start.
which means 70-100% MCR.
2) briel description the worl<.
the long , ! is ! possible to achieve safe and
optimum economical running without an effective 3) Relerence any work which must be carried
maintenance system. !before the maintenance worl< can start.
The structure and amount inlormatIon the main- 4) Related procedures - indicates other works,
tenance programme mean that it can be Integrated depending the present work - or worl<s
the ship's!power station's maintenance system which ! would be epedient carry !.
or ! can be used separately.
5) Indicates numberof men number hours
The core the maintenance system is the I<ey dia- accomplish the worl<.
gram, see pages 500.25 and 500.26, indicating the
inspection intervals ' the components!systems, The stated consumption hours is only intended
so that the crew can make the necessary overhauls as a guide.
based the engines' condition and!or the time
cri1eria.
<>11'0'
9
Eperience with the specilic planVpersonnel should '"
6
be used adjust the time between overhauls. It
should also be used adjust the timetable stated
lor guidance the working cards.
98.19' ESO
+ DieseII
500.24 Introduction to Planned Mzintenznce Programme
Description
Page 2 (2)
Edilion 03
General
Experiece with the specific station/personnel may 8) Various requisite hand tools.
lead to updating.
9) Indicates the components/parts which l is
6) Refers to data required to carry ! the work. advisible 10 replace during the maintenance
work. Please note that \11is is a condition for
7) Special tools which must be used. Please l the inlervals stated.
that ! all tools are standard equipment.
98.19- ESO
f+1,}f'!.'IMAN DieseII
Descrfn 500.25
Page 1 (4) Pl:l Maintenance Programme Editon19H
23/30
900 RPM
Operaling Engine:
06.02' ESO
500.25 Planned Maintenance Programme
Description
Edition " 9 Page 2 (4)
23/30
900 RPM
Card
Roller guide lor valve gear . __ .. _.. ____ . _________________ ._ lIiI 508-01,00
Valve gear - valve bridge, spring, push rod, etc _______ _ 508-01-10
Roller guide luel injection pump _____ _ ________ _ liII 508-01_05
Roller guide housing. __ . ___ ._____ . ________ ._- ___ . ___ _ 508-01-10
Inlet and exhaust valve - check and adjustment valve
clearance ____________________________ - , ______ ,___ , ___ _ 11 508-01-10
Main- and guide bearing cap - retightening _____ ,, ____ _ 200 510-01,05
510-01,10
, 1I screw can be tightened then the screw have to be
loosened and retIghtened alter page 500.40.
06,02 - ESO
f,!ifM'lMAN DieSeI!
Description 500.25
Page 3 (4) P/anned Maintenance Programme Edition "19
23/30
900 RPM
Turbocharger SysIem:
.......... -
Compressed System:
06.02 - ESO
500.25 Planned Maintenance Programme
Description
Ed!tion 19 Page 4 (4)
23/30
900 RPM
Lubricating l System:
Cooling water pump . enginedriven (sea water and
.f
Iresh water) ................................................................... .. 51604.00
51604.00
:3cn
Thermostatic valve ...................................................... .. 11
cn
Cooling water system . check the system ...................... . 51601.90
Coolng water system water samples, see sec. 504 .....
~
00
06.02 ESO
Description 500.25
Page 1 (4)
Planned Maintenance Programme dtn 21
23/30
7201750 RPM
Operating Engine:
Cylinder Head:
06.02 - ESO
500.25 Planned Maintenance Programme
Description
Edition 21 Page 2 (4)
23/30
720/750 RPM
..- - - -..........---~........- _.....- ..- - -..........J---~ ...... - ....... 1- ~"--I- "1-- .......- ..-...._-
Crankshafl and Main Bea,ing:
06.02 ESO
Descriplion 500.25
Page 3 (4) Planned Maintenance Programme Edilion 21
-
23/30
7201750 RPM
Turbocharger Syslem:
Compressed System:
06,02 - ESO
} DieseII
500.25 Planned Maintenance Programme
Description
Page 4 (4)
Edition 21
23/30
7201750 RPM
Description
.. = Overhaul 10 be carried out
~
Q
.~ ~ ~
-" ~E
.~
Worl<ing
Card
= Check Ihe condition
" C:S ;:5
13~.!:
00
':'!
~o
C
~ ~
1~ffi.
U < "
Fuel injection valve - adjustment opening pressure .... 200 lIiI 514-01.10
Fuel il high-pressure - dismantling and check ....... lIiI 514-01.05
Adjustment the maximum combustion pressure .......... ~ 514-05.01
Lubricating l Syslem:
Cooling water system - water samples, see sec. 504 " .., ! liII
06.02 ESO
Description 500.30
Page 1 (2) Operation Data & Set Points Edijion 46
23/30
drop acro55 filter PDAH 21-22 0.5-1 bar <0.5 bar PDAH 21-22 1.5 ba!"
Fuel System
Leaking L 42 !eakage
Press. nozz. coo!. l, l 011g. 50 2-3 bar L50 1.5 bar (8)
Temp. nozz. cool. , l eng. 51 80-90" C ()
Specific ptanIs !1 not comprise alarm equipment and autostop for aH parameters listed above. For specific plants additional parameters
can be included. For remarks 10 some parameIers, overleaf.
~ for 720/750 rpm ** for 900 rpm.
06.06 - ES1
I Dieseil
500.30 Operation Data 8< Set Points Description
EdiIiOI1 46 Page 2 (2)
23/30
AcceptabIe
l sho
NormalValue at Full load test Alarm Set point Autostop of engine
after
f------ _.. ---
Speed Control System
Engine speed
Mechanical
Elec. SI90 720 rpm 820 rpm SAH 81 815 rpm SSH 81 825 rpm
Mechanical SSH81 815 rpm
Elec. SI90 750 rpm 855 rpm SAH 81 850 rpm SSH 81 860 rpm
Mechanical SSH 81 850 rpm
Elec. SI90 900 rpm 1020 rpm SAH 81 1015 rpm SSH 81 1030 rpm
SSH 81 1015rpm
Turbocharger speed SI89 SAH 89 ()
--
The system pressure has to be adjusted according D. Press. -system, ll engine ( 01)
to the fuel il preheating temperature.
With two-string cooling water system the normal
value can be higher, max. 4.0 bar.
. Nozzle Cooling il System
The cool;ng 0;1 system is only applied for . LimiIs forTurbocharger Overspeed Alarm
stationary eng;nes. (SAH 89)
Engine type 720 rpm 750 rpm 900 rpm
5L23/30H 55.290 55,290
6L23/30H 55,290 55,290 42.680
7L23/30H 42,680 42,680 42,680
8L23/30H 42,680 42.680 42.680
06.06 - 1
Description
"Greer Passport" 500.33
Page 1 (1) Edition
Gereral
PIastic Materials
Type
f--''''-'--------------- ...............Location
- ......-..--.- Approximate quanIiIy/votlJme
Copolymer, based acrylnitriie and O-rings (Inside engine) ')
butadiene: 8
Copolymer, based vinyIidene-fluOl"ide O-rings (!nsidc engine) ")
and Ilexafluoro-propene: FPM
FP1155, Flame retar"dant according 10 Cable jacket < 100 m
IEC 332-3 cat. 3
~~~~~~=-lI~::~-j
Other Substances engine
Type ..:_L-O.:C-"--t-~~-n.-.__.________________..___.__________ . __ ~?E~?~~_~_~~~~_ty/_volume
-----:-.-------'.-
Fuel l Engine F.o. syst:::e:::m'-_____--J_<:::0=',-"02=-0:...::.m:::3_____._
Lubricating l Engine frame See instruction manual
~-----~--------------I--~----------------+---- ---
Filter cartridge Lub. l filter on engine 2 pCS. 1)
1-,, -.,... ,...,..",." ..,.....,..,..,." ... - .. - ---1-----
Filter cartridge
.. _.. _._---_._-------_. __ .. __
Lub. filter engir)c/fi!ter candles 2 pcs.l48 pCS. 2)
.. _--------- --_._._-----_...__ ... _.. --_..-
Mercury
....."..,..."....", ...,., ...,. ', ......,... ', ......,.. ,............,", ..',.,.,',.........,.................,...,., .... ,.._-- ,._="'-----
Uthium baItery (if installed) Electronic cabinet 1 pcs.
r-.---.---.-.... --.-..---......-...-- .....-----.-....-........-.-.--...- ..-.----.-.-.-.-................- ...-- .-.---..--.-.-.-....-----------1
---_._.._-_.. __..._.._-_._-_..._--_.__.__._---_.----_._-----..------ -,---_._----.-'.------._-._-_.-----
Lead Pb - fo' so!dering circuit board Electronic cabinet < 10 g/engine 2)
__
...._. __ .... _-_ ... __._. ._--------._-------_._--
07.36 - ESO
Mi# :( DieseII
Descriptiol1 500.35
Page 1 (1) Data for Pressure I::!
Edition 29
23/30
506 Piston and piston ring grooves (see working card 506-01.1 )
Clearance big-end bearing 0.15-0.20 mm
Clearance between connecting rod bush and piston pin 0.15-0.25 mm
Maximum clearance between connecting rod bush and piston 0.35 mm
Maimum ovalness big-end bore (without bearing) 0.08 mm
New cylinder liner, inside diameter 225,000-225,046 mm.
Maximum inside diameter cylinder l, ma. ovalness 0.1 mm 225.50 mm
508 Valve clearance, Inlet valve (cold engine 15 - 55"C) 0.50 mm.
Valve clearance, Ehaust valve (cold engine 15 - 55"C) 0.90 mm.
Maimum clearance between rocker arm bush and rocker arm shaft 0.30 mm.
Measurement "" belween thrust piece and roller guide housing 5 .5 + 2.5 mm
--1.5 mm
For L23/30 900 rpm version a pressure 135 bar measured at the
indicator cock correspond 10130 bar the combustion chamber
08.03 - ESO
',lJ,@':MAN Die~
Destn 500.35
Page 1 (1) Data for Pressure and Tolerance Edlion 22
23/30
506 Piston and piston ring grooves (see working card 506-01.1 )
Clearance big-end bearing 0.15-0.20 mm
Clearance between connecting rod bush and piston 0.15-0.25 mm.
Maximum ovalness big-end bore (without bearing) 0.08 mm.
cylinder liner, inside diameter 225,000-225,046 mm.
Maximum inside diameter cylinder Iiner, max. ovalness 0.1 mm 225.50 mm
Measurement "" between thrust C and roller guide housing 5.5 2.5 mm
1.5mm
For L23/30 900 rpm version a pressure 135 bar measured at the
indicator cock correspond 130 bar the combustion chamber
06.18ESO
/ Die~~
Description
Data for Tightening Torque 500.40
Page1(1)
Edi\ion 21
23130
72050 rpm
Tightening
Section Descriplion Thread Torque Pressure Lubricant
Nm bar
__ __..._-
-~ --_._._._----_.. - . .
505 Cylnder cover stud ( frame) Stud 48 200 Loctite 243
. cylinder cover stud 45 750 Oil/Molykote
(Unimol gl 82)
Cooling jacl<et cylinder cover Screw 22 -~.
07.10
Description 500.40
Page 1 () Data for Tightening Torque Edition 22
23/30
900 rpm
Tightening
SecIion Descriplion Thread Torque Pressure Lubricanl
Nm bar
_.. __ .. _._----_.- " "-""-._-_..- ....._.....-_. __ .. _.....
._""---~~_.~
--- --_._.__._-- . -.-... _-_. .. _._.- ---- ._..."._----_.. ._-_._"---......._"--
505 Cylinder cV' stud (n Irame) Stud 48 200 Lc 243
, cylinder cV' stud 45 750 Oil/Molykote
(Unimol gl 82)
Cooling jacket cylinder cover Screw 22 -
Nut 12 85 ..-
507 Camshaft assembly
Intermediate wheel shaft 20 1.5 250 -
Intermediate wheel gear 12 40 --
Gear wheel camshaft Screw 12 70 -
23/30
97.06 - ESOU
DcscripIion
Ordering Spare Parts 500.50
Page 1 (2)
Edition 02
General
When spare parls are ordered (or referred 10 These dala are necessary 10 ensure supply the
correspondence, etc.) Ihe following data must be correct spare parts lor a particular engine, even
indicaled for the engine concerned: though the spare part illustrations contained Ihis
bool< may 110 always be complete accordance wilh
Name customer/ship Ihe individual components of a specilic engine.
number
Engine Type Nole: For ordering spare parls for governor, turbo-
Engine chargerand alternator, please see Ihe special chapter
il by the instruction book lor these components.
Plate number
lIem
Description
Oty.
07.04
DescripIion 500.50
Page 2 (2) Ordering of Spare Parts
Edition 02
General
Name of customer/ship no
L ____ ~~_._._._._._
---- --.---.---.-.-.--+-~--....--....--------------.--.--.------I--~~
I-~~~_._-_.~-----I----~----- -----.-.-.--.-...---~~---
07.04
Description
Service Letters 500.55
Page 1 (1)
Edition
Gereral
Description
orderto ensure the most efficient, economical and Since new service letters might be great impor-
up-to-date operation our engines, regularly send tance the operation the plant, we recommend
! "Service Letters" con!aininglirs!-hand inlorma!ion that engine staft l them as supplements to the
regarding accumulated service experience. relevant chapters this instruction book.
97.40 ESO
Description
Corversior Table 500.60
Page 1 (3) Edition
Gereral
Quantty Nanle SYfnbo! 1 kn (knot);;;: 1 naticaJ mile/h 1.852 km/h = 0.5144 m/s
Cincerning ottler conversions, see IabJe for Iength
lengtt1 metre ,
mass kilogram kg
tirne second s Densi!y
electric current
absoJute temperaIuI'e*
amount of substance
ampere
kelvin
mole
L[t_1_lb_k_U_b._ft____________1_6__ .02k~_m_'___________ J
Uminous inlensity candela cd
Force (1 kg m/s' =1 )
AIso named "thermodynamic tempcI'atre"
1 kp (kHopouncJ)' 9.80
Supplementary SI Units 1 poundal" 138.3 10-~
1 Ibf (poLInd force) 4.448
QU8fJtity Narne SynIbof
Can occasionaIIy be found staled as kgf (kiJogram force).
plane angle raclian rad Standard acceleI'at1on of free fall gn ;;;: 9.80665 m/s2
sold angle steradian sr .. Unit force in the ft-Ib-s system
Area (m')
04.37 . ESO
500.60 Conversion Table Description
EditIon Page 2 (3)
General
Momeni Force, Torqtle (kg m2fs' = Nm) 1 caII.r/(cm s "C) 418.7 WI(mK)
1 kcal./(m h "C) 1.163 WI(m )
Can oly be cIerived from the above labJes. 1 (11 11 "F) 1.731 ( )
Temperature levels ()
(see "Derived 51 Unils wilh special Names)
Irequency horIz 1 1 SI
lorce newton 1 1 kg m/s~
pressure, pascal 1 Pa 1 N/m 2*
energy, working quantity heat joute J 1J 1 Nm
power watt W 1 1 J/s
lCc potentIal (DC) ! 1 1
temperaure Celsiu$ "C 1"C 1 k"
04.37 - ESO
+#,' DieseIj
Description
Conversion Table 500.60
Page 3 (3) Edilion
Generai
Mass (kg)
Pressure
(1 N/m' = 1 Pa, 1 bar = 1 ' Pa, 1 mbar = 10-' bar)
1 kp/cm2 ;:.: 1 al :::: 0.9678 98.07 1 ::: 0.9807 bar
1 aI :::: 735.5 mm Hg* ::: 10 m *" (" 277 )
750 mm Hg' 105 Pa := 1 bat'
1 mm Hg* ("273 ) 133.3 Pa '" 1.333 mbar
1 mn1 H~O" ("277 ) 10'4 at ::: 9.807 Pa := 98.07 10-3 mbaI'
1 Hg" (" 273 ) 3386 ::: 33.86 mbar
1 ;>" (:= 277 ) 249.1 Pa ::: 2.491 mbar
1 alm (standarc! atmosphere) 760 mm Hg, 1.013 105 Pa:::: 1013 mbar
1 alm == 1.033 a!
1 Ibf/sq.in (psi) 6895 Pa =: 68.95 mbar
Mercury. 1 mm Hg := 1 Torr
Values table provided gn ::: 9.80665 m/sz
.. Water coJumn (WC)
Nomenclature
t ::: temp. in "C :::: temperature difference
r =: density kg/m 3 Cp ::: heat capacity J/(kg )
c, C"
range
Water 18 999 4.1810 3
04.37 - ESO
DescripIion
Page 1 (3) Basic Symbols for Piping 500.65
Edition
General
-----2'-----'--- ! w1TrlcficatioilOfCfi?ectlon
_._--"........ - ......
of flOW------' [-2 -------"
l><I -3-
---- [J+ApjJfailCeS -----I:8 9>-+< ""iio coupIIng------------
r"T.S- -c':)' ----!-rncflcaTng ana measurmg'1ilstrumenis--' --'2 -' '--pneumatrcrrow o""Tiaio atmosrJ"f1ere-
V
-r- ....,---.-- ~ign-pressTeprp-e-',---------- . ---- -.---- _ _.M.__. _L..... .._ _ _ _ _ .. - - - - - - . - - ... ~"-"."-.
05.02 - ESO
J
General
J ~
-'-g:-~ "---"--"'--'-. __._- 5c;sfragfifrcgF[W1ff60f-m corYi".-- -----r.Ti-+---------------rusFbun~ .--....-.--------.--
;J.t:::f --w[X!rJ
"', ang!e, wrtfil5'Qm"connectIon 2. ~
<J=C
wIffi"'50ttom .. _. ._.-
~
. ----COCoffiree-Way, connea~ --:;r.:- ;:,oenoldr---------
. L __ rz:C
1--3:3"'1---(:..~ - Tlieiios'a"c valve-------------~-- zu:[- ----SOen<iinaI10Cffi'ecnaiaiie----------
"3:35"'- "'-~-"-'--:J72sPlng retrn l., normally closed .-.. ''''''''' 1----ij". . 'HeTor s'raineT--_ --.-
-[[[,r k:::'..J
afJIS)"
-:;'
-o:3~'-I-----''----+-,:--:-:-:-:-
.._.~"1-
-_ ...1
"R""educng iav"{adi3{al------ .. --."5~~L......--- ...
- ...........,.,--..- _ c _
a/ l contro!led by solenoid and l
direclional valve and with spring return
'"
____--+-""'-1-
0.0
.
~3T- -..-.".".--- 372"""Srlng re..'vale conr". by solenOiCf-!---5J.1.- -----+~"'o'"araIo----,- - - - - -..- . - . - -
QJ
D
"""Sfeam trap---- ....-...---.,-----
L>enIrt ugarpImm'"p,-----------1
05.02 - ESQ
Description
Page 3 (3) Basic Symbols for Piping 500.65
Edition
General
5.17
--_.-
Observation glass
5.20
5"23
05.02 - ESO
5ection 501
Operation of Engine
Description
Operating 501.01
Out-of Serice 501.05
Stag-u after Out of Serice Periods 501.10
Guidelines for Longterm Low-Load Operation HFO 501.15
Guidelines Regarding Dlesel GenSets 501.16
Operatingon Low Sulphur Fuel l
Description
Operating
501.01
Page 1 (2)
Edition 01
23/30
b) When starting without preheated cooling water, 8. Disengage the turning gear, iftitted. Check that
the engine must only be started (Ma-rine it is locked in the ' position.
DieseI Oil).
Starting HFO: circulate preheated luel through the 3. Check that all alarms are connected.
pumps until correct working temperatures have been
obtained. This normally takes 30-60 minutes. See also "checks after starting-up".
96.02 - ESOU-G
501.01 Operating Descriplion
Edilion 01
Pag. 2 (2)
23/30
96.02 - ESOU-G
'li/(MAN Dieserl
Description
Out-of Service
501.05
Page 1 (2)
[difion 01
23/30
1. Standby Engines 4.3. Open all lilters check that l l ' elements
are intact. Filter cartrid ges the lub. l filter is be
During engine standstill stand-by position the replaced belore start, after repai r, or after excessive
media cooling water and luel l should be con- dillerential pressure. After removal, dirty elements
tinuously circulated at temperatures similar the can be examined for parti cles bearing metal at
operation conditions. the botom of the paper lamella. (the elements can
be used again).
The engine shall be prelubricated 2 minutes prior
start. l there is intermittent or continuous pre- 4.4. Check the cylinder walls.
lubricating installed. intermittent prelub. is 2 min
every 1 minutes. 4.5. Take dellection measurements the crank-
shalt.
During the lay-up period (and alsowhen laying-up the The lollowing should be made during major re-
vessel) recommend that our special instructions pairs.
for preservation the engines are followed.
5.1. Retighten all bolts and nuts the crankcase
and check their locking devices. Also, retighten
4. Work before Major Repairs loundat on bolts.
4.1 After stopping the engine. while the l is sIill 5.2. Check the various gear wheel drives lor the
warm. start the el-driven prelub. pump, open the camshalt(s).
crankcase and camshaft housings and check th at
the l is Ilowing free ly Irom al l bearings. Also, take 5.3 . Remedy leakages water and l the en-
off the covers the cylinder heads and make gine, and blow through blocked-up drain pipes.
sure that l is supplied for lubrcaton rocker
arms, as non-return valves are fitted which do 5.4. Drain starting air pipes water.
open l th e il pressure at the l the rocker
arms exceeds 1 bar. 5.5. Empty the oil sump lubricating l and remove
the sludge, l done within a period one year.
Alter overhaul of pistons, bearings, etc. this check Clean the sump very thoroughly and subsequently
should be repeated before starting the engine. coat with clean lubricating l.
96.02 - ESOU-G
501.05 Out-of Service
DeSCfIplion
Page 2 (2)
EdiIIon 01
23/30
The differential pressure across the lub. l filter 6.7 b) Adjustmentspeed: Switch-in thealternator
must be watched very carefully after cleaning and on the switchboard and set the load about 40%.
starting-up the engine. Be sure replace ( cart- an reaching normal l temperatures in governor
ridges in due time. and engine, increase th e load instantlyto about 80%
(by starting the major pump compressor). This
6.2. After restoring normallubricating l circulation, must not cause the frequency fall by more than
turn the engi ne at least revolutions by means of some 8%, and the engine must return a constant
the turning rod check the movability ofthe relevant no rpm after about 3 seconds (although this rpm
parts of the engine. ll be a lttle lower than before owing the speed
droop of
6.3. Close the drain cocks in the turbocharger (or the governor). If the engine is operated in paraIIel
in the ehaust gas system, if mounted). with other engines, an even sharing ! load shall
be established within about 3 seconds. If the gov-
6.4. Lubricate th ebearings and rod connections in ernor reacts slowly, compensating adjustment
the manoeuvring gear. Disconnect the governor and is effected as indicated in Woodward's instruction
move the rod connections by hand check that the manual (Compensating Adjustment).
friction in bearings and fuel pumps is sufficiently low.
If repair of bearings alignment of engine has been Note: It is a condition for this test that the eng ine
made, check no 1, 2, and 5 should be repated. and turbocharger are in perfect operating condition.
so that possible sources of error immediately can
6.5. Checks be made just before starting of the be eliminated
engine are mentioned under 501.0 1.
6.7 c ) Hunting: Run the engine at synchronous
6.6. Add cooling water and check the leakage rpm , and withou t load. Provided the governor l is
pressure system on at the upper and l wer cy-linder warm, the regulating lever must not perform any
lner sealings and at cooling water connection s. major periodical movments, and neither must there
be any variation th e engine speed. If that is the
6.7. Check the governor as follows: case, repeat the compensating adjustment accord-
Start the engine and run at the synchronous ing to Woodward's instruction manual.
number ! revolutions.
6.7 d ) Speed droop: in case ! unsatisfactory
6.7 a) Speed-setting: Before switching-in the load sharing between two ore more engines this
alternator the switchboard please check that the can be rectified by increasing the speed droop !
servomotor adjusts the rpm with a su itable quick- the engine that is subject the greatest load (or
ness after actuation ! the synch ronizer knob on the by reducing the setting of the other engines).
switchboard. The range from - 5% + 5% from the
syn-chronous rpm should be tested. The setting should not normally be increased beyond
70 on the scale, and satisfactory paraIIel operation
can generally be obtained at settings between 40
and 60.
96.02 ESOUG
Oescription 501 ,10
Page 1 (1) Starting-up after Out of Serice Periods
Edition 01
23/30
The lollowing enumerate checks are be made After the last leel-over, repeat check 4 page 501.05,
immediately alter starting, during load increase, see also Ignition Crankcase page 503.04
and duri ng normal running. section 503.
tI,e lo//owing is assUIned Ihat tl1e engine has Alter repair renewal cylinder liners, piston
been service lor some , lor il1stal1ce due rings bearings. allowance must be made lor a
repairs and that c/1ecks duril1g service runn ing-in period, .. the engine load should be
periods have beel1 carried as described 1 tI,e increased gradually as indicated in the tables below.
previous chapter. The engine is determined the basis the
luel index and the load the elec tric switchboard.
When starting alter such an out-ol-service period, the The turbocharger speed gives some indication
lollowing checks must be made in the stated order the engine output, but is directly proportional
in addition normal surveillance and recording. the throughout the service period.
1.5. Check by simulation the overspeed shut- The pump index indicated the tables has been
down device that the engine stops. The overspeed given as a percentage the index at lull load .
setting should be according ' Set Points and enable the index to be read directl yoff the luel pumps,
Operation Data ' section 500. the 10lIowing lormula can be employed:
; J..% Ir
2.
be Checked during Starting-up, buI 100
f Required after Repairs Alterations :
, ; Index at lull load (Irom testbed table)
2.1 .
the condition the machinery is not well-
known, especially after repairs aiterations, the % Index expressed as % lull ioad index
'feel-over sequence' shouId always be lollowed, (stated the preceding starting-up
..: sequence).
After 5-15 and 30 minutes' idle ru nning, open the Following the alteration the pump index the
crankcase and the camshalt housing and perlorm
cylinders concerned must be checked
l - the surlaces all moving parts where that when in STOP position the governor is able
Iriction may arise and cause undue heating. move all the luel pumps an average pump index
not exceeding 2 3.
Feel: Main, crankpin, (aI ternator), and camshaft
bearings, piston pins, cylinder liners, roller guides After completing the star ting-up sequence, make
and gear wheels. su re that all luel pumps are set at the same index
and th at the governor can cause aII lue pumps to
move '' index.
96.30 ESOU-G
Oescription
Guidelines for Longterm Low-Load Operation HFO 501.15
Page1(1) Edition 03
General
Load %
20
Admissible lo\v-Ioad operation Necessary operating period
(Ioad percenIIperiod) HFo. with min. 70% load after low-
load operation HFo.
15
10 - - -- - \ a
--- - - - - - - - - -- - -- b
---
Running-up period 10 70%
load: approx. 15 min .
70% load
HFOorMDO
.
5
1 5 10 20 30 40 50 607080 90 1 2 3
Operating period (h) Operating period (h)
Example: a) with 10% load 19 hours maximum operalion HFO admissible, then change-over 10 D
b) operate engine for approx. 1.2 hours with 70% raling minimum, order 10 burn residues.
Aftewards l load operalion HFO can be continued.
Fg 1 Lowload oper8tion.
08.20 - ES1
f':'HMi(MAN DieseI!
Description GuideIines Regarding DIeseI GenSets Operating 501.16
Page 1 (1) SuIphur FueI Edilion
GeneraI
07.12 - ES1
Section 502
Engine Perfonance and Condition
Description
Working card
Descriplion
Engine Performance and Condition 502.01
Page 1 (3) Edition 01
L23/30
V28/32S
Perlormance DaIa and Engine CondiIion increase of~e ajrtemperature involves a cOf-
responding increase the exhaust gas temperature
D operation small alterations the engine l!M1! a ratio about 1: 1.5, .. 1' C higher charge
condition continuously take place as a result com- air temperature causes about 1.5' C higher exhaust
bustion, including l ouling airways and gasways, gas temperature.
lormation deposits, wear, corrosion, etc. 1I conti-
nuously recorded, these alterations the condition Reduction the charge air pressure resu lts a
can valuable inlormation about the operational corresponding reduction the compression pres-
and maintenance condition the engine. Continual sure and max. combustion pressure. When checking
observations can contribute lorming a precise the max. pressure adjustment the engine, ! is
and valuable basis lor evaluation the optimal therelore be ensured that the existing charge air
operation and maintenance programmes lor the pressure is correct.
individual plan t.
The injected amount l e l is equivalent supplied
We recommend taking weekly reco rds the most energy and is thus an expression the load and
important perlormance data the engine plant. D mean pressure the engine. The l l pump ;ndex
rin g recording (working card 502-01.00 can be used), can therelore be assumed be proportional to the
the observations are be continually compared mean pressure Consequently, can be assumed
order ascertain alterations at an early stage and that the connected values th e pump index are
belore these exert any appreciable inlluence the proportional the load.
operation the plant.
The specilic lel consumption, SFOC (measured by
As a relerence condition lor the perlormance data, weight) ll , the whole, remai n unaltered whether
the testbed measurements the or possibly the engine is operating HFO or D , when
the measurements taken dur;ng the sea trial at the considering the diffe rence calori metric combustion
delivery the ship can be used. 1I considerable value. However, when operation HFO, the combi-
deviations Irom the normal condi tion are observed, nation densi ty and calorilic value may result an
ll , a majority cases, be possible to diagnose alteration 6% the volumetric consumption
the cause such deviations by means a total at a given load. This ll result a corresponding
evaluation and a set measurements, after which alteration th e l l pump index, and regard should
possible adjustmenVoverhauls can be decided and be paid this when adjusting the overload preven-
planned . tative device th e engine.
02.47 - ESO
502.01 Engine Performance and Condition Description
Edition 01 Page 2 (3)
23/30
V28/32S
Th e operati onal observations supplemented by Normally, the luel nozzle temperature l l be higher
the daily routine monitoring contribute ensuring than the approx. 180' C, at which cold corrosion
that laulty adjustments and other deviations in the starts occur.
performance individual components are observed
in time avoid operational disturbances and so Abrasive particles in the luel l involve a heavier wear
th at normal routine overhauls can be carried as the luel valve needle, seat, and luel nozzle holes.
scheduled. Therelore, abrasive particles are, tothe greatest pos-
sible extent, be removed at the purilication.
1I abnormal or incomprehensible deviations in the
operation are recorded , expert assistance lor the
evaluation these should be obtained . Exhaust Valves
11, lor any reason , the surface temperature th e l uel The use rotocaps ensures a unilorm distribution
valve nozzle is lower than the condensation tempe- temperature on the valves.
rature sulphuric acid, sul phuric acid condensate
can lorm and corrosion take place (cold corrosion).
Th e lorma ton sulphuric acid lurther depends on
the sulphur content in the luel l .
02.47 - ESO
',Ji$MMAN DieseII
Description
Engine Performance and Condition 502.01
Page 3 (3) Edition 01
23/30
V28/32S
InIet VaIves Engine Room VentiIation, Exhaust System
The operational conditions the air l valves are Good ventilation the engine room and a suita-
substantially altered when using residual luel. ble location the Iresh air intake the deck are
important. Seawater the intake air might l
corrosive attack and inlluence th e overhaul intervals
FueI Pumps lr the exhaust valves.
Assuming effective purilication the luel l, the The Iresh air s uili' (ventilation) to the engine room
operation the luel pumps ll not be very much is correspond approximately 1.5 times the air
affected. consumption the engines and possible boilers
operation. Sub-pressure the engine room ll
The occurrence increasing abrasive wear l l an increased exhaust temperature level.
ger and barrel can be a consequence insullicient
purilication the luel l, especially l using a luel The exhaust back-press!Jre measured after the
which contains residues Irom catalyticcracking. Water turbochargers at lull load should exceed 250-
th e luel l involves an increased risk cavitation 300 mm water gauge. increase the exhaust
connection with pressure impulses occurring at th e back-pressure ll also involvean increased exhaust
cutting-oll the luel pump. luel with a high asphalt valve temperature level.
content has deteriorating lubricatin g properties and
can, extreme cases, result sticking th e luel
pump plungers.
02.47 - ESO
" Dieserl
Descriplion EvaIuation of Readings Regarding 502.02
Page1(1) Edilion 01
Combustion Condition
23/30
PRESSURE
INCREASING
(Jimit50% )
Air fillers
fouled .
PRESSURE
INCREA81NG
(limit50%)
side
cooler fouled.
L CYLINPEBS
Exhaust temp. increasing:
' DIFFERENCE
system fouled
LARGE
( fitter-blower-cooler).
flow 100 5ma!1
Exhaust system fouled
(nozzle ring, lurbine wheel).
~I----+- +--
LARGE
cooler fouled.
92.03 - ESOS-G
Description
Condensate Amount 502.05
Page 1 (2) Edition 03
General
10 20 30 40 50 60 70 (' C)
0.08
0.06
Max.
c
c
8
0.04
0.02
==:>
Aelative
air humidily 30 40 50 60 70 ('C)
General
As a guidance, an air consumption 8.2 kg/kWh (Le) Amount Condensate Water Tanks
at lullload can be used lor & engines.
The volume condensate in the air tank iS determi-
Solution according diagram: ned by means the curve at the bottom Ihe right
the diagram, representing an operating pressure
Water content air () 0.033 kg/kg 30 bar.
Max. water cont. air (11) 0.021 kg/kg
Example:
Amou nt condensate in charge air receiver.
Amoun t condensate in air tank.
= (1-11 ) le
= (0.033 - 0.021) 8.2 1000 = 123 kg/h Volumetric capacity tank (V) 4000 dm'
Temperature in tank () 40 C=313K
Internal press. tank () 30 bar
Draining of Condensation Waler = 31 1' N/m2 (abs.)
Gas constan t lor air () 287 Nm/kg.K
This phenomenon l l occur on all turbocharged Ambient air temperature 35 C
engines. For & Four-stroke engine, th ere Relati ve air humidity 90 %
is no risk with a small amount water in the charge Weight air in tank
air receiver. l the charge air receiver is l lled with
water, there is a risk getting water into the cylinder. pxV 3tx10' x4
This water have be drained away. As standard a m= Rx T = 287 313 = 138 kg
valve is mounted on the charge air receiver/cooler
on the engine. This valve is be used lor draining
Ihe water. there is a great amount, the valve can Solution acc. above diagram:
be lelt hall-open. 1I the amount is small, the charge
air rece iver can be drained periodically. Water conten t air ( ) 0.033 kg/kg
Max. water cont. air (111) 0.0015 kg/kg
= (1- III)xm
(0.033 - 0.00 15) 138
04.31 - ES2
"l,!iNMAN DieseII
Working Card 502-01.00
Page 1 (4) Engine Performance Data Edilion 01
L23/30
Slarling position:
Engine is running.
Relaled procedure:
Dala:
96.37 - ESOU-G
502-01.00 Working Card
Edition 01 Engine Performance Data Page 2 (4)
23/30
Switchboard
Effect (kW) Vottage (V) Current () cos lkVr
Cylinder Data
Ave-
15 Cylinder . 1 2 3 4 5 6 7 8 9 161 rage
17 FueJPump Index
20 Exhau$1Temp. ( C)
Turbocharger
Tem. l blower ( C) Pressure before blower (mmWC) Temp. after blower ( C)
22 23 24
Press. cooler (mmWC) Temp. charge air ( C) Press. charge air (bar)
25 26 27
e m p. ex hausl gas before C ( C) Temp. exhaust gas after TC ( C) PreS$. exhaust 985 alter TC (mmWC)
28 29 30
Lubricating l System
Temp. after engine ( C) Press. before l (bar) Press. after filler (bar)
31 32 33
Temp. inlel engine (" C) Press. before TC (bar)
34 35 36
Fuel l System
Fuel l temp. inlet engine (" C) Fuel l press. before engine (bar)
46 47
Sign.
48 49 1501
96.37 - ESOU-G
,, DieseII
Working Card 502-01.00
Pag. 3 (4) Engine Performance Data Edition 0 1
23/30
InsIrucIion for Filling n Ihe Diagram ''Engine 13. Current () - can be read the switch-
Performance DaIa" board.
The numbers the instruction are commensurate 14. Cos /kV r - can be read the switch-
with the numbers the diagram. board.
Engine Performance DaIa 16. Average lor all engine cylinders lor : 17-
18-19-20-21.
1. Name ship, l stationary name plant.
17. Fuel pump index - can be read each
2. Engine type. the high pressure luel l injection pumps.
9. Turbocharger: type and serial number are 22. Thermometer l blower ("C) can be read
stated the rating plate turbocharger and page by means a therm ometer placed the engine
500.00. room near the air l l ' the TC.
10. Turbocharger revolutions per minute () 23. Pressure belore blower (mmWC) - can be
- can be read the tachometer 81 89. read by means a mmWC instrument placed
the engine room near the TC.
12. Voltage (V) - can be read th e switch- 26. Charge air temperature ("C). Temperature
board. the charge air the charge air receiver.
- thermometer 31.
96.37 ESOUG
502-01.00 Working Card
Edition 01 Engine ermance Data Page 4 (4)
23/30
27. Pressure charge air (bar). Pressure ! the 39. L temperature (L) cooling water pressure
charge air the charge air receiver. (sea, raw or fresh) at inlet charge air cooler (bar)
- pressure gauge 31. - pressure gauge 01.
28. Gas before temperature exhaust TC (' C) 40. L temperature (L) cooling water tempera-
- thermometer 62. ture (sea, raw or Iresh) at inlet lub. l cooler (' C)
- thermometer 07.
29. Exhaust gas temperature after TC (' C)
- thermometer 61. 41. L temperature (L) cooling water tempera-
ture (sea, raw or fresh) al outlel lub. l cooler ' C)
30. Exhaust gas pressure after the TC (bar) - thermometer 03.
- pressure gauge 61.
42. L temperature ( L) cooling water l empera-
ture (sea, raw or fresh) at inlet alternator (' C)
Lubricating l System - thermometer 04.
31. Lub. l inlel cooler lemperalure (' C) 43. L temperature (L) cooling water tempera-
- Ihermomeler 20. ture (sea, raw Iresh) at outlet alternal or (' C)
- thermometer 05.
32. Lub. l pressure belore Ihe filter (bar)
- pressure gauge 21. 44. High temperature ( ) Iresh water tempera-
ture (FW) at inlet engine (' C)
33. Pressure Ihe lu b. il afler Ihe filler (bar) - thermometer 10.
- Pressure gauge 22.
45. High temperature () fresh waler tempera-
The Iilter e/ement should be replaced with a pres- ture (FW) oullet engine (' C)
sure drop across the lilter 1.5 bar (see sec/ion - thermometer 10.
615).
96.37 - ESOU-G
Section 503
Troub.shoot
Description
General
Engine turns as soon as shut- Faults electrical system. Check electrical parts.
off valve is opened, without
start button being acti vated.
Engine turns slowly - Worn air motor parts. Remove and disassemble the
regularly when start button is air motor. Examine all parts
activated. and replace any that are
ordamaged. Use the guidelines
for determining unserviceable
parts, see Working Card 513-
01.30.
starter works, but the drive Clutch drive shaft broken. Dismantle the air starter and
shaft does rotate. repair
04.31 . ESO
. '' DieseI[
Descriplion
FauIts FueI System 503.02
Page 1 (3)
Edition 01
23/30
EngIne turns starting al(, buI Sluggish movemenl manoeuve- LubncaIe and I10bilIze rod cOI-
ignition lals. Fuel pumps ring gear. nections manoelvering gear.
acluated.
Governor settIng Incorrect. AdjusI governor, see specIalIn-
slruction manual.
I:ngine turns a starting air, but Fuel l service lank empty. Pump l the lank.
fuelrs rnjecled o\ving 10 l-
res l systern. fuel pumps and l inJeclion Vent Ihe pumps wlth l
valves (2). wrth-ouI air bubbIes appears.
1I ignition fails just cyl.,
I the re-spectlve luel lnjecIton
valve. 1I igni-lion sIill lails, insIall a
spare valve before altempting 10
slart the engi-ne again.
Engine turflS starting , fueI Ihe fuel. Orarn 011 water and repeaI venling
is injecIed, but ignition fails. fuer pump s.
Cont.
96.37 - ESOU-G
503.02 Faults FueI System DescriplIon
EdilIon 01
Page 2 (3)
23/30
FIrsI IgnItions 100 vlolerlt (sa- has coIlected pIs!on crown Slow turning with open indicator
fety valves are opening). Engine (7). alves. locate defective fuel
runs erratically. I - , remove !.
Remarks
1) 1I Ihe shutdown lunction is due 10 overspeed, 4) 1I the luel is lorced the cylinder through
the shutdown impu lse is cancelled by setting the a delective luel valve through worn-out atomizer
overspeed governor and thus ven ting the stop cy- holes, sluggish atomization may prevent
l n d e r. igniti on, possibly lollowed by l ignition.
2) Whenever air is present the luel l system 5) Toobtain ignition temperature in the cylinders,
repeat ven ting luel pumps. The cause may be the compression pressure during starting should
that a luel valve is kept open position (spind le be normal, see the testbed repor t. This can be
sticking spring broken). Heating luel a checked by measuring the compression pressure
high temperature may have a similar ellect owing du ring starting. Cylinders having l compres-
lor mat on gas in the luel. 1I a sticking valve sion should be inspected.
is lound, should be changed and overhauled.
should be cheked that no l has collected on the
piston crown. in the luel l system may also be 6) Major alterations the combustion charac-
the result the luel l leed pump suckin gin air teristics the luel may demand adlustment the
through a delective stulling bo a leaky seal. timing the luel pumps. One more camshalt
sections may be incorrectlyl itted (after dismantling).
high opening pressure the luel valves l l also
3) If the luel l pressure drops, the l may be delay the injection.
c logged up, the by-pass at the leed pump may
have opened.
96.37 - ESOU-G
f,f,I#,r/iMAN DieseI[
Descrption
FauIts n FueI System 503.02
Page 3 (3)
EditIon 01
23/30
7) l the piston crown ll most cases have 1I a repai r cannot be made th e spot, is decided
leaked down Irom a delective luel valve. As these l l running may continue, wilh orwithout the delective
accumulations are dangerous, the leakage should charger blanked 011.
be lound and remedied belore the engine is started
again. When con tinuing the running with the lurbocharger
operation, the engine must be redu-
ced. The exhaust temperature must exceed
Turbocharger Failure the normal valve, lr lull load running with an intact
turbocharger. For lurther details see the separate
1I heavy vibrations, bearing lalure other trouble turbocharger instr. manual .
ari se a turbocharger, the engine load must be
reduced l the vibrations cease. When possible,
the engine is stopped order locate and remedy
the lault (see turbocharger instr. manual).
96.27- ESOU-G
Descripllon
Disturbances during Running 503.03
Page 1 (3)
Edition 01
23/30
Exhaust lemperature(s) ( cyJs.) Increased chargll1g alr See WorkIng Card 512-01 .00.
Increase(s) lemperature due 10 ineHeclive air
coolers.
( cyls.) f ouling air and gas Reduce load and waler-wash tur-
passages. bIne. CJean ,illers and coolers.
(
cyls.) Insufftcieol cleanlng See Descriplion 504.25.
l 011
changed combuslion
characlerisltcs.
Engrne decreases Pressure beIore f pumps 100 Ratse l feed pump pressure
low. to normal. Check .
COnl.
96.37 - ESOUG
503.03 Disturbances during Running
Oescriptron
Page 2 (3)
EditIon 01
L23/30
Smoky exhaust. Turbine lagging behind en- Aeasonably smoke is norma! when
gine RPM. increases; measures cal-
led for. 1I smoky exhaust durrng
normal ru nning, clean turbine(s)
and check valves.
Exhaust valve knocking. Adjusting screw valve setting !nspect and replace defeclrve
loose. Push rod Ihrust disc da- parts as necessary.
maged.
Rising coolrng water lempera- Pump slopped. Increased friction Slop the engine. Check the
ture. (7). coollng water. Find cause Incre-
ased friction and rernedy lau11.
LubrrcaIing l pressure larls. Lubricaling 011 pump defective. SIop the engine. For further
Fillers/cooler fouled. details, see "Ignitron crankcase".
See also Working Card 515-01.00
lub. l pump and Working
Card 515-01.10 lor the lub. 'rlter
Remarks
1) This manifests itself by the exhaust tempe- 2) Blow-by means a serious danger of piston
rature rising and falli ng of the compression and seizure, and the engine must, if possible, be stop-
maximu m combustion pressure of the respective ped and the piston question pulled. If this is
cylinder dropping. possible, the fue l pump index must, as described
above, be moved stop. Leaky piston rings l l
limit the damage to the valves these should be normally result a heavy excess pressure the
changed immediately, if possible, the fuel pump crankcase.
of the cylinder concern ed should be of
operati on by moving the index to stop and locking
this position.
96.37 - ESOU-G
Description
Disturbances during Running 503"03
Page 3 (3)
Edition 01
23/30
3) 1I this happens the lel pump barrel and 6) If the cooling water temperature lor the
plunger must be changed, and l, is necessary engine has risen 90-1 00' C, should be checked
increase the luel pump inde by more than 1 whether steam has developed by opening the test
inde degrees, obtain lll load the respective cocks, l fitted the discharge Irom cylinders. If
cylinder, the ll pump is ot most cases. this is the case, there is water the cooling
Usually this is conlirmed by inspection the lel surlaces, which may therelore be heated unduly
pump plunger which the helical ct-oll edge ll avoid heat stresses arising cylinder lners and
show a pitted and corroded area where material is cylinder heads, l the water returns early, the
plucked ot. that case the pump can be provided engine should be stopped and left cool, while
with a barrel and plunger. the discharge valve is closed. After 15 mintes
is opened a Iittle allow the water rise slowly
the cooling jackets. Check lilling at test cocks . Make
4) The governor ll reduce the luel pump crankcase inspection ascertain that internal water
delivery zero case 01, lor instance, lalre leakage has arisen. Remember slow turning with
the governor l pump, but the engine speed ll open indicator valves at subsequent starting-up.
start Iluctuating.
When the governor is delective the engine is pro- 7) If the lubricating l pressure drops below the
tected against racing by the overspeed , .. the minimum mentioned "Data" lnd the cause the
engine is stopped automatically case ecessive pressure drop and remedy the delect before re-st-
speed. It is therelore, essential, that the overspeed arting the engine. Feel over 5-15-30 mintes after
is kept ll perfect order. Regarding governor starting, and again when lullload is obtained. See
lailure, see special instruction book. section 502.
96.37 - ESOU-G
Descriplion 503.04
Page 1 (1) Ignition Crankcase Edilion 03
General
During running the atmosphere the crankcase 2) Leave Ihe engine room. Shut doors and keep
contains the same gases (N,-O,-CO,) Ihe same away from them. Make readyfire-fighting equip-
proportions as Ihe ambienl air, but an inlense menl.
spray l drops iS slung around everywhere.
undue friction , and thus heating, arises belween Warning: Do open crankcase l 1 minutes
sliding surfaces, heal iS olherwise Iransmitted 10 afler slopping the engine. When opening up, keep
Ihe crankcase, Ihe healed surface w ll cause eva- clear possible flames. Do use naked light and
poralion Ihe lubricaling l splashed . When do l smoke.
the l vapours condense they form milky white l
mist which can ignile. Such ignition may be caused 3) Cut starting air.
by the same "hot spot" thal produced Ihe l mist. Sel Ihe conlrol panel "610cking Mode" see
a large quantity l misl has developed before descriplion 501 .01.
ignilion, Ihe burning may cause considerable pres- Take all doors one side the crank-
sure rise Ihe crankcase, forcing the relief valves case.
10 open. ln a few cases, presumably when Ihe whole
crankcase has been filled with l misl, a subsequenl 4) Locate the hot spot. Powerfullamps shou ld be
explosion has thrown the crankcase doors and employed al once ( explosion-proof fitti ngs).
caused fire the engine room. Feel over all sliding surfaces (bearings, liners,
pistons, roller guides, etc.).
Every precaution should therefore be laken 10 ()
avoid "hot spots" and (6) discover l mist l ime. Look squeezed-out bearing metal and discol-
oration by heat (blislered painl, burnl l, healed
steel).
''Hot spots" n Crankcase
5) Prevent furlher heating, preferably by making
Overheating bearings is a result inadequate a permanent repair.Special attenlion should be
failing lubrcalon, possibly caused by l l l paid 10 ensuring lubricaling l supply and Ihe
the lubricating l. salisfactory condilion the frictional surfaces
involved.11 is equally imporlanl 10 replace fi ller
is Iherefore imporlanl Ihal the lubricaling l fillralion elemenls time.
equipmenl is perfecl condition. Filter carl ridges may
l be used again Ihey have been removed from 6) Starl eleclrically driven lubricaling l pump
the filler. Checking th e l condition by analysis is and check l l w from all bearings and spray
recommended. pipes crankcase while turning Ihe engine
through at least w revolutions.
The presence l misl may be nol ed al Ihe venl Especially the frictional surfaces thal caused the
pipe which is usually fitted the l the engine heating should be felt over (5-15-30 minules after
frame. starling , and again when ful lload is obtained). Sec-
501.10.
Measures ( case while l misl).
8) has been possible locate the hot spot,
Warning: Keep away from doors and relief valves step 7 should be intensified and repealed l
crankcase. Do l slay unnecessaril y doorways Ihe cause the l mist has been found and
near Ihe doors Ihe engine room casing. remed ied. very rare cases l mist could be
due 10 "atomi zalion" lubricaling l by the
action an air jet ( instance blow-by,
blow-by through cracked pislon).
00.12 . ESO
Oesc riptIon
Trouble Shooting GUde for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 01
23/30
96.30 - ESOU
' DieseI!
Description 503.06
Page 1 (2) TroubIe Shooting Guide forTurbine Starter Edition 01
23/30
Orive (57) will engage. pressure 10 drive housing por" Check air supply.
Mo!or runs, engages, but Damaged broken drive !rain. Disassemble drive ! and replace
does l ro!ate ftywheel. damaged par!s.
Excessive bull engagement. Damaged drive (63) Inspect drive and ftywheel
flywheel. and replace, if necessary.
Cont..
96.38 - ESOU-G
''" DieseII
503.06 Desc rpt ion
Ed ition 01
TroubIe Shooting Guide for Turbine Starter Page 2 (2)
23/30
l blowing l exhausl. l i air supply Jine. Inspect air l and remove $ource
l.
Splash deflector retaining $Cf ew (5) In51atl splash defleclor reta ining
ptug missing. screw pe plug.
Oilleaking from gear case (28). Worn damaged 0-r;n95. Replace 0-95.
96.38 - ESOU-G
IIl1 MAN DieseII
Descriplion 503.09
Page 1 (1) TroubIe Shooting for CooIing Water System
Edition 03
GeneraI
l water flows ! the inspec- Worn rotating sealing. See working card 502-05.00.
l holes.
The pump does l work afler slarl. Pump draws ai r l suction side. Check packings and pipes 'or tightness.
Pmp capaciIy drops alter normal leakages from shaft seal. Overhaul the shaft seal.
operalion.
Fouled impeller. Clean Ihe imeller,
Pump does l give maximum SucIion valve l fully open. Qpen the suclion alve.
delivery.
Defec1ive seals. Replace Ihe seals.
98.20 - ESO
Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Cooler Edition
General
Trouble Shooting Faligue Iracture ll normally necessilale replace-
menl all plales and gaskel s as Ihere may be a
1I is necessary 10 replace damaged plales ga- risk laligue Iracture all Ihe malerial.
skels. case corrosion , all plales musl be examined
carelully!
Firsl examine Ihe exlernal condilions around Ihe Concerning Ihe work 10 be carried l see Working
plale heal exchanger order 10 localize Ihe cause card 515-06.00.
Ihe damage. 00 Ihis very carelully.
Visible Leakage
Leakage. Fouled deformed plates. Searate Ihe plate heat exchanger and
(Phase 2) Inelastic deformed gaskets. check if the plales are deformed
fouled.
Check that the gaskels are eIastic and
non-deformed, and Ihal Ihe faces of the
joinls are clean.
Replace deformed plates and gaskets,
if any.
Before assembling clean all plales and
gaskets very carefully.
Assemble Ihe pJate heal exchanger and
start again.
Note: l impurities such as sand
grains may cause leakage.
l eakage. Defeclive gasket badly corroded Separate the plaIe heat exchanger.
(Through the drain hoJes the gas- plaIe. Replace defecIive plaIes and gaskets,
kets.) if any.
Assemble the plaIe heat exchanger and
slart again.
98.20 . ESO
'+41' DieseII
503.10 Description
Edilion TroubIeshooting for Lubricating CooIer Page 2 (2)
GeneraI
Non-Visible Leakage
Reduced heat transmission and/or Fouled plates choked l chan- Separate the ptale heat exchanger and
increasing pressure drop. nels. check f Ihe ptaIes are fouled.
Clean the plates carefully.
Assemble Ihe plate heat exchanger and
51art again.
98.20 - ESO
Section 504
Lubcatng l Specification
Description
Description 504.01
Page 1 (1) Lubricating Specification Edition 09
Generai
Requirement Th e selection is based typical load proliles
lor marine GenSet (50-60% rated power) and lor
Thi s document is valid lor the lollowing engine slationary GenSet (50-100% raled power)
types: L16/24, 21/31 , 21 /31 CR, 23/30 , 27/38 ,
2 8/3 2 , V28/32H, V28/32S and L32/40. For all engines excepl 32/40
Marine
Engine SAE class
23/30, L+V28/32H
30 105 cSt @ 40' C For engines 32140
Gas l 12-15
Stationary
L16/24, 21 /31 , L27/38, 23/30 , Marine diesel 15-25
L+V28/32H , V28/32S
40 145 cSt @ 40' C Heay fu el (8<1.5%) 2535
08.20 - ES 1
Description
Maintenance of Lubricating l Condition 504.03
Page 1 (2) Edition 06
General
Contamination lubricating l with water, Iresh The optimum cleaning effect is achieved by keeping
salt, can also take place. the lubricating l a state lw viscosity lor a long
period the centriluge bowl.
certain amount contaminants can be kept sus-
pended the lubricating l without affecting the Sufficiently l viscosity is obtained by preheating
lubricating properties. the lubricating il a temperature 95C - 98C.
the condition the lubricating l should be Slow passage the lubricating l throug h the cen-
kept under observation by analyzing il samples. trilugal separator is obtained by using a reduced
See also 504.04 "Criteria lr Cleaning/Exchange Il rate and by operating the separator 24 hours
Lubricating l". a day, stopping only when manually cleaning the
bowl is necessary.
The engine bearings are protected by the lull-Ilow
lubricating l l l built the engine, the l l ter order keep the amount lubricating l the
cartridges having a l neness 15 micron and the engine good condition , is necessary treat
salety l lter a lneness 60 micron. minimum 0.3 l/kWh.
The condition the lubricating l can be main- For cleaning the lubricating l system after over-
tained/reestablished by exchanging the l at led hauls and inspection the lubricating l piping
intervals based analysis results. system, see section 515.
The built-on lu ll - l w dept l lter cleans the l thor- l seldom loses its ability lubricate, .. lorm
oughly. For operation recommend a Iriction-decreasing l lilm, but may become cor-
install a built-on centrilugal by-pass llter too. rosive the steel journals the bearings such a
way that the surface these journals becomes
rough and wipes the bearing surface.
OperaIion Heavy FueI l (HFO)
that case only must the bearings be renewed,
HFO operating engines requires effective lubricating but the journals must also be polished. The cor-
l cleaning. order secure a sale operation is rosiveness the lubricating l is ei ther due lar
necessary use a supplemen t cleaning equipment advanced oxidation the l itsell () the
together with the built lull Il depth l l. For presence inorganic acids (SAN).ln both cases the
this purpose a centrilugal , a decanter an presence water ll multiply the effect, especially
automatic by-pass l l can be used. an l sea water as the chloride ions act as an
inorganic acid.
07.11 - ESO - G
504.03 Maintenance of Lubricating Condition Description
Edition 06 Page 2 (2)
GeneraI
normal serice temperature the rate oxidation Machined surfaces crankcase become coffee
iS insignilicant, but the lollowing lactors wl l accele- brown with a thin layer lacquer.
rate the process:
Paint crankcase peels blisters.
CataIytic Action
Water the
Oxidation the l wll be accelerated consider-
ably l catalytic particles are present the l . Wear 1I the is lw, a minor increase the Iresh water
particles copper are especially harmlul, but also content olthe l is immediately detrimental while
lerrous particles and rust are actie. Furthermore, the engine is running. Naturally, should be brought
the lacquer and arn i s h - l ike oxidation products down again as quickly as possible (below 0.2% water
the l itsell hae an accelerating ellect. Continuous content, which ispermissible). lltheengine is stopped
cleaning the l is therelore important keep the while corrosion conditions are unsatislactory itshould
sludge content low. be turned just over 1/2 reolution once eery hour
(i.e. stop different positions) while the l circula-
and purilying at a high preheating temperature
Signs Deterioration continue remove water. Water the il may be
noted by steam lormaton the sight glasses, by
1I circulating l inlerior quality is used and the appearance, ascertained by immersing a piece
oxidatie inlluence becomes grae, prompt action glass a soldering heated 200-300 C
is necessary as the last stages the deterioration an il sample. 1I there is a hissing sound, water is
may develop surprisingly quickly, i.e. within one present. 1I a large quantity water has entered the
w weeks. Een l this seldom happens, is wise l system, may be prolitable suck sedimented
be acquainted with the signs deterioration. water Irom the bottom the tank. Taste the water
These may be some all the lollowing: lor salt. 1I salty, an l sample should be analysed
immediately lor chloride ions.
- Sludge precipitation purilier multiplies.
07.11-ESO-G
+' DieseI!
Descriti o n 504.04
P_g.' (2) Criteria for CIeaning/Exchange of Lubricating il Edition 07
GeneraI
Possible tesl
method ASTM 0 -2896, ISO 3771
07.11 ES1
504.04 Description
Edirion 07 Criteria for CIeaning/Exchange of Lubricating Page 2 (2)
GeneraI
Additiona lly
5. Total Acid Number () test Ifthe leel n-Heptane insolubles
is considered high for the type of
Ma. value 3.0 acc. 10 fresh l value l and application, the test could
be fol lowed by a supplementary
mg KOH/g determination Toluene.
07.11-ESI
I'l DieseII
Description 504.05
Page 1 (1) Lubricating Points Edition 01
23/30
96.02 ESOUG
',I':' DieseI!
Description
Page 1 (1) Lubricating n Base Frame 504.06
Edition 16
23/30
Max.
Min.
3
2
06.39 - ES1
DescripIion
Lubricating Base Frame 504.06
Page 1 (1) Edition 1 7
23/30
900 rpm
06.39 - ES1
MiB DieseI!
DescripIion
Specific Lubricating Consumption - SLOC 504.07
Page 1 (2) Edilion 03
GeneraI
order evaluate the correct engine SLOC, The engine maximum continuous design rating ( MCR)
th e following circumstances must be noticed and must always be used order be able compare
subtracted from the engine SLOC: the individual measurements, and the running hours
since the last lubricating l adding must be used
: the calculation. Due inaccuracy .) at adding
Desludging interval and sludge amount from the lubricating l, the SLOC can only be evaluated
lubricating l separator (or automatic lubricating l after 1,000 running hours or more, where only the
filters). The expected lubricating il content ! the average values a number lubricating l addings
sludge amount is 30%. are representative.
08.20 - ESO
Descrition 504.07
Page 2 (2) Specific Lubricating Consumption - SLOC Edition 03
GeneraI
Plant / Ship
Lube 011 consumDtion
Engine type: Eng ine #:
Lube l brandltype:
Density@15 C: [kg/m3]
- ~
_.
- - - -
- -
- - -
-
~ - .
-
-
- -
08.20 ESO
,, lifMAN DieseII
Description
FueI Specifcation
504.20
Page 1 (5) Edition 05
GeneraI
MGO is a medium class distillate l which therefore is offered as heavy distillate (CIMAC) as
must ! contain any residual components. a blend distillate and small amounts residual
l (C IMAC) exclusively marine appl ications.
The key property ratings refer to CIMAC #2 1 The commonly used term the blend, which is
/2003. dark brown to black colour, is Blended .
is produced from crude l and must be free from
organic acids.
Units Value
Densily at 15C min. kg/m3 820.0 The key properties are based the test methods
rnax. kg/m3 890.0 specified.
Kinematic Viscosily
l 40C mm2fs >1.5
mm2/s <6.0
ProperIy Units Value
Flash ! c >60
CIMAC #2 1 12003 DB DC
WaIer conlenl % by volume <0 .05
Densityal15C kg/m 3 :s 900 < 920
SuIphur conlent % by weight <1.5
Kinematic Viscosily
Ash % by weigh! <0.0 1 at 40C c$I (mm2Js) <11 <14
Minimum injection viscosity at entering the engine Sulphur conlenl % byweight <2.0 <2.0
>1.5c5t. Ash conIent % by weighl <0.01 <0.05
05.37 - ES 1
IIi'( MAN DieseI/
504.20 Description
Edition 05 FueI Specification Page 2 (5)
GeneraI
Current analysis inlormation is not sufficient lor es- FIA CeIane Number ...
timating the ignition and combustion properties
the l . This means that service results depend
l properties which cannot be known belorehand. m/m = mass VN=volume
This especially applies to the tendency th e l to
lorm deposits combustion chambers, gas pas- ') May be increased to 1.01 (kg/m' ) provided
sages and turbines. adequate cleaning equipment is installed, and
modern type centriluges.
Guiding Heavy Fue! ! Specification ") 1I the CCAI value exceeds 840 it is recom-
mended to have the FIA index measured
Based our general service experi ence we have, revealing l ignition and combustion problems
as a supplement to the above-mentioned standards, mayarise.
drawn the guiding HFO-specilication shown
below. 1I the CCAI value exceeds 840 ignition and
combustion problems can occur.
Heavy luel oils limited by this specilication have, to
the extent the commercial availability, been used "') 1I the FIA value is below 20 increasing ignition
with satisfactory results & four-stroke and combustion problems may be loreseen at
medium speed diesel engines. lw load operation.
05.37 ES1
Oescription
Fuel il Specification
504.20
Page 3 (5) Edilion 05
General
1I heavy luel oils, with analysis data exceeding the 1I the sodium content is lower than 30% the vana-
besides ligures, are be used, especially with regard dium con tent, the ri sk high-temperature corrosion
viscosity and specilic gravity, the engine builder wll be small. It must also be prevented that sodium
should be contacted lor advice regarding possible the lorm sea water enters the engine together
changes the luel l system. with the intake air.
The admixing used engine l the luel involves Under certain conditions, high-temperature corrosion
a substantial danger because the lubricating l addi- may be prevented by a luel additive that raises the
tives have an emulsilying effect and keep dirt, water melting temperature the heavy luel l ash.
and catfines linely suspended. Therelore, th ey impede
preclude the necessary cleaning the luel. We
ourselves and others have made the experience that Ash
severe damage included by wear may occur the
engine and turbocharger components as a result. Heavy luel oils with a high ash content the lorm
loreign particles such as sand, corrosion elements
The admixing non-mineral l constituents (such and catalyst ln es (catfines) heavy luel oils coming
as coal l) and residual products Irom relining Irom catalytic cracking processes. most cases,
other processes (such as solvents) is harmlull these catfines w ll be aluminium oxides, silicium
the engine! The reasons are, lr example: the ides, which causes high wear the injection system
abrasive and corrosive eIIects, the adverse combus- and the engine.
properties, a poor compatibility with mineral oils
and, last but least, the negative environmental
effects. The ord er letter lor the luel should expressly Sulphuric Acid Corrosion
mention what is prohibited, as this constraint has
yet been incorporated the commonly applied The engine should be operated at the cooling water
luel specilications. temperatures specilied th e operating manual lor
the respective load. 1I the temperature the com-
The admixing chemical waste materials (such as ponent surlace exposed the acidic combustion
solvents) th e luel is lor reasons environmental gases is below the acid dew , acid corrosion
protection prohibited by resolution the Marine can OCCOUf.
Environmental Protection Committee 1 Jan. 92.
Should the vanadium/sodium ratio be unlavourable, As practically all luel l specilications including the
the melting temperature the heavy luel l ash may above standards reler the same luel type as sup-
drop the range the exhaust valve temperature plied , the luel supplied a ship has be treated
which l l result high-temperature corrosion and board belore use. For running the l quality
deposits build up. precleaning the heavy luel l mentioned above is necessary that equipment ex-
the settling tank and the centrilugal separa- ists board, which can treat, respectively clean and
tors, the water, and with the water-soluble sodium preheat, the luel l with optimum efficiency.
compounds can be largely removed.
05.37 - ES1
504.20 Descriplion
Edition 05 Fuel il Specification Page 4 (5)
General
The prehealing charl page 5 illuslrales Ihe expecl- - True measuremenl (pressure drop a cali-
ed prehealing lemperature as lunclion Ihe specilic braled tube)'
luel l viscosily. - Ultrasonic vibralion
The viscosily leaving Ihe healers should be 10-15 ') The difticulty Ihis melhod is Ihal Ihe equip-
cSI and approx. 12-18 cSI enlering Ihe engine. menl has 10 be mainlained and calibraled
regularly. However Ihis melhod is by lar 10 be
prelerred.
ViscosiIy Adjustment
05.37 ES1
Description 504.20
Page 5 (5) FueI Specification Edition 05
GeneraI
. viscosily
aher preheater
Temperaure
sec.
cSI Rw.
after preheater C
7 43
170
160
10 52
150 12 59
140 15 69
130 20 87
120
30 125
110
100
90
80
70
60
40
30
,
Log scaIes 10 15 25 35 45 1 55 cSV100' C
05.37 - ES1
Description 504.25
Page 1 (3) Fuel l Qualty Edition 03
General
The quality of a fuel l is stated, in analysis data, in Combustion quality is the ability of the l l to
terms of physical and chemical properties, which are ignite and burn in a way. The ignition quality,
decisive the suitability of the fuel l for different combustion IntensIty, and length and completeness
applications. For diesel engine fuels the combustion combustion are properties influenced bythe chemical
quality, the content of impurities and the handling composition and structure of th e l l.
properties are the main quality criteria.
Ignition quality relates ignition delay, . . the time
Since residual fuels are traded and designated ac- elapsed between the start of injection and the start
cording viscosity, has become common practice of combustion.
associate viscosity with quality. This practice can
be very misleading, especially with modern residual Ignition quality is epressed by the cetane number,
fuels, as a fuel l of lw viscosity can often be just diesel ind e cetane ind e. In all cases th e higher
as bad, even worse, than other fuel oils of very the value, the better the ignition quality. For diesel l
high viscosity. the ignition quality is ep ressed 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 condi tions.
origin of the crude il, the grade of utilization when
refining th e crude l, and the refinery technique Fordistillatefuels the ignition qualitycan be epressed
used. by the diesel inde cetane inde, both be cal-
culated from physical properties such as the aniline
Some of the residues used in fuel l production point, specificgravity and mid-distillation temperature.
are of a viscosity requiring visbreaking, a process The cetane number, diesel inde cetane ind e of
which w ll reduce the viscosity without improving a certain fuel l w l l show reasonable correlation
the quality at all . between the numerical values.
When producing residual fuels from visbreaked, For residual fuels ignition quality is an even more
cracked residues and from "straight run" residues, Important parameter. The reason why does not
the final adjustment of viscosity fulfil the require- appear in the international specifications is that a
ments of the different grades of intermediate fu els standardized testIng method is non-eistent. There-
is achieved by adding gas l . fore, parameters such as the Qalculated Qarbon
Aromaticity jnde (CCAI) are resorted as an aid
However, must be noted that considerable reduc- which is derived from determinable fuel parameters.
tion of the viscosity is achieved by adding a relatively According our eperience, only a rough assess-
small amount of gas l, which w ll give only a minor ment of th e igniti on quality of the heavy fuel l is
improvement of the quality of the blend. This means possible with the help of this method.
that the quality a major etent depends on resi-
dues present in the blend. Therefore the quality also However, the CCAI has become so well-known in
depends on the density. widespread publications that, in spite of the reserva-
tions menlioned above, we were compelled toclassify
As a consequence of the possible variations in the Ihe respective & Diesel AJS, four-slroke
quality of residues and the influence of adding gas engines according 10 CCAI-rating, 100, see also 11
l , the quality of blended fuels can vary, even for "Nomogram lor Determination CCAt".
fu el oils of equal nominal viscosity.
FIA cetane number test is also good for evalualion
of the combustion qualily.
04 .46 - ES1
DieseII
504.25 Descrilion
EdiIion 03 FueI Ol QuaIity Page 2 (3)
Genera!
Fuel ignition analyser FIA 10014 measure- However, the inlormation about the differences
ments the luel behaviour makes possible to see the el-
lects the luel composition the ignition and
the FIA 100 instrument, the ignition delay is delined the heat release patlern which may may have
as a time delay ( millisenconds, msec.) Irom the any impact the particular engine.
start injection, l the pressure has increased
0.2 bar above the initial chamber pressure. The engine load also influences the performance
the luel' l load operation, ignition must take
The start the main combustion phase is delined place at lower temperature. This increase the
as being the time ( msec.) Irom when the pressure demand lor ignition quality and l the lighter luel
has increased 3 bar above the intial chamber Iractions are highly aromatic, lw load combustion
pressure. problems may be lound.
The start the combustion is used establish the As mentioned above, the longer time the engine has
ignition quality a tested luel expressed as a FIA ignition, the less sensitive the engine is the
CN (Cetane Number). The basis FIA CN isa rele r- ignition delay quality the l .
ence curve lorthe instrument question showing the
ignition properties mixtures the rele rence luels This consideration has been proved lately a small
15 and 22 from PhiIIips Petr. l This reference number ships with auxiliary engines and main
curve establishes the re lationship between ignition engine operating th e same luel. lgnition problems
quality, recorded miIIiseconds, and Cetane Number have been observed the auxiliary engines during
the diffe rent mixtures the reference fuels. For lw load operation only, having effect the
heavy luels, the ignition properties range from CN stroke low-speed engine.
=18.7 above CN = 40.
The combustion condi tion the l oils is normally
The rate heat release ( ) is used evaluate evaluated Irom Conradson Carbon residue and the
the combustion properties the l. asphaltene contents.
Comparing th e FI A test and CCAI, the FI A gives a The content impurities diesel engine fuels should
relative picture ignition qualities fuels, which be kept as lw as possible. Harmful and unwanted
may be use the ship operator before buying th e impurities should, be removed the pre-treatment
l . The CCAI does provide sufficient inlorma- system order to minimize wea r and corros ion
and has some tests shown very inconsistent engine components. Impuriti es derive from the
indications, .. the FIA test should be carried out crude l itself, Irom processes and from
when the CCAI value is higher than 840. handling and storage oils. The amount water
and solid impurities can be reduced by centrifuging
and filtration.
Conversion of FIA 10014 test result actual
engine performance Sand, rust, metal oxides and catalyst particles can
be lound as solid particles l l.
When using the FIA 100/4 test conditions tem-
perature and pressure, the differences between the Fuel-related wear and corrosion diesel engines
dilferen t luels are more pronounced than what would take th e form mechanical wear and chemically
actually be seen the engine, and the results must induced corrosion, the latter the form high and
l temperature corrosion.
be seen this context and relation the engine
types question.
04.46 - ES1
DescripIion 504.25
Page 3 (3) Fuel l Quality Edition 03
General
Th e solid impurities and particles produced during The Ilash ! is related the volatility the amount
combusti on, co llectively kn own as ash, cause me- and nature ollighter lractions theluel oi l, and might
chanical wear engine components. thu s be used estimate the propensity gasilication
non-pressurized parts the luel system.
Especially catalyst particles, silicone and aluminium
oxides and silicates the lorm sand are very abra- The pour ! delines the temperature at which wax
sive. From sulphur, vanadium and sodium corrosive crys t a ll zation will take place and prevent the luel l
ash the lorm oxides, carbonates and sulphates, Irom Ilowing and Irom being pumped.
is created during combustion.
Therelore, the pour ! must be taken account
Further the sulphur content a luel l may lead when deciding the presence and capacity heating
low temperature corrosion combusti on cham- coils bunker tanks.
ber components and the lor ma t on deposits
these. The corrosive effect is due the lormation
sulphuric acid.
Quality FuelOil EffecIs
Sea water the luel l may lead several detri - Crileria CharacIerisIics
mental effects to the l uel system and th e diesel
Combuslion Conradson carbon Ignilion ability.
engine general by giving rise mechanical and
quality asphaltenes + Combustion condiIion.
corrosive wear, as well as louling. FIA test Fouling of gasways.
04.46 ES1
Descriplion
Nomogram for Determination of CCAI
504.26
Page 1 (1) Edilion 03
General
D CCAI
800 800
820 810
840
820
2 860
Normal
830 operating condition
880
3 ~
4 900
840
t ;
=>
5 850 Difficullies
920 =>
may be !f-
encountered ,
860 '
210
+
~
10 E~
870 !D
~
"-
~"-
20 Increased difficulties _m
880 "'-'"
30 10 engine 2"
",
damage after -
LLU)
50 1000 a short time
890
1020
900
1040
910
920
Legend
930
V Viscosity, mm'is (cSt) at 50 C.
D Density, kg/m 3 at 15C.
CCAI Calculated Carbon Aromaticity Index.
04.25 - ES1
,.f DieseI!
Description 504.27
Page 1 (4) AnaIysis Data Edilion 02
GeneraI
Comments Analysis Data for Fuel Oils Asphaltenes also inlluences the lubricating properties
olthe luel l and, in extremecases, high asphalteness
Carbon Residue content may lead to luel injection pump sticking.
The carbon residue a luel l indicates its coke- Fuel oils with a high asphalteness content ll have
lorming tendency and can be used to determine the a tendency to lorm sludge, especially l the water
tendencyto lorm deposits in the combustion chamber content is also high. The asphaltenes content a
and gasways. The higher the carbon residue value, luel l is inlluenced by pre-treatment. The heaviest
the higher the louling tendency. semi-solid asphaltenes, and asphaltenes bound to
water as sludge, can be separated by centriluging.
Some changes in the combustion process, requ ir-
ing adjustment the maximum pressure, may also
be attributed to a high carbon residue content. The Diesel lndex
value is measured by standardized tests, such as
the Conradson Ramsbottom tests which give Diesel index is a calculated value to determine the
similar results. ignition quality a l uel oil. Th e ignition quality is re-
lated to the hydrocarbon composition, paraffin being
The non-vaporized residue Irom the carbonizing test high quality, n-heptanes moderate quality and
consists carbonaceous materi al and inorganic im- aromatics low quality.
purities and is expressed as percentage weight ol the
luel sample tested. Carbon residue and asphal tenes With certain exceptions the properties the aniline
con tent generally move in parallel, both in relati on to point and the specilic gravity rellect the hydrocarbon
the carbon-to-hydrogen ratio, with increasing values composition a l uel oil, and are therelore used in
lor a higher ratio. the lollowing simple lormula as an expression
ignition quality:
The carbon-to-hydrogen ratio and thus also the
carbon residue depends on the source the crude Diesel index = (aniline point F gravity)
l and the type relinery processing used. 0.01.
The effect carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment the luel oil, as centriluging equal volumes the luel and aniline become just
only inlluences solid inorganic contaminants and miscible. The test relies on the lact that aromati c
hard asphalts, which are only small amounts the hydrocarbons mix completely with aniline at compara-
percentage weight called carbon residue. tively low temperatures, whereas paraffin s require
considerably higher temperatures belore they are
completely miscible.
Asphaltenes
high aniline point thus indicates a highly paraffinic
Asphaltenes is delined as the part a luel l sam- luel, and consequently a luel l good ignition qual-
ple which is insoluble in heptane. The content ity. Similarly, a high gravity number denotes a
asphal teness is expressed as percentage weight low specilic gravity and high paraffinicity, and again
the luel l sample tested. a good ignition quality.
Aspha ltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea the
solid hydrocarbon compounds dispersed in the luel ignition quality, but generally gives ligures slightly
oil , has a similar ellect on th e combustion process above the cetane number.
to the carbon residue, the main impact being louling
gasways. The stability the luel l is related to Fuel oils with poor ignition quality and a low diesel
the asphaltenes content. index might in particular cause problems in startIng
diesel engines and running at low load.
02.16 - ESO - G
,,' DieseII
504.27 Description
Edition 02 AnaIysis Data Page 2 (4)
Generai
In addition starting difficulties, a prolonged ignition Especially l the weight ratio sodium vanadium
delay may give rise alternations in the maximum exceeds t :3, ash with a very l w melting poinI and
pressure, leading increased mechanical or ther- stiction temperature is lormed , giving rise high
mal load. temperature corrosion exhaust valves and deposit
10 rm aon in turbochargers.
Furthermore, luel oils with poor ignition quality may
cause reIarded combusIion and subsequent louling is possible reduce the tendency lor 10rm aon
gasways. detrimenIal vanadium-sodium ash by effective
centriluging, which ll remove sodium salts
geth er with water. 1I a very l content sodium is
Sulphur ensured, a relatively high vanadium content might
be acceptable.
Sulphur is present in luel l , mainly as organic
compounds, the amount present being expressed
as percentage weight an l sample tested. 1I Iree Water
sulphur is present may cause corrosion in the luel
system. The main problem caused by sulphur is l w The water content luel l is measured by a
temperature corrosion . During combustion, sulphu r sIandardized disIillaIion test and is expressed as
oxides are produced in the lorm gases. Since percentage volume the sample Iested. Water in
humidity is also present sulphur and sulphuric acid the luel l may lead several detrimental effecIs
may be lormed on components in the combustion on the l uel l system, and corrosion and cavitation
chamber and in the gasways, where the temperature luel injection pumps and luel valves, and cause
is below that the dew point lor sulphuric acid. louling exhaust systems and turbochargers.
Th e deIrimenIal effect sulphur in luel l is coun- Due its content sodium, salt water in combina-
teracIed by maintaining an adequate temperature tion with vanadium conIribuIes th e 10rmaon
th e combustion chamber components and by using low-melting corrosive ash , which attacks exhaust
alkaline lubricating l neuIralize the sulphuric acid valves and turbochargers. When disturbs the luel
produced during combustion . atomization, water ll lead poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
is possible reduce the water content a luel l
Vanadium and sodium are consti tuents the ash primarily by centriluging, and this should be done
content. The amounts these are measured by th e widest possible extent in order avoid the
analyzing the residue Irom the combusIion test used deIrimenIal effecIs water in the luel .
lor deIerminaIion the ash content. The amount
vanadium and sodium present is epressed in ppm,
parts per million, by weight in relaIion the luel l Ash
sample being tested lor ash content. Vanadium de-
ri ves Irom the crude l itsell and, being l soluble, Ash content is a measure the non-combustible
cannot be removed Irom the luel l by convenIional material present in the luel l. The ash content is
pre-treatment. Sodium derives Irom th e crude l, and determined by a combustion test and is expressed
also Irom contamination with salt water during storage as a percentage weight residue Irom complete com-
and transport the luel l. Sodium is water- soluble bustion the l sample tested.
and, regard less derivation, tends combine with
the water present in the luel l. Ash-Iorming materials are present in the luel l as
natural components crude l and due exIernal
Owing iIs water solubility, is possible remove contamination the luel l.
or reduce the amount sodium present in the luel
l . During combustion, corrosive ash is lormed Irom
vanadium and sodium .
02.16 - ESO - G
DescripIion 504.27
Page 3 (4) Analysis Data EdiIion 02
General
Ash-forming materials exist both as solid contami- Viscosi ty Marine Gas l (MGO) and Marine
nants and soluble compounds. The solid contami- Diesel l (D) are expressed centi stokes (cSt)
nants may lead abrasive wear the fuel injection at 40 C.
system. Ash formed during combustion may lead
abrasive as well as corrosive wear combustion Viscosity is an important parameterin connection with
chamber components and give ri se formation pumping, pre-treatmentand injection offuel l, since
detrimental deposits. is therefore essential, the the possibility and efficiency these processes a
greatest possible , reduce the amount large depend adequate viscosity.
ash-forming materi als by centrifuging.
Adjustment viscosity adequate values is possible
Solid contaminants such as sand, rust, certain by taking advantage ofthe interdependence between
metal oxides and catalyst fines can be removed by the temperature and viscosity index the fuel l.
centrifuging, and the same goes for water-soluble
salts such as sodium. The nominal viscosity a fuel l is the factor de-
termining the preheating temperatures necessary
Some the components included th e ash content obtain adequate viscosity for pumping, centrifuging
have been found be particularly harmful and are and injection the fuel l , and thus also the factor
therefore stated individually the analysis data. determining the capacity ofthe preheating equipment
the l il system.
02.16 - ESO - G
504.27 DescripIion
Edilion 02 Analysis Data Page 4 (4)
General
The water separation ability luel l is increased Pour
by preheating the luel l centriluging since
the densities luel l and water change with the The pour point is the lowest temperature at which an
temperature at different rates, thus making possible l ll Il orcan be poured. The , point is meas-
to optimize density differences. ured under specilic test conditions. Fuel l must be
stored, handled and pumped at temperatures above
some extent the quality a luel l can be judged the pour point avoid wax crystallization, which may
by the density, since this is directly proportional the result in precipitation in storage tanks, blocking
carbon-to-hydrogen ratio, which again is indirect pro- l ilters and lines and prevention pumpability.
portion aromativity, carbon residue and asphaltene Normally, the pour point residual luel l does not
content, but in reverse ratio calorilic value. create any problems, since the temperature needed
reduce the viscosity to pumpable levels l l be
adequately in excess the pour point.
02.16- ESO - G
DieseII
DescripIion 504.30
Pag.' (2) FueI il CIeaning Edition
GeneraI
Purification Recommendations Especially fuels above 180 cST/50'C (1500 sec.
RW/1 OO' F) th e highest possible temperature 98'C
Fuel oils are always contaminated and should there- (208' F) should be maintained in the centrifuge l
lore be cleaned thoroughly solid as well as liquid preheater.
con taminants belore use. The solid contami-nants
in the fuel are mainly rust, sand, dust and re-linery The fuel is kept in the centrifuge lor as long as pos-
catalysts. Liquid contaminan ts are mainly water, i.e. sible by adjusting the Il rate through the centrifuge
either Iresh water sea water. so that ! corresponds to the amount luel required
by the engine without excessive re-circu lating. Con-
The impurities can cause damage to luel injection sequently, the centrifuge should operate lor 24 hours
pumps and l uel valves, result in increased cylinder a day except duri ng necessary cleaning.
lner wear and cause th e exhaust valve seats to
deteriorate. Increased fou ling gasways and tur- Taking today's fuel qualities into consideration the
bocharger blends may also result Irom the use need to clean centrifuges ("shooting freq uency")
inadequately cleaned luel oils. should not be underestimated. Correct choice and
adjustment the regulating screws and/or the grav-
Effecti ve cleaning can only be ensured by means ity discs are special importance lor efficient water
a centrifug e. We recommend that the capacity removal. The centriluge manual states the disc
the centrifuges installed be at least according to screw adjustment which should be chosen on the
the centrifuge maker's recommendati ons. obtain basis the specific gravity the l uel.
opti mum cleaning ! is the utmost importance to
operate the centrifuge with as lw a viscosity the Normal practice is have at least two centriluges
fuel l as possible and to allow the fuel l to remain available lor fu el cleaning. Results from experimen-
in th e centriluge bowl lor as long as possible. tal work on centrifuges, treating today's qualities
residual fuel, have shown that the best cleaning ef-
fect, especially as regards re moval catalyst fines,
is achieved when the centrifuges are operated in
CIeaning of HFO by Centri fuging
series, in purilier/clarifier mode.
Single centrifuge as purifier.
Operating Therefore series operation centrifuges to ensure
opIions centrifuges parallel.
cenrrifuges series.
maximum saIety is a ll accepted alternative to the
previously recommended parallel operation, provided
OpIimum OperaIing ConfiguraIions the operating capacity each individual centrifuge
can handle the total amount fuel required by the
WaIer content Paral l eloeralion engine, without exceeding theflow rate recommended
below 1 % i Purifier by the cen tri fuge maker the operating mode in
Normal question .
condilons
Density at 15"C Series operation
below 0.991 Purifier + Clarjfjer the centrifuge capaci ty installed is on the l w side,
corresponding to the speci fi c viscosity the fuel
Water content il used, and l more than one centriluge is avail-
below 1 % Parallel operaIion able, parallel operati on may be considered in order
to obtain an even lower Il rate. However, in view
Extreme DensiIy at 15C Purifier Purifier the above results and recommendations serious
conditions below 0.991 considerati on should be given to installing new equip-
ment in accordance with today's luel qualities and
High conlent Series operalion l recommendations.
cataryst fines + Clarifier
97 .40 - ESO
',l,l$'( MAN DieseII
504.30 Descriplion
Edilion FueI CIeaning Page 2 (2)
GeneraI
as a guideline. %
100
Separation Temperature
'F 'C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
Log scales
15
30 60 80
25
45
75
180 380600
-
cSV80"C
cSTl50C
RI/ 100"F
97.40 ESO
Descriplion
Page 1 (5) Freshwater System Treatment 504.40
Edition 02
General
Protection against Corrosion n Freshwater Cleaning agenls emulsilied waler as we ll as slightly
Cooling System alkaline cleaning agenls can be used lor Ihe degrea-
sing process, whereas ready-mixed cleaning agenls
The engine Iresh waler mus/ be carelu lly Irealed , which l Ihe risk lre musl obviously l be
mainlained and monilored so as avoid corrosion used. For descaling wilh acid, especially producls
or Ihe lormalon deposits which can result insul- based amino-sulphonic acid, cilric acid, and l ar-
lcenl heattransler, l is necessarylolreal Ihe cooling laric acid are recommendable, as Ihese acids are
waler. & W recommend Ihal Ihis Irealmenl is usually oblainable as solid substances, easily soluble
carried l according the lollowing procedure: waler, and do l emil poisonous vapours.
Belore slarling Ihe inhibilion process, any exisling The lilling-up with cooling water and the admixlure
deposils l me or rusl, or any l sludge, should be Ihe inhibitor is be carried directly aller Ihe
removed order 10 improve Ihe heal Iransler and 10 cleaning order prevent lormation rust Ihe
ensure unilorm proleclion Ihe suriace by means cleaned suriaces.
Ihe inhibilor.
RawWaIer
The cleaning should comprise degreasing 10 remove
l sludge, and descaling wilh acid afterwards 10 The lormalon l me stone cylinder ln ers and
remove rusl and l me deposils. cylinder heads may reduce the heat transler, which
w ll result unacceptably high temperatures Ihe
Ready-mixed cleaning agenls, specially made lor malerial.
cleaning the cooling water syslem, can be oblained
Irom companies specializing cooling water Ireal- Therelore, ! is recommended that deionized ordistil-
menl. These companies offer assislance and conlrol led water (Ior example Irom the Ireshwater genera-
Ihe Irealment all major porls. number Ihese tor) is used as cooling water. However, account
companies are menlioned Ihe enclosed lisl. We its lack hardness, this water w ll be relatively
l l Ihal Ihe directi ons given by Ihem should corrosive, and a corrosion inhibitor should therelore
be closely lollowed. It is parlicular imporlance 10 always be added.
Ilush Ihe syslem complelely after cleaning.
OO. 11-ES1
504.40 Freshwater System Treatment
Description
Page 2 (5)
Edition 02
General
1I deionized distilled water cannot be obl ained, Checking the C ooling Water System and
normal drin king water can be used exceplional the Cooling Water during Service
cases. 1I so, the total hardness th e water must
l exceed 90 dH (German hardness degrees). Th e 1I the cooling water is conlaminated during service,
chloride, chlorine, sulphate, and silicate contents sludge deposits may lorm. The condition the
are also be checked . These contents should l cooling water system should therelore be regularly
exceed th e lollowing values: checked, especially l deionized distilled water is
used. 1I deposits are lound the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces , l necessary, Ihe system
Chlorine 10 ppm (1 mg/litre) should be cleaned.
Su lphate 100 ppm (100 mgIIitre)
Silicate 150 ppm (150 mgIIilre) According experience, a zinc galvanized coating
the Ireshwater cooling sysl em is often very suscep-
There should be sulphide and ammonia contenl. tible corrosion, which results heavy lormal on
Rain water must be used, as may be heavily sludge, even l the cooling water is correctly inhibited.
contaminated. Th e initial descaling with acid l l , a greal ,
remove Ihe galvanized coating . Generally, therelore,
should be noted th at softening water does advise against the use galvanized piping the
reduce its sulphal e and chloride conl ents. Ireshwal er cooling sysl em.
Treatment ofthe cooling wal er with inhibting oils is The concentration inhibilor must under
recommended, as such treatment involves the risk circumslances be allowed lall below that
l adhering 10 Ihe heat transmitting surfaces. recommended by the producer, as Ihis would
increase Ihe risk corrosion,
Chromale inh ibilors musl l be used planls
connecled 10 a Ireshwater generalor. clear record all measuring results should be kept,
so that th e actual condilion and trend th e sysl em
Evaporated cooling water is be replaced with may be cu rrenlly ascerlained and evalualed.
noninhibited water, whereas a loss water Ihrough
leakage must be replaced wi th inhibited water. sudden gradual increase the chloride content
Ihe cooling water may be indicative salt water
When overhauling individual cylinders, a new dosage leakages. Such leakages are 10 be traced and repai-
inhibitor must, l necessary, be added im-mediately red al the lrs t .
after completing the job.
OO .1 1 ES1
Description
Page 3 (5) Freshwater System Treatment 504.40
Edition 02
General
chloride content the cooling water higher than The cooling water system must not be kept under
the 50 ppm specified might, exceptional cases pressure.
be tolerated. However, that case the upper limit
specified by the individual inhibitor supplier must Check, and repair any leaks.
be exceed.
Drain the system and l ll completely with clean
clear record all measuringresu lts should be kept, tap water, order flush any l grease from
so that the actual condition and trend the system the tank.
may be currently ascertained and evaluated.
Circulate the water 2 hours, and drain again.
sudden gradual decrease value, an
increase the sulphate content, may indicate
haust gas leakage. The value can be increased DescaIing with Acid SoIution
by adding inhibtor; however, major quantities are
necessary, the water should be rep laced. Fill with clean tap water and heat 70-750 C.
Every third month a cooling water sample should be Dissolve the necessary dosage acid compound
sent ashore laboratory analysis, particular a clean drum with hot water.
ascertain the con tents inhibtor, sulphate, and ,
as well as the total salinity the water. Fill the drum half with water and slowly add the
acid compound, while stirring vigorously. Then ll the
drum completely with hot water while continuing
CIeaning and Inhibiting Procedure stir (e.g. using a steam hose).
The engine must be run ning during the cleaning Be careful - use protective spectacIes and
procedure, as this may l the risk overheating gloves.
when draining.
For engines which have been treated before the trial
,
the lowest concentration recommended by the
Degreasing supplier ll norm ally be sufficien t.
Use clean tap water fill ing-up. The cooling water For untreated engines, a higher concen tration - de-
the system can be used, does contain pending the condition the cooling system - ll
inhibitors. normally be necessary.
Heat the water 600 C and circulate the water Drain some water from the system and add the acid
continuously. solution via the expansion tank.
Drain lowest water level expansion tank. The cooling water system must not be under
pressure.
Add the amount degreasing chemical specified
by the supplier, preferably from the sucti on side Keep th e temperature th e water between 700 C
th e freshwater pump. and 750 C, and circulate it constantly. The duration
the treatment l l depend the degree ul
Drain lowest water level the expansion tank ing. Normally, the shortest time recommended by
directly afterwards. the supplier l l be sufficienI engines which are
treated before the trial . For untreated engines,
Ci rculate th e cleaning chemical the period speci- a longer time must be reckoned with. Check every
fied by the supplier. hour, example wi th pH-paper, that the acid th e
solution has been used up.
00." - ES ,
',I,HM'iMAN DieseI!
504.40 Freshwater System Treatment
Description
Page 4 (5)
Edition 02
GeneraI
The solubility acids water is often limited. Weight ! th e quantity inhibitors specilied by th e
Therelore l, exceptional cases, a large amount is supplier and dissolve a clean drum wilh hot
required, descaling can be carried ! two stages water from the evaporator.
with a new solu ti on compound and clean water.
Normally th e supplier w ll specily the maximum Add Ihe solution via the expansion tank to the system.
solubility. Then lll to normal water l l with water from the
evaporator.
After completing the descaling, drain the system and
Ilush with water. Acid residues can be neutralized ll w the engine to lor ! less than 24 hours
with clean tap water containing 1 kg soda per ton ensure that a stable protection the cooling surfa-
water. Circulate the mixture lor 30 minutes, then ces is lormed.
drain and Ilush the system.
Subsequently, test the cooling water with a test
The cooling waler syslem musl l be l under kit (available Irom the inhibitor supplier) to ensure
pressure. that an adequate inhibitor concentration has been
obtained.
Continue to flush until water used is neutral (
approx.7). This should be checked week.
OO.11 ES 1
Oescription
Page 5 (5) Freshwater System Treatment 504.40
Edition 02
General
Maker's minimum
Company Name Inhibitor Delivery Form Recommended
Dosage'
The list is for guidance only and must be consid- The suppliers are l sted alpabetical order.
ered complete. We undertake responsibility for
difficu lties that might be caused by these other Suitable cleaners can normally be supplied by
water inhibitos/chemicals. these firms.
Description
Working card
23/30
The individual cast-iron cylinder heads, for each The l and ehaust valve s indles are identical
cylinder , are equied with a centrally situated and therefore interchangeable.
fuel injection valve, l valves, ehaust
valves and indicator cock. Th e valve s ind les are made heat-resistant ma-
terial. Hard metal is welded the valve sindle
The head has a thi ck, bore-cooled flame late for seats.
satIsfactorycontrol ofmechanical and thermal loads
and stress. The valve sind l es are fitted with valve rotators
which turn the sindles a lttle each time the valves
The cylinder head is attached by means 4 nuts .
and 4 studs screwed dee bosses the engine
frame late. The nuts are tightened by means The cylin der head is equ i ed with relaceab l e
hydraulic Iools. seat rings for l and eha ust valves.
95.50 - ESOU-G
',, DieseII
Working Card
DismantIing of CyIinder Head
505-01.00
Page 1 (2) Edition 01
23/30
Shut-off startIng air
Shut-off cooling water 52021 011 l injector,
Shut-off fuel l 52021 011 (Complete)
Shut-off cooling l
Stopped lb. l circul.
52021
52021
52021
501
513
155
4 pieces
1 piece
52005 014
52021 25 1 Hydraulic tools
Descriplion:
Hand lools:
Relaled procedure:
Manpower:
Replacemenl and wearing parls:
Working time 1 hour
Capacity 2 men Plate Item Qty/
Dala:
95.50 - ESOS
f,J,IIM DieseII
23/30
.
FIg 1
,
95.50 - ESOS
'( DieseII
~~~~91 ~;;d Inspection of In Iet VaIve, Exhaust VaIve and VaIve Guide 5~~I~~~5
23/30
De5criplion :
Relaled procedure:
95.50 - ESOS
505-01.05 Inspection of Inlet Valve, Exhaust Valve and Valve Guide WorkIng Card
EdillOn 01 Page 2 (3)
23/30
Or as an Allernalive:
Place wooden blocks under Ihe valve spindle 9) Remove valve rolator and springs.
heads.
10) Remove the supporling devices under Ihe
3) back Ihe rocker arm and remove Ihe work lable and lake Ihe valve spindle.
FIg 1.
95.50 - ESOS
',tlM"I MAN DieseII
Working Card
Page 3 (3) Inspecti on of InIet VaIve, Exhaust VaIve and VaIve Gu ide 5~~;~~5
23/30
Fig4.
12) For mounting valve spindle lw the in-
structions in point 4 - 10 in reversed order.
95.50 - ESOS
DieseI!
WorkIng Card Reconditioning of VaIve SpindIe Seat 505-01.10
Page 1 (3) Edition 01
and VaIve Seat Rin
L23/30
De5criplion:
Relaled procedure:
Dala:
95.50 - ESOS
505-01,10 Reconditioning Valve Spindle Seat WorkIng Card
EdiIIon 01 Page 2 (3)
and Valve Seat Ring
23/30
Reconditioning VaIve Seat Ring I-Iowever, when theseat 'S' has been ground such
an extent that the recess 'R' disappears, see Iig 1,
Reconditioning of valve seat rings by machining is the valve seat ring has be scrapped and a new
carried by means of a grinding machine, the must be installed, see working card 505-01.35
l spindle of which is be mounted the valve
spindle guide. Foroperation the grinding machine,
see separate instructions. Reconditioning VaIve Spindte
95.50 - ESOS
,' Dieserl
Working Card Reconditioning of VaIve SpindIe Seat 505-01"10
Page 3 (3) EdiIIon 01
and VaIve Seat Ring
23/30
"2
Fig3.
95.50 - ESOS
+$' DieseI!
Worklng Card 505-01.15
Page 1 (2) VaIve Rotator EditIon Q1H
23/30
Descriplion:
Small screwdriver.
Ring and open-end spanner 24 mm.
Slarling posilion:
Relaled procedure:
Dala:
95.50 - E50S
l$% DieseI!
505-01.15 WorkIng Card
Editfon 01 VaIe Rotator Page 2 (2)
23/30
Dismantling Rotocap
FIg /.
See work;ng card 505-01.05, po;nl 3 10 9.
1) Clean the valve rotator. See work;ng card 505-01.05, po;nl3 10 9, Oppos;le
d;recl;on.
2) Inspect lor wear and ball impressions.
95.50 - ESOS
Working Card 505-01.20
Page 1 (2) Replacement of Valve Guide Edilion 01
L23/30
Descriplion:
Hammer.
Nitrogen (,). similar.
Mandrel lor 'knocking out the valve guide.
Slarling posilion:
Relaled procedure:
95.50 - ESOS
f,J,I'MI.lfMAN DieseI!
505-01.20 WorkIng Card
EdiIIon OSH RepIacement VaIve Guide Page2 (2)
23/30
When 10 RepIace Ihe VaIve Guide 4) Belore mounling - cool down the new valve
guide 10 approx. -70"C with nilrogen or similar.
Illhe cIearance exceeds Ihe max. Iimil , see page
500.35, Ihe vaIve guide musl be repIaced. 5) Inserl Ihe valve guide the bore.
M andrel
Fig2.
Valve guide
7) Belore mounling Ihe valve spindle inserl a
O-ring Ihe valve guide.
2) Clean th e bore the cylinder head careluIIy. Screw-drivers or other sharp lools should never be
used lor Ihis purpose.
3) Inspect lor marks th al can prevent mounting
valve guide. 8) For mounting valve spindle, see working
card 505-0. 05.
95.50 ESOS
WorkIng Ca rd
Indicator Valve
505-01.26
Page 1 (2) Edition 01
23/30
Stopped engine
Shut-off starting air
Shut-off cooling wa ter
Plate Item Note
Shut-oll luel l
Shut-olf cooling l
Stopped lub. l circul.
Slarling 05:
Relaled procedure:
Dala:
95.50 - ESOS-G
,, DieseII
505-01,26 Worktng Card
EditIon 01 Indicator VaIve Page 2 (2)
23/30
MainIenance
95.50 - ESOS-G
I+I@,!"iMANDieseI!
Working Card
RepIacement of SIeeve for FueI Injector
505-01.30
Page 1 (2) Edition Q1H
23/30
Descriplion:
Brass mandre).
Hammer.
Lub.oil.
Slarling posilion: sma)) screw-d rivers.
Loctite 572.
The cylinder head has been dis-
mounted Irom engine 505-0 1.00
The fue l injector has been removed 514-0 1.1 0
Relaled procedure:
96.19 - ESOS
505-01.30 WorkIng Card
Edillon 01 Replacement of Sleeve for Fuel Injector Page 2 (2)
23/30
Dismounting Sleeve for Fuel Injector 4) Coat the sealing ring the bore with
grease l b. l.
1) Remove the snap ring by means screw-
drivers.
~
- snaPjng
by a brass mandrel and a hammer.
~ / O-lng
Sleeve
LocIIte 572
Fig2.
96.19 - ESOS
Wo(king Card
Replacement of Valve Seat Ring
505-01.35
Page 1 (4) Editlon 01
23/30
Descriplion:
Slarling posilion:
05.02 ESO
505-01.35 Replacement of Valve Seat Ring
Working Card
Edition 01 Page 2 (4)
23/30
10
6
5 .
[~-'
05.02 - ESO
.i( DieseI[
L23/30
3) pumping Ihe pack, see working card 3) facililale mounling Ihe valve seal ring is l
520-01.05 for Ihe use ! hydraulic lools, Ihe valve cooled down, however, a min. of -25C olherwise,
seal is pressed l max. 6 mm, and Ihe pressure is Ihe o-ring can be damaged.
released again. The collar nut heagon is lighlened
and Ihe operalion is conlinued unlil Ihe valve seal 4) Place Ihe o-ring on Ihe valve seal ri ng and
ring can be removed. coal wilh oil/loclile as shown in Iig 4, jusl before
posilioning l in Ihe bore.
Fig4.
1 Handle 2 Std
Fig3. Fig5.
05.02 - ESO
505-01.35 WorkIng Card
Editlon 01 Replacement of Valve Seat Ring Page 4 (4)
23/30
05.02 - ESO
WorkIng Card
Mounting of Cylinder Head
505-01.40
Page 1 (2) EdiIion 01
23/30
11
Stopped engine
Sht-oll starting air
Plate Item Note
Sht-oll cooling water 52021 011
Shut-off lel 52021 501 4 Pieces
Sht-oll cooling l 52021 155
11 Stopped lb . circul. 52005 014
52010 011
52021 251
Descriplion:
Hand lools:
Relaled procedure:
~
50501 338 2/cyl
3
> Dala: 505 10 075 1/cyl
Data lor pressure and tolerance (Page 500.35) 51202 024 2/cyl
Data lor torque moment (Page 500.40) 51625 097 1/cyl
Declaration weight (Page 500.45) 5 1625 132 1/cyl
95.50 - ESOS
505-01.40 WorkIng Card
Edilton QIH Mounting of Cylinder Head Page 2 (2)
23/30
Check 10 be Done belore Lifting Place Ihe spacer ring around Ihe nls wilh Ihe slol
1) Check Ihe joinling surlaces Ihe cylinder such a posilion thallhe lommy bar can be used.
head/cylinder ler see thal they are clean and
wi l hol damage marks, see working card 50.6-0.1.45. Tighlen Ihe hydraulic jacks and make sure that Ihe
Fit new O-rings Ihe waler passage, lbrcale the cylinder Ihe jacks bears lirmly againsllhe spacer
O-rings with a lllle l. ring . Tighlen aII Ihe nuls, see page 50.0..40. For
using (he hydraulic (ools, see working card 520.-
2) Check aII conlacl laces Ihe cylinder head 0.1.0.5
and nuts, including threads, and make sure Ihat
Ihese are level and smoolh and absolutely Iree Irom
loreign parlicles.
Fg2.
95.50 ESOS
WorkIng Card 505-01.45
Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 01
23/30
Descriplion:
Steel brush
Slarling posilion :
Relaled procedure:
Dala:
95.50 - ESOS
505-01.45 WorkIng Card
EditIon 01 Inspection of Cylinder Head Cooling Water Space Page 2 (2)
23/30
,.
95.50 - ESOS
1,j,j@'.ifMANDesel
Plate
Page 1 (2) CyIinder Head 50501-10
23/30
255i~
363
2~279
243 039 ____- 267
231 292
147
1 59~
:::~
637
35 1
~k--- 076
064
649
338-_
160
015
172
184 ~
196 :=----e
184 ---------..
07.32 - ESO
Plale
50501-10 Cylind er Head Page 2 (2)
L23 / 30
Ilem Item
. Qty. Designalion Benrevnelse . Qty. Designalion 8enrevnelse
015 I/C Cylinder head (as 649) Cylinderdreksel (som 363 4/C O-rlng 0 - 9
with brackels 80d 649) monlere! med
rocker arms insIalled bukke og . 637 1/C Cylinder hea d with Cylinderdceksel mon-
valve guide sIeeve for !l med spindelslyr,
039 I/C Sleeve Forlng fuel l and l forin9 for br. venlil 09
seat r ings venlilscederinge
040 /C - -
649 1/C Cyllnder head (as 637) Cylinderdcekse l (som
052 I/C Snap ring L~sering wlth valve splndles, 637). monterel med
spring and rotocap venlilspindler, fjeder og
064 2/C Valve seat ring, VenIllsredering, installed rolocap
(ll) (indstr0mning)
338 2/C - -
When orderng spare parts, also page 500.50. Ved besIilling al reservedele, se ogsf side 500.50.
Only avail able as part of a spare parts kit. Kun lilgc:engelig som del af l reseredelsset.
Oty./C = OtyJCyllnder Antal/C = Antal/Cylinder
07.32 - ESO
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-01
23/30
\\
50501
453
607 178
095 '"
V a
083
- - 130 298
See l ate
50501
512
512
02.38 - ESO
Plate
50502-01 Vale Spindles and Vale Gear Page 2 (2)
23/30
Item Ite m
. Qty. Desig nation Bencev nelse . Oty. Designation Benre vnelse
010 2/C Vale brIdge , compl. Ver1!rJl)rQ kllet rnkl. 489 4/C Inner s prlng Illdvendig fjeder
incl.item022,034, 046, Ilem 022, 034, 046. 07 1,
071,083,095,105,117, 083,095,105,117,129 490 4/C Outer sprlng Udvendig fjeder
129 a nd 130 og 130
512 4/C Valve splndle, Inlet Ventilsprndel, rnds. og
022 2/C Valve bridge Ventilbro and outlet uds.
071 2/C Thrust piece Trykslykke 548 4/C Spring washer Fjederskive
105 4/C hrust piece Trykstykke 607 lIC Rocker arm shaft Aksel vippearm
When ordering spare parts, see a lso page 500.50. Ved bestilIing af reservedele, 5 ogsa side 500.50.
Only available as part of a spare parts kit. tlg cen g e l i g som en del af reservede lssc.el.
OtyJC OtyJCylinder Anta l/C = Antal/Cylinder
OtyJ = Oty./lndividual Anta l/ = Antal/lndividuell
02.38 - ESO
Plate
Page1 (2) Indicator Va l e 50508-01
23/30
052
051
050
049
Handwheel for indicator
valve, see plate 52005
0 37 -
~
013
025~
. ,
... ,
"'.,,',
...
.'., , ..
06.41 - ESO
Plate
50508-01 Indicator Valve Page 2 (2)
23/30
Item Item
. Oty. Desfgnation Bencevnelse . Oty. Des lgnatlon Bencevnelse
When ordering spa re parts, see al50 page 500.50. Ved bestilling af reservedele, 5e ogsA side 500.50.
Only avallable as part of a spare parts kit. Kun Iilgcengelig som del af et reseredelsscet.
Oty./C = OtyJCyllnder AntalfC = Antal/Cylinder
06.41 - ESO
,],
. Diese~1
Plate
-
Page 1 (2) Cylinder Head, Coer 50510-01
~
23/30
94.22 - ESOS
f,J+tNIIMAN DieseI[
Plate
50510-01 CyIinder Head, Cover Page 2 (2)
23/30
Item Item
. Q,y. Designation Bencevnelse . Qty. Designation Bencevnelse
When ordering arts , see al so page 500.50. Ved bestilling af reservedele, se ogsf side 500.50.
Only avallable as part of a spare parts kit. t Hgengelig som del af et reservedelssceI.
Q'y./C = Q'y./Cyl1nder Anlal/C = Antal/CYIInder
94.22 ESOS
Section 506
Pstoo, Connecting Rod and CylinderUner
Description
Working card
Plates _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.1
23/30
The piston, which is oil-cooled and the monobloc The connecting rod is die-Iorged. The big-end has
type made nodular cast iron, is equipped with 3 an inclined joint in order lacilitate the piston and
compression rings and 1 scraper ring. connecting rod assembly 10 be withdrawn through
the cylinder liner. The joinl laces on the connecting
use a combination compression rings with rod and the bearing cap are serrated ensure
different barrel-shaped proliles and chrome-plated precise location and prevent relative movement
running surface on all rings, the piston ring pack is Ihe parts.
optimized lor maximum sealing effect and minimum
wear rate. The big-end bearing is the trimetal type, .. steel
shells lined with tin-aluminium lead-bronze coa-
The piston has a cooling l space close 10 the pisl on ted with a running layer. Designed as plain type
crown and the piston ring zone. The heat transport, rillenlype. The bearing shells are the precision
and Ihus the cooling effect are based on the sha- type and are Iherelore be fitted without scraping
ker effect arising during the piston movement. l any other kind adaption.
Irom the engine's lubricating l system is used as
cooling l. The small-end bearing is the trimelal type and is
pressed into the connecting rod.
The piston is provided with a turned edge at the
due the Ilame ring mounted in the cylinder liner.
Cylinder Liner
96. 19 ESOU
Working Card
Dismounting of Piston and Connecting Rod
506-01.00
Page 1 (3) EdiIion 01
23/30
Stopped engine
Shut-off 8tarting air
Plate Item
Shut-off cooling water 52006 021
Shut-off fue l l 52006 033
Shut-off cooling l 52006 094 2 pieces
Dala:
96.20 - ESOS
506-01.00 Working Card
Edition 01 Dismounting of Piston and Connecting Rod Page 2 (3)
23/30
l: is th e used piston ring which pushes the 6) Attach a wire rope the eye bolt by means
flame ring out the cylinder. a shackle, hook the 10 a tackle and ll Ihe
wire rope light.
96.20 - ESOS
',,,,II DieseI!
Working Card 506-01.00
Page 3 (3) Dismounting of Piston and Connecting Rod EdiIion 01
L23/30
--l
- - ~ ---~
@
@
96.20 - ESOS
Working Card 506-01.05
Page 1 (2) Separation of Piston and Connecting Rod Edition 01
23/30
Description:
Related procedure:
Data:
95.50 - ESOS
DieseI!
506-01.05 Separation of Piston and Connecting Rod
Working Card
EdiIion 01 Page 2 (2)
23/30
Land ing Piston and Connecting Rod Separation Piston and Connectin g Rod
1)
Land the pisIon and connecting rod carelu lly 6) Take the securi ng ring, (seeger circlips),
wooden supports damage piston push oU the piston and l the connecting rod
and scraper ring, see fig 1. away.
Assembly Piston and Connecting Rod
95.50 - ESOS
I I1 ' DieseII
Working Card 506-01.10
P_ge 1 (4) Piston Edilion 01
L23/30
Cleaning and inspection piston. Control piston Tools lor cleaning pisIon, steel brush,
ring, scraper ring and ring grooves. scraper etc.
Slarling posilion:
Relaled procedure:
Dala:
95.50 - ESOS
506-01.10 Working Card
Edition 01 Piston Page 2 (4)
23/30
For removal piston rings, which are be used 1) Remove the piston and scraper rings.
again, and lor all mounting rings, only the special
ring opener which prevents local over stressing 2) Clean and examinethe piston rings todetermine
the rings should be used. l reuse is acceptable, see page 3.
Straps 10 expand the ring gap or tools working 3) Clean the piston the outside and the
Ihe same principle must not be used, as this would inside.
result permanent delormation which might cause
blow-by or broken rings. 4) Inspect the piston ring and scraper ring grooves
lor wear, see page 3.
95.50 ESOS
,,I( DieseI!
Workin g Card 506-01.10
Page 3 (4) Piston Edition 01
23/30
he cy/inder Iner must be honed according Tabfe 1. Nomina/ siz, new ring groove toferance and wear
Iimit (or ring grooes.
the instructions.
0.45 mm
Wear lm l .
95.50 - ESOS
506-01.10 Working Card
Edition 01 Piston Page 4 (4)
23/30
Piston Ring 1:
marked wi th ident.
"top 881500-3"
''0946''.
Piston Ring 2:
marked with ident.
" 881502-7"
''0947'',
Piston Ring 3:
marked wi th ident.
' 881501-5"
''0945'',
Scraper ring:
marked with ident.
" 881503-9"
''0120'',
Identification marks 10 face upwa rds against Ihe pislon crown when mounted.
Note! The marking may include olher figures than mentioned above, for instance trade mark and
production codes.
95.50 ESOS
~Orkjng Card 506-01.15
Page 1 (4) Connecting Rod Edition 01
L23/30
Descriplion:
Hand lools:
Relaled procedure:
Dala:
95.50 - ESOS
f,j,J,$H'fMAN DieseII
506-01.15 Connecting Rod
Working Card
Edilion 01 P_g.2 (4)
23/30
1. CIean aII machined surfaces the connecting For check ovalness the bearing cap has be
rod. mounted onto the big-end bore without bearing
sheIis.
2. Degrease the serrated jointlaces, tapped hoIes
and connecting rod screws with a voIatiIe soivent and Note !! The ident. the connecting rod and the
bIow dry with working air. bearing cap must aIways be the same, see fig 3.
6. Inspect the connecting rod screws ' seizures 10. Measure different diameters the middIe
the threads and pittings the contact surfaces the boring, see fig 1.
the screwheads.
11. Register the measurements the scheme
7. Turn 'he connec'ing rod screws bottom "Connecting Rod Inspection". See page 4.
posi'ion th e threaded screw hoIes by hand.
12. Calculate the maximum ovaIness as the dif-
screws Then lerence be'ween biggest and smaIlest diameter
measured.
have seizures Renew the screws
threads or pittings 13. Check maximum ovalness is exceeded, see
contac' surface page 500.35.
95.50 - ESOS
Working Card 506-01.15
Page 3 (4) Connecting Rod Edition 01
23/30
---
~oo_
~t.ou.!O<....-.gf<J
....
.
,
-0,5 -3,0
,
3. Check max clearance is exceeded, see page
500.35.
-
111110 .....
- 1,5 5. & Diesel NS, Holeby replacement.
..5,0 +5,5
0 1 9S_ . 3. .3.
~'IId1_
~OI_._
.... _
-
~!O< ___ o -~
0-
00_
0 --0- 0 """- ""
0-
...,.,
0-
..""
Inspection Bearing Shells lr Big-end
~ Son."",
0 :::;- O~' 0::;-'
bearing, see working card 506-01.16.
"""
~
-
-~
reused ,eIectod
_m
-,--.., ........... -
-"' ................ MfWog
~""",,,,,.,,,,,. ,,,,,,
95.50 ESOS
Z~ "SO'P6/09l9H/OO-Sl080
"
~w
~
u- PlantlShip: Engine Type: ~
0>" .,.;
~ ~ '"
~
Connecting Rod Inspection for 23/30 Engine . : Running Hours:
~ "-
Sign.: Insp. Date:
Cylinder . 1 2 3 4 5 6 7 8
Connecting rod ident. .
~~-
1{100 mm 8
C
Nominal D
diameter
0195 mm
' Condition serration Serration < SerraliQ < Seation Dseation < Serration Serri1tion < Serration Serration
Tghtening l measurement see
: instruclion.
Wear Weat Wea.t Wear Wear Wear Wear Wea,
Crac Cracks OCclCkS Cracks
Cracks
D CrilCks
Coro$ionl "".,..,.,
OCr3C1<S
Deorosiool
Cracts
CorroSIO\'
-
DI DCcos,onl CorfO$loI\' Dcorrosionl Corros,onI
::: Pitling PinIng Pitting Pirung Pittng PItting Prg Pit!Irg
Impnct mark Impac marl. Impact mark ImpaC1 mark Impac mark Impac: mark Impact mark Impac! mark
u
~
:::
:::
U
Serration
/'
~ f D
Remark.s: Remark.s: Remark.s: Remark.s: Remark.s: Aemark.s: Remarks: Remark.s:
YJ'y.
+
J Connecting rod
Ident. .
Lt
""' ::::: Note! The ident. . the con
,....' 0-
necting rod and the beang
9 .
<D:a ~
C'II
cap must always be the same.
o w ...
Lt
Working Card Criteria for Replacement of 506-01.16
Page 1 (8) Connecting Rod Big-end and Main Bearing Shells Edilion 01
23/30
Descriplion:
Magnifier (30).
Slarling posilion:
Relaled procedure:
91.07 - ESOS-G
I,,l$'IMAN DieseII
506-01.16 Criteria for RepIacement of Working Card
Edilion03H Connecting Rod Big-end and Main Bearing Shells Page 2 (8)
23/30
Thi s paper gives inlormation about the evaluation Wear the bearings running surface starts primarily
the connecting rod big-end and main bearing shells the soft overlay, where the overlay the slots is
when wear appears the running surface under reduced approx. 0.001 mm. Th e dillerence between
normal operating conditions. the light-alloy metal and the overlay is by lurther
wear almost constant, .. approx. 0.005 mm.
Bearing damages caused by incorrect running con-
ditions, like Th e gravity the running surface's wear must be
determined with a magnilier ( 30), hereby the over-
Scoring the running surface due loreign lay can be seen as the dark area and the light-alloy
particles the lubricating oil. metal as the light area.
Cavitation.
Corrosion The ratio between the width the light-alloy metal
Overloading, overheatin g a.s .o. and the width the slot as we ll as th e dimension
the worn area are important lor determining the wear
are described this paper. the bearing.
In these cases, the bearing shells must be exchang- Th e bearing can also operate although part the
ed, course, and order avoid lurther bearing overlay is missing the slots. Practi ce has shown,
lail ures, th e cause the la lure must be lound and th at bearings with partly empty slots can run without
eliminated. any negative inlluence the operation the bea-
ring.
91.07 ESOS-G
',,4'I DieseII
Working Card Criteria for RepIacement of 506-01.16
9 3 (8) Connecting Rod Big-end and Main Bearing SheIIs Edition 01
L23/30
Condit ion: The sIot geometry corresponds a Condit ion : The overlay is equally worn, approx.
bea ng
shell. The ove~ay the slots is fu lly preser 0.005 mm the slots. The lightal)oy strips show
ved, see fig 2. wear, see fig 3.
Dark spots are mainly l coke remains. Dark spots are mainly l coke rema ins.
VaIuation: The between lightalloy metal and VaIuation : Due running surface the light
overlay is 75 % 25 %. Reuse! alloy strips are sIightly widened. Reuse!
Fig2. Fig3.
91.07 ESOSG
506-01.16 Criteria for Replacement of Working Card
Edition 01 Connecting Rod Big-end and Main Bearing Shells Pag84 (8)
23/30
1.3. Bearing Shells for Re-use. 1.4. Bearing Shells for Re-use.
Condition: Small particles all overthe overlay. The CondiIion: The overlay has been dragged and
lighlalloy melal shows changes importance. smudged over the light-aIIoy metal. These are only
see lig 4. partly visible, see lig 5.
Valuation : Re-use the shell . as the particles are Valuation: Re-use the shell.
wedged the slots.
Fig4. Fig5.
91.07 - ESOS-G
+ DieseI!
Worklng Card Criteria for RepIacement of 506-01.16
Page 5 (8) Connecting Rod Big-end and Main Bearing SheIIs Edition 01
23/30
2. Limiting Case - Wear Condition: The bearing shell is locally so worn , that
th e ratio between th e light-alloy metal and the
lay is 1:1, see fig 6. The width the light-alloy metal
has increased from 100 % (new bearing shell)
175 %. the slots some overlay is still left, see fig
7.
Fig8.
Fig6.
175%
100%
......
..... ............. :: :
, ............ ... .
.....
.. , .... .......
. ... ... .
Fig9.
Fig 7.
91.07 ESOS-G
,', Dieserl
L23/30
3. Limit Ca5e Levelling Val uation: Ihe limils shown fig. 11 and 12 are
e cee ded Ihe bearing shells musl be ec hang e d .
Condition: The 5101s are locally tolally levelled as
shown fig . 10.
max. 10% widlh
Fig. 70.
~
L()
max. 10% width
max. 5 mm
u Fig. 12.
11
Fig.1 1.
91.07 ESOSG
,, DieseI!
Working Card Criteria for RepIacement of 506-01.16
Pag. 7 (8) Connecting Rod Big-end and Main Bearing SheIIs Editon 01
L23/30
4. Limil Case Permanenl Breakage Ihe Condilion: Breakage the overlay due 10 local
Running Surlace overload, as shown fig 13 and 14.
Fig 15.
ma 10% width
ma. 10 mm
LJ
Fig 13.
.6
~~
i.t :>;:
j~
ii!
:
)~:
:(
:t
:;;;
: ,:
:~~
,~:
,'' !
@
W ~:
~ i:"
~
\
n
91.07 ESOSG
iIJ,i,gNIfMAN DieseI!
506-01.16 Criteria for RepIacement of Working Card
Edilion 03H Connecting Rod Big-end and Main Bearing SheIIs Page 8 (8)
23/30
5. Limit Case - Empty Slots ValuaIion: If the limits shown the belowfig. 18 and
19, are exceeded, the bearing 5he l1 5 mU5t be
Condition: l 50me areas there is overlay the changed.
510t5, see fig . 17.
r-
width
~
max. 5 mm
\ LlgtI moInl
Fig. 17.
IU
c
Fig.19.
,
<f'-
'.
~ .-
'"
~
'"
n
.-
Fig. 18.
91.07 - ESOS-G
Working Card 506-01.20
Page 1 (4) Mounting of Piston and Connecting Rod Edition 01
23/30
Stopped engine
Shut-off starting air
Plate Item Note
Shut-off cooling l 52006 116
Stopped lub. l l. 52006 141
52006 224
Descriplion:
Relaled procedure:
~
Working time 1 1/2 hours Plate Item Qty/
~
Capacity 2 men
~
50601 093 1/cyl
Dala: 50601 103 1/cyl
:;
50601 11 5 1/cyl
"
Data lor pressure and tolerance (Page 500.35) 50601 127 1/cyl
"
Data lor torque moment (Page 500.40)
Declaration weight (Page 500.45)
95.50 ESOS
506-01.20 Mounting of Piston and Connecting Rod
Working Card
Edition 01 Page 2 (4)
23/30
2) L the piston and conn ecting rod and Mounting Big-end Bearing
mount the piston and scraper ring s, see 14,
and working card 506-01.10. 6) Lower the piston lurlher down, l ubr cate the
ends Ihe bearing shells (as fig. 2) wilh copaslip,
3) Remove Ihe backstop lor cylinder Iiner and molycole pasla similar and mounl Ihe upper shell
place Ihe pislon guide ring l Ihe cylinder Ihe big-end bearing.
liner, see fig 1.
r-~~~--- -
Fig 1.
Fig2.
95.50 - asss
- '' DieseII
Working Card 506-01.20
Page 3 (4) Mounting of Piston and Connecting Rod Edition 0 1
23/30
Note: The ident. . the connecting rod and the
bearing cap must always be the same, see fig 4.
1) Lubricate threads and contact face of the con-
necting rod screws with copaslip, molycote pasta
similar.
Fig3.
Fig5.
Fig4.
95.50 - ESOS
,,],,6' DieseII
23/30
1I the rings are opened lurther than necessary there Belore l itting th e coil spring loaded scraper ring, the
is a ri sk overstressing , which means that rings w ll coil spring is dismantled Irom the ring by removal
become permanently distorted and wll not conlirm th e joint pin.The coil sprin g is placed and assembled
to the inner running surface the cylinder. in the ring groove. Then th e scraper ring is litted in
the groove in such a way that the ring joint is approx-
The piston rin gs should be installed with the identi- imately 180 offset to th e spring joint.
lication mark, which is stamped into the ring close
to the ring joints, lacing upwords, see working card Ascertain correct assembling by checking the back
506-01.10 "Pis/on". clearance.The back clearance is sufficient when the
lace the ring is below the groove edge when the
ring is pressed against the bottom the groove.
\, .:;:~: : :~
. gjOint can be moved all th e way round.
95.50 - ESOS
Working Card
Tightening and Check of Connecting Rod Screws
506-01.25
Page 1 (3) Edition 01
23/30
Description:
Related Procedure:
Data:
95.50 -ESOS
506-01.25 Tghtening and Check of Connecting Rod Screws
Working Card
Edition 01 Page 2 (3)
23/30
1st Step:
Mark
5crew collar
Tightening the screws tightening order, illustrated
fig 1, using an initial torque 250 Nm . Mark
bearing cap
Fig2.
4th Step:
--
<
Check the screw tightening prescribed order using
a torque 325 Nm.
--
5th Step:
3 4
Checkof Connecting Rod Screws,Tightening
Condition:
95.50 - ESOS
Working Card 506-01.25
Page 3 (3) Tghtening and Check of Connecting Rod Screws EdiIian 01
23/30
order ensure observation any movement, the Any turning Ihe screws during Ihe 325 Nm lest
screws and Ihe connecling rod should be applied wilh indicates insufficient tightening condition, and this
coinciding l- marks the test, see fig 3. case Ihe big-end assembly has 10 be dismantled and
invesligated lor evaluati on and correction la lure.
Mark
screw callar
Cainciding
mark
bearing cap -
Fig3.
Fig4.
95.50 - ESOS
f,!,j,tH'lMAN Dieserl
Working Card 506-01.25
Page 1 (2) Hydraulc Tghtening of Connecting Rod Screws Edilion 04
23/30
Description:
Starting Position:
ReIated Procedure:
Data:
00.28 -ESO
/ i( DieseII
23/30
00.28 - ESO
',,,.J DieseII
WorkIng Card 506-01.30
Page 1 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edilion 01
23/30
Stopped engine Plate Item Note
Shut-off starting air
Shut-off cooling water 52006 070
Shut-off l l
Shut-off cooling l
52006
52006
224
273 80-360 Nm
Relaled procedure:
Dala:
96.30 - ESOS
506-01.30 WorkIng Card
EdiIion 01 In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
L23/30
Fig 1. Fig2.
96.30 - ESOS
Worklng Card 506-01.30
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 01
23/30
9) Clean aII components, see workng card 506- Tghtening Connecting Rod Screws
01.20.
18) Tighten the screws accordng 10 "Tighlenng
Procedure lor Conneclng Rod Screw", see workng
Mounting Upper Bearing Shells card 506-01.25.
96.30 - ESOS
''!: DieseI!
Working Card
Inspection and Honing of Cylinder Liner
506-01.35
Page 1 (4) Edition 01
23/30
Stopped engine
Shut-off starting air
Plate Item Note
Shut-off cooling l 52006 606 275-300 mm
Stopped lub. l circul.
Descriplion:
Relaled procedure:
Dala:
96.04 - ESOS
'}'i DieseI!
506-01.35 Inspection and Honing of CyIinder Liner
Working Card
Edilion 01 Page 2 (4)
23/30
80 160 rpm.
Fig 1.
96.04 - ESOS
Working Card
Inspection and Honing Cylinder Liner
506-01.35
page 3 (4) Edition 01
23/30
96.04 - ESOS
"80' tr6/0SZSH/OO-BZOSO
<J)
C>
<J)
> W
<n;;t
0- g
0> "- <ri
c
Engine type Report . >
:tg
~.
Measurement of Cylinder Liner Engine . EncI. .
Cy. . 1 2 3 4 5 6 7 8
Cyl.liner den .
...
Running hours
L
e
c: n
:::
...
I ~ :< J
9
t
h
w
C
"
c: .,. s
e
>- ~
-
U
c:
~
C
r
s
s
w
c:
s
e
::::
C lner
"
c: temp.
'c
a:
c: Remarks ...
a.
n
c:
J
~
:: .n
::::
.~
,.... C>
05
~ ~
~
~
ow C\I
..J
.n
. !+!iM'MAN DieseI!
Working Card 506-01.40
Page 1 (2) RepIacement of CyIinder Liner EdiIion 01
23/30
Stopped engine Plate Item Note
Shut-off starting air
Shut-off cooling water 52006 452
Shut-off l l
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Replacement cylinder l.
Hand lools:
Adjustable spanner.
Slarling posilion:
Relaled procedure:
96.27 - ESOS
IM",, MAN DieseI[
506-01.40 Working Ca rd
Edition 01 RepIacement of CyIinder Liner Page 2 (2)
23/30
Dismounting Cylinder n
Fig 2.
96.27 - ESOS
Working Card Grinding of Seal Face 506-01.45
Page 1 (2) Cylinder Liner and Cylinder Head Edilion 01
L23/30
Shut-off sIarting air
Shut-off cooling water 52005 205
Shut-off luel l
Shut-off cooling l
Stopped lub. l circul.
Description:
Starting position :
Related procedure:
95.50 - ESOS-G
506-01.45 Grinding of Seal Face Working Card
Edition 01 Cylinder Lner and Cylinder Head Page 2 (2)
23/30
Grinding l
Fig3.
Fig 1.
1) Loosen the sealing ring in linerflange and take 4) When having ground the contact faces, ! must
! !. be observed th at the gap between cylinder head
and Iiner is no less than 0.5 mm , . . the difference
2) Face-grind the sealing grooves in the cylinder between measurements and must not be less
lner flange, see Fig 2, and the sealing surface on than 0.5 mm, see Fig 4.
th e cylinder head, see Fig 3, with the use ! grinding
pasta and the grinding tool.
95.50 - ESOS-G
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2) Edition 0 1
at Overhaul Heights
23/30
Stopped engine Plate Item Note
Shut-off starting air
Shut-off cooling water 52050
Shut-off luel il 52006 094 2 pieces
Shut-off cooling l
Stopped lub. l circul.
52006
52010
224
011 1I necessary
Cylinder head has been dismounting Irom the Inside micrometer (195 mm).
engine. Feeler gauge 0. 15 - 0.20 mm.
Crankcase open.
Relaled procedure:
Dala:
03.34 - ESO
506-01.50 Dismantling of Piston and Cylinder Lner Working Card
01 Page 2 (2)
Edilion
at Overhaul Heights
23/30
2) MounI the collar on the connecting rod , see 2) Carefully pull the cylinder l ner half-way
pfate 52050, item 045. Ihe frame.
3) Place Ihe pisIon wilh Ihe collar on Ihe cylinder 3) Mounl a special lifting 1001 for cylinder liners
liner. al lw overhaul heights, see pfate 52050, item
033.
4) MounI pull-lifts on Ihe collar.
4) Atlach puII-lifts on the lifting 1001 lor the cylinder
If Then liner, see pfate 52050, item 033.
Ihe overhaul height is dismounl Ihe pislon Irom 5) Take l the l ne r over the camshaft side.
100 lw 10 ll oul pislon Ihe connecting rod, re-
and connecling rod in move the piston and
one piece. Ihe connecting rod
by the pull-lifts.
03.34 - ESO
'I DieseI!
Plate
Page 1 (2) Piston and Connecting Rod 50601 -01
23/30
72050
081
~~ 103
~ 115
127
020'
032
056
139
068
152
140'
97.05 ESOS
'+I,zM'iMAN Dieserl
Plate
50601-01 Piston and Connecting Rod Page 2 (2)
23/30
72050
Item Item
. Deslgnation Benrevnelse . aty. Deslgnatlon Bencevnelse
When ordering spare parts, see al50 page 500.50. Ved besti lling af reservedele, se ogs~ side 500.50.
Only avalJable part of a spare parts kit. Kun tilgoongeHg som en del af et reseredeIssoot.
QtyJC = QtyJCylinder AntaIIC = Antal/Cylinder
97.05 - ESOS
"'. DieseII
PIate
Page 1 (2) Piston and Connecting Rod 50601-02
23/30
900
093
103
115
127
056
139
152
140'
97.05 ESOS
',,/" DieseII
Plate
50601-02 Piston and Connecting Rod Page 2 (2)
23/30
900
Item Item
. Qty. Designation Ben ;ev nel se . . Deslgnatlon Benrevnelse
When ordering spa re parIs, see al50 page 500.50. Ved besIiIling af reservedele, se ogso3 side 500.50.
97.05 ESOS
l
50601-05 Piston and Connecting Rod (Hydraul ic Tightened) Page 2 (2)
23/30
72050
Item Ilem
. Oty. Deslgnatlon Benoevnelse . Oty. Deslgnatlon Benc:evnel se
When orderlng spare parts, also page 500.50. Ved bestil ling af reservedele, se ogsa side 500.50.
= Only aval lable as part of a spare parts kit. tilgrengelig som del af et reseredelssreI.
Oty./C = OtyJCylinder Antal/C = Antal/Cylinder
00.27 - ESO
.J DieseII
Plale
Page 1 (2) Piston and Connecting Rod (Hydraulic Tghtened) 50601-06
23/30
900
c ___ :>
103
115
127
044'
056
139
068 -
~140'
00.27 - ESO
Plate
50601-06 Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)
L23/30
900
Item Item
. Qy. Deslgnation Ben~vnelse . Qy. DesignaIlon Benaevnelse
When ordering spare parts, see al50 page 500.50. Ved beslilling af reservedele, se ogsA side 500.50.
Only avallable as part of a spare parts kit. lilg .engel ig som en del af el reservede l ss.et.
QlyJC = QlyJCyllnder Antal/C = Antal/Cylinder
00.27 ESO
',I,I,.( DieseII
Plate
Page 1 (2) CyIinder Liner 50610-01
23/30
72050 RPM
031
043 ~
97.05 ESOS
M,l}H'(MAN DieseI!
Plate
50610-01 CyIinder Liner Page 2 (2)
23/30
72050
Item Item
. Oty. Designation Bencevnelse . Qty. Oesignation Benrevnelse
When ordering spare parts, see al50 page 500.50. Ved beslilling af reservedele, 5e og5(\ side 500.50.
Only avallable as part a spare parts klt. tilgrengelig som del af reservedelssC'e1.
OtyJC = OtyJCyllnder AnIal/C = Antal/Cylinder
97.05 - ESOS
",, DieseII
Plate
Page 1 (2) Cylinder Liner 50610-02
23/30
900
043
97.05 - ESOS
Plale
50610-02 Cylinder Lner Page 2 (2)
L23/30
900
Item Item
. Deslgnation Benrevnelse . aty. Designation Bencevnelse
When orderlng spare parts, see al50 page 500.50. Ved beslilHng af reservedele, se ogsI side 500.50.
= " available as part of a spare parts kit. Kun tilgrengelg som del af l reserede l ssret.
Qty./C = QtyJCyIInder Antal/C = Antal/Cylinder
97.05 ESOS
Plate
Page 1 (2) Cylinder Liner 50610-05
23/30
031
092 -~
-~-
018 - - - -
043 ~
~"
01.08 - ESO
+, DieseII
Plate
50610-05 CyIinder Liner Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Q. Designation Benrevnelse
When ordering spare parts, see a l50 page 500.50. Ved beslilling af reservedele, se ogsa side 500.50.
01 .08 - ESO
Section 507
Camshaft and Camshaft Drive
Description
Working card
23/30
The camshaft is located in a high level housing Engine seen from aft - fly wheel end
the engine frame.
The camshaft runs replaceable, identical, steel-
backed bronze bushings fitted borings th e
transverse girders the housing.
-- -----'
FIg. 1. Infermediate wheef
94.26 - E50S
WorkIng Card 507-01.00
Page 1 (2) Check of Camshaft and Camshaft Drive EdiIion 01
L23/30
Stopped engine
Shut-off starting air
Shut-off cooling water
Plate no
52006
Item no
261
Note.
20 - 120 Nm.
Shut-off fuel l
Shut-off cooling l
Descriplion:
Relaled procedure:
" Data for pressure and tolerance (Page 500.35) 51106 237 1/cyl.
Data lor torque moment (Page 500.40) 51106 058 1/cyl.
Declaration of weight (Page 500.45) 5 11 06 693
97.06 - ESOU-G
',Ji@,,,,i MANDieseII
507-01.00 WorkIng Card
EdiIIon 01 Check of Camshaft and Camshaft Drive Page 2 (2)
L23/30
1) Dismount the covers which give access the 3) Examine all lubricating l spray nozz
gear wheels, camshalt and crankcase. les.
Examine all gear wheels lor cracks, wear and delor- 4) Start the electrical lubricating l pump and
mations. While turning the engine enable inspec- check theoil I lw everywhere. Be particularly carelul
allover the circumlerence the gear wheels. check that the l jet hits the gear wheels correctly
at the points where the wheels mesh.
2) Check all screws, nuts and bolted connections.
including locking devices everywhere the gear
wheel housing, camshaft housing and crankcase
check that they have worked loose. Tightening
torques, see page 500. 40.
97.06 - ESOU-G
Working Card 507-01.05
Page 1 (2) Inspection and Replacement of Camshaft Bearing Edition Q1 H
L23/30
Shut-oll starting air
Shut-off cooling water 52006 261 20 - 120 Nm.
Shut-off luel l
Shut-oll cooling l
Stopped lub. l circul.
Descriplion:
Relaled procedure:
95.02 - ESOS-G
507-01.05 WorkIng Card
EditIon 01 Inspection and Replacement of Camshaft Bearing Page 2 (2)
23/30
Check Roller Palh of Cams.
Camshaft bearIng
discs and in parlicular, check Ihe roller palh all Hole for lubricaIing l
cams for cracks. crackles and ruffle. Also eamine
the rolle rs Ihe ro ller guides.
Check Ihe lubricaling l ducls 10 Ihe bearing for Mounl all roller guides as well as Ihe fuel l feed
free flow. pump.
95.02 - ESOS-G
Working Card
Adjustment of Camshaft
507-01.20
Page 1 (2) Edition 01
23/30
Descriplion:
Depth gauge.
Slarling posilion:
Dala:
96.30 - ESOS-L
507-01"20 Adjustment of Camshaft
WorkIng Card
Edillon 01 Page 2 (2)
23/30
Roller guide
ehaust valve
Cam for fueJ .- FIg2.
l pump
96.30 - ESOS-L
I,I'l}g..'( MAN DieseI!
Plate
Page 1 (2) Intermediate WheeI 50701-01
L23/30
, 288
~ 181
144
048
168
132
264
" - 227
024
120 %------- 215
203
~- 239
215
061+
193
94.22 ESOS
",.f DieseII
Plate
50701-01 Intermediate WheeI Page 2 (2)
23/30
Item Item
. Qty. Design ation Bencevnelse . Oty. Designation 8encevnelse
239 1 / Ror
When ordering spare parts, see also page 500.50. Ved beslilling af reservedele. se ogsa side 500. 50.
On ly avai lable as part a spare parts kit. Kun tilgrengelig som en del af et reservedelssret.
OtyJE = OtyJEnglne Antal/E = AntalfMotor
94.22 ESOS
',l+tN'iMAN DieseII
PlaIe
Page 1 (2) Camshaft and Camshaft Bearing 50705-07
23/30
'JL).j!.--------- 217
325 051
' ----/ -:::::..;;:~ --
337 063
349
350
026 362
229
230
242
063
026 --__
075 254
266
278
109
099
087
134
146 11
158 038
291
171 301
313
183
195
205
99.4 1 - ESO
1,:,:,'!III DieseII
PlaIe
50705-07 Camshaft and Camshaft Bearing Page 2 (2)
L23/30
Item Item
Designatlon Bencevnelse
Deslgnatlon Ben a!vnelse
026 4/ Camshaft, aftfnterme- Styreaksel agter/mel- 230 1/ Camshaft "aft" Syreaksel, agler
dlate. 5 cyI. englne lem, 5 cyl. motor 7 cyI. engine 7 cyI. rnolor
038 1 / Camshaft "fo re " SIyreakseI "Ior" 242 1/ Camshaft "aft" Sty reaksel, agter
5 cyl. englne 5 cyt. moor 8 cy. engine cyl. moIor
099 10/ Sprlng washer Fjederskive 301 1 / Camshaft "fore" Styreaksel "for"
7 cyl. engine 7 cyl. motor
109 1 0/ Screw Skrue
313 l Camshaft "fore" Styreaksel "Ior"
110 Self locking nut Selvl ~se nde m0trik 8 cyl. englne 8 cyl. motor
50/ 5 cyl. engine 5 cyl. motor
40/ 6 cyl. eng ine 6 cyl. moIor 325 1/ Camshaft complete, Slyreaksel komplet,
52/ 7 cyl. englne 7 cyl. moIor 6 cyl. eng, inci. item 6 cyl. molor Inkl. Item
66/ 8 cyl. engine 8 cyl. motor 109, 11 , 122, 134, 146, 109, 11 0,122,134,146,
158, 171 , 183, 195,205, 158.171,183,195,205,
122 1 / Hub Nav 229,254,291,374 229.254.291,374
217 1 / Camshaft, compl ete Styreaksel komplet, 362 Packlng rlng Pakningsring
for 5 cyl. engine, incl. 5 cyt. molor, inkI. Ilem 6/ 5 cyl. eng ine 5 cyl. moIor
item 026, 038, 109, 11 , 026.038. 109. 110. 122. 7/ 6 cyl. englne 6 cyl. motor ~
,.;
122,134,146, 158, 171 , 134,146,158,171,183, 8/ 7 cyl. engine 7cyl. moIor
183,195, 205, 374 195, 205. 374 9/ 8 cyl. engine 8 cyl. moIor
~'"
~
229 1 / Camshaft "aft" Styreaksel, agter 374 1/ Shaft Aksel ~
When ordering spare part5, see al50 page 500.50. Ved besIiJling af reservedele, se ogsa side 500.50.
Only avallabl e as part a 5pare parts kit. tilgcengelig som del af et reseredelsscel.
QtyJE = QtyJEngine Antal/E = AntalfMotor
99.41 - ESOS
,,:,:,,, MAN DieseII
PJaIe
Page 1 (2) Camshaft and Camshaft Bearing 50705-17
23/30
))J.J'----r- 217
325 051
337 063
349
350
026 362
229
230
242
063
026
075 254
266
278
109
099
087
134
146 11
158 038
291
171 301
313
183
195
205
05.24 - ESO
,:,:,:,l'[ DieseII
PIate
50705-17 Camshaft and Camshaft Bearing Page 2 (2)
23/30
Item Item
Oty. Designation Bencevnelse Oty. Oeslgnation Bencevne lse
038 1 1 Camshaft "fore" Styreaksel fo, 242 1/ Camshaft "aft" Styreaksel, agter
5 cy!. englne 5cyl' rnotor 8 cyl. engine 8 cy!. molor
When ordering spare parts. see also page 500.50. Ved bestilIing af reservedele, se ogsA side 500.50.
= avai IabIe as part a spare parts kit. tilgrengelig som deI af reserede i ssaat.
OtyJE = QtyJEngine Anla1/E = Antal/Motor
05.24 ESO
5ection 508
Operating Gear for Vale and
Fuellnjection Pumps
Description
Working card
Plates
23/30
Roller Guides
The luel injection pumps and the rocker arms lor inlet
and exhaust valves are operated by the cams, the
camshaft through roller guides. The roller guides lor Valve bridge Rocker arm
luel pump, inlet and exhaust valves are located
bores a common housing for each cylinder, this
housing is bolted to the engine Irame.
The movment Irom the rol ler guides lor inlet and Roller
ehaus t is transmitted via the push rods the rocker
Camshatt
arms and spring-Ioaded valve bridges to each
th e two valve seats. Th e bridge is placed between
the valve spindles and the one end it is provided
with a pressed-on thrust shoe and the other end Fig. 1. Vafve Operating Gear.
it is litted with a thrust screw for adjustment the
valve clearance.
08.17 - ESOS
,, DieseII
23/30
Descriplion:
Relaled procedure:
08.17- ESO
Mi.I(MAN DieseII
508-01.00 Working Card
EdiIion Inspection VaIve Roller Guides Page 2 (2)
23/30
Dismounting Roller Guide. 5) Dismount the screws (3) which secure th e roller
guide coer, take off the coe r l out the roller
1) Turn the engine so that the roller, rests the guide (5).
circular part th e cam.
Disconnect any pipes that may be the way (Iub.
2) Unscrew the nuts which secure th e rocket arm l
and fu el l pipes).
brackets, and l off the rocker arm with brackets.
6) 1I the roller guide housing is be dismantled,
3) Remoe the push rods (1), see fig 1. the luel injecIion pump and the luel injection pump
roll er guide are to be dismounted, see working card
514-0 1.05 and a number al lubricating l and luel
l pipes are also be disconnected.
08.17 ESOS
+ DieseI!
Working Card
Inspection of FueIInjection Pump RoIIer GUde
508-01.05
Page 1 (2) Edilion 01
23/30
Stopped engine
Shut-off startIng air
Shut-off cooling waler
Plate Item Note
Shut-off fuel l
Shut-off cooling il
Descriplion:
Relaled procedure:
Dala:
96.03 - ESOS
DieseI!
23/30
Make sure that there is Iree ply between the roller
and the bush and the shaft , and replace the bush
l necessary.
96.03 ESOS
Working Card
Control and Adjusting of Valve Clearance
508-01.10
Page 1 (3) Edition 01
23/30
Stopped engine Plate no Item no. Note
Shut-off starting air
Shut-off cooling water 52008 022 Ehaust
Shut-off fuel l 52008 010 Inlet
Shut-off cooling l 52010 011
Stopped lub. l circul.
Descriplion:
Slarling posilion:
Relaled procedure:
Dala:
Data lor pressure and tolerance (Page 500.35) See also plate 50502.
Data lor torque moment (Page 500.40)
Declaration weight (Page 500.45)
96.38 - ESOS
508-01.10 Working Card
Edition 01 Control and Adjusting of Valve Clearance Page 2 (3)
L23/30
-------
Adjusting Inlet Valve Clearance.
Fig2.
Fig.1.
7) Adjust the clearance beIween valve bridge and
valve spindle by means th e adjusment screw
the valve bridge, and tighten the lock , see fig
3) Clearance beIween valve bridge and valve 2.
spindle, see page 500.40.
8) Checkthatthe clearance is correct simuItaneo-
4) Place the leeler gauge marked with "correct" usly at both valve spindles.
0,50 mm above the valve spindle nearest the
rocker arm bracket, see fig 1.
96.38 - ESQS
,, ,,,t MAN DieseII
Working Card
Contro! and Adjusting of VaIve CIearance
508-01.10
Page 3 (3) Edition 01
23/30
Fig3.
96.38 - ESOS
ptate
Page 1 (2) Roller Guide and Push Rods 50801 -07
L23/30
268
293 303
268
185
173
185
090
219
11 2
197
124
207
089
148
100
281
028
077
053
041
053
065 065
~ 244
.; 256
"
v
~ 016+
~
~
161
'!
136 232
"
"
08.16 - ESO
Plale
50801-07 Roller Guide and Push Rods Page 2 (2)
L23/30
Item Iteln
. Qty. Designation Benmvnelse . Qty. Deslgnatlon Benc:evnelse
016+ 1/C Housing for Hus ' 315 1/C Valve gear complete, Vent il bevegelse
roHer guides rulleslyr as s hown plate komlet, som visl ~
50801 exce pt Item plale 50801 undtagen
028 1/C Roller guide for Rulleslyr 'or pu me 161 ,173, 185,220,232, ilem 161,173,185,220,
pump 244,256,303 232,244,256,303
053 31C Bush Foring + Item 016 requlre + Ilem . 016 krever
IndIvldual match- individuel tilasning
065 3/C Roller Rulle ing before mounting, f0r montering, konlakt
contact Dlesel Diesel
077 31C Lock screw Pinolskrue
When orderlng spare parts, see also page 500.50. Ved beslilling af reservedele, se ogs~ side 500.50.
l aval lable as part of a spare parts kit. lilgeng e li g som del af el resered el sse l.
QtyJC QtyJCyllnder Antal/C = Anlal/Cylinder
08.16 - ESO
Section 509
Control and Safety Systems
Description
Plates
Thermometer 50907.09
Lambda ControIIer 5090802
PreIubricating AIarm ( 25) 5091901
LeveI Switch Sump (L 28) 5092013D
LeveI Switch Sump (L 28) 5092013
LeveI Switch Sump ( 28) 5092014
LeveI Switch Sump (Dipstick ) 5092015
FueI Leakage AIarm ( 42) 5092508
LocaI Stag 1 5093511
LocaI Stag 2 5093512
LocaI Stag 2 (incl. high Iub. temp.) 5093513
Engine ControI 5093513
TerminaI 5093620
Motor ControI 5094801
Cveer 5095601
Oescltion 509,01
Page 1 (2) Control and Safety Systems Edition 01
23/30
Pick-up for Turbocharger The overspeed tripping device is fitted the end
cover th e lubricating l pump and is driven
See Urbocharger instruction book, section 5 12. through this pump.
The spring-Ioaded l l rod permits the governor the same time th e arm (2) presses down the
give ll deflection the stop cyli nder ! the spindle (5), and the pneumatic valve (6) opens,
manoeuvring system keeps the fuel pump regulating whereby compressed air w ll be led th e Lambda
shaft at 'no fuel' position. cylinder. see descri ption 509. 10, which th e piston
is pressed lorward and, through the arm, Urns the
Each fuel pump is connected the common , lon- luel pump regulating rod STOP position, thereby
giudinal regulating shaft by means ! a two-piece, the engine stops, the spring-Ioaded ll rod con-
spring-Ioaded arm. nection the governor being compressed.
96.38 - ESOS-G
509.01 OescrIption
Editlon 01
Control and Safety Systems Page 2 (?)
23/30
1. Flyweight
2. Arm
3. Lock
9
4, SprIng
5, Spindle
6. PnemalIc valve
Overspeed
actIvaled 7. ul
8, Lever
9. micro swIlch
10. t
2 5 3 4 10 10
96.38 . ESOSG
Desc r ptIon 509.05
Page 1 (3) Instruments and Automatics Edition 01
L23/30
As standard the engine is equipped with an instru- The instrument panel is mounted flexibly rubber
ment paneI, comprising instruments visual indi- elements and aII manometer connections are con-
cation the most essential pressures. nected the panel by means flexible hoses, as
Illustrated I;g. 1. shown I;g. 2.
00
11
00
11
FlexIble hose
-=
00
11
Rubber etement
QQ Q Valves
QQ QQ
l Push button
The following incorporating preSSlIre gauges the mosl Fig. 2. Cross section insIrument panel
essentIal pressures.
PIessure gauge :
96.03 - ESQS
!/( Dieserl
509.05 Instruments and Automatics
DescrrpIioll
Page 2 (3)
Editron QIH
23/30
ThermomeIer 30 Charge ll 10 cooter Waste and leak l from the comparemen t, for the
herffiomete r 31 Charge l - outlet from coler injection equipment. fuel valves, high-pressure pipes
Thermometer 140 Fuel l - ll 10 engine and engine feed pump ( mounted) is led a ll
Thermomeler 60 Exhaus! gas - outlel each cYIInder leakage alarm .
ThermomeIer 61 Exhausl gas - ull turbocharger
96.03 - ESOS
DescripIIon
Instruments and Automatics 509"05
Page 3 (3)
Edition 01
23/30
The alarm unit consists a b o wi th a Iloat switch Alarm 'or Prelubricating (LL 25)
lor l ee l monitoring, see {ig. 4.
Alarm lor missing prelubri cating, wh en the engine
The supply luel l the engine is led through the is stopped is given by means a leel swi tch (LL
unit in order keep heated , thereby ensuring 25) mounted the main lubricating l .
Iree drainage passage lor high-viscous wa-
ste/leak l.
Alarm and Shut-down 'or Overspeed
Under normal conditions there l l always be a smal-
ler amount waste/leak l Irom the comparement, When the mechanical overspeed is actIvated, see
this ill be led through the bore "" the 509.01 {ig. 2, a micro-switch ll release the alarm
" " as illustrated. lor overspeed (SAH 8 1) and activate the shut-down
solenoid the governor.
case a larger than normal leakage, the leel
the bo ll rise and the level switch "C" ll be The latter lncton is a back-up lr the mechanical
activated. The larger amount leak l l l be lead overspeed .
through the the "" .
96.03 ESOS
'$2, .f DieseII
Descri ption
Lambda ControIIer 509.10
Page 1 (2)
Edition 09
23/30
Reduction visible smoke case sud- During th e start procedure the lambda controller is
den momentary load increases. used as an index Iimiter.
04.15 - ESO-G
509.10 Lambda Controller Desc rptlon
Page 2 (2)
EdiIIon 09
23/30
1. Regulating arm
2. Switch (Pick-u)
3. Piston
4. Solenoid valve
5. Lambda controller
6. Overseed device
(mecanical activated 3/2 valve)
5 Charge air
receiver
3
2
1
"'=<
4 Engine's
compression
air system
04.15 - ESO
Description 509,35
Page1(1) Starting
Edilion 01
23/30
The starting box is mounted the engine's control activating the "Engine RPM/TC RPM ' button, the
side. Iront the box there are the lollowing indication is changed.
indications/pushbuttons:
Engine RPM indication is green light-emitting diodes
Indication engine turbocharger RPM and turbocharger RPM indication is red light-emit-
Indication electronic overspeed ting diodes.
Pushbutton ' Manual Start'
Pushbutton ' Manual Stop" ExIernal Indications
Pushbutton ' Remote'
Pushbutton lr "Local' There are signals engine RPM and tur-
Pushbutton lr ' Blocking' bocharger RPM.
Pushbutton lor change-over between engine Engine: 1200 RPM - 4-20 mA
and turbocharger RPM TC: - 60000 RPM - 4-20 mA
The luncton chosen is indicated the pushbut- The pushbuttons lor "Remote", "Local' and 'Block-
ton. See lig 1. ing' have potential Iree switches eternal indi-
cation.
Manual Start
components the starting box are wired the
Th e engine can be started by means the start built-on terminal bo.
button, but only l the button "Local' is ac tivated.
(3
- ,-- --- -
~w
Manual Stop
Blocking
94 .26 - ES2S-G
Description 509.40
Page 1 (1) Converter for Engine- and Turbocharger Signal
Edilion 01
L23/30
Engine signaI The ' engine ' signalswill be given through a relay.
One lor synchronizing and lor start!stop pre.
For measuring the engine's RPM, a pick-up mounted l b. l pump alarm blocking at start/stop.
the engine is used giving a Irequencydepending
the RPM. be able show the engine's RPM
an analogue tachometer, the Irequency signal Safe start
is sent through an f/I converter (Irequency/current
converter), where the signal is translormed a When the sale start signal is activated th e engine
proportional 4-20 mA - 0-1200 RPM signal. can start. When the engine reac h 140 RPM the air
starter ll be shut-oll.
Further, the converter has lollowing signals:
Further, the sale start signal is a blocking luncton
overspeed lor the air starter during rotatIon.
engine run
sale start
tacho lail Tacho faiI
Engine
96.30 - ES2S-G
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2)
Alarm and Monitoring Equipment Edilion 01
23/30
Description
Starting position
Related procedure
Data
03.32 ESO
509-01.00 Functional Test and Adjustment Salety, Worki ng Card
Edilion 01 Page 2 (2)
Alarm and Monitoring Equipment
23/30
Maintenance monitoring and salety sy For check these lunctions use the working card s
stems mentioned under related procedure page 1.
03.32 ESO
DieseII
23/30
Descriplion:
key, 4 mm.
Allen key, 2 mm.
Slarling posilion:
Relaled procedure:
Dala:
96 .03 - ESOS-G
}%,"l DieseII
L23/30
1) The engine is run manually, (on governor the engine l the adjusting screw is opposite
'synchronizer') and at load, while watching the the opening the side ! the housing. w loosen
tachometer. the lock screw and turn the adjusting screw, using
the tubular spanner supplied, see fig 2.
On reaching the revolution number indicated
page 500.30 'Test Report" the overspeed
ping device must function, thus actu ating the stop
cylinders. The fuel injection pump control rods are
now moved zero index, and the engine stops.
FIg2.
96.03 - ESOS-G
.:,,' DieseII
WorkIng Card 509-05.00
Page 1 (2) Adjustment and Test of On/Off Pressostate Edilion 01
L23/30
Stopped engine
Shut-off starting air
Plate Item Note
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Screw driver.
Testing pump.
Ring and open end spanner, 1 mm.
Slarling posilion:
Relaled procedure:
Dala:
91.45 - ESOSG
' '( DieseII
509-05.00 Adjustment and Test of On/Off Pressostate
WorkIng Card
EdilIon 01 Page 2 (2)
23/30
Adjustment:
1. TrIal flange.
2. Drain screw.
3. Valve.
1. Range spindle.
2. Range scale.
3. Differenlial spindle.
4. DifIerentIal scale. FIg2.
5. Locking screw.
It is possible make a functional test of the pres- Alarm for Rising Pressure:
su re switch. This is be carried according
th e following procedure. 7) Pump th e pressure l the switch chang-
es, and check that happens at the stated alarr
3) Shut off system pressure with the valve pos 3, !.
fig 2.
8) After the final check and adjustment, remove
the testing pump, mount the screw pos 2 and
the valve pos 3.
91.45 - ESOSG
Working Card
Adjustment and Test of On/Off Thermostate
509-05.01
Page 1 (2) Edition 01
23/30
Shut-off fuel l
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Screw driver.
Special testing devices.
Slarling posilion:
Relaled procedure:
Dala:
96.26 - ESOS-G
, DieseI/
23/30
Adjustment: Test:
1) When the thermostate cover iS removed and 3) The funcional test of the thermostate is be
locking screw pos. 5, fig 1 is loosened, the range carried according the following procedure.
can be set with the spindle pos. 1 while at the same
time the scale pos. 2 is read. 4) Take the sensor of the pocket.
96.26 - ESOS-G
WorkIng Card 509-05.02
Page 1 (2) Function and Test of Level Switch (LL 25) Edition 0'1
L23/30
Stopped engine
Shut-oll starting air
Shut-oll cooling water
Plate no. Itemno. Note
Shut-off luel l
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Slarling posilion:
Relaled procedure:
Dala:
91 .03 - ESOS-G
509-05.02 WorkIng Card
Edition 01 Function and Test Level Switch ( 25) Page 2 (2)
23/30
13/
Function.
Test:
91.03 - ESOS-G
Working Card 509-05.03
Page 1 (2) Adjustment and Test of Analogous Pressure Transmitter Edition 01
L23/30
Stopped engine
Shut-off starting air
Plate Item Note
Shut-off cool ing water
Shut-ofl luel l
Shut-off cooling l
Descriplion:
Slarling posilion:
Relaled procedure:
Dala:
91.45 - ESOS-G
509-05.03 Wrking Card
Editin Q1H Adjustment and Test of Analogous Pressure Transmitter Page 2 (2)
23/30
1.
2.
TrIalllange.
Drain screw.
_ j If the alarm plan t has an instrument unit, the pres-
sure can be read this. Other wise the test can
be carried out by watching ! the alarm plan t gives
,--_
3. v_aIve. _ _
any alarm, when the alarm lm t which is stated
an page 500.30 is exceeded (! the alarm plant is
adjusted).
Fig 1.
9 t .45 - ESQS-G
Working Card Adjustment and Test of 509-05.04
Page 1 (2) Edition Q1H
Analogous Temperature Transmitter
23/30
Descriplion:
Slarling posilion:
Relaled procedure:
Dala:
96.26 - ESOS-G
509-05.04 Adjustment and Test of WorkJng Card
EditIon 01 Page 2 (2)
Analogous Temperature Transmitter
L23/30
The 100 sensor consists a resistance wire Otherwi se the test can be carried by watching
which changes resistance depend ing the tem- l the alarm plant gives any alarm , when Ihe alarm
peratre. limit which is stated an page 500.30 is eceeded
(l the alarm plant is adjusted).
Look and design varily depending the place
measurement and manulactre. 5) The sensor is mounted again.
Adjustment:
Test:
96.26 - ESOS-G
i,,@'.if Desel
Workiflg Card 509-10,00
Page 1 (3) Lambda ControIIer Edition 13
23/30
Starting position
Related procedure
Data
03.13 - ESO
+' DieseII
509-10.00 WorkIng Card
Edition 1 3
Lambda Controller Page 2 (3)
23/30
~--~-- 3
4
1. Band stee!
2. Pick-up
3. RegulaIing arm
1. Lambda cylinder 3. Adj ustment screw
-.
:;;
c e
~ ~ 3
2) Turn the lever (Iig 2) the governor a few
2 times to lull load with an adjustable spanner
(spring between governor and luel rack fu ll
com-pressed). Check thal the luel index is 17
Fig 1 Check of free sace at Ihe fue l pump.
~::i:~~I ~l
Stop screw
4) Adjustmenl compleled.
7) Turn Ihe lever (Iig 2) the governor lullload
with an adjustable spanner. Adjust the slop
screw (Iig 2) 10 110% load (slalionary 100%)
Fig2 Adjustment Qf the stop screw according 10 Ihe test bed, plus 1.5 index.
03.13 - ESO
WorkIng Card
Lambda Controller
509-10.00
Page 3 (3) Edition 13
23/30
Use the index arm on th e luel injection pump Note : In case start lailure due to wear the luel
nearest to th e lambda con troller as the control pump, the start index must be raised to a higher level
lor the index. by turning the self-Iocking nut anticlockwise.
03.13 - ESO
+:( DieseI!
Plale
Page 1 (2) Governor and Governor Drive 50901-21
23/30
393
~ 415
403
439
f~ 141
~ 153
~ 165
189 ~~-- 177
100 ro3
200 _________ 'Q' __
____ ~ 045
o~ 224
212 + ~- _____
057 ~
i-"':::::::::':') ~ 236
[:261 248
273
~ 285
m.YM-.l.. 297
:-""'--'J _ /L--- 307
332
320
06.44 ~ ESO
Plate
50901-21 Governor and Governor Drive Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Benaevnelse . Qty. Designatlon Benrevnelse
070 1 / O-rlng 0- 9
+ Item . 212 requlre + Item nr. 212 krrever
082 1 / Castle Kronernatrik an Indlvldual m atc h ~ en individual Iilpasn ing
Ing (by shIms) before (med shims) for monte-
094 1 / Spllt l Splil mountlng , contact, ring, kontakt B&W,
B&W, Holeby Holeby.
141 1 / Shlm (set 0,1 - Mellemlceg (se I 0,1 -
0,3 0.51,0 mm) 0,30,5 - 1,0 mm)
189 1 / Feder
248 1 / Plug
332 1 / feder
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs~ side 500.50.
= Only aal l ab l e as part of a spare parts klt. tilgrengelig som en del af et reseredelssrel.
QtyJE = QtyJEnglne AnIal/E = Anlal/Molor
06.44 - ESO
Plale
Page 1 (2) Governor and Governor Drive 50901-22
23/30
021 -~ l - - - - 104
!!!/-\...--- 153
@ - - 165
189 f
190
177
033
200 ~
045
o~ 224
212+ - ___
057 ~
~~~~ 236
~ 273
r:t:-- 248
261
~ 285
flm,1WJ:;(, 297
" ,,-,, "Sh _ - 307
332
320
06.32 - ESO
Plate
50901-22 Governor and Governor Drive Page 2 (2)
23/30
Item Item
. Designation Benrevnelse . Designation Benre vnel se
200 1 / S l Split
236 21 l 8Iift
When ordering spare parts, see a/5o page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
Only aval lable as part of a spare parts klt. tilgrengelig som del af et reservedels$Get.
OtyJE = OtyJEngine Antal/E = Antal/Motor
06.32 ESO
DieseII
Plate
Page 1 (2) Governor and Governor Drive 50901-23
23/30
For actuator,
see speciaI
instruction book
116
141
~>---- 153
~ 165
189 ~ 177
190
033
200 ~
045
o~ 224
212+
057 ~
069 ~ .. -r-~""1 ~ 236
070 ~
082
1
~
1:261 248
273
285
f!{J!:;; 297
~- 307
332
320
06.45 - ESO
"J,I,tHiI MAN DieseI[
Plale
50901-23 Governor and Governor Drive Page 2 (2)
23/30
Item Item
. Deslgnatlon Benatvnelse . Deslgnation B e B
057 4/ Motrik
+ Item .212 requlre + Ilem nr. 2 12 krcever
069 2 Stud Tap an individual match- individual Iilpasning
ing (by shims) before (med shims) for rnon-
070 1 / 0-rln9 0-rln9 mounting, con tac t, tering, kontakt
Diesel /5 . D S l A/S.
082 1 / Castle nut Kronemolrik
236 21 l Stifl
When ordering spare parIs, see also page 600.50. Ved bestiJling af reservedele, se ogsf side 600. 50.
= Only ava llable as part of a spare parts klt. tilgrengeHg som del af et reservedel sseI.
QtyJE = QtyJEngl ne AnlaVE = Antal/Molor
06.45 ESO
l~H!'lMAN DieseI!
Plate
Page 1 (2) ReguIating Deice 50902-06
23/30
-------
::: --~~~
.
052 ?t~:
088 --.// .
111 ~ /
123 - /
076
135 ---.-/
147
159
160 /
11 R
~ 243
064
172 -
184 - / ;,.
' ...._~_
11
196 ---// / / , 255
206 ~'! . .!~~ 267
218 -
231 /1- " ~ 027
279
08:52 ~ ~ 280
040 / ~ 292
- -~.
302
363 ~
375 ~~, '-- _____ 326
, ""-- 351
~see
am 10
bda controller
plate 509
387
i - / 338 745
314
~~::
. ~ 422
399 /' 757
409 769
410 , 434
/ '-- 446
~
o . ~ 458
483 ~ '" 471
495
530
U 542
<!:r--'---.. 554
06.45 - ESO
f,J,J,@II'fMANDieseII
Plate
50902-06 Regulating Device Page 2 (2)
23/30
Item Item
. Qty. Deslgnatlon Benrevnelse . Qty. Deslgnatlon Benmvnelse
064 21 Screw for ball head Skrue for kuglehoved 399 1/C Pln 51
076 1/ Sprlng loaded ll Fjederbelastet t rek - 409 1/C Sprlng arm Fjederarm
rod, complete stang, komplet
410 1/C Spring Fjeder
088 21 ll rod head Trcekslangshoved
422 3/C Spring n Fjederstift
111 1/ Splt SpliI
434 1/C Armholder Armhotder
123 1/ Pull rod end Trcekslangsende
446 1/C Screw Skrue
135 1/ Cylindr/cal ln Cylind risk 51ift
458 1/C Bushing Bosning
147 1/ Spring housing Fjederhu5
471 1/C Bearing bracket Lejebfik
159 1/ Po/nted screw PinoJskrue
483 21C Spring Fjederstift
160 1/ Spring Fjeder
495 21C Screw Skrue
172 1/ Cylindrical Cylindrisk sllft
530 21 Screw Skrue
184 1/ Gulde rlng Styrering
542 21 Screw Skrue
196 1/ Guide ring Styrering
554 21 Washer Skive
206 1/ rod Traakslang
566 21 Nut Molrik
218 1/ ! Molrik
578 1/ Bracket Konsol
231 1/ Locking plate Lfseb lik
745 1/ Regulating shaft, Reguleringsa ksel,
243 1/ Arm Arm 6 cyl. engine 6 cyl. motor
When ordering spare parts, see a/so page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
Only avallab/e as part of a spa re part klt. tilgaangelig som en del af et reservedelssaat.
QtyJE Qty./Engine =
l/ Antal/Motor
QtyJC QtyJCyllnder AntaVC = Antal/CyIinder
QtyJR = QtyJRegulating device AntaVR = Antal/ Reguleringsmekanisme
06.45 - ESO
, ~'H:'!IIIMAN DieseII
Plale
Page 1 (2) ReguIating Device 50902-07
23/30
052 -
040 J
~ 280
292
363 ~~
302
375 ~/ ~ 326
Lambda controIIer
see pIate 5091
387 ~ / 351
/~A
~''> ~ "--- 422
338 314
399
409 ~ 745
757
410 ' ~"'-- 434 769
446
483 --~
,-- - '" " 458
471
495 ---------
530
U
@r--'~ 554
542
566
'---'- - 578
06.45 - ESO
I,,l$'MAN DieseI[
Plate
50902-07 ReguIating Device Page 2 (2)
23/30
Item Item
. aly. Deslgnatlon Bencevnelse . aly. Deslgnatlon Benmvnelse
064 21 Screw for ball head Skrue for kuglehoved 399 1/C Pln Stjfl
076 1 / Sp rlng loaded l FjederbelasleI trrek 409 1/C Spring arm Fjederarm
rod, complete 51an9, komplet
410 lIC Sprlng Fjeder
088 21 U rod head Trreksrangshoved
422 3/C Spring Fjederstift
111 1/ Split Split
434 1/C Armholder Armholder
123 1 / U rod e nd Trrekslangsende
446 1/C Screw Skrue
135 l Cyllndrica l Cylindrisk stif!
458 1/C Bushing Besning
147 1 / Sprlng houslng Fjederhus
471 1/C Bearing bracket Lejeblik
159 1/ Polnted screw Pinolskrue
483 21C Sprlng l Fjederstift
160 1 / Spring Fjeder
495 21C Screw Skrue
172 1 / Cyllndrlcal l Cylindrisk slift
530 21 Screw Skrue
184 1/ Guide ring SIyrering
542 21 Screw Skrue
196 1/ Gulde ring Styrering
554 2/ Washer Skive
206 1 / ll rod Trcekstang
566 21 l r k
218 1/ Nul Motrik
578 1/ Bracket Konsol
231 1/ Locking plate LAseblik
745 1/ Regulating shaft, Aeguleringsaksel,
243 1 / Arm Arm 6 cyl. englne 6 cyl. motor
When orderlng spare parts, see also page 500.50. Ved beslilling af reservedeJe, se ogs:' side 500.50.
= Only avail able as part of a spare part klt. ti lgengelig som en del af et reservedelsset.
aly./E OtyJEnglne AntaIIE = AntaVMotor
alyJC OtyJCylinder Antal/C = AntaVCylinder
alyJR OtyJRegulating device AntaVR = AntaVReguleringsmekanisme
06.45 ESO
Plale
Page 1 (2) Overspeed Device 50903-02
23/30
D ______ ~~~
~_ _ _ 034
s-_ - - - - 046
~ ~ 058
~~ 071
~ ?fj- ~~~
095 ---11 ?; 117
-i3~ 1 29
r 130
142
178J~ ~)~
' 154
191 -:../ 166,524
ID-- 201
500 -~ ~, ______ 213
237
~ ~ 225
249 . 262 ~
286
512 489
~ 490
[-mt
06.45 - ESO
f,II@lIiMANDieseII
Plate
50903-02 Overspeed Device Page 2 (2)
23/30
Item Item
. Oly. Deslgnation Benrevnelse . Oly. Deslgnation Benrevnelse
191 1 / Flywelght Svingvregl 512 1/ Spare parts kit for Reservedelskit for
item 489 item 489
201 1/ Key
524 1/ Spring Fjeder
213 1/ 8all bearing Kugleleje 900 rpm 900 rpm
237 1/ Cover O e k se l
262 l l 81
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
= Only ava il able as part of a spare parts klt. tilge ngeli g som en del af l res erve d e l ssel.
Oty./E = OtyJEngine Antal/E = Antal/Motor
06.45 ESO
'i( DieseII
Plale
Page 1 (2) Instrument PaneI 50905-07
23/30
143
322
310
765
00
o
309
202 192
299
180 753
179
263 226
167
226 ---:9,'t;i ~:Jt::::;- 287
238
F)r 728
()
" "
/ 741
11'-; -'
96.29 . ESOS-G
',I,l.f DieseI!
Plate
5090 5-07 Instrument PaneI Page 2 (2)
L23/3 0
Ite m Item
Qty. Deslgnatlon Bencevnelse Qty. Designation Benrevnelse
263 1 / Plpe
When orderlng spare paris , see aJso page 500.50. Ved bestilling af reservedete, se ogsa side 600.50.
96.29 - ESOS-G
!+l$M MAN DieseI!
Plate
Page 1 (2) Instrument PaneI 50905-11
23/30
417 202
310
143
192 214
309
202 192
299
179-180
167 155
287
226
QQ Q
238
251
QQ QQ
334 334
263 371 346
275
287 358 358
98.35 - ESOS-L
I,I,HM'fMAN DieseI!
PlaIe
50905-11 Instrument PaneI Page 2 (2)
23/30
143 / Hou slng for HU5 for 395 4/ Lock was her LCses kive
instrument panel inslrument pa nel
417 / Instrument panel, Inslrument paneJ,
155 / Bracketforinstrument Konsol 'or instrument complete, 23/30 komplet, L23130
panel 23/30 panel, L23130
179 M0trik
When ordering s pare parts, see also page 500.50. Ved beslilling af reservedele, se ogs:' side 500 .50
Only ava IIa ble as part a s pare parts ki IilgrengeHg som en del af re se rved e l ssel.
QtyJE QtyJEnglne. Qly./E AntalJMoIor
98.35 - ESOS-L
:,!II DieseII
Plate
Page 1 (2) Instrument PaneI 50905-12
23/30
49 07 06 07
19
17
18 07 08
L),. 48
16
07 06
15
05 47
04
03 12 09
09 14
10 l
11
/ 14 20
13
~ 43
21
22
44
'' 10 20
22 02
------ 23 -'
fi
:>
45 -' -'
46
~ , -'
00
q
~
,
10 fresh water, l engine
; 12 1 /22 Lubricating l, ll 10 filIer
~
00021 ,ESO
Plate
50905- 1 2 Instrument Panel Page 2 (2)
23/30
Itern Item
aty. Design atIon Be nrevnelse Qty. Des lgnation Benrevnelse
09 7/ Needle l Nflll
11 1 / Washer Skive
12 1/ Pipe
13 1/ Ang le / Vinkelforskruning
14 2/ Straight l Ligeforskruning
20 21 Reductlon Aeduklion
When orderin g spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
00.2 1 - ESO
Plate
Page 1 (2)
Instruments 50907-17
23/30
Pressostate
L 10 2m 061
5m 073
2m 085
5m 097
8m 107
12 2m 119
TSH 12 5m 120
22 8m 132
TSH 22
Thermostate
[ ]
43-40
~
~
.;
"
~
~
~
~ gJ
i
9
'"
"'"
" Difference Pressostate
07.45 - ESO
150907 -17 Instruments Plate
Page 2 (2)
L23/30
0-10bar 22 181
40
'-- -
0- 16 bar 70 203
~
U~
Pressure Transmitter
~
Need)e Valve with 3/8' thread 239
r
r-
Needle valve with 1/2' thread 240
~ ~(I~
\J ~
Needle Valve
10
-
-
1-10 bar L 40 048
11
I.U.nJ
LJ
Pressostate
07.45 - ESO
Plate
Page , (3) Thermometer IS0907-09H
L23/30
02
31
20
R
1J
~
40-600 0-300 150 100 30 276
. L1
.1
40-400 0-200 110 40 40 288
51
i
10
11
'- LH
e L1
.-----'
L.. ~
04.11 - ESO
150907 -09 Thermometer
Plate
Page 2 (3)
L23/30
~ 100-
@
1300 50-650 100 115 60 323
r--T'------.
\- 1
1
'--
,..., -
100-
1300 50-650 65 215 61 347
~
@ =
ru
-
359-
@
04.11-ESO
',N@,'''iMANDieseII
Plate
Page 3 (3) Thermometer 1 50907-09
23/30
F,II" =-
L-,"H'=---'l~J--')
1 Thermo-
meler 372
384 Feeler
J)1 r ~
-
(~ ~>~
Q=\
11 ....J
')43
'-
- J 1=
L-L JI
....J
Feeler
NiCr-Ni 431
'"
v
i';
~
-
The rmo-
~
meler 443
i
:1
""
455- 1 L1
~ Pockel 200 455
04.11 - ESO
Plate
Page 1 (1) Pick-up 1 50908-02
23/30
Length Item
Fig. Range Code
Lmm no
J: 1 81 Working temp. SE 90 018
1 F==='
-25"C - 70"C
]
r
<>
'"
[[
Cabel length: 3
~ .
r
"---.J
1==
f=
0 - 1 kH z 55 SE 89 031
Pick-up
,J
: ~
0748 - ESO
Mi'.{MAN DieseII
Plate
Page 1 (2) Lambda ControIIer 50910-02
23/30
__________________ _ _ _ J
_
D'
, ,
019
020
032
~
<
a"
v
~
:!;
"
"
97.14 - ESQS
Plate
50910-02 Lambda Controller Page 2 (2)
23/30
Item Ilem
. Qty. DesJgnation B e n a: vn e l se . Qty. Deslgnatlon Benrevnelse
When ordering spare parts, see also page 500.50. Ved bestilling af r8servedele, se ogs~ srde 500.50.
97.14 - ESOS
',ll$%. MAN DieseII
Plate
Page 1 (2) PreIubricating AIarm ( 25) 50919-01
23/30
r
J 018
031
1 r
043
(,
- -~ - ~
, Switch t
~!
' -
,,~ 055
-.J
07.11 - ESO
l
50919-01 Prelubricating l Alarm ( 25) Page 2 (2)
23/30
Item Item
. Qy. Deslgnation Benm vnelse . Qty. DesIgnatlon Bencevnelse
When orderlng spare parts, al50 page 500.50. Ved bestilJing af reservedele, se ogsf side 500.50.
= Only available part of a spare parts klt. Iilgc:engelig som en del af reseredelssa3t.
QtyJE = aIyJEngine AnIaVE = Anlal/Motor
07. 11 -ESO
Plale
Page 1 (2) LeveI Switch Sump (LAULAH 28) 50920-13D
L23/30H-7201750RPM
694
~~ ----
,..!.i
574
rf'Tl ..'- ----
l---- 562
586 r:: ;: ~ 669
621 ~ 670
~ ~_ 580
550 812
PIate
50920-13D LeveI Switch Sump (L 28) Page 2 (2)
L23/30H-7201750RPM
Item Ilem
. Qty. Designation Benaavnelse . Qty. Designation Benrevnelse
574 8/ ! Mutter
586 2/ ! Mutler
When ordering spa re parts, see al50 page 500.50. Ved beslilling af reservedele, se ogsA side 500.50
Only avallable as part a spare parts kit. u tilgcengelig som en det af el res ered e l ssaa I.
Qty.lE QtyJEnglne aty./E Antal/Motor
QtyJI QtyJlndlvJdual aty.ll AntaVIndividuel
llJ Dieserl
PlaIe
Page 1 (2) LeveI Switch n Sump ( 28) 50920-13
L23/30H-900RPM
454
501 --t:"
07.18 - ESO
"lJ,MAN DieseII
Plate
50920-13 LeveI Switch Sump ( 28) Page 2 (2)
L23/30H-900RPM
Item Item
. Qy. Designatlon Ben ce n e l se . Qy. Designation Benaevnelse
961 1 / 0 -rl"9 0- 9
When orderlng spare parts, see al50 page 500.50. Ved bestilllng af reservedele, 5 ogsA side 500.50
Only available part a spa re parts klt. lilgrengelig som en det af el reservedelsscet.
Qly./E Qty./Englne Qly.lE Anlat/Molor
QlyJI = QtyJlndividual Oly./1 Anlal/tndividuel
07. 16 - ESO
'l Dieserl
Plate
Page 1 (2) LeveI Switch n Sump (LL 28) 50920-14
L23/30
454
501
07. 18 ESO
f,J'i DieseI!
Plale
50920-14 LeveI Switch Sump ( 28) Page 2 (2)
23/30
Item Item
. Qy. Deslgnation Benre vnelse . Qy. Designation Benrevnelse
430 21 l M0trik
981 1 / 0-rln9 0- 9
When orderlng spare parts. see al50 page 500.50. Ved besIilling af reservedele, se ogsf side 500.50
On ly ava ilable as part of a spare parts kit. Kun tilgrengelig som del aI el reserede l $sre l.
Qly./E QtyJEnglne QIy.lE Antal/Motor
QlyJI QtyJIndJvldual Q Antal/lndividuel
07.18 - ESO
Plale
Page 1 (2) LeveI Switch Sump (Dipstick ) 50920-15
23/30
454
501
@
07 .18 - ESO
Plate
50920-15 Level Switch n l Sump (Dipstick only) Page 2 (2)
23/30
Item Item
. Designatlon Benrevnelse . Oeslgnation Benrevnelse
When orderlng spare parts, see also page 500.50. Ved beSlilling af reservedele, se ogsa side 500.50
Only aai l ab l e as part a spare parts kit. u IIgreng e lig som del af ! reseredelssre l.
QtyJE QtyJEnglne Q'y./E Antal/ Molo r
QtyJI QtyJlnd ividuaI Q,y.1I AnIal/ lndividuel
07.18 - ESO
, Dieserl
Plate
Page 1 (2) FueI Leakage AIarm ( 42) 50925-08
23/30
035 023
059
047
1_-- 060
072
084
096 106
07.18 ESO
Plate
50925-08 Fuel l Leakage Alarm ( 42) Page 2 (2)
23/30
Item Item
. Oty. Designation Benrevnelse . Oty. Deslgnatlon Benrevnelse
When ordering spare parts , see al$O page 500.50. Ved beslilHng af reservedele, se ogsl side 500.50
OnJy ava llable as part of a spare parts kIt. lilgcengelig som del af et reservedeIssreI.
Oty./E = QtyJEngine. Qty./E = AntallMolor
07. 18 - ESO
l iJ Dieserl
Ptate
Page 1 (2) LocaI Starting - 1 50935-11
23/30
~
OVE'SPEO
O~OO~
"'"
B&W
#20000
300 '
~oooo
0"900 029
~"ooo
I~O~ TC
-8
8
V
ENG.
' """"'cP,,., :/
",
/"
( REMOTE
O
)( OCAL BOCKIN<tJ
~ 017
./
V
07.45 ESO
DieseI!
Plate
50935-11 LocaI Starting - 1 Page 2 (2)
23/30
Item Ite m
. . Designation Bencevnelse . . Oesignation Benmvnelse
When orderln g spare parts, see al50 page 500.50. Ved bestill ing af reservedele, se ogsA side 500.50.
= Only availabl e as part of a spare parts kit. tilgcengeHg som del af et rese redelsscet.
QtyJE = QtyJEnigne. Q ty./E = QIy./Motor
07.45 - ESO
Plate
Page 1 (2) Local Starting - 2 50935-12
23/30
~
oYRSPEED
A~
0&- """" CiJ
L(JNLUU,
I PRESS. 300 - 0- 900 029
HQIt HIESII
I.
~"'"
I~O\ C
-~
/
G:NCV
STQP
ENG.
' "'" 08
"'.,
/
/'
~"
( REMOTE
O
)( OCAL BOCKIN%)
~ 017
/
./
07.45 - ESO
lll$'MAN DieseII
Plale
50935-12 LocaI Starting - 2 Page 2 (2)
23/30
Item Item
. Q. Designation 8encevnelse . Qty. Designation Benrevnelse
When orderin g spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsfl side 500.50.
= Only avaJlable as part of a spare parts kit. tilgcengelig som del af l reservedelssret.
QtyJE = Qty./En igne. Qty./E = Qly./Motor
07.45 - ESO
lIlg..'MAN Dieserl
PIate
Page 1 (2) LocaI Starting - 2 (incl. high Iub. temp.) 50935-13
23/30
~
O\IRSPEED ~~~
w R. ooQ20000 30000 40000 ~
IL POSS. 300 - 0-900
EMERGF'NCV
STQP
,40.0
q."
'-b
TC
50000
60000
J
ENG. 1200
fllGH .
QLTEMP.
017
//
07.45 ESO
III'l$'IMAN DieseII
Plale
50935-13 LocaI Starting - 2 (incl. high Iub. il temp.) Page 2 (2)
23/30
Item Item
. Qty. Designatlon Ben;:evnelse . . Deslg nation Bencevnelse
When ordering spare parts, see atso page 500.50. Ved bes liring af reservedele, se ogsA side 500.50.
= Only aa ll ab l e as part of a spare parts kit. Kun lilgcengelig $om en del af re servede lss ce
QtyJE = QtyJEn lgne. Qly. /E = Qty./Motor
07.45 ESO
Plate
Page 1 (2) Engine Control 50936-13
23/30
11 _____ 536
345
=
095 u .z 585
573 333
656 644
,,;
404 274
'"
v
~
~ 394 561
142 548
'"
07.45 - ESO
" Dieserl
Plale
50936-13 Engine ControI Page 2 (2)
23/30
Item Ile m
Deslgnation Benrevnelse " Designation Ben cevnelse
When orderin g spare parts, see also page 500.50. Ved bestilling af reservedele, ogs<\ side 500.50.
Onl y avallable as part of a spare parts klr. tilgcengelig som en del af eI reseredelsscet.
Qty/E = Qty/Engine Qty/E = Qty/Motor
07.45 ESO
,,'( Dieserl
Plate
Page 1 (2) TerminaI / S0936-20H /
23/30
619
607 620 250
tY .- ~
!.)'
597 ;;;;;;",
--
'" :2
632 w ..
wwo
703 ~ ~~~~g ~ ~ ~ ~ ~ ;
:
--------~ 274
644
225 668
394 : 1
416 ----- ~
JV
07.45 - ESO
PIate
Poge 1 (2) Motor Control 50948-01
General
--;:======::;----,
@ WOODWABD @
98_13 -
f,zlM!:II MAN DieseII
l
50948-01 Motor Controi Page 2 (2)
Generai
Item Item
aty Designation Bencevnelse aty Design ation Bencevnelse
When ordering spare parts, see also page 500.50. Ved beslll ing af rese rvedele, se ogsA side 500.50.
= Only avail able as part of a spare parts kit. litgrengelig som del af l reservedelssceI.
Qty/E = Qty/Engine Qly/E = I/
96.13
PJate
Page 1 (2) Converter 50956-01
General
021
(ftS ... 1 ~
:]
' . ~lSm ~
~~ ~~~ 5
033
045
07.37 - ESO
@" DieseII
Plale
50956-01 Converter Page 2 (2)
GeneraI
Item Item
no Qy Deslgnation Benmvnelse aly Deslgnatlon Benrevnelse
When orderlng spare parts, see al50 page 500.50. Ved bestilling at reservedele, se ogs~ side 500.50.
Only ava ll able as part a spare parts klt. tilgrengelig 5Qm del af el reservedelssret.
Qly/E = Qly/Englne Qly/E = Qty/Motor
07.37 - ESO
Section 510
Crankshaft and Main eags
Description
Working card
Plates
Crankshaft 51001-04
Coupling for Central Drien Lub. l Pump 51002-01
Resilent Gear Wheel 51002-02
Flywheel with Flexible Coupling and Gear Rim 51002-01
Flywheel with Gear Rim 51002-02
Flywheel with Gear Rim 51003-03
Flywheel with Gear Rim 51003-22
Flywheel with Gear Rim 51003-23
Flywheel with Gear Rim 51003-24
Torsional Vibration Damper 51 004-01
Torsional Vibration Damper 51004-26
Torsional Vibration Damper 51004-27
Torsional Vibration Damper 51004-28
Torsional Vibration Damper 51004-29
Torsional Vibration Damper 51004-30
Torsional Vibration Damper 51004-31
Torsional Vibration Damper 51004-32
Plates
23/30
The crankshaft, which is a one-piece forging with l special cases a vibration damper is mounted
ground main bearing and crankpin journals, is sus- the crankshaft ( lmt torsional vibrations. The damper
pended inderslung bearings. The main bearings consists essentially ! a heavy flywheel totally
are equipped with insertion-type shells, which are closed a light casing. small clearance is allowed
coated with a wearing surface. attain a suitable between the casing and the flywheel, and this space
bearing pressure the crankshaft is provided with is fi lled with a highlyviscous fluid. The casing is rigidly
counterweights, which are attached ( the crankshaft connected ( the Iront end the engine crankshaft
by means (w screws. and the l connection between the crankshaft
and the damper flywheel is through the Iluid. Under
At the flywheel end the crankshaft is fitted with a gear conditions ! vibration, the casing and damper
wheel which through an intermediate wheel drives flywheel tend ( rotate as unit, since the force
the camshaft. Also fitted here is the flywheel and a required ( shear the viscous fi lm is consi-derable.
coupling flange for connection ! a reduction gear or As the torsional vibration amplitudes increase, the
an alternator. At the opposite end there is a claw-type casing lollows the movement the crankshaft but
coupling for the lb. l pump or a f l e i ble gear wheel the flywheel tends ( rotate unilormly by virtue !
connection for lb. l and water pumps. its inertia, and relative moti on occurs between the
flywheel and the casing. The viscous fluid film there-
fore undergoes a shearing action, and vibration
energy is absorbed and appears as heat.
96.03 ESOU
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 1 (7) Edition 04
(Hvdraulic Tghtened Connectin~ Rod)
23/30
Stopped engine
Shut-off starting air
Shut-ofl cooling water
Plate no.
520
Item no.
011
Note
Slarling posilion:
Relaled procedure:
Dala:
00.27 - ESO
44' Dieserl
510-01.00 Checking of Main Bearings AIignment (DefIection) Working Card
Edilion 04 Page 2 (7)
(Hydraulic Tightened Connecting Rod)
23/30
As the magnitude such axiai Iengthening and "CIosing" the throw dead centre is regard ed
shortening during the turning the throw increases as negative, (compression the gauge).
the difference the height th e
beari ng, is measured as a check th e aIignment the exampIe, page 3, the delIecti on reading is
and condition the bearing. th erelore negative.
'"
00.27 ESO
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 3 (7) Edition 04
(Hydraulic Tightened Connecting Rod)
23/30
As during the turning the throw, the gauge and the The total dellection (''opening-closing'') the throw
connecting rod ill meet near the bottom position during the turning Irom bottom to top position is
the throw, the measurement lor the bottom position entered lig. 4.
is to be replaced by the average the two near by
positions either side. These ligures are due to vertical misalignment
the main bearings.
The dial gauge is set to , when the crank throw
is the near-bottom ( lig. 8) and during the Similarly, horizontal misalignment procedures the
turning the throw is stopped the position horizon- ligures the table lig. 5.
tal-top-horizontal-near bottom (P-T-S-Y lig. 8) lor
reading the gauge. Besides misalignment the bearings, the readings
can be inlluenced by ovality eccentricity the
journals.
Checking The Deflection Measurement.
The reading is entered the table page 6, see Engines Equipped with Turning Gear.
example lig. 2 - 6.
When taking these dellection readings lor the three
As "bottom" reading is used the mean value the aftmost cylinders, the turning gear should at each
two "near bottom" readings and , lig. 3. stoppage be turned a l ttle backwards to ease 011
the tangential pressure the teeth the turning
wheel as this pressure may otherwise lalsily the
readings.
00.27 ESO
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 04
"(Hvdraulic Ti~htened Connectin~ Rod) Page 4 (7)
23/30
3 -2 4 5 -2 3
DefJeclion trom hori-
Right side S 3 -2 2 1 zontal misalignment
Fig.2. Fig.5.
Fig.6.
Front end .
Closing" the crankthrow is considered 81art position .
negaIive. Turn anli clockwise
Fig.7. Fig.8.
00.27 - ESO
Working Card Checking of Main Bearings Alignment (Deflection) 510-01.00
Page 5 (7) Edition 04
lHvdraulic Tiahtened Connectina Rod\
23/30
00.27 - ESO
510-01.00 Checking of Main Bearings Alignment (Deflection) Working Card
Edition 04 Page 6 (7)
(Hydraulic Tightened Connecting Rod)
23/30
Process/Proces 1. 0. .
Instruction/lnstruktion
,
/;J '.,. \
.' ' : 1,
'\
\,
" \
r
, {
~
r t \ !
~ \~\,,i' (~
\ {
\~
\
~ ~ ~ ~
jY
Righl side Left side
\(,i
1/100 mm
(g )
Boltom end/ Bottom starV
Bund slut Bund 51art
CyI. 2 3 Cyl. 2 3
Left side
Aemarks/Bemcerkninger
00.27 ESO
"l DieseII
Working Card Checking of Main Bearings AIignment (Deflection) 510-01.00
Page 7 (7) Edition 04
(Hydraulic Tightened Connecting Rod)
23/30
ComponenVKomponent Type 1. 0. .
Engine .:
Motornr.:
Cyl . . 1 2 3 4 5 6 7 8 9
8oltom
Left side
Righl side S
Botlom V
Botlom
(0.5)=
Deflection from
vertical misalign-
menl.
- bottom
orT - = V
Deflection from
horizontal mis-
alignment.
Left side - Right
~ sideorP-S = H
~
~~
'-
~ readIngs.
~ += C
~
+ S=
00.27 - ESO
Working Card 510-01.00
Page 1 (6) Checking of Main Bearings Alignment (Autolog) Edition 05
L23/30
11
Stopped engine
Shutoff starting air
Shutoff cooling water
Plate no.
52010
Item no.
011
Note
Descriplion:
Slarting posilion:
Relaled procedure:
DaIa:
01.46 ESO
$%'" Dieserl
510-01.00 Working Card
Edilion 05 Checking of Main Bearings AIignment (AutoIog) Page 2 (6)
L23/30
Th e cause incorrect main bearing position may The total deflection (''opening-closing'') the throw
be wear the bearings misalignmnet the during the turning from bottom position is
engine. entered fig. 4.
As during the turning the throw, the gauge and the When taking these deflection readings the three
connecting rod wll meet near the bottom position aftmost cylinders, the turning gear should at each
the throw, the measurement the bottom position stoppage be turned a l ttl e backwards ease off
is be replaced by the average the w near by the tangential pressure the teeth the turning
positions either side. wheel as thi s pressure may otherwise falsi fy th e
readings.
The dial gauge is set , when the crank throw
is the near-bottom ( fig. 8) and during the
turning the throw is stopped the position horizon-
tal-top-horizon tal-near bottom (- T-S- fig. 8) lor
reading th e gauge.
01.46 - ESO
Working Card 510-01.00
Page 3 (6) Checking of Main Bearings A/ignment (Aut%g) Edilion 05
23/30
3 -2 4 5 -2 3
Oeflection Irom hori
Righl side S 3 -2 2 1 zonlal misalignment
Fig2. Fig5.
Fig6.
C and D should be nearly Ihe same, reading lor crank throw 4 10 be repeated.
~
S(Lo~p
(g;
)
Front end view.
Closing the crankthrow is considered Slart in position .
negalive. Turn anti clockwise
Fig 7. Fig8.
01.46 - ESO
510-01.00 Working Card
Edilion 05 Checking of Main Bearings Alignment (Autolog) Page 4 (6)
23/30
01.46 - ESO
"I,I,'. DieseII
Working Card 510-01.00
Page 5 (6) Checking of Main Bearings AIignment (AutoIog) Edition 05
23/30
Process/Proces !., .
InsIructIoll/lnsIruklion
1
l----
- ----
-------
-~
~l Rightside
~ ~ leffside
--0- (Q )
1/100 mm
Boltom end/ Boltom startJ
Bund slut Bund slart
-
Cyl. 1 2 3 Cyl.no 1 2 3
I~O~O~O~~ ~o ~~
Left side Cyl. 110 1 2 3
Left side
RemarksJBemcerkninger
01.46 - ESO
' DieseII
510-01.00 Working Card
Edition 05 Checking of Main Bearings AIignment (AutoIog) Page 6 (6)
23/30
Engine . :
Molornr.:
Cyl. . 1 2 3 4 5 6 7 8 9
Botlom
side
Right side S
Boltom V
BoIIom
(0.5xV)=B
DeIlection from
verlica l misalign-
ment.
botlom
or T =
Defleclion from
horizonIal mis-
alignmenI.
Left s ide RighI
sideor p S= H
"-
readIngs.
+ = C
01 .46 - ESO
Working Card
Inspection of Main Bearing Shells
510-01.05
Page 1 (3) Edition 01
23/30
Relaled procedure:
Dala:
96.30 - ESOS-G
510-01.05 Working Card
Edilion 01 Inspection of Main Bearing Shells Page 2 (3)
23/30
96.30 - ESOS-G
Working Card 510.01-05
Page 3 (3) lnspection of Main Bearing Shells Edition 01
L23/30
Inspection Main Bearing Shells Lubricate the bearing shell and journal with clean
lubricating l.
13) Inspect the main bearing shells according 10
working card 50.6-0.1.16.
Mounting the Main Bearing Cap
Note: he bearing is marked according 10 size and
when rep/aced l musl be by a new bearing of Ihe 18) Raise the bearing cap position, dismount
same size. the guide tubes, coat the beari ng studs with molycote
pasta similar and the bearing stud nuts.
Mounting the Main Bearing Shells Make sure that the bearing cap and bearing shell
are their correct position.
14) Push the bearing shell as far position
as possible. 19) Dismantle the straps.
15) Fit the l main bearing the l b 20) the hydraulic tools, see working card
ricating hole the crankshaft and turn the 520.-0.1.0.5, and tighten the nuts as prescribed
bearing shell by turning the crankshaft . page 50.0.-40..
Make sure that the shell enters its correct position 21) Coat the back side the bracing screws' (side
then remove the l main bearing. screws') hexagonal head with a thin coat silastene
or similar.
96.30 - ESOSG
Working Card 510-01.10
Page 1 (3) Inspection of Guide Bearing Shells Edition 01
23/30
Hand 10015:
Relaled procedure:
DaIa:
96.20 - ESOS
',l'I@',,,(MANDieseII
510-01.10 Working Card
Edition 01 Inspection of Guide Bearing SheIIs Page 2 (3)
23/30
23/30
---
---1
i
~
1/,
'1
1:/,1
~'
~ Guide for mountirlg of upper SllelI.
The bearing shells Ihe guide bearing , which are Make sure thal the Ihrusl washers, bearing shell and
identical those the main bearings, are narrower bearing cap are their correcl position .
than the bore lor the guide bearing and is therelore
essen ti al that the shells are positi oned perfectly cor- 20) Dismanlle Ihe straps.
recl the bore.
21) the hydraulic lools, see workng card
For this purpose a guide l is supplied lor posilio- 520.-0.1.0.5, and tighten Ihe nuts as prescrbed
ning the engine Irame when the upper bearing page 50.0.-40..
shell is be litted, see lg 5.
22) Coat the back side the bracing screws' (side
15) Push Ihe bearing shell correct position screws') hexagonal head with a thin coat silastene
thraugh this guide tool, by using l item 202, l similar.
necessary use a plastic hammer.
23) the screws and tighten with a torqu e
16) Fil th e thrust washers and clamps. spanner as ndcated page 500.40..
96.20 - ESOS
Working Card 510-04.00
Page 1 (3) Vibration Damper Edition 01
23/30
Stopped engine Plate lIem Note
Shut-off starting air
D Shut-off cooling water
D Shut-off l l
D Shut-off cooling l
Descriplion:
Slang posilion:
Relaled procedure:
96.03 - ESOS-G
510-04.00 Vibration Damper
Working Card
Edilion 01 Page 2 (3)
23/30
The vibration damper is equipped with extraction 3) Rotate the engine in orderto bring the extraction
plugs which provide the opportunity testing th e plugs (6) the damper in optimal positi on, see fig
viscosity the silicone l inside the damper without 2.
having dismantle .
-!J--- 6
=r.J-J-- 7
96.03 - ESOS-G
' DieseII
Working Card
Vibration Damper
510-04.00
Page 3 (3) Edilion 01
23/30
5) Unscrew and remove one Ihe exlraclion 8) Tighlen bolh exlraclion plugs wilh Ihumb and
plugs (6) and replace l wilh Ihe sample conlainer fo refinger Ihen turn Ihem furlher 450 (aboul 20 Nm) .
(1 ). Seal bolh plugs by caulking Iheir grooves.
meeling Ihe inerlia ring (3) unscrew Ihe conlainer 9) Send Ihe sample conlainer 10 &
one revolulion . Holeby, a l: Service Deparlmenl , logelher wilh Ihe
label filled in wilh:
6) Remove Ihe second cap from Ihe sample
conlainer and wail unlil silicone flui d (5) begins 10 Name ship.
l oulfrom Ihe free end. Depending on Ihe silicone Engine Iype.
viscosily Ihe process needs a cerlain amounl lime. Engine no.
possible l, can be speeded by means : Running hours.
Dala for vibralion damper.
Turning Ihe damper unlil Ihe sample conlai -
ner is undernealh Ihe crankshaft. 1) For hours belween laking new samples, see
Temporarily removing Ihe second exlraclion page 500.25.
plug 100.
The quanlily s il cone l removed l so small th al
7) As soon as Ihe silicone fluid begins 10 l , 10 1 such samples can be laken wilhout risk.
shul Ihe sample conlainer by Ihe cap. Remove Ihe
conlainer from Ihe damper casing, wipe off Ihe sea-
ling jace round Ihe exlraclion hole and screw in Ihe
plugs logelher wilh new sealing washers (7).
close Ihe second side Ihe conlainer.
96.03 - ESOS-G
PIale
Page 1 (2) Crankshaft I S1001-04H
23/30
128
177 -----
094
070
189
069 190
021+ 200
153
~
.;
:;"
q
9
>
>
082
98.34 - ESOS
f,!,J,MI,,(MAN DieseII
IS1001-04H Crankshaft PlaIe
Page 2 (2)
23/30
Item Item
. Designation Benaavnelse . Qty. Deslgnatlon Benaavnelse
When ordering spare parts, see also page 500.50. Ved bestilIing af reservedele, se ogsA side 500.50.
Only aval lable as part of a spare parts kit. n lilgcengeHg som en del af et reseredelssret.
QtyJE = QtyJEnglne Antal/E = AntaI/MoIor
QtyJW = QtyJCounterweight IW= AntaJIKontravcegt
QtyJC = QtyJCyllnder AntaIIC = AntalICyJinder
96.34 - ESOS
,,:, DieseI[
PlaIe
Page 1 (2) Couplng for Centrai Drien Lub. Pump 51002-01
L23/30
\
'\ \
\
~crankShaft
(Plate 51001)
~ 279
015
027
' - - - 038
06.43 ESO
51002-01 Couplng for Central Driven Lub. l Pump Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Deslgnation Bencevnelse
When orderi ng spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
Only available as part of a spa re parts kit. tilgengelig som del af re se re d e l ssre l.
QtyJE = QtyJEngine Anlal! E = Antal/Motor
06. 43 ESO
'' / DieseII
Plale
Page 1 (2) ResiIient Gear WheeI 51002-02
23/30
/~
Crankshaft
(Plate 51001)
123 ~
111
206
088 \
267
052 - \ \
160
196 - \
)fp~
\ ~_x ~~
218 "< "-- 147
172 '--- , 0/ ~~ 111
111 --- 159
231 ----
\\~:t::..~\ ~ 172
L 184
040
064
'---- 076
06.41 - ESO
Plale
51002-02 Resilent Gear Wheel Page 2 (2)
23/30
Ilem Item
. aty. Deslgnation Benrevnelse . Qy. Designation Benrevnelse
111 1 21 l M0trik
267 21 ll ll
When ordering spare parts, see also page 500.50. Ved beslillng af reservedele, se 095a side 500. 50.
= Oniy ava iIabIe as part of a spare parts kit. Kun tilgrengelig som en dei af et reservedelssrel.
QtyJE = Qty./Englne Anlal/E = Anlal/Molor
06.41 - ESO
MiM'.MAN DieseI!
Plale
Page 1 (2) FIywheeI with FIexibIe CoupIing and Gear Rim 51003-01
23/30
071+
083
\/
105 ~
/
\
/./'' \/
\
~ /
o ~,
o .~,
0' ."
.
117 ~
0 095
d \ - 046+
- - 058
/
/
~
'--.. 022
96.03 - ESOS
,, .J DieseII
PlaIe
51003-01 FIywheeI with FIexibIe Coupling and Gear Rim Page 2 (2)
23/30
Item Item
. Qty. Desigation 8encevnelse . Qty. Designation Bencevnelse
When orderlng spare parts, see also page 500.50. Ved beslilling af reservedele, se ogsA side 500.50.
l ava ll able as part of a spare parts kit. tilgC'e ngelig som en del af el rese rve delsset.
OtyJE = OtyJEnglne Qly. /E = Antal/ Motor
96.03 ESOS
Plate
Page 1 (2) Flywheel with Gear Rim 51003-02
23/30
105
\
\
\
\ ,
\
046+
058
Crankshaft
(PlaIe 51001)
- - - - - - 010
/'
~ 022
96.03 ESOS
Plate
51003-02 Flywheel w ith Gear Rim Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Benrevnelse . Qty. Des lgnatl on Benrevnelse
When orderin g s pa re pa rls, see al$o page 500.50. Ved besIilling af reservedele, se ogsa side 500.50.
Only available as part of a spare parts kit. tilgcengelig som en del af el reservedelssaeI.
QtyJE = Qty./Eng ine Qty./E = I!
96.03 - ESOS
PIaIe
Page 1 (2) Flywheel with Gear Rim 51003-03
23/30
105 -'.
\ '.
046+
-----~ 010
~ 022
96.03 - ESOS
I,, !: DieseII
Plate
51003-03 FIywheeI with Gear Rim Page 2 (2)
23/30
Item Item
. . Designatlon Benrevnelse . . Designatlon Benmvnelse
When ordering spa re arts , see also page 500.50. Ved bestilling al reservedele, se 0953. side 500.50.
23/30
105 -,
\
\,
\
\
/
:(\
\ 046+
- - 058
'-----------
/'
~ 022
07,14 ESO
Plale
51003-22 Flywheel with Gear Rim Page 2 (2)
23/30
Item Item
. Qty. Deslgnatlon Bencevnelse . Qty. Designatlon Benrevne lse
When ordering spare pa rts, see al50 page 500.50. Ved bestilling af reservedele, S ogs:' side 500.50.
= Only ava il able part of a spa re kit. tilgcengelig som del af el reservedelsscet.
./ = QtyJEngine Qty.lE = Antal/Motor
07.14 - ESO
Plate
Page 1 (2) Flywheel with Gear Rim 51003-23
23/30
105 \
\
,,
046+
- - - - - - 058
./
~ 022
07. 14 - ESO
Plale
51003-23 Flywheel with Gear Rim Page 2 (2)
L23/30
Item Item
. Qty. Deslgnation Benrevnelse . Qty. Deslgnatlon Bencevnelse
When ordering spare p arts, see al50 page 500.50. Ved bestilling af reservedele, se ogsc\ side 500.50.
23/30
105 ,
\
\
,
"
O
o~ /
0/ '------- 058
/' ,
/ / \
, \
\ "LCrankshaft
\
\ (Plate 51001)
'- 034
---------
~ 022
~
~
,n
08.21 , ESO
''" DieseII
Plate
51003-24 FIywheeI with Gear Rim Page 2 (2)
23/30
Ilem Ile m
. . Designation Benrevnelse . Qty. Des ignatlon Ben cene l se
When ordering spare parts, see a/5o page 500.50. Ved besIilling af reservedele, se ogsA side 500.50 .
Only availabIe as part of a spare parts kit. tilgrengelig som en del af l reservedelssoo t.
QtyJE = QtyJEngine Qty.lE = AntaVMotor
08.21 ESO
,+, , DieseII
Plate
Page 1 (2) TorsionaI Vibration Damper 51004-01
23/30
____- 016
~ 02'
053
r 041
'
, 0
94.23 ESOS
+ DieseI[
Plale
51004-01 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. . Designation Benrevnelse . aty. Deslgnatlon Benrevnelse
When ordering spare parIs, see al50 page 500.50. Ved bestilling at reseredele , se ogsC side 500.50.
= Only aval lable as part of a spare parts kit. Iilgrengelig som en del af l reservedelssret.
QtyJE = QtyJEnglne AntalIE = Anlal/Motor
94.23 - ESOS
Plate
Page 1 (2) Torsional Vibration Damper 51004-26
23/30
~- 016
~028*
053
r 041
*
, 0(1
07.14 - ESO
'}2,.lf DieseII
PIale
51004-26 Torsional Vibration Damper Page 2 (2)
23/30
Item Item
. Designation Bencevnelse . Qty. Designation Bencevnelse
When order/ng spare parts, see also page 500.50. Ved besliJling af reservedele, se ogS3. side 500.50.
Only aval lable as part of a spare parts kit. tilgenge l ig som del af et reseredelssret.
QtyJE = QtyJEngin_ Antal/E = ll/
07 .14 - ESO
PlaIe
Page 1 (2) Torsional Vibration Damper 51004-27
23/30
~- 016
~028*
053
r 041
*
07.14-ESO
PlaIe
51004-27 Torsional Vibration Damper Pag" 2 (2)
L23/30
Ile m Ilem
. aty. Deslgnation B e n ;;ene l se . . Deslgnatlon Bencevnelse
When ordering spare parts, see al50 page 500.50. Ved besIilling af reservedele, se 095<\ side 500.50.
On ly aval lable as part a spare parts kit. lI939 " 9 l9 som del al re s eredelsse t.
QtyJE = QtyJEnglne Anlal/E = Antal/Motor
07.14 - ESO
Plate
Page 1 (2) Torsional Vibration Damper 51004-28
23/30
~- 016
~028*
053
r 041
*
07.14 - ESO
Plate
51004-28 Torsional Vibration Damper Page 2 (2)
L23/30
Ile m Ilem
. aty. Deslgnatlon B e n cenel se . . Deslgnation Bencevnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedeJe, se ogsa side 500.50.
On ly avallable as part of a spare parts klt. tilgcengelig som del af l reserede l sseI.
QtyJE = QtyJEnglne Antal/E = Anlal/Motor
07.14 - ESO
Plate
Page 1 (2) Torsional Vibration Damper 51004-29
23/30
~- 016
~028*
053
r 041
*
07 .14 - ESO
'' 'l Dieserl
Plate
5 1004-29 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. Qty. Designation B e n ev n e l se . Qty. Deslgnation Benrevnelse
When orderlng spare parts, see a/5o page 500 .50. Ved bestHling af reservedele, se 0958 side 500.50.
= Only avallable as part of a spare parts klt. tilgrengelig som del af l res e redel ssret.
QtyJE = QtyJEn glne Antal/E = Antal/Motor
07. 14 ESO
Plate
Page 1 (2) Torsional Vibration Damper 51004-30
23/30
___- 01 6
~028*
053
r 041
*
07.1 4 - ESO
,$1,I DieseI!
Plate
51004-30 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. Qty. Designation Benrevnelse . Qty. OesI9"atlo" Bencevnelse
When orderlng spare parts, S also page 500.50. Ved besIilHng af reservedele, se ogsA side 500.50.
On ly aval lable as part a spare pans klt. Kun Iilgrengelig som del af reservedelsscet.
QlyJE = QlyJEngine Antal/E = Antal/Motor
07.14 - ESO
PlaIe
Page 1 (2) Torsional Vibration Damper 51004-31
23/30
~- 016
~028*
053
r 041
*
07.14 - ESO
I DieseII
Plate
51004-31 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Ilem
. aty. Oeslgnation Bencevnelse . aty. Designation Bencevnelse
When orderlng spare parts, see al50 page 500.50. Ved bestilling at reservedele, 5 095'" s ide 500.50.
= On ly avaiIable as part a spare parIs kit. tiJgrengeIig som en del af el reseredel sscet.
QtyJE = QtyJEngine Anlal/ E = Anlal/Motor
07.14 - ESO
+'. DieseII
PlaIe
Page 1 (2) TorsionaI Vibration Damper 51004-32
23/30
~- 016
~028*
053
r 041
*
07.14 - ESO
Plate
51004-32 Torsional Vibration Damper Page 2 (2)
23/30
Item Item
. aty. Oesignation Bencevnelse . Qty. Designation Bencevnelse
When ordering spare parts, see al50 page 500.50. Ved bestilling af reservedele, 095<\ side 500.50.
Only ava iIable as part a spare as kit. Kun titg.engelig $om en del af el re serede l ssre I.
QIyJE = QIyJEnglne AnIal/E = AntallMolor
07. 14 - ESO
PlaIe
Page 1 (2) Torsional Vibration Damper 51004-33
23/30
____- 016
~028*
053
r 041
*
, 0
07.14 ESO
PIale
51004-33 Torsional Vibration Damper Page 2 (2)
23/30
Item Ilem
. Qty. Designation Benrevnelse . Qty. Deslgn ation Bencevnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
Only avallable as part of a spare parts kit. tilgc.engeJig som en del af el reseredelssret.
atyJE = QlyJEnglne Antal/E = l/
07.14 ESO
Plale
Page 1 (2) Torsional Vibration Damper 51004-34
23/30
___- 016
~028*
053
r 041
*
07 .14 - ESO
Plate
51004-34 Torsional Vibration Damper Page 2 (2)
23/30
Item Item
. aty. Des ignatlon Bencevnelse . Qty. Designation B enre nel se
When ordering spare parts, see a l50 page 500.50. Ved beSlilling af reservedele, 5 ogsa side 500.50.
On ly ava llable as part a spare parts klt. Kun Iilgrengelig som del af el reseredeJssret.
Qly.lE = QlyJEngin" l/ = Antal! Motor
07 .14 - ESO
+'I DieseII
Plate
Page 1 (2) TorsionaI Vibration Damper 51004-35
23/30
~- 016
~028*
053
r 041
*
07. 14 - ESO
Plate
51004-35 Torsional Vibration Damper Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Des ignatio n Be ncevne lse
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
On ly avallable as part of a spare part s kit. tilgcengelig som del af l re sere delssc I.
aty./E = QtyJEnglne Anta l/E = l
07 .14 - ESO
Plate
Page 1 (2) Torsional Vibration Damper 51004-36
23/30
~- 01 6
~028*
053
r 041
*
07. 14 - ESO
Plate
51004-36 Torsional Vibration Damper Page 2 (2)
L23/30
Item Item
. Qty. Deslgnation Bencenelse . Qty. Designation Bencevnelse
When orderlng spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
Only avallable as part a spare parts kit. u tilge ngetig 50m en del af el re se re d e l sset.
aly./E = alyJEnglne Antal/E = Antal/ Motor
07.14 ESO
Plale
Page 1 (2) Torsional Vibration Damper 51004-37
L23/30
~- 016
~ 028*
053
r 041
*
07. 14 ESO
DieseII
Plale
51004-37 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Bencevnelse . Qty. Designation Bencevne lse
When ordering spare parts, see also page 500.50. Ved beslilling al reservedele, se ogsA side 500.50.
07.14 - ESO
PlaIe
Page 1 (2) Torsional Vibration Damper 51004-38
23/30
~- 016
~028*
053
L 041
*
07 .14 - ESO
,, DieseII
Plale
51004-38 TorsionaI Vibration Damper Page 2 (2)
23/30
Item Item
. Deslgnation Bencevnelse . Qty. Designation Benrevnelse
When ordering spa re parts, see al50 page 500.50. Ved besIilling reservedele, se 09s:' side 500.50.
07.14 - ESO
'+,' DieseII
Plale
Page 1 (2) Tuning WheeI IS1004-02H
23/30
065
94.23 - ESQS
,,' DieseII
23/30
Item Item
. Qty. Deslgnation Bencevnelse . aty. Designation Bencevnelse
When ordering spare parts, see also page 500.50. Ved bestilling af reseredele , se ogsfl side 500.50.
Only avallable as part a spa re parts kit. Iilgcengelig som del af l reseredelssret.
Qty,/E = QtyJEngfne Antal/E = Antal/ Motor
94,23 - ESOS
"l'l, DieseII
Plate
Page 1 (2) Tuning WheeI 151 04-39
23/30
065
07. 18 ESO
IS1004-39H Tuning Wheel Plale
Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Designation Bencevnel se
When ordering spare parts, see a l50 page 500.50. Ved bestilling af reservedele, se ogsf side 500.50.
= Only avallable as part a spa re parts kit. tilgrengelig $om del af l reserede l sscet.
Qty./E = QtyJEngine AnlalfE = Antal/Motor
07.18 ESO
"'' DieseII
Plate
Page 1 (2) Tuning WheeI 51004-40
23/30
065
07.18 - ESO
"+!:( DieseII
PlaIe
51004-40 Tuning WheeI Page 2 (2)
23/30
Item Item
. Qty. Oeslgnation 8 enrevnelse . Qty. Des ignatlon 8enrevnelse
When ordering spa re p a rs , see al50 page 500 .50. Ved bestifling af reservedele, se 095 side 500.50.
Only availabte as part of a spare parts kit. Kun tlgre n ge l i g som del af reservedelssrel.
Qly./E = QlyJEnglne Antal/E = Antal/Motor
07.18 ESO
I':'l$H MAN DieseII
Plate
Page 1 (2) Tuning WheeI !S1004-41H !
23/30
065
07.18 - ESO
" DieseI!
23/30
Item Item
. . Deslgnation Bencevnelse . aty. Deslgnation Bencevnelse
When orderlng spare parts, $ee also page 500.50. Ved bestiJling al reservedele, 5 ogs~ side 500.50.
07.18 - ESO
Section 511
Engine Frame and Base Frame
Description
Working card
Plates
23/30
Frame the sides the Irame there are covers for acces
10 the camshaft, Ihe charge air receiver and crank-
The engine Irame iS made cast , and iS at- case. Some of the covers are ltted with relief valves
tached the the base Irame by means which ll act, should l vapours the crankcase be
bolts. The cross girders the Irame are provided ignited, for instance the event of a hol bearing.
with bores lor the main bearings which the crank-
shalt iS underslung, .. iS carried by the main The charge air cooler housing iS a integrated part
bearing caps. of the frame.
94.26 ESOU
Working Card
Functional Test of Crankcase Safety Relief Vales
511-01.00
Page 1 (2) Edilion 10
23/30
Shut- off starting air
Shut-off cooling water
Shut-off luel l
Shut-oll cooling l
De5criplion:
Slarling 05 :
Relaled procedure:
!
Capacity 1 man
511 06 058 1/cyl.
Dala: 511 06 071 1/reliel valve
51106 740 12/reliel valve
Data lor pressure and tolerance (Page 500.35)
Data lor torque moment (Page 500.40)
Declaration weight (Page 500.45)
06.46 - ESO
511-01.00 Functional Test of Crankcase Safety Relief Valves
Working Card
Edition 10 Page 2 (2)
23/30
FunctionaI Testing
When Painting
2) Place the cover on the Iloor with the pressure Fig 1 Cover with reIief va/ve
area upwards.
06.46 - ESO
, ,,,' Dieserl
Plate
Page 1 (2)
Frame "th Main Bearings 51101-10 J
L23/30
050
049
062
lf
324 Bearings,
see plate 507
05
086
397
098
Coolerbox see 312
plate 51203
Guide screw,
see plate 50705
- - 157
. " "
- - 253
" "
216 300+
157
170
336
00.09 - ESO
I+l$z."IMAN DieseII
Plate
51101-10 Frame with Main Bearings Page2 (2)
23/30
Item Item
. Qty. Deslgnatlon Ben:evnelse . Qty. Deslgnation Benoovnelse
025 5/ Braclng bolt Sideskrue 397 1/ Frame complete, inci. Stativ komplet. inkl.
item 049, 062, 108, 133, item049,062, 108, 133,
049 4/C Nut for cylinder M0trik cYIInder 145, 169,170,216,241 , 145,169,170,216,241,
head stud drekseltap 290,300,324,348,361 , 290,300, 324,348,361,
plate 50701 item 048, plate 50701 Item 048,
050 4/C Protective cap Beskytlelseshrelte 061 , 073, 276, plate 061 , 073, 276, pIate
50705 Ilem 350, 362 50705 iIem 350, 362
062 4!C Stud for cyllnder lap for cylinderdcek-
head sel
When orderlng spare parts, see also page 500.50. Ved bestIIing af reservedele. se ogS8. side 500.50.
Only available as part of a spare parts kt. u tilgrengelig som en del af et reservedelssret.
QlyJE = Oty./Englne Aotal/E = Antal/Motor
QlyJC Oty./Cylinder Antal/C = AnIal/Cyl inder
QlyJB Qty./Bearlng Antal/B = AnIal/Leje
QlyJJ = QtyJIndividual Antal/I = AntaJ/lndivIduelt
00.09 - ESO
PlaIe
Page 1 (2) Mounting of Pumps 51102-05
23/30
093
High temperature
fresh water pump,
see Plate 5161
164
temperature
fresh water pump,
see Plate 5161
247
06.50 - ESO
Plale
51102-05 Mounting of Pumps Page 2 (2)
23/30
Item Item
. Qy. Designation Bencevnelse . Qy. Designatlon Ben:evnelse
247 21 l MoIrik
When orderlng spare parts, see al50 page 500.50. Ved bestilling af reservedele, se ogsA side 500.50.
= l ava ll able as part of a spa re parts klt. Kun Ilgrengelig som del af rese redelsscel.
QlyJE = QlyJEnglne Antal/E = Antal/Motor
06.50 ESO
Plate
Page 1 (2) Front Cover for Lubricating l Pump 51102-10
23/30
081
Q Q
Q
Q Q
For Iubricating
pump, see
Plate 51501 Q
Q
Q Q
020
019
032
06.50 ESO
Plate
51102-10 Front Coer for Lubricating l Pump Page 2 (2)
23/30
Item Item
. Qy. Designatlon Benrevnelse . Qly. Deslgnation Bencevnelse
247 21 l Motrik
When ordering spare parts, see also page 500.50. Ved beslilling af reseredel e, se ogsA side 500.50.
Only aval lable as part of a spare parts kit. tilgcengelig som del af l reservedelsscet.
QlyJE = Qly./Englne Antal/E = Antal/Motor
06.50 ESO
Plate
Page 1 (2) Mounting of Pumps 51102-11
23/30
093
235 \ "-
223 ",
164
247
152
451
~
<
152
~
~
06.50 - ESO
Plate
51102-11 Mounting of Pumps Page 2(2)
23/30
Ite m Item
. a l y. Designatlon Benmvnelse . a l y. Des ignatlon Benm vnelse
247 2 l trk
When orderlng spa re parts, see al50 page 500.50. Ved bestilling af reservedele, 5 0950:\ side 500.50.
Only avail able BS part a spare pa rts klt. li lgrengelig som del reservedelssrel.
Qty./E = QtyJEn gine Antal/E = Antal/Motor
06.50 - ESO
PlaIe
Page 1 (3) Covers Frame 51106-17
23/30
490
")"\ffi12!-t - - 058
-'----- 071
071 083
764
752 ~t-
~
ro 715
~ 058
416
""
2> 703
5 cyl. OOOOrllOOOO
~
394
~
693 6 cyl . OOrllOOOOrllOO
~ 489
~
7 cyI.
OOrllOOrllOOrllOO
"
8cyl.
OOrlllJrllOOOOrlllJ
"
Cover see When ordering cover fo r
plaIe 51102 crankshaft with re lief valve,
please see diagram with covers.
07.09 - ESO
l:+~Z' !I'[MAN DieseII
Plate
51106-17 Covers Frame Page 2 (3)
2330
Item Item
Qty. Desi " atlo" Benrevnelse Qty. Desi " atlo" Bencevnelse
30/ 7 cyl. engine 7 cyl. motor on ly for 72050 r pm kun for 72050 omdr. :
~
34/ 8 cy/. engine 8 cyI. motor
~
9
ro
ro
When ordering spare parts, see also page 500.50. Ved besli lling af reservedele, se ogS8. side 500.50.
Only avaiiabIe as part of a spare parts kit. tlgrengeIig som del af reseredeIS$a31.
Qty./E QtyJEngine Antal/E = Antal/Molor
QtyJC QtyJCyllnder AnIal/C = Anlal/CyHnder
Qty./D QtyJSafety cover Antal!D = AnIal!sikkerhedsdreksel
07.09 - ESO
',:,,"MAN DieseI!
Plale
Page 3 (3) Covers Frame 51106-17
23/30
Item Item
Qty. Designation BencevneIse Qty. Designatlon Bencevnelse
When ordering spare parts, 8ee al80 page 500.50. Ved bestilling af reservedele, se ogS8. side 500.50.
Only avai lable as part of a spare parts kit. Kun lilgoong elg som del af et reseredelsscel.
Qly./E Qty.lEngine Antal/E = AntallMoIor
Qty./C OtyJCyIinder Antal/C = AnlallCylinder
QtyJD = OtyJSafety cover AnlallO = AnlaI/sikkerhedsdceksei
07.09 ESO
Plale
Page 1 (2) Covers Frame 51106 -30
23/30
644
07.09 ESO
,,' DieseI!
Plate
51106-30 Covers Frame Page 2 (2)
23/30
Item Item
. aly. Deslgnation Benrevnelse . aly. Deslgnatlon Benrevnelse
619 21 M0trik
When ordering spa re parts, see also page 500.50. Ved bestilling af reservedele, 5 ogs:' side 500.50.
= Only avallable as part of a spa re parts klt. tilgrengelig som en del af el reseredelssret.
aly./E = QtyJEngine Anlal/E = Antal/Motor
QtyJIndlvlduaI Anlalll = AntalIIndividuelt
07.09 ESO
,,.' DieseII
Plate
Page 1 (3) Covers Frame 51106-31
23/30
490
:~~- 058
010 J.-j---- 071
071 083
764
752 ~tl1
428
~
416
058
703 394
693
489
Cover see
plate 51102
06.49 - ESO
Plate
51106-31 Covers Frame Page 2 (3)
23/30
Ilem Ile m
. Designatlon Bencevnelse . Deslgnation 8encevnelse
083 6/0 5elf locking Selvlflsende ffi0trik 333 21C S Iud Tap
129 8/C Screw Skrue 345 1/ Guard end fore Skcerm, for
154 28/ Screw Skrue 357 1/ Guard end fore Skerm, for
191 21C Stud Tap 382 1/ Guard end fore Skcerm, for
<:
Q
:.\
~
ro
Wh en orderlng spare parts, see aIso page 500.50. Ved bestilling af reservedele, se ogs<.\ side 500.50.
"
Only avaIlable as part a spare parIs klt. tilgcengelig som del af reseredelssce t.
atyJE QtyJEngine Antal/E = Antal/Motor
atyJ C QtyJCy/inder AntaIIC = Antal/Cylinder
atyJD = QtyJSafety cover Antal/D = Antal/sikkerhedsdc:ekseJ
06.49 - ESO
',liM MAN DieseII
Plale
Page 3 (3) Covers Frame 51106-31
23/30
Item Item
. Oty. Deslgnatlon Benrevnelse . Oty. Design ation Ben mvnelse
When ordering spare parts, see al50 page 500.50. Ved besIilling af reseredele , se ogsf side 500.50.
Only avai lab/e as part of a spare parts klt. tilgc:engelig som en del af et reservedelssc:el.
Oty./E Qty./Englne AnIa l!E = Antal! MoIor
Oty./C Qty./Cylinder AnIal/C = AnIal!Cylinder
OtyJD Qty./Safety cover AntaVD = AnIal/sikkerhedsdc:eksel
06.49 ESO
Section 512
Turbocharger System
Description
Working card
23/30
Water washing , turbine side, inlet 7 Exhaust gas, oullet 2 1 air, inlet
Waler washing,
compressor side wilh
quick coupling, inlet
Water washing
compressor side
The turbocharger pumps the air through the char- The ehaust gas receiver iS made pipe sections,
ging air cooler to the charging air receiver. From the one each cylinder, connected to each other, by
charging air receiver, the air flows to each cylinder, means compensators, to prevent ecess i ve stress
through the inlet valves. the pipes due to heat epansion.
95.26 - ESOS
1,J,IIMi,,MAN DieseII
512.01 Turbocharger System Description
Page 2 (2)
EdiIion 01
23/30
the cooled intermediate piece a thermometer for avoid excessive thermal loss and ensure a
reading the exhaust gas temperature iS fitted and reasonably l w surface temperature the exhaust gas
there iS also possibility ! fitting a sensor for remote receiver is insulated.
reading.
95.26 - ESOS
',I,I,/( Diesell
General
Fouling airlilter, compressor charging air cooler The intervals between cleaning by injection water
may be observed as changes in performance para- should be adjusted alter assessing the degree and
meters: rate of louling in the particular plant, .. based on
observations and experience.
Decreasing charging air pressure.
Decreasing turbocharger rotor speed.
Increasing exhaust gas temperature.
Severe louling airways may even result in
compressor surge.
94.26 . ESOU-G
',,, Dieserl
23/30
V28/32S
Description
The tendency louling the gas side turbo- Heavily contaminaled turbines, which where
chargers depends the combuslion condilions, cleaned periodically Irom the very beginning after
which are a resull ofthe load and the mainlenance an overhaul, cannol be cleaned by Ihis method.
condilion the engine as well as Ihe quality Ihe
le l l used. 1I vibration the turbocharger occur after waler-wa-
shing has been carried out, the washing should be
Fouling Ihe gas ways will cause higher exhaust repealed. 11unbalance slill exisls, this is presumably
gas temperatures and higher surlace temperatures due 10 heavy louling , and Ihe engine must be sl op-
the combusti on chamber components and will ped and the turbocharger dismanlled and manually
also lead 10 a lower performance. cleaned.
Tests and practical experience have shown thal The washing waler should be taken Irom Ihe Iresh
radiaHlow turbines can be successlully cleaned water syslem and Irom Ihe Iresh cooling waler
by injection water the inlet Ihe turbine. system sall water system. cleaning agenls and
The cleaning ellecl is based th e water solubility solvents need be added 10 Ihe water.
the deposils and the mechanical action th e
impinging water droplets and Ihe water Il rale. avoid corrosion during slandstill , the engine must,
compleling waler washing al least 1
The necessary waler Il is dependent the gas hour belore slop so Ihat all parts are dry.
Il and the gas temperature. Enough water musl be
injected per time l so Ihal, l the Il will
evaporale, but abou t 0.25 I/min. wi ll I l 011Ihrough Water Washing System
the drainage opening the gas outlet. Thus ensuring
Ihal sullicienl waler has been injected. The water washing sysl em consisl s a system
equipped with a regulaling valve, a manoeuvring
Service experience has shown thal Ihe above men- valve, a 3-way cock and a drain wi th a drain
tioned waler l gives the optimal cleaning ellect. 1I valve Irom the gas outlel, see illuslration working
the waler f is reduced the cleaning effect wi ll be card 512-15.00.
reduced disappear.lfthe recommended waterllow
is exceed, there is a cerlain risk a accumulalion The waler lr washing the turbine, is supplied Irom
water Ihe turbine casing , which can result Ihe extern al fresh water system through a Ilexible
damage Ihe lurbocharger. hose wilh couplings. The Ilexible hose musl be
disconnecled after waler washing.
The besl cleaning ellecl is obtained by cleaning at
lw engine load approx. 20% MCR. Cleaning al lw activaling the manoeuvring valve and Ihe regu-
load ll also reduce lemperature shocks. lating valve, water is led Ihrough the 3-way cock 10
Ihe exhausl inlermediate flange, equipped with
Experience has shown, Ihal washing al regularinler- a channel 10 lead Ihe waler 10 Ihe gas inlel Ihe
vals is essential 10 successfuI cleaning, as excessive turbocharg er.
louling is thus avoided. Washing al intervals 100
hours is Iherelore recommended. Depending the Th e wal er which is evaporated, is led l through
l qualily Ihese inlervals can be shorler longer. Ihe drain Ihe gas outlet.
However, the turbine musl be washed al Ihe lalesl
when Ihe exhaust gas lemperature upstream the
turbine has risen aboul 20 C above Ihe normal
lemperature.
96.39 - ESO
Working Card 512-01.00
Page 1 (2) Oerhaul of Charging Air Cooler EdiIion 01
23/30
Shul-off slarling air
Shul-off cooling water
Shul-off fuel l
Shul-off cooling l
Stopped l b. l circul.
Descriplion :
Relaled procedure:
~
51201 11 3 6!cooler
~ Dala: 51201 029 1!cooler
9w
~ 51201 066 1!cooler
w
" Dala pressure and lolerance (Page 500.35) 61203 035 1!cooler
Dala lorque momenl (Page 500.40)
Declaralion weight (Page 500.45)
96.20 ESOS
iJ DieseII
23/30
The charging air cooler is normally cleaned and 4) Clean the cooler elemenI the water and air
overhauled at the inIervals indicaIed the "Planned sides.
Maintenance Program", or l observations prove thaI
the cooler does work satislactory, see section After using cleaning agents the manulacting recom-
502. mendation must be lollowed.
2 these blocks.
3 ! Service Periods.
96.20 - ESOS
Working Card 512-05.00
Page 1 (1) Water Washing of Compressor Side Edition
General
Starting position
Related procedure
02.20 - ESOS-G
Working Card Water Washing of Compressor Side 512-05.05
Page 1 (2)
TurbochargerType 15/ Edition 01
5,6L23/30H
Descriplion:
Slarling posilion:
Relaled procedure:
Manpower:
Replacemenl and wearing parls:
Working time 1/4 hour
Capacily man Plate Item Qty/
91.45 - ESQS
!'( DieseI!
512-05.05 Water Washing of Compressor side Working Card
Edition 01 Turbocharger Type 15/ Page 2 (2)
5,623/30
91.45 - ESOS
I+Hg.:MAN Dieserl
Working Card Water Washing of Compressor Side 512-05.05
Page 1 (2)
TurbochargerType 20/ Edilion 02
7,8L23/30H
Descriplion:
Slarling posilion:
Relaled procedure:
91.45 - ESOS
512-05.05 Water Washing of Compressor Side Working Card
Edition 02
rbocharaer Tvpe 20/ Page 2 (2)
7,823/30
Cleaning Procedure. 1I necessary, carry out Ihe washing once more, but
wilh 1 minutes interval from Ihe initial washi ng.
The cleaning process is only 10 be carried l, when
Ihe engine is al oeral in g lemperature and when l Compressorcleaning by injection olwater is sufficient
is loaded as close as possible 10 lull load . l a normal degree louling is present.
The engine musl l be shut immedialely after case severe dirt being deposited the compres-
cleaning but should be allowed 10 operale conlinuous- sor, dismantling the compressor components lor
lor some tim e ensure drying th e charge manual cleaning is necessary.
air system.
For manual cleaning compressor side , see spe-
cial instruction.
Sequence Operalions.
For water washing compressor side, see also
1) Run the engine with as high a load as pos- description for water washing.
sible.
4) Run th e engine lor aboul 1 minutes at unal- 1 Charge air line 2 Pipe
tered high load. 3 Manoeuvring l 4 Hose or pie
91.45 - ESOS
DieseII
Working Card 512-15.00
Page 1 (2) Water Washing of Turbine Side Edition 01
23/30
Descriplion:
Slarling posilion:
Relaled procedure:
91.04 - ESOS
512-15.00 Working Card
Edition 01 Water Washing ofTurbine Side Page 2 (2)
23/30
Cleaning Procedure. 3) Turn the 3-way cock 10 position 2 ' " , see
lig . 2 and check lor Iree passage. 1I ok turn the
1) Adjusl Ihe engine load 10 approx. 20 % and lel water wash position 3 "Wash".
Ihe engine stabilize lor 1 min.
4) Connect the water supply the water wash
2) Open th e drain cock at the turbocharger outlet system.
and check lor Iree passage, see fig 1.
5) Activate the manoeuvring valve, see fig 1.
Cleaning
-
... ... ."
that the water drain Il has stopped .
inlel - ... --
8) Continue at this load at least 5 min . belore
Drain cock increasing the load the normal condition.
Fig 1. Arrangement for water washing. Note: The regulaling valve has be opened
slowly.
91.04 - ESQS
Plate
Page 1 (2) Charging Cooler - Freshwater 51201 -04
523/30-72050
623/30 -72050
- 294
221
101
113
029
030
042
054 " ' -
066
078
091
-~ c
"-
233
030
- 208 017
97.06 ESOS
PlaIe
51201-04 Charging Cooler - Freshwater Page 2 (2)
523/30-72050
623/30-72050
Ilem Item
. Qty. Desig rl atiorl . Oty.
030 2/ I A.r
1 4/ Nu' Motrik
11 3 8/ Screw Skrue
When ordering spare parts, see also page 500.50. Ved beSlilling af reservedele, se ogs<\ side 500.50.
97.06 - ESOS
l,,' DieseI!
PIate
Page 1 (2) Charging CooIer - Freshwater 51201-05
6L23/30H-900
7-823/30-7205900
- 294
221
/
101
066
233
208 - 017
(j \ ...+
>'(1
~ \ \
\ - 304
282
97.06 - ESOS
Plale
51201-05 Charging Cooler - Freshwater Page 2 (2)
6L23/30H-900
7-823/30-72050/900
Ilem Item
. Oty. Oesignation Benrevnelse . Qty. Oesignatlorl 8erJrevneIse
233 1/ 0-rl"9 0- 9
When orderlng spare parts, see also page 500.50. Ved besIilling af reservedele, se ogsa side 500.50.
Only ava llable as part of a spare parts klt. Iilgrengelig som del af el reseredeI ssceI.
Oty./E Qty./Englne. = Anlal!Motor
atyJK = Cooler Antal! K = l
97.06 - ESOS
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-01
5L23/30
6L23/30-72050
132
073
132
061 085 107
097
r--~
] ~
000
~-~
fu
132
,~
168
144
156
239
~ 012-181
(240
024 024
_ ,
/ '
'Q
~~~;'
7:36
193
203 264
v-
~ 252
264
98.34 - ESOS
Plale
51202-01 Exhaust Pipe Arrangement Page 2 (2)
523/30
623/30-72050
Ite m Item
. Des lgn ation Be n ev n e l s e no. aly. Designation Benre vnelse
When orderlng spa re parts, see also page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only avallable as part of a spare p arts kIt. tilgrengelig som del af el reservedelsscet.
Qly.lE QtyJEn g/ne AnIal/E = Antal/ MoIor
Q y.C = QtyJCylInder Antal/C = AnIal/cyIinder
98.34 - ESOS
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-02
7-823/30-72050
6-7-8L23/30H-900
132
073
132
]
'--'~ ,
'" t. 2Jr;1~
144
156
=..J
239
012-181
240
024 ( 024
_
215
193
203 1-:
~ 252
264
227
264
98.34 ESOS
/ DieseI[
Plale
51202-02 Exhaust Pipe Arrangement Page 2 (2)
7-823/30-72050
6-7-8L23/30H-900
Item Item
, Qty. Deslgn atlon Benrevnelse no. aty. Deslgnation Benrevnelse
156 8/ l Molrik
When orderl ng spa re pa rts, see also page 500.50. Ved beslilling af reservedele, se ogs~ side 500.50.
Only ava iIabIe as part of a spare parts klt. tilgrengelig som del af re serede lss ret.
Qly./E QtyJEnglne Antal/E = AnIal/Motor
QlyJC = QtyJCy ll nder Antal/C = Antal/cylinder
98.34 ESOS
"+ DieseI!
Plate
Page 1 (2) Turbocharging Arrangement 51203-09
523/30-72050 RPM
623/30 -72050 RPM
151
246 ---I;:o\'""",,~
234
209
210
449 ______
450 -_---.:::~
462
295 ---)
138
114
378
,,\ ~,
, ;'
----:::::::~~,;:::::= 295
"....- - 283
305
391~ 391 317
401 413
401 6 425
401
305
03.18 - ESOS
fN" , MAN Dieserl
Plate
51203-09 Turbocharging Arrangement Page 2 (2)
523/3072050 RPM
623/3072050 RPM
Ilem Item
. Qty. Designation Be nrevne lse . Qty. Designation Be n ~ v n eI se
378 11 ac ki ng Si licone
sillcone paste
When ordering spare pa rts, see also page 500.50. Ved bestilJing af reservedele, se ogs~ side 500.50.
= On ly avaiIable as part of a spare parts klt. til gengelig som en del af et rese rve d e l sse l.
Qty.lE OtyJEnglne Antal/E = AnIal/Motor
Qty./C OtyJCylinder AntaVE = Antal/CyJinder
Qly./1 = OtyJlndi vidu al Antal!1 = Antal/lndividuell
03.18 ESOS
'}1',,, DieSeII
Plate
P_ge 1 (2) Turbocharging Arrangement 51203 - 10
6L23/30H-900
7-823/30-72050/900
151
354
246
209
067
055
449
450 ---=:::::~
295
283 '""'~-- For charge cooler
see plate 51201
533
378
138
114
378
Ifl ",.,~..
....
~:::::::;J.~~~ 295
~I~
\ ....- - 283
305
391 ~ ~ 391 317
401 413 305
~425
401 401
97.06 ESOS
+ Dieserl
Plate
51203-10 Turbocharging Arrangement Page 2 (2)
623/30-900
7-823/30 -72050/900
Item Item
. Qty. Designation Bencevnelse . Qty. Designation Benrevnelse
138 1/ Cooler box for K01erboks for ladeluft 533 1/ Flange Flange
charge
354 1 6/ M0trik
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs~ side 500.50.
Only avai lable as a a spa re as kit. Kun tilgrengelig som en del af el reservedelsset.
Qty.lE = QtyJEngine Antal/E = Antal/Motor
Qty./C = Qty./Cylinder Antal/E = Antal/Cylinder
QtyJI QtyJIndividual Antal/l = AnlaVlndividuelt
01.30 ESOS
PlaIe
Page 1 (2) SteamTrap / 51208-01 /
23/30
V28/32S
015
052
064
039
040
97.07 - ESOS
f,I,:,tH'fMAN DieseII
151208-01 SteamTrap ptaIe
Page 2 (2)
23/30
V28/32S
Item Item
. Deslgnatlon Bencevnelse . Qty. Designatio n Bencevnelse
052 / House, t op HU $,
When orderlng spare a s, see al50 page 600.50. Ved beSlilling af reseredele, ogSt' side 600.50.
97.07 - ESOS
5ection 513
Compressed System
Descrition
Working card
Filter 513-01.21
Oerhaul, Test and Inspection of Turbine Starter 513-01 .30
Main Starting Vale 513-01.40
Check of Compressed Piping System 513-01.90
Plates
23/30
On011 valve
for jel system
Reduclion
l
Emergency
valve
Standard
Optionals
The compressed air system the engine contains The air starter is activated electrically with a pneu-
a starting system, starting control system and saIety matic 3/2 way solenoid valve. The valve can be acti-
system . Further, the system supplies air ( the jet vated manually from the starting bo the engine,
system. and ! can be arranged ' remote control, manual
or automatic.
The compressed air is supplied from the starting
air receivers (3 bar) through a reduction station, For remote activati on, the starting spool is connected
where from compressed air at 7-9 bar is supplied so that every starting signal ( the star ting spool goes
( the engine. through the safe start function, which is connected
( the converter ' engine RPM .
avoid dirt particles the internal system, a strainer
is mounted the l ! line ( the engine. Further, the system is equipped with an emergency
starting valve which makes ! possible to activate the
air starter manually case a power fai lure.
Starting System
OO.1 1 -ESO
MlM,, MAN DieseII
513.01 Description
Edilion 05 Compressed System Page 2 (2)
L23/30
OO.11-ESO
Working Card 513-01.21
Page 1 (2) Filter Edition
General
Starting position
Related procedure
~
.; Manpower Replacement and wearing parts
"
v
~
~
Working time hours Plale no Ilem no Qy/
~
Capacity man
"
~
Data
"
"
Data for pressure and tolerance (Page 500.35)
Data lor torque momenl (Page 500.40)
Declaration weight (Page 500.45)
02.46 - 50
,,'.J DieseII
513-01.21 Working Card
EdiIion FiIter Page 2 (2)
GeneraI
Cleaning Filter replace filter element
1) Depressurize !. 7) Depressurize !.
2) Remove bowl and bowl guard assembly by 8) Remove bowl and bowl assembly by turning
turning counter-clockwise. counter-clockwise.
3) Inspect bowl lor damage seals and replace, l 9) Unscrew ballle by turning counter-clockwise.
nessesary.
1) Remove lilter element and discard.
4) 1I bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth mild detergen!. 11) Install new filter element and reassemble
reverse ord er.
5) Before returning to service, insure that aII seals
have been rein stalled replaced. 12) Belore returning to service, insure that all seals
have been reinstalled replaced.
6) ReinstaII bowl and bowl guard assembly and
rotate bowl guard clockwise to securely lock 13) Reinstall bowl and bowl guard assembly and
place. Align arrow bowl guard with arrow lilter rotate bowl guard clockwise to securely lock
body. place. Align arrow bowl guard with arrow lilter
body.
~ L
1f
Fig 1 Fi/ter
02.46 - ESO
WorkIng Card
Overhaul, Test and Inspection ofTurbine Starter
513-01.30
Page 1 (9) EditIon 01
23/30
Descriplion:
03.4 7 - ESO-G
III,,zN'fMAN DieseII
513-01.30 Worklng Card
Ed itlon 01 OverhauI, Test and Inspection ofTurbine Starter Page 2 (9)
23/30
General lformato
7 6
1) Always mark adjacent parts the housing
exhaust cover (1) , motor housing (8), intermediate
gear case (13), gear case (28) and drive housing
(40) so these members can be located the same
relative position when the starter is reassembled.
4) When grasping a part a vice, always use 5) Remove the dellector retaining screw (5) , de-
copper-covered vice jaws protect the su rface the Ilector retaining spring (4) and the splash dellector
part and help distortion. This is particularly (3) Irom the housing exhaust cover (1), See fig 2.
threaded members.
4) u the housing exhaust cover (1) Irom Ihe 7) Grasp the rearofthe motor assembly (12) and
motor housing (8). dislodge the housing exhaust ll Irom the rear the motor housing (8).
cover, rotale l the ears clear the motor housing. 1I the motor assembly (12) is difficult remove , lightly
Using a plastic hammer, tap the ears alternately l push the motor which is the the
Ihe housing cover can be removed Irom Ihe motor motor assemblyloward the exhausl side the motor
housing. housing order Iree the motor assembly.
03.47 - ESO-G
',lI,.., MAN DieseII
23/30
8) Tap the intermediate gear case (13) with a 13) Remove Ihe planet gear Irame assembly Irom
plastic hammer dislodge Irom the gear case Ihe inlermediale gear case. Using a sleeve that con-
(28). lacls Ihe ouler race Ihe Ironl gear Irame bearing
(17) , pre ss the planel gear Irame shalt seal (16) and
9) Position the intermediate gear case (13) on a Ihe Iront gear Irame bearing (17) Irom the Ironl end
bench in a copperfaced vice so that th e inlermediale and Ihe rear the inlermediate gear case.
pinion (26) is secured in the jaws the vise. Tighten
Ihe vice only enough 10 hold the inlermediate pinion 14) Remove Ihe rear gear Irame bearing (24) Irom
securely. the planet gear Irame (18), using a bearing puller
and remove Ihe gear shaf1 relaining washer (23) ,
1 ) Loosen Ihe inlermediale pinion relaining screw see fig 4.
(27) 1-1 /2 turns only. 00 nol remove. Remove Ihe planet gear shaf1s (22), planet gears
(19), planet gear bearings (20) and bearing spac-
Warning: 1I Ihe inlermediate gear case is nol sup- ers (21).
porled on a bench and l the inlermediale pinion
retaining screw is completely removed , Ihe interme- 15) Remove Ihe Iront bearing spacer (25) , using
diate gear case and compomenls cou ld lall causing a bearing puller and Ihe gear shalt relaining washer
injury. (23) Irom Ihe Ironl Ihe planet gear Irame by press-
ing on Ihe Ironl th e planel gear Irame shaf1.
11) Tap the inlermediate pinion lighlly 10 back the Remove Ihe gear shaf1 retaining washer only l Ihe
planet gear Irame assembly Ihe inlermediale washer Ironl bearing spacer is damaged.
gear case.
14
Fig4.
03.47 - ESOG
513-01.30 WorkJng Card
EditIon 01 Overhaul, Test and Inspection of Turbine Starter Page 4 (9)
23/30
2) Remove the drive retaining screw (61) ment is necessary and new parts are available. The
which has a right-hand thread. bearing and/orthe seal 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 washer (62) and the (54).
drive (63).
16) Press the clutch spring cup (50) down and
5) Slide the spring sleeve (64) and the remove the clutch spring cup retainer (49).
spring (65) off the drive shaft (57).
17) Remove the clutch spring cup and clutch spring
6) Unscrew the drive gear screw (34). Using an (51 ).
impact wrench with a 5/16" (8 mm) 8" (203 mm)
log hex inserted the end of the drive shaft. 18) Remove the clutch jaws (52).
7) Unscrew and remove the drive housing cap 19) Remove the front drive gear bearing (30), drive
screws (38) and lock washers (39). gear cup (36), drive gear lock washer (35) , drive gear
screw ring (37) and drive gear screw (34).
8) Tap the drive housing (40) with a plastic ham-
mer help dislodge from the gear case (28). 20) Remove the large drive shaft bearing retainer
(53) using a screwdriver.
Warning: Failure followthis procedure could result
injury personnel. 21) Press the rear drive shaft bearing and drive
shaft (57) of the piston. If the rear drive shaft
9) Place the drive housing (40) an arbor press, bearing needs be replaced, proceed as follows:
piston end . Apply a load the piston (54) using
the arbor press compress the piston return spring a. Cut and remove the small drive shaft bear-
(59) before removing the bulkhead retainer (45). 00 ing retained the drive shaft, using a small
use compressed air load the piston. chisel.
b. Press the rear drive shaft bearing (58) off
1 ) Remove the bulkhead retainer (45). Using a the drive shaft.
screwdriver and the arbor press.
22) Place the gear case (28) a workbench.
Caution: Make sure the tension of the spring pushes
the bulkhead of the drive housing before removing 23) Remove the drive gear bearing retainer (32),
the drive housing from the arbor press. using retaining ring pliers and working through the
access holes the gear web, See fig 5.
11) Remove the bulkhead (46) from the piston
(54). 24) ll the drive gear (29) of the gear case.
12) Remove the bulkhead ring (47) and the Note: 00 disassemble the drive gear and clutch
bulkhead ring (48). parts ofthe turbine powered starters. lf the drive shaft
is defective, instaII a factory-rebuilt !.
13) Slide the drive shaft (57) from the drive housing
(40). 25) Remove the drive gear shaft bearing retainer
(33), using retaining ring pliers.
14) ll the piston ' spring (59) off the drive
shaft. 26) Remove the rear drive gear bearing (31) from
the drive gear.
Note: 00 remove th e front drive shaft bearing
(42) the drive housing seal (43) unless replace-
03.47 - ESO-G
Working Card 513-01.30
Page 5 (9) Overhaul, Test and Inspection ofTurbine Starter EditJon 01
23/30
Assembly the Starter 10) Grasp the drive shaft (57) a vice, external
splined end down. Place assembled drive shaft screw
1) Always press the inner ring a ball bearing the drive shaft, screwhead down. lubricate
when installing the bearing a shaft. the inside diameter the drive shaft with SHELL
I grease.
2) Always press the outer ring a ball bearing
when pressing the bearing a bearing recess. 11) Slide the drive gear bearing (30) the drive
shaft.
3) Whenever grasping a part a vice, always use
leather-covered, copper-covered vice jaws protect 12) lubricate with SHELL I grease
the surface the part and help prevent distortion. and install the driving clutch jaw teeth lacing and
This is particularly true threaded members. driven clutch jaw teeth lacing down the drive
shaft.
4) Always clean every part, and wipe every part
with a thin Iilm l belore installation. 13) Insert the clutch spring (51) the drive
shaft.
Gear Case 14) Insert the clutch spring cup (50) the drive
shalt.
1) Place the drive gear bearing retainer over the
rear end the drive gear. 15) Press the inserted parts the drive shaft,
and install the clutch spring cup retainer (49).
2) Press the rear drive gear bearing (31) the
rear end the drive gear, using an arbor press. Note: 1I is necessary replace the drive hous-
ing (40) and drive components, make sure that the
3) Seat the rear drive gear bearing the gear piston seal has been removed Irom the rear th e
case by tapping th e opposite end the drive gear, new piston (54).The piston seal must be removed
using a plastic hammer. prevent pressure build-up which ll cause move-
ment the planet gear Irame shaft seal (16). 1I this
4) Install the drive gear shaft bearing retainer conditions occurs, the piston cannot retract and the
(33), using retaining ring pliers. drive (63) ll remain engagement with the
Ilywheel, causing damage the starter drive train
03.4 7 - ESO-G
513-01.30 Working Card
EditIon 01 Overhaul, Test and Inspection ofTurbine Starter Page 6 (9)
23/30
andlor starter motor. remove the piston seal, Warning: Make sure the bulkhead retainer is properly
sert a screwdriver inside the lip the seal and pry seated the motor housing groove belore easing 011
loose Irom the piston. the arbor press. Failure do so will allow improperly
retained parts separate when removed Irom the
16) Install the piston (54) the drive shaft til arbor press resulting injury personnel.
the rear drive shalt bearing seats the piston.
27) Remove the drive housing Irom the arbor
17) Coil the large drive shaft bearing retainer (53) press.
the groove the piston retain the outer race
the drive shaft bearing, using a thin Ilat blade 28) Lubricate and install the drive housing O-ring
screwdriver assist this operation. (41) the groove the drive housing.
18) Lubricate the piston O-ring (55) and install 29) Position the assembled gear case a work-
the groove the piston. bench. The as-sembled must be upright accept
the drive housing.
19) Position the drive housing an arbor press, Carelully position the assembled drive housing (40)
pinion-end down and install the dri ve housing seal the gear case so as damage the piston
(43) intothedrive housing . Using a pressing sleeve seal. Align th e punch marks the gear case and
the proper size, press the seal the drive housing drive housing.
so that the lip the seal laces away Irom the drive
. 30) Install the drive housing cap screw lock wash-
ers (39) and the drive housing cap screws (38) and
20) Press the bearing the drive housing l tighten 28 Nm torque.
seats, using a sleeve that contacts the outer race
the Iront drive shalt bearing (42). Drop the piston 31) Tighten the drive gear screw (34) 77.3 Nm
return spring seat (60) Iront drive shaft torque, using an impact wrench with a 8 mm 203
bearing. mm long hex inserted the end drive shall.
21) Slide the piston return spring (59) the 32) Grease and slide the spring (65) and
drive shaft and snap the Iront the piston so the spring sleeve (64) the end
that is against the large drive shaft bearing retainer the drive shaft.
(53).
33) Grease the end the drive shaft and
22) Lubricate and insert the assembled drive shaft install the drive pinion (63).
the drive housing.
34) Grasp the drive a copper-covered
23) Lubricate and install the outer bulkhead 0- vice with the starter supported a workbench.
ring (47) and the Inner bulkhead O-ring (48) the
bulkhead (46). 35) Place the drive washer (62) drive
retain ing screw (61).
24) Slide the bulkhead the piston.
Note: The thread the drive retaining screw
25) With the drive housing the arbor press, press is right-hand thread.
down the rear lace the piston.
36) Install the drive retaining screw
Note: Feel the underside the drive housing make the end the drive shalt and tighten 108.5 Nm
sure the drive shaft passes through the bearing. torque.
03.47 ESOG
Working Card 513-01.30
Page 7 (9) Overhaul, Test and Inspection ofTurbine Starter Edition 01
23/30
llermediale Gear Case, Molor Housig, Molor 6) Install the other planet gear shaft retaining
Assembly ad Housig Exhausl Cover washer over the shalt at the rear the planet
gear.
1) Press the gear Irame bearig (17)
the rear ofthe intermediate gear case (13), using a 7) Press the rear gear Irame bearing (24) the
bearing pressing 1001 the proper size. shaft at the rear the planet gear Irame, using the
proper size bearing inserting l.
2) Press the planet gear Irame shaft seal (16)
the rear the intermediate gear case over the Iront 8) Slide the planet gear Irame assembly, coupling
gear Irame bearing, using a sleeve which contacts end lirst, the rear the intermediate gear case
the ring the seal. (13) , making surethatthe planetgears mesh withthe
ri ng gear. Use care so as damage the seal.
: Make sure the Ilat side the seal is installed
against the beari ng. 9) Install the intermediate (26), making
sure that the notches at the rea r the align
3) Install the rear gear case O-ring (14) the with the notches and tangs the shaft the planet
groove al the rear the intermediated gear case gear Irame.
and the Iront gear case O-ring (15) the groove at
the Iront the intermediate gear case. Coat both 10) Clean the threads the intermediate
O-rings. retaining screw (27) and apply 2-3 drops Perm-
abond 118 the threads approximately 3 mm
4) Install gear shaft retai ning washer (23) Irom the end the screw. Install screw and tighten
the Iront the planet gear Irame (18). Press the Iront enough hold assembly together.
bearing spacer (25) the Iront shaft the planet
gear Irame hold the gear shaft retaining washer 11) For lna l tightening , position the intermediate
snugly position. gear case so the intermediate is secured
the jaws the copperfaced vice. Tighten the
Nole: Coal the Ironl bearing spacer with gear Lube mediate retaining screw 122 Nm torque.
belore installing . Be carelul gouge scratch
the Iront bearing spacer during installation as this 12) Remove the intermediate gear case Irom the
could resu lt leakage between the planet gear vice and set a bench.
Irame and gear case.
Nole: The intermediate gear case l l work only
5) Place planet gear Irame a bench, shalt side one orientation.
down. Place the planet gear bearing (20) inside
planet gear (19). Place bearing spacers (2 1) Align the punch marks the intermediate gear
and boom bearing and gear. Slidethecomponents case and gear case and tap the intermediate gear
the slots the side the planet gear Irame. case with a plastic hammer l seats the rear
Align holes spacers and bearing with holes the gear case. Make sure the intermediate
planet gear Irame and insert planet gear shaft (22), meshes with the drive gear.
integral keyed end down, through the spacers and
bearing so that Ihe larger Ihe keyed end Coat the O-rings the motor assembly and the
the shaft contacts the planel gear shaft retai n- inside the cylinder belore installing the motor
ing washer (23). Repeat the procedure lor the assembly.
remaining planet gears and components.
13) Install the motor assembly through the rear
Nole: move turn the planet gearlrame the motor housing with the geared end the rotor
l step 6 and 7 have been completed. Movement toward the Iront.
the planet gear Irame assembly could dislodge
assembled components, making necessary
repeat step 5.
03.47 - ESO-G
DieseII
513-01.30 WorkIng Card
EdiIIon 0 1 Overhaul, Test and Inspection ofTurbine Starter Page 8 (g)
23/30
Note: Turn the intermediate so that the gear and tap the housing exhaust cover with a plastic
the rotor meshes with the planet gears. Make hammer l seats.
sure that the rear the motor assembly is installed
Ilush with the rear the cylinder. 18) InstaIi the housing exhaust cover the rear
the motor housing using the starter assembly cap
14) Align the punch marks the motor housing screws (6) and cap screw washers (7). Use an 8 mm
with the punch marks the intermediate gear case hex-head wrench tighten each a l ttl at a time
and tap the motor housing with a plastic hammer l a lna l torque 61 68 Nm increments.
seats the rear the intermediate gear case.
19) the exhaust cover (68) the housing
15) Install the splash dellector (3), dellector retain exhaust cover (1).
ing spring (4) and dellector retaining screw (5) th e
rear the housing exhaust cover. Note: Use Intersoll-Rand 5MB-441 sealant
all plugs.
Note: Coat the threads the deflector retaining
screw with Ingersoll-Rand 5MB-441 sealant. 20) Install the bottom housing plug (1 ) and the
housing plug l boss (11). the starter its
16) Coat the exhaust cover seal (2) and instaIi side with the side plug hole upward. Add 175 ml
the groove the housing exhaust cover. automatic transmission Iluid Iullilling 11 D
specilication, e.g. SHELL , through the
17) Align the punch marks the housing exhaust side plug hole.
cover with the punch marks the motor housing
03.47 - ESO-G
WorkIng Card 513-01.30
Page 9 (9) Overhaul, Test and Inspection of Turbine Starter EditIon Q1 H
23/30
Caution: Do overfill. Remove the pressure Irom the "" por!. Measure
Install the side housing plug (1) and tighten all plugs the distance lorm the lace the drive shaft
6.8 13.6 Nm torque. the the lace the mounting Ilange. should be
Test and Inspection Procedure 45.0 +2.0 mm.
1) CluIch Ratcheting: Turn the drive shaft 4) Action: Secure starter a vise and ap-
(63) by hand the direction the starter rotation. ply 90 psig (6.2 bar/620 kPa) pressure using a 3/8"
The clutch should rachet smoothly with a slight click- (9 mm) supply line the inlet the motor. starter
ing action. should smoothly.
3) Engagement: Apply 50 psig (3.4 There should be leakage the housing joinls
bar/345 kPa) pressure the engagement " " por!. Ihe gear case area the shall seal the
drive shall (63) should move outward and air inlermediate gear system. 1I the starler is properly
should escape Irom the ' " por!. sealed, bubbles w ll appear.
03.47 - ESO-G
WorkIng Card 513-01 ,40
Page 1 (2) Main Starting Valve Edition Q1H
23/30
Stopped engine
Shut-off starting air
Shut-off cooling water
Plate Item Note
Shut-off fuel l
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Soft hammer.
Locking ring plier.
Allen key, 1/4' .
Slarling posilion:
Relaled procedure:
94.22 - ESOSG
$%'!/ DieseII
513-01.40 Main Starting VaIve
WorkIng Card
Edition 01 Page 2 (2)
23/30
Warning: Disassembly:
l aIIempl any mainlenance Ihe main slarl- 4) Clamp Ihe main slarling valve, a vice wilh
ing valve belore Ihe slarling air syslem has been Ihe locking ring (9) end up.
bled off.
5) Carelully remove Ihe locking ring (9). The end
plug (3) should spring .lf l does l , lap Ihe valve
Important: housing (1) lighlly wilh a soft hammer l does.
The main sl arling valve should be periodically lubr 6) Remove Ihe end plug (3), spring (8) and pislon
caled as lollows: (2) assembly.
1) Blend Ihe air pressure. 7) Remove and discard all used O-rings, O-rings
relainer (5), bumper (7) and spring (8).
2) Remove lhe plugscrew () . see fig 1and squirl
aboul 30 9 1 w l Ihe valve Ihrough Ihe plug 8) Wash all olher parls a clean, nonllammable
opening . so l ven.
94.22 - ESOSG
WorkIng Card 513-01.90
Page 1 (2) Check of Compressed Piping System Edition Q1H
23/30
Slarling posilion:
ReIaled procedure:
Dala:
94 .21 - ESOU-G
',.f DieseI!
513-01.90 Worklng Card
Edi!Ion 01 Check Compressed Piping System Page 2 (2)
23/30
1) Examine the piping system for leaks. 6) Move aII valves and cocks in the piping system.
Lubricate valve spindles with graphite similar.
2) Retighten all boltsand nuts in the piping system.
7) Connect the air supply and make a function test
3) Drain the system for condensed water.. This of the emergency valve. See description 513.01.
should be based on observati ons.
5) Check manometers.
94.21 - ESOU-G
+ DieseII
Plate
Page 1 (3) Turbine Starter 51309-01
23/30
\
\,
)
96.26 - ESOS-G
l~HZ'IIIIMAN DieseII
Plate
51309 -01 Turbine Starter Page 2 (3)
23/30
Item Item
. aly. Oesignation Bencevnelse . aly. Designatlon Benrevnelse
014 I/S Housing exhaust Hus udsI0ds-drek- 254 I/S Bearing spacer LIgemellemstykke
cover sel
266 '/S Planet gea r s haft PlaneIgearaksel
026 1/S Exhau st c over seal Telningsr ing for ud-
sl0dsdreksel 278 2/S Gear shaft retalner Spcenderingsskive
wa sher gearaksel
038 1/S Spl ash deflector Stccnk doflcktor
291 ,/S Rear gea r frame Bagersle gearstelleje
051 I/S Deflector return Ret r fJeder for de- bearlng
spring Ilektor
301 I /S Front bearing spacer Forreste gearslelleje
063 1/S Deflector retaining Spcendeskive
sc rew deflektor 313 1/S Intermedl ate nl Mellemlandhjul
075 4/S Starter assembly cap Ocekselskrue lr mon- 325 1/S Intermediate Spendeskrue mel-
screw lage aI slarler retaining screw lemtandhjul
087 4/S Cap s crew washer Skive deksel skrue 337 1/S Gear case Gearkasse
109 I/S Housing plug Prop l molorhus 350 I/S Front drIve gear Forreste dr lvgearleje
bearing
110 1/S Housing plug Inlet Tilgangsknast p rop
boss molorhus 362 1/S Rear drive gear 8agerste drlvgearleje
bear/ng
122 1/S Motor as sembly Motor samling
374 ,/S D gear bearIng Sprendskrue driv-
134 2/S CylInder o-rlng seat. O- r ings letnlng retainer gearleje
cyllr1der
386 1/S D gear shaft Spen d skrue drlv-
146 2/S Housing o-rlng seal. O- r Ingste t n I ng for bearlng retalner g earakselleje
motorhus
398 1/S gear screw Drvgea r sk r ue
158 1/S Intermedlate gear Mellem gearkasse
case 408 1/S Drive g ear lock Skive drivgear
washer
171 1/S Rear g ear case - 8agerste gearkasse
ring o-rlng 421 gear cup Deksel for drivgear
' /S
183 1/S Front gear case Forresle gearkasse 433 I/S Drlve gear screw O-rlng drivgearskrue
o -rlng o-rlng o-rlng
195 I /S Planet gear fram e Tetnings r ing pla- 445 8/S houslng cap Dekselskrue driv-
shaft seal. netgearakselstel screw gear
205 I/S Spacer ring Afstandsring 457 8/S Drlve housing cap Skive drekselskrue
screw lock washer l l drivgearhus
217 l Front gear frame ForresIe gearstelleje
b earlng 469 1/S Drive houslng kit Drivgearhus
229 1/S Planet gear frame Planetgearstel 470 I/S houslng o-ring O-ring for drivgea rhus
230 I /S Planet gear Plalletgear 482 I /S Front shaft bearlng Forresle akselleje
~
::
When ordering spare parts, see al so pag e 500.50. Ved bestilting af reservedele, 5 og$~ side 500.50. ""
On ly available a$ part ot a spare part$ kit. tilgreng elig som del af el reservedelsscet.
alyJ/E = Oty./Englne Oly./E Oty./Motor
alyJS = Oty.rrurbine Staer O' y./S Oty.rrurblneslar Ier
96.26 - ESOS-G
Plate
Page 3 (3) Turbine Starter 51309-01
23/30
Item Item
. Qty. Deslgnatlon Benmvnelse . Qty. Deslgnation Bencevnelse
504 1/8 Dr/ve hous/ng vent Aflflningsprop (or 768 Spare parts kit, Incl. Reservedelsscet ,nkI.
plug drivgearhus Item 026, 134, 146, ilem 026. 134, 146. 171 ,
171,183, 195,205, 183,195,205,217, 254,
516 1/S Bulkhead reta/ner SkoIholder 217,254, 278,291, 278,291,301,470.516,
301 , 470,516, 541 , 541, 553. 624, 685 og
528 1/8 BUkhead kit Skotscel 553,624,685 and 697
697
541 1//8 Outer bUkh ead Ydre skot o-rlng
o ring
When orderlng spare parts, see also page 500.50. Ved besliIIlng af reservedele. ogsa side 500.50.
Only avalable as part a spare parts klt. tilgcengelig som del af el reservedelsscet.
Qty./E = OtyJMotor Oty./E Qly./Molor
QtyJS OtyJTurbIne Staer Oty./8 Qly./Turbfneslarter
96.26 . ESOSG
Plate
Page 1 (2) Main Starting Valve 51310-01
23/30
045'
021'
082' --J1---~~~~~;;jt
~~~---- 069'
094
070'
94.22 - ESOS-G
Plate
51310-01 Main Starting Valve Page 2 (2)
23/30
Item Item
. aty. Designation B e n ;ev n e l se . Qty. Designation Ben;evnelse
When ordering spare parts, see al50 page 500.50. Ved bestillIng af reservedele, se ogsfl side 500.50.
Only ava iIable as part of a spare parts kit. Kun lilgrengelig som del reservedelssret.
Oty,/E QtyJEnglne Antal/E = Antal/MoIor
OtyJV = Qty.IValve AntalN = AntalNentil
94.22 - ESOS-G
'M,',"MAN DieseII
Plate
Page 1 (2) MuffIer I S1312-01H
23/30
r
010
J
-- - - - - - - - - - --- ----------
111 111
'\
94.22 - ESOS-G
',6' DieseII
23/30
Ile m Ilem
. aly. Deslgnation Bencevnelse . aty Oeslgnation Benrevnelse
When ordering spare parts, see also page 500.50. Ved besIilllng af reservedele, se ogsA side 500.50.
Only aval lable as part a spa re parts kit. Kun tilgcengelig 30m en del af reservedelsscet.
QtyJS = QtyJStartlng air motor Anlal/S = Antal/Startemotor
94.22 . ESOSG
',"i DieseII
Plate
Page 1 (2) Emergency Starting VaIve 51313-01
23/30
053'
01 6 .
089' 100'
090'
028'
100'
~~ 136
94. 22 - ESOS-G
l
51313-01 Emergency Starting Valve Page 2 (2)
23/30
Ilem Ile m
. Qty. DesignaIion Bencevne Ise . Qty. Designation Bencevnelse
When orderlng spare parts, see al50 page 500.50. Ved bestIlling af reservedele, se ogsfl side 500.50.
Only available as part of a spare parts kit. u tilgcengelig som del af et reservedelssa!t.
Qty./E QtyJEnglne AntalIE = Antal/Motor
QtyJV = Qt yJVa lve AnIa!N = ArJtalNentl
94.22 - ESOS-G
Dieserl
Plate
Page 1 (2) Starting VaIve 51314-01
L23/30
084'
011
059'
060
023'
072'
047'
035'
94.22 - ESOS-G
Plate
51314-01 Starting Valve Page 2(2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Designation Bencenelse
084- 1 l M0trik
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele. se ogsA side 500.50.
= Only avai lable as part of a spare parts klt. u tilgcengelig som en del af reservedelsscet.
Qly./E = Qty./Englne Antal/E = Antal/Motor
Qly.N QtyJVa lve AntalN = AntalNentil
94.22 - ESOS-G
":,, Dieserl
Plale
Page 1 (2) Main Stop VaIve 51315-03
L21/31 , L21/31CR
L23/30, L27/38
066 - -
042
00.41
,:, DieseI[
Plate
51315-03 Main Stop VaIve Page 2 (2)
21/31 , L21/31CR
23/30, 27/38
Item Item
. DesIgnation Benrevnelse . Qty. Deslgnation Benrevnelse
When orderlng spare parts, see page 500.50. Ved bestilling af reservedele, se ogsfl sId e 500.50.
00.4 1
i( DieseI!
Plate
Page 1 (2) Strainer I S1316-01H
23/30
012- _____
----..._.-
085
048 -__
---FT-(;-'',,,,,--r~~
__ 1 t
024--------- /
061 \
097 107 ~
073- ________ _
94 22 - ESOS-G
I,IIl$N MAN DieseI!
Plale
51316-01 Strainer Page 2 (2)
23/30
Item Item
. Designatio n Bencevnelse . aty. Des ignation Bencevnelse
When ordering spa re parts, see al50 page 500.50. Ved bestilling af reservedeJe, se og5a side 500.50.
= Only available as part of a spare parts klt. Kun tilgcengelig som del af et reservedelssrel.
atyJE Qty./Engine. Antal/E = Antal/Motor.
atyJF atyJFiIter. AntaljF = Antal/Filter.
94.20 . ESOSG
PlaIe
Page 1 (2) Safety Valve 1 51319-01
23/30
019
'- -
h D h D r
WUr " - - - 020 uru r
r----J ~ -JI
------_.---- 044
032
94.22 - ESOS-G
IS1319-01H Safety Valve Plate
Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Bencevnelse . Qty. Designation Bencevnelse
When ordering spare parts, see al50 page 500.50. Ved beslillrng af reservedele, se 0958: srde 500.50.
94.22 ESOSG
'M'NI/fMANDieseIJ
Plale
Page 1 (2) ON-OFF VaIve for Jet System 51320-01
23/30
.=====>
11
014
V
026
/
J
/
J !
/
[ -[ 1/,
!
~
/ 038
'-- 051
063
075
~
087
---
r--
/ \
---
f---
- '----
94.22 - ESOS-G
Plate
51320-01 ON-OFF Valve for Jet System Page 2 (2)
23/30
Item Item
. Deslgnation Bencevnelse . . Designation Bencevnelse
026 1 Housing
When ordering spare parts, see al50 page 500.50. Ved besliJlIng aI reservedele. se ogsa stde 500.50.
= Only avaiiabIe as part of a spare parts kit. u tilgoongelig som en del af et reservedelsseet.
OtyJE = QtyJEngine. An1al/E = Antal/Motor.
OtyJV QtyJValve. AntalN = AnlalNentII'
9422 - ESOS-G
f,l,j,$N'iMAN DieseII
Plate
Page 1 (2) FiIter 51321-02
GeneraI
177 - - ,
02.46 - ESO
Plate
51321-02 Filter Page 2 (2)
General
Item Item
. DesIgnatlon Bencevnelse . aty. Des ignation Bencevnelse
When ordering spare parts, see a l50 page 500.50. Ved beslilling af reservedele, se 095.3. side 500.50.
OnJy available as parI of a sare parIs kit. Iilgrengelig 50m del af el reservedelssret.
aly.lE = Qly.lEngine. Antal/E = AntalJMotor.
02.46 - ESO
Mi4'IMAN Dieserl
PlaIe
Page 1 (2) Pressure Reduction VaIe 51322-02
16/24
23/30
039*
218
015 ~ 027
039* :;'6,"~
231
172 ~ (j "" ""
243 184* ~~;;~
~~- 040
064* ~ 052*
076* ----=::-~::-
_c:>
~--
-C>
088* ------~~~-
255
111
r-----
123* --c:::>
135* = - - f I
(2) (2)
147* ---------=c;
159* -----c=::>
160' ~
70 - Inlel 10 engine
99.03 ESOG
"li/(MAN DieseII
Plale
51322-02 Pressure Reduction VaIe Page 2 (2)
L16/24
L23/30
Item Item
Designation Benrevnelse Qty. Deslgnatlon Benrevnelse
052* 1 0-rl"9 0- 9
147" 1 0 -rl"9 0- 9
159' I O-rl"g 0- 9
184 2 0-rln9 0- 9
When orderlng spare parts, see also page 500.50. Ved beslilfing af reservedele, se ogsA side 500.50.
= Only availabIe as part of a spare parts kit. lilgrengeJig som en del af et reservedelssret.
/ = Oty/Englne Anlal/E = Anlal/Molor
OtyNalve AnlalN = AntalNenlil
99.03 - ESO-G
5ection 514
InternaI FueI System
Description
Working card
Plates
23/30
Flywheel end
Cyl.1
Leak from
FueI - ilvalv~
feed
pump " "',-~
Drain -
from cyl.
head
"""
pipe
-~
pressure
pump
_ _ Fueloil
inIet
'-4+r-",
~~--t=~=-=========:=::j ~/-----f
FuelIeakage alarm ILeak from
Fueloil fuel pump
filter
3 2 1
WasIe , FueI l, FueI ,
inieI outlet inIel
General
The internal built-on luel l system consists the The salety l l ter is a duplex Iilter the split type with
lollowing parts: a llter lineness 50 my. The llter is equipped wi th a
common three-way cock lr manual change both
the luel l leed system the inlet and outlet side.
the high-pressure injection equipment,
comprising luel l injection pumps, luel l During normal operation both lilters should be
injection valve and luel l high pressure operation. Single operation only to be used when
dismantling the llter s lr manual cleaning
the waste l system inspection.
94.26 ESOS
514.01 Descrjplion
Internal Fuel System Page 2 (3)
Edilion 01
23/30
Forcirculation luel duri ng stand-still the engine, The injection valve is lor "deep" building-in 10 the
a by-pass l ne iS mounted with a non-return valve centre Ihe cylinder head.
parallel to the leed pump.
94.26 - ESOS
Description 514.01
Page 3 (3) InternaI FueI System Edition 01
23/30
The connection between injection pump and l Waste leak l from the compartm ent, l valve and
injector is a shielded high pressure . The high engine leed pump is led ( a lel leakage alarm
pressure is equipped with connection tapers uni!.
matching ( simiular taper facing s on the threaded
connectors on the injection pump and the l in- The alarm unit consists a box with a Iloat switch
jector. for level monitoring. ln case a larger leakage th an
normal leakage, the float switch l l initiate alarm.
The supply l l the engine is led through the
unit in order ( keep this heated , thereby ensur-
ing free drainage passage even for high-viscous
waste/leak l.
94.26 - ESOS
'( DieseII
Working Card
FueIInjection Pump and FueI Injection Pipe 514-01.05
Page 1 (4) Edilion 1 2
L23/30
Shut-off starting air
Shut-ofl cooling water 52014 013
Shut-oll luel l 52014 025
Shut-off cooling l 52014 204
Stopped lub. l circul . 52014 253
52006 261 20-120 Nm
52006 273 80-360 Nm
De5cription:
Hand tOOI5:
Starting 05n:
Ring and open end spanner 13 mm
Cover Iron! luel 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
l' lor lock ring.
Tools lor cleaning.
Related procedure: Clean kerosene or gas l.
Clean lubricatin g l.
Inspection roller guide lor ! seize product (Copaslip, Molykote GN Plus
luel injection pump, 508-01.05 or similar).
Manpower:
Spare and wearing part5:
Working time : 4 hours
Capacity 1 Man Plate . Item . /
08.03 - ESOS
',l DieseII
514-01.05 FueI Injection Pump and FueI Injection Pipe Working Card
Edition 12 Page 2 (4)
23/30
Dismounling luel injeclion pump 8. Take out the plunger spring () , upper spring plate
() and (J) . 1I necessary remove the lock ring ()
1. Dismount the le l injection pipe pos. 1 fig 1 and guide () and dismount the regu lating rod () as
and the lel inlet pipe pos 2. well as the cap screw the opposite end the regulating
rod () .
2. Separate the spring loaded lever Irom the
regulating rod the luel injection pump.
D,F
2
G
3
5
6
J R
Fg 1 View from Contro/ Side
3. Remove the pipe lor lb. ol and drain.
06.03 ESOS
Working Card
Fuel Injection Pump and Fuel Injection Pipe 514-01.05
Page 3 (4) Edilion 12
L23/30
12.
par ts must be cleaned, using kerosene Assemblng luel injection pump:
gas l
and a hand bru sh ( a steel brush).
l through the holes lor sealing l th e pump 17. When assembling the injection pump, proceed
houses and th e barrel (). the reverse ord er disassembling. PayattentIon
the lollowing:
Inspection luel injection pump: . initial tightening new parts the lollowing
(C) lr barrel ().
13. Insert plunger () and non-return valve (F) Tighten screws 55-65 Nm.
the barrel () alter wetting with clean gas l. Plunger
and non-return valve must slide the barrel by . Renew all sealing rings. For placing the rings,
their weigh!. see fig 2.
14. The axial clearance between lower spring plate C. Coat all the threads with an anti seize pro-
and plunger l t must exceed 0.25 mm. Th e duc!.
clearance between lower spring plate and plunger
l t is 0.05 0. 1 mm when new. See fig 3. D. dry with paper plane sealing surlace
barrel () and connecting piece ().
~ Spring ()
t Marking on
regulating rod
Tooth with chamfer
Fig 3 Clearance between Lower Spring Plate and P/LInger Marking on pinion
08.03 - ESOS
514-01.05 Fuel Injection Pump and Fuel Injection Pipe
Working Card
Edilion 12 Page 4 (4)
23/30
G. The marking Ihe guide cam Ihe plunger 20. Reconnect the regulating rod ( ) the spring
(), must be l ne with the marking the slots loaded lever and all the pipes the luel pump.
the (J). ( shown lig 4).
18. After assembling, the easy motion the re Fuel injection pipe:
gulating rod (), must be checked and the plunger
() must be moved Irom the noload stop lulHoad normal working conditions the luel injection
stop. require very lttl maintenance ecept replacement
O-rings and gaskel connection with the normal
overhaul luel injection equipment.
Mounting luel injection pump:
08.03 - ESOS
Working Card
Fuel Injection Valve
514-01.10
Pag. 1 (4) Edilion 02
23/30
Stopped engine
Shutoff starting air
Shut-off cooling water
Plate
52006
Item
26 1
Note
20- 120
Shut-off fuel l 52014 013
Shut-off cooling l 52014 108
Stopped lub. l circul. 52014 204
520 14 300 Et ra tools
52014 361
52014 407
Descriplion:
cover the cylinder head and cover Ring and open end spanner 12 mm
the fuel injection pump has been dismounted . Ring and open end spanner 24 mm
Fuel injecti on pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools cleaning.
Clean kerosene gas l .
Antiseizure product.
(Copaslip, Molykote GN Plus similar).
Relaled procedure:
95.50 - ESOS
+' DieseI[
514-01.10 Working Card
Edilion 02 FueI Injection VaIve Page 2 (4)
L23/30
The luel injection valve is the single component that 3. Clean the lower part Ihe nozzle (J) Irom
has the greatest influence the diesel engine con- carbonized oil deposits belore dismantling the nozzle
dition. Various lorms operation and quality luel ! (). Remove the nozzle ! () and th e nozzle
oil aHect the overhaul intervals.ln some cases ! may (J).
be necessary shorten the prescribed intervals.
. Lock F
c. Sealing ring
D. Adjusling screw G
. Sealing ring
F. Nozzle spring
G. Spring spindle
. Nozzle ul J
J. Nozzle
AIIenIion!
! damage the lapped surface.
95.50 ESOS
',.f DieseI!
Working Card 514-01.10
Page 3 (4) FueI Injection VaIve Edition 02
23/30
8. Nozzles are matched by lapping and are the- 14. The most effective checking the luel valves
relore only interchangeable as units. Insert nozzle is obtained through pressure testing, prelerably
needle with gas l the needle guide. It must be carried alter each overhaul and also in case
controlled whether the nozzle needle slides down irregularities in operation. The pressure testing
by its dead weight on its seat. is carried in the lollowing way by means the
pressure testing apparatus supplied.
9. 1I the holes are oval worn. which is checked
with a magnilying glass, the nozzle must be scrap- 15. Mount the luel injection valve in the bracket
ped. VTO-W020. (see p/ate 520.14 item . 25) again. The
bracket be in such a position that the nozzle
10. The best way, however, check l the holes the injector is pointing downwards.
are worn is control the Ilw rate the nozzle
which, in general, only can be made at the manu- 16. For test the injection pressure and ato-
lacturer's works on a special test stand. mizing mount the test VTO-W0.21 (see p/ate
520.14 item 0.49), increase pressure by means
11. Every ellort relinish w l l result in alterations the lever on the test pump, and adjust the opening
these values and mallunction the nozzle. 1I pressure 320. bar, by the adjusting screw (D), see
heavy abrasion symptoms, respectively damages fig 2, then tighten lock nut () and check opening
are observed at the visual inspection the parts, pressure again.
the parts in question must be replaced . Do not epect chattering, but make sure that the
nozzle spray Irom all holes in the same angle. The
nozzle might chatter l the lever is worked very last,
Reassembling: actually by hitting .
Do not expect a nozzle with more than 10.0.0.
12. When all parts have been overhauled, lound running hours perform l ke a new nozzle in the
in good order and carelully cleaned, assemble the test pump.
luel injection valve again. Then increase the pressure 30.0. bar and keep the
pressure by working the leer slowly downwards.
13. When assembling the injection valve, proceed When the pressure is kept at 30.0. bar, there should
in the opposite order compared the disassembly. be no more than one drip Irom the nozzle lor
Pay attention the lollowing: approx. 3-5 sec.
. Lubricate the threads on the adjusting screw WARNING: Keep oul Ihe luel jets as they wll
(D) with lub. l, and the threads the nozzle holder penelrale Ihe skin. Fuel which has penelraled
lor the nozzle nut. The shoulder the nozzle which Ihe skin can cause painlul inllammalions (blood
is in contact with the nozzle nut, must be lubrcated poisoning).
with an antiseizure product.
95.50 - ESOS
: DieseII
23/30
Mounting the luel injection valve n cylinder 19. ! the high pressure before tightening
head: the nuts then ! is easier to ! the threads.
Fig 3 Grinding tool$ for seat and Iner lor (l injecton va/ve.
18. Coat the O-rings and the lower part the valve Fig 4 Grinding toofs for fue/ injection va/ve (exfra tools).
with an an tiseizure product, place the valve the
cylinder head and press ! down to the seat.
95.50 ESOS
"i( DieseII
Working Card 514-01.15
Page 1 (2) Fuel SpIit FiIter Edition 01
23/30
11
Shut-off starting air
Shut-oll cooling water
Shut-off luel l
Shut-off cooling l
Stopped lub. l circul.
Descriplion:
Relaled procedure:
Dala:
91.08 - ESOS-G
',, DieseI!
514-01.15 Working Card
Edilion 01 FueI SpIit FiIter Page 2 (2)
23/30
1) During normal operation both lilters should be 3) Position three way cock, see lig 2.
in operation, single operation only be used when
dismantling one the llt ers lor manual clean ing or
inspection.
-
left Filter 80th filters Right Fllter
This position is operalion. This posilion is
only cleaning only cleaning
the righl 'ilter, the left filIer,
l for conIinu- l co n
ous operaling. ous operating.
5
(c!f~I@~Foo
Fig 2 . Fuef splt filter ( view).
@
3
: Shut-off luel l , belore dismantling ll ' ele-
ment.
91 .08 - ESOS-G
',!,' DieseII
Working Card 514-01.90
Page 1 (2) Check of FueI Piping System EdiIion 01
23/30
V28/32S
Descriplion
Slarling position
Engine is running .
Relaled procedure
Dala
92.04 - ESOSG
MiM / DieseII
514-01.90 Check of FueI Piping System
Working Card
Edilion 01 Page 2 (2)
23/30
V28/32S
Fuel l System 4) Move all valves and cocks in the piping sy-
stem.
1) Dismount the covers the injection pumps. Lubricate valve spindles with graphite si-
Blow-through drain pipes. milar.
2) Examine the piping system for leaks. 5) Check flexible connecti ons for leaks and da-
mages.
3) Retighten all bolts and nuts in the piping sy-
stem. 6) Check the condition of the lower O-ring for the
fuel injectin g valves by means of th e venting
.
Venting ipe
92 .04 - ESOS-G
',:,' DieseII
Working Card
Adjustment ofThe Maximum Combustion Pressure
514-05.01
Page 1 (3) EdiIion 01
23/30
Descriplion:
Hand l ools:
Relaled procedure:
91.45 - ESOS-G
,, DieseII
23/30
Iffuel l valve, piston, inlet and exhaust valves as well Thinner and/or lewer shims (increase the distance
as turbocharger and charge air cooler are working "") results in a delayed injection timing and a lower
correct and the compression pressure comp iS normal ma~
the maximum combustion pressure will indicate the
injection timing the luel l pump. Thicker and/or more shims (reduction the distance
"") results in an advanced injection timing and a
", is too low it indicates that the injection timing higher 3 '
is delayed.
the distance "" is to be changed the trigger (1) is
",
is too high it indicates that the injection timing used dismantling the thrust piece (2), where-
is advanced. after the thickness and/or the number shims (3)
can be changed.
The injection timing can be altered by inserting
removing shims under the thrust piece on the roller changing "X"with 0.1 mm the maximum combu-
guide, thus changing the measu re "", see lig 1. stion pressure is changed with - see page 500.35.
2
{~5
Total height 3
3
4 . / 4
Fig 1
Fig3
Action AU
Fig2
91.45 - ESOS-G
Working Card
Adjustment ofThe Maximum Combustion Pressure
514-05.01
Page 3 (3) Edilion 01
23/30
9 1.45 - ESOSG
'IIII@,iI'JMANDieserl
Working Card 514-10.00
Page 1 (3) FueI Feed Pump Edi!ion 01
23/30
Stopped engine
Shut-off starting air
Shut-off cooling waler
Plate no. IIem no. Nol e.
!! Shut-off fuel il
Shut-off cooling l
Stopped lub. l circul .
Descriplion:
Relaled procedure:
96.26 ESOS
Plate
Page 1 (2) Fuellnjection Pump 5 140 1- 10
23/30
189 ~ 1"
236 ~" ~
190 ~' '~, 021
033
045
082 -.
/ A(J
~
261 -', ~ 045
273 ~~
\
Wr.:-..1-----1-fly ~ 033
116 ~~ '1?
~
~ \ [ 104
,.. ~
~_ \ \ 057
,.
356+ - ~. "-
069
----- 319
153
-.------
~ _ _- ' 65
U
~,__ 177
Qi-- 200
03.36 ESO
Plale
51401-10 Fuel Injection Pump Page 2 (2)
23/30
Item Item
. Qty. Designatlon Benrevnelse . Qty. Oesignation Bencevnelse
273 1/ ! MIGIIrik
When ordering spare parts, see also page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only ava il able as part of a spare parts klt. tilgcengelig som del af res ered el ssce I.
Qty./P QtyJPump Antal/P = AntaVPumpe
QtyJC QtyJCyIInder Antal/C = Antal/Cylinder
03.36 ESO
Plate
Page 1 (2) Fuel Injection Vale - NICO 51402-16D
23/30
273
285
297
177
221
224--+--(
,.,."'-_- 307
248"---
320
261
23/30
Jtem Item
. Qty. Designatlon Bencevnelse . Qty. Designatlon Bencevnetse
When ordering spa re parts, see al50 page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only available as part a spare parls kit. tilgengelig som del af el reseredelsseI.
Qty.N Qty.Nalve Qly.N QIy.NenIil
QtyJG QtyJCyllnder. Qy./C QIy./CyHnder.
Plale
Page 1 (2) Fuel Injection Valve 51402-16
23/30
153
021*
~--
._-....;..-:
._~
~ ..
~
~~ 094
177
116
045
033*
1/ ~
057
l .----.--.
~ '"
-----_
07.20 - ESO
Plale
51402-16 Fuel Injection Valve Page 2 (2)
23/30
Item Ilem
. Deslgnation Bencev nelse . Qty. Designation Ben e vne l se
104 1 l MoIrik
11 6 3 0-rl"9 0-rl"9
153 1 l Boll
When orderlng spare parts, also page 500.50. Ved beslilling af reservedele, se ogsf side 500.50.
= Only aval lable as part of a spare parts klt. Kun tilgrengelig som del af et reseredelssre l.
QJV QtyJValve Qly.N Qty.Nentil
QlyJC QtyJCyllnder. Qy./C Qty./Cylinder.
07.20 - ESO
Plate
Page 1 (2) Fuel Injection Valve 51402-17
L23/30
__
153 ----- -~ ~ ,,,
------ ~
189
165 ---------
----------,
------ ~/
. /'
104
189
~
021*
~,-
~~ 094
177
116
045
033*
1/ ."
057
" "- ~
"_._'"
....... ,.
:. :.'
r- ~
._------- ---.,
* When ordering, please state I -17_06
07,20 - ESO
Plate
51402-17 Fuellnjection Vale Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Bencevnelse . Qty. Designation Bencevnelse
104 I M0trik
153 I 8011 ll
When ordering spare parts, see al50 page 500.50. Ved besIilling af reservedele, se ogsA side 500.50.
Only available part a spare parts kit. u tilgcengelig som en del af et reservedelssce
QtyJV Qty.NaIve Qly.N Qty.Nentil
QtyJC = QtyJCyllnder. Qly./C Qty./Cylinder.
07.20 - ESO
l( Dieserl
Plate
Page 1 (2) Fuel lnjection Valve - NICO 51402-18
23/30
273
190----~
297
325
22 1
224 --f--<
,.,.'--_- 307
236---_ 319
248~ _ _
320
07.20 -
Plale
51402-18 Fuel Injection Valve - NICO Page 2 (2)
23/30
Item Item
. Qty. OesJgnation Bencevnelse . Qty. Design atlon Bencevnelse
224 3 0-rl"9 0- 9
285 1 ! Molrik
When ordering spare parts, see also page 500.50. Ved besIilling af reservedele, se ogs<1t side 500.50.
= Only available as part a spare parts kit. IiIgengelig som en del al et reservede l sset.
QtyJV QtyJValve Qly.N I.l l
QtyJC QtyJCyli nder. Qly./C Qly./Cylinder.
07.20 -
'/ DieseI[
PlaIe
Page 1 (2) FueI Injection VaIve - NICO 51402-19
23/30
273
190-----
297
325
221
224 --(--<
,.,-"'--_- 307
236--. 319
248*--_
320
261 --...
07.20
Plale
51402-19 Fuel Injection Valve - NICO Page 2 (2)
23/30
Item Ilem
. Qty. Designation Bencevnelse . . Deslgnation Ben<evnelse
320 1 S in d l e Spindel
When ordering sp3re parts, see al50 page 500.50. Ved besIilIing af reservedeJe, se ogsl side 500.50.
= Oniy avai lable as part of a spare parIs kit. Kun tilgrengelig som deJ af et reseredelssGe
QtyJV QtyJValve Qty.N Qty.Nenlil
QtyJC QtyJCylinder. Qty./C Qly./CyJinder.
07.20
Plate
Page 1 (2) FueI FiIter DupIex 51403-03D
23/30
02.08 ESO
''!:f DieseII
Plate
51403-03D FueI FiIter DupIex Page 2 (2)
23/30
Item IIem
. Designation Benrevnelse . Qty. Designation Bencevnelse
lIF Housing
2 2/F Cover
3 1/F Valve
4 2/F cover
7 2/F Support
9 21F NuI
12 420F Flter
13 360/F Filter
14 1/F Screw
16 1/F OMring
18 4/F Spacer
20 2/F Bush
21 2/F Spring
25 2/F 0-rin9
When ordering spa re parts, see al50 page 500.50. Ved bestilling af reservedele, se Og5<\ side 500.50.
Only available as part of a spare parts kit. jilgcengelig $om del a1 et reservedelsscet.
atyJE = QtyJEngine. Oty.lE Qty./Engine .
atyJF QtyJFllter Oty.lF Qly./Filler.
02.08 - ESO
II' DieseII
PIate
P_ge 1 (2) Fuel Injection Pipe 51404-01
23/30
130
237
010
250
262
142
130
178
154 262
142
154 - - '
166
095
~
.;
~
~
201
89 213
'"
'"
225
94,22 ESQS
Plate
51404-01 Fuel Injection Page 2 (2)
23/30
Item
. Qty. Designatlon Benrevnelse . Q Designation Ben cevnelse
When ordering spare parts, see a tso page 500.50. Ved bestilling af reservedele, se ogsfl side 500.50.
Only aval lable part of a spa re parts kit. tilgengelig som del af el reseredelsset.
Qty./C QtyJCy linder. Qty./C QIy.lCylinder.
94.22 - ESOS
Plate
Page 1 (2) FueI Feed Pump 51410-01
23/30
013
1'- 300
/~ ~
049 -
241
025 - -___
'-----=~/ / ~ 108 ~
098 \ ~~. ~/ 265
086 "---~ 062
~::f:
~ : --r-:~~~;~./
--- 074228
277
121-169 - 289
204 216
- - - 194
145 312
170
182
290
96.20 - ESOS
Plate
5 1 410-0 1 FueI Feed Pump Page 2 (2)
L23/30
Item Item
. Oesignation Benrevnelse . Oty. Designati on Bencevnelse
When ordering spare parts, see al50 page 500.50. Ved bestiliing af reservedeie, se ogsf side 500.50.
Only ava lla ble as pa rt of a spare parts kit. tilgrengefig som del af et reseredeissret.
OtyJP OtyJPump. Qty./P Qty.lPumpe.
OtyJE OtyJEngine. Qly./E Qty./Motor
96.20 ESOS
~
~
;g
m"
~"
:
132
144
Section - ;
""
~.
i
156 168
~
. , 1 } 384
~~~~~
107 -
372 "tI
(1)
181 396
406
::
' 418
(")
~:::
'<
::
215 024 a.
, . 239
073
061
...
(1)
097 fJ)
(1)
n
288 ~ , / 431 !:!.
311 .~
;+~~_'!-_-_. ::
323 ?t C
---r /
335 / 276
311
---
347
443
. \,-'~@.
[ ~@-+ "
~~211
\i' ,., U ....
U
~
\)
359 360
~ ,
::
....
::
':' DieseI[
Plate
51430-01 Pipes CyIinder Section Page 2 (2)
523/30
Item Item
. Qty. Deslgnation Benrevnelse . Qty_ Designation 8encevnelse
119 1/C Straight male Ligeforskruning 396 1/C Screwed connectlon Forskruning
stud coupling
406 1/C Screwed connectlon Forskruning
120 1/C Straight male Ligeforskruning
stud coupling 418 1/C Screwed con nec tlon Forskruning
132 21C Plug sc rew Proskrue 431 lIC Plpe clamp A0rholder
wlth SRG
443 1/C Bracket, complete Beslag, komplel
144 21C Packlng ring Pakningsring
Only avallable as part of a spare parts kit. filgrengelig som en del af el reserede i sscel.
QtyJE EngIne Anlal/E = Motor
QtyJC QtyJCyllnder AntaVC = AntaVCylinder
07.17
:-<
"
;?
"'."
"
-a;
:
132 ;;:
144
Section - !;
f
c. -
156 168
384
"'tJ
.W-I.--- 107
036
'<
j
203
239
a.
061
....
097 n
288
311
323
~+,
L::"::!9:l-e'
iJ ~ _
/ 431 -
n
"
j
/ .
335 276 ~443
311 347
~ "'- __ L1.
\ @:@
193 . ~-I +--""
r-..~
'@; ~\
~ 240
t'\ -\j --- U1
.....
252
264
359
360
,::..
.....,
Q
U1
:::::
"'I DieseII
Plate
51430-15 Pipes CyIinder Section Page 2 (2)
623/30
Item Item
. Designation Ben e nel se . Deslgnation Bencevne lse
061 1/C Branch Slik ror 323 1/C Pipe clamp Rorholder
cylinder sectlon cylindersektion
335 1/C Hexagon screw Skrue
073 1/C Screwed Vinkel
connection forskruning 347 21C Hexagon screw Skrue
119 1/C Straight male Ligeforskruning 396 1/C Screwed connection Forskruning
stud coupH ng
406 1/C Screwed connection Forskruning
120 1/C Stralght m ale Ligeforskruning
stud coupling 416 1/C Screwed connection Forskruning
132 21C Plug screw Proskrue 431 lIC Plpe c lamp R"rholder
with SRG
443 1/C Bracket, complete Beslag, kompleI
144 21C Packlng rlng Pakningsring
Only aai/ab/e as part a spare parts kll. tilgaengelig som del af el res eredelssa! 1'
OtyJE Englne AntalfE = Molor
OtyJC QtyJCylinder AnIaVC = AnlaIICylinder
07.17
~
....
cl'
<"
"'"
'::(6"
.!'J
;;:
132
144
Section -
i!i:
f
156
"tI
"
n
~
(")
'<
~
215 024 a.
061
...
097 (J)
n
288 ~~
. . ~V'
.;,- 431 ::!:
311 ' __ , ~
..3~
" . ---T~-t ~
240
~ @ -~
252
-\ ,.
\ 1 \!
-.-!-
-...
....
c.n
.;:.
264 J\)
35'9 360
~
....
:::
'':'I. DieseII
Plate
51430-16 Pipes Cylinder Section Page 2 (2)
723/30
Item Item
. Design ation Benmvnelse . Designation Benm vn else
= Only avallable as part of a spare parts kll. tilgrengelig som en del af l reseredelssret.
QtyJE Englne Antal/E =
QtyJC QtyJCylinder AntaVC = AnlaVCyJn der
07.17
~
" "
"
"'"
~;;
:
:;:
132
144 Section - i!i
,, ''1 ~
::
156
"tJ
-
(!)
181
;::,
(")
'<
;::,
.
073 120
061
...
(!)
097 (J)
-ho.3
(!)
288
n
/ 431 :::!:
311 ,. . . , . ,')
;::,
2
048
323
--' ~ +-
335 / 276 ~443
311 347
\
r;j, ' "-,,
&"
\ ' ~
[(0)~ +-
- 240 '~ \,f\',_
-\
! . ....
U'I
252
~
~ 264 359 360
....
......
:::::
1':II'[ Dieserl
Plate
51430-17 Pipes CyIinder Section Page 2 (2)
823/30
Item Item
. Qty. Designation Benrevnelse . Qty. Designation Bencevnelse
061 1IC Branch plpe SIikrOf 323 1IC Pipe clamp Rorholder
cyllnder sectlon cylindersektion
335 1IC Hexagon screw Skrue
073 1IC Screwed Vinkel-
connectlon forskruning 347 2fC Hexagon screw Skrue
132 2fC Plug screw Propskrue 431 1IC Pipe c lamp Aorhoider
wlth SRG
443 1IC Bracket, complete Besiag, kompiet
144 2fC Packlng rin g Pakningsring
On ly avai lable as part a spare parts klt. IiIgrengelig som del af reseredelssret.
QtyJE Engine AnIal/E = Motor
QtyJC = Qty./Cyllnder Antal/C = AnIal/CyJinder
07.17
Section 515
Intemal Lubcatng l System
Description
Working card
Plates
Descrition
InternaI Lubricating System 515.01
Page 1 (5) EdiIion 11
23/30
C3
C16 C15
,, ---.,,
- - - - ......
Drain 110m
vapoor
dischargo
,,
'
cyshaII G9'lernor
"~
,.~
,
,, -'-
''' ---- -.J .... C4 C9
,,, ,,
,
" Sepcf(l.Ie ll Ilow \
r- _:::;:. _ ., Whcn ul tow filtor
\,..:;'"
SIandard
\~1-~~:~~-::~-~7 [] 1 ploco lor 5-6 cyl. enginos.
2 pcs.lor 78 cyl. engines OplionaJs
C7 ' , - - - - - ' C8
GeneraI
Plpe descrIption for connectlon at the engIne
07.47 - ESO
515.01 Internal Lubricating l System Description
Edition 1 1 Page 2 (5)
23/30
! there are connected external , - l w filters etc. , 1) For priming and during operalion, theturbochar-
the quantity ! l in the external piping must also be ger is connecled 10 the lubricating l circuit !
taken into account. the engine, the l serves lorbearing lubrcat on
and also lor dissipalion ! heat.
Max. velocity recommendations for external lubrica-
ting l pipes: The inlet lne 10 Ihe turbocharger is equipped
with an orifice in order adjusl Ihe il lw and
Pump suction side 1.0 - 1.5 m/s a non-return valve to prevent draining during
- Pump discharge side 1.5 - 2.0 m/s stand-still.
should, however, be observed that during the ru n- 2) Lubricating l for Ihe main beari ngs is sup-plied
ning in period the lubricating l consumption may through holes drilled in the engine frame. From
exceed the values stated. the main bearings l passes through bores in
the crankshaft 10 the connecting rod big-end
bearings.
QuaIity
The connecting rods have bored channels for
Only D lubricating l (Detergent Lubricating l) supply ! l from the big-end bearings 10 Ihe
should be used, characteristic stated in "Lubricating small-end bearings, which has an inner circum-
l Specification 12 15 0/504.01". ferential groove, and a pocket for distribution
l in the bush itself and lor supply ! l 10
Ihe pin bosses and Ihe piston cooling through
System FIow holes and channels in the piston pin.
The lubricating l pump draws l from the l sump From Ihe front main bearings channels are
and presses the il through the cooler and l bored in the crankshaft for lubricating ! the
the main lubricating l , from where the l is pump drive.
distribu ted 10 Ihe individual lubricaling poinls. From
the lubricaling poinl s Ihe il returns by gravity 10 3) The lubricaling l pipes, for the camshaft drive
the l sump. gear wheels, are equipped with nozzles which
are adjusled apply Ihe l at the points where
The main groups ! components 10 be l ubrcated the gear wheels are in mesh.
are:
4) The lubricaling l , and the gear wheels
for Ihe governor drive are adjusted to apply the
1 Turbocharger
l at the points where the gear wheels are in
2 - Main bearings, big-end bearing elc. mesh.
07.47 - ESO
Description
InternaI Lubricating System 515.01
Page 3 (5) Edition 11
23/30
Lubricating l Pump
The lubricaling l pump, which is Ihe gear wheel Fig 2 TI)ermosfafic Valve
Iype, is mounled on Ihe fronl end Ihe engine and
is driven by means the crankshalt Ihrough a cou-
pling. The l pressure is conlrolled by an adjuslable 1I Ihe llt chamber in operalion needs 10 be servi-
spring- loaded ll valve built-on Ihe il pump. ced, Ihe operalion can be swilched 10 Ihe olher llter
chamber wilhoul any inlerruplion in lubricaling l
supply 10 Ihe engine.
Thermostatic Valve
Servicing is generally reslricled 10 replacing th e
The Ihermostalic valve is designed as a T-piece wilh paper carlridges, cleaning Ihe radial mesh inserl
the inlel in Ihe cover () underwhich Ihe thermoslatic and inspeclion sealings, Ihe laer 10 be replaced
elements are localed. l damages observed .
The outlel 10 the engine (by-passing cooler) is Each Iillerchamberis equipped wilh 1 2 replaceable
marked () and outlel 10 Ihe cooler is marked (C). paper carlridges lineness 10-15 microns.
In Ihe warming period, the il is by-passing the
cooler. When th e l Irom Ihe engine reaches Ihe In Ihe cenlre each llt chamber a llter baskel
normal lemperature see "Operation dala & sel poinls (cenlral element) is situated. Thi s l basket is
500.30" a controlled amounl al il passes Ihrough acling as a safely llt, having a lneness aboul
Ihe cooler. 60 microns.
The thermoslalic elemenls musl be replaced l the During operalion an increased pressure drop across
temperature during norm al operati on deviales es- the llte r ll be observed as dirl parlicles ll deposit
senlial from Ihe one slaled in Ihe lesl report. on Ihe lltralon surfaces Ihe paper cartridges and
Ihus increase Ihe l resislance Ihrough the lt.
The valve cannot be set adjusled, and l requires
maintenance. 1I Ihe pressure drop across the ll eceeds 2.0
bar, a release valve ll open and by-pass Ihe 10-15
microns l element, and Ihe engine ll run wilh
l-n Full-flow Depth Filter only Ihe 60 microns salely lt.
The lubricaling l llter is a double llter which is ensure safe filtering Ihe lubricating l, none
generally used wilh only one t chamber being in the by-pass valves musl open during normal service
operalion, Ihe olher llter chamber being sland-by. and the elements should be replaced al a pressure
drop across Ihe ll 1.5 bar.
07.47 - ESO
515.01 Internal Lubricating System Descriplion
Edition 11 Page 4 (5)
23/30
Servicing iS essential the exchange the paper However, a manilold arrangements is used, its
cartridge s. arrangements are be as follows:
When exchanging cartridges, iS advisable release 1) The vent pipe Irom each engine is run
any old l remaining in the lilter housing by means indepently the manilold, and be litted with
the drain plug provided lor this purpose, and corrosion resistant flame screen within the
w the housing with a cloth. manilold.
The llterchambers can be serviced successively du- 2) The manilold is be located as high as practi-
ring operation when the engine iS at standstill. cable so as allow substantial length piping
separating the crankcase.
iS essential lllw the instructions in work card
515-01.1 closely when replacing l ilter cartridges. 3) The manilold is be vented the open air,
such that the vent outlet is litted with corrosion
Filter cartridges must under no circumstances be resistant Ilame screen, and the clearopen area
cleaned and used again. the vent outlet is not less than the aggregate
area the individual crankcase vent pipes
entering the manilold.
Pre-Iubricating
4) The manilold is be provided with drainage
As standard the engine is equipped with an electric- arrangement.
driven pre-Iubricating pump mounted parallel the
main pump. The pump must be arranged lor automatic The ventilation should be designed eliminate
operation, ensuring stand-still the pre-Iubricating the risk watercondensation in the pipe Ilowing back
pump when the engine is running, and running dur- into the engine and should end in the open air:
ing engine stand-still in stand-by position.
- The connection between engine (C13) and the
Running period the pre-Iubricating pump is preler- ventilation must be Ilexible.
ably be continuous. 11intermittent running is requi- - The ventilation should be con tinuously
red lor energy saving purpose, the timing equipment inclined (min. 5 degrees).
should be set lor shortest possible intervals, say 2 - continuous drain has be installed near the
minutes running, 1 minures stand-still, etc. engine. The drain must not be lead back the
Further, is recommended that the pre-Iubricating engine.
pump is connected the emergency switch board Dimension the Ilexible connection DN50.
thus securing that the engine is not started without - Dimension the ventilation after th e flex-
pre-Iubrication. ible connection min. DN65.
It is recommended use the separator suction pipe Besides the standard components, the lollowing
lor draining the lubricating l sump. optionals can be built-on:
07.47 - ESO
Description
Internal Lubricating l System 515.01
Page 5 (5) EdilIon 1 1
23/30
Pressure transmitting
- 22 Lubricating l inlet after cooler
Temperature element
- 20 Lubricating l inlet before cooler
Temperature element
- 22 Lubricating l inlet after cooler
Temperature element
- 29 Lubricating l inlet main bearings
Branches for:
07.47 ESO
Oescripllon
Lubricating CooIer
515.06
Page 1 (1)
Edition 01
23/30
The built-on lubricating cooIer iS a pIate heat Alter cIamping the pIate pack, the pIates - which
echanger. are litted gaskets - ensure an eflective seaI between
IIuids andatmosphere. addition, intermiing olthe
The pIate heat echanger consist a number IIuids iS eIiminated by a double gasket seaI around
coId pressed pIates which are compressed between the inIet ports.
a Irame pIate (head) and the pressure plate (l)
by means boIts. Every second pIate iS turned through 1800. This
means that the doubIe gasket seaI occurs around
The pIates are made with speciaI cOugations, every second inIet the channeis between the
which ensures turbolent and high heat transler pIates.
cofficients.
The pIate pack lorms a series paraIIeI
channeIs which the fIuids a counter cur-
rent regime.
96.26 - ESOU-G
Description 515.15
Page 1 (1) Centrifugal By-Pass Filter
EdiIion 01
23/30
V28/32S
DescripIion
The cenlrilugal liller is a bypass liller mounled directly For proper liltration, l is imporlant that the rolor is
al Ihe engine base Irame. The cenlrilugal liller is a always correctly balanced.
supplemenl , Ihe main Iiller.
out-ol-balance condition can occur as a result
During service, a parl Ihe lubricaling l supplied an uneven built-up sludge or as a result
Irom Ihe engine driven lubricaling l pump enlers cessive bearing or spindle wear.
Ihe cenlrilugal liller and returns 10 'he l sump
Ihe base Irame.
Principle of OperaIion
96.03 - ESOS-G
':' / esel!
Worklng Card 515-01.00
Page 1 (3) Lubricating l Pump, Engine Driven EdiIion 01
L23/30
D
Stopped engine
Shut-off starting air
Shut-off cooling water
Plate no
52005
Item no
273
Note
80 - 360 Nm.
D Shut-off fuel l
D Shut-off cooling l
Stopped lub. l circul.
Descriplion:
96. 26 - ESOS-G
515-01.00 Worktng Card
Editlon 01 Lubricating Pump, Engine Driven Page 2 (3)
23/30
2) Remove screws (2) and dismount the cover 8) Inspect all other parts for wear and damage,
(3). and renew. necessary.
,----_._--- ------,
1::;g. 2.
Assembly:
6) Clean all the parts with gas l and a hard 11) the gear wheel coupling part (1).
brush, (never use a steel brush) . The partsare blown
clean with working air. For tightening the lor gear wheel, see page
500.40.
7) If the bearing bush is be removed the
existing bearing bush is plugged out by means 12) Mount the spri ng loaded by-pass valve, nut
a mandrel, the bores are c leaned and W bearing (10) wi th gasket, cap nut (9) and plug screw (15).
bush is mounted, see fig. 1.
96.26 - ESOS-G
,:,' DieseII
Working Card
Lubricating Pump, Engine Driven
515-01.00
Page 3 (3) Edilion 01
23/30
Adjusting lub. l Pressure. turning the spring housing clockwise the pressure
is raised and reverse the pressure is lowered by
13) The outlet pressure the lub. l pump. can turning the spring housing (11) anticlockwise. When
be adjusted by means a adjusting screw the the correct pressure is reached . see page 500.30.
by-pass valve. the spring housing (11 ) is locked with U (1 ) and
finally the gasket and cap (9) are mounted.
Remove the cap U (9) and loosen the (10).
96.26 - ESOS-G
Workrng Card 515-01.05
Page 1 (3) Prelubricating Pump Edrlion 08
General
11
Stopped engine
Shut-off starting air
Shut-off cooling water
Plate Item Note.
Shut-ofl fuel l
Shut-off nozzle cooling l
Hand \ools
Descrip\ion
Bench vice.
Dismounting, replacement the rotary shaft seal Spanner.
and assembly prelubricating pump. Torque spanner.
l lr lock ring.
Soft hammer.
S\ar\ing posi\ion
Rela\ed procedure:
02.39 ESO
,.{ DieseII
515-01.05 Working Card
Edilion 08 PreIubricating Pump Page 2 (3)
GeneraI
Spare Parts
Replacement mechanical seal
Belore any overhaul is done, please nole Ihe 101-
lowing: 1) Disconnecl Ihe cable and connection
Ihe pump.
1I a pump gets unusable by wear, l musl be repla-
ced. Inslallation spare parls cannol bring l back 2) Remove the pump from the engine base
10 normal condilion. Irame.
1I pays keep el ra pumps stock orto have repairs 3) Separate Ihe pump and Ihe el-molor.
(overhauls) carried out at our repair shop.
4) Remove the coupling parl and key (109), see
The shaft seal needs only 10 be replaced case fig. 1, Irom Ihe driving gear shaft (051).
leakage after dismounting drive shaft. Th e
marks Irom the seal do necessarily mean that 5) Tighten Ihe pump tothe Ilange. Pressure conlrol
Ihe sealing is deleclive, but there is a risk leakage valve (038) upwards.
after rep lacement sealing.
6) Loosen screws (075) and take 011 Ihe pressure
conlrol valve (038).
02.39 - ESO
'+I@",'fMANDieserl
Working Card 515-01.05
Page 3 (3) PreIubricating Pump Edition 08
Genera!
7) Take off the gear box (026), necessary use Mounting
a soft hammer for separation.
13) The mounting process follows reverse order,
8) Remove the gear wheels from the cover (014). it is stressed that an exact cleaning works is
Dismounting is only possible by disturbing the necessary.
rotor shaft seal and by breaking the bearing
bush. Especially the sealing faces must be clean.
9) Remove the security ring (099) and take off Tightening screw pos. (075):
the rotary shaft seal (122).
25 10Nm
1) Press out the driving gear shaft bearing bush, 3 5 50 Nm
ll ! the running bearing bush with the '
wheel puller. connection with the bearing bush, attention must
be paid to the placement th e butt joint and the
11) Gear box (026) . Dismounting is only possible mounting depth.
by damaging the shaft bush. Press out the
shaft bushes. The shaft seal cannot be pressed into the pro-
tection cover before exact mounting the pump.
12) Pressure control valve (038). The pressure
control valve can be dismounted also Wi tllOut O-ring must be changed.
dismounting the pump.
02.39 - ESO
Working Card
Lubricating l Filter
515-01.10
Page 1 (3) Edition 01
23/30
Stopped engine
Sht-olf starting air
Sht-off cooling water
Plate no Item no Note
Shut-off luel l
Shut-oll cooling l
Description:
Related procedure:
~
Working time 2 hours Plate no Item no Qty. /
~
Capacity 1 man
39 51502 01 3 See plate 51502
ro
9 1.45 - ESOS-G
515-01.10 Lubricating FiIter
Worklng Card
EctitIon 01 Page 2 (3)
23/30
The three-way valve is marked with lw directions 7) Clean the l housing and the cap. Be careful
and the figure indicates the operation modes accor- not let the l from the dirty side go into the
ding valve positions. clean l channel in the middle bottom.
-~~o'-
..
-
t
80th filter camber
operation.
2) Open Ihe vent screw (5) on the the l 8) Check the seal on the bottom the l hou-
get the pressure the filter half. sing and in the cap. Change needed.
3) Open the drain plug (8) underthe filter housing 9) Assemble the t in opposite order.
and drain off oil.
9 1.45 - ESOS-G
Workin~J Card
Lubricating FiIter
515-01.10
Page 3 (3) Editlon 01
23/30
"
W
'"
~
U
r
'"
m
"
11) Close the vent screw (5) after the housing is
filled with l.
111::1
12) Open the three-way valve (6) and close the
Switch in normaJ SwJtch IiJl l ll -
valve (7) by trning position CLOSED,
operation positlon osition see lig. 3.
91.45 - ESOS-G
Worklng Card 515-01.20
Page 1 (2) Lubricating l, Thermostatic Valve Edition 01
23/30
11
Stopped engine
Shut-off starting air
Shut-off cooling water
Plate Item Note
Shut-off fuel l
Shut-off cooling l
Descriplion:
Slarling posilion:
Relaled procedure:
ro
Manpower:
"
~
~
Working time 2 hours Replacemenl and wearing parls:
~
Capacity Man
~
:: Plate Item No Qty/
ro Dala:
92.05 - ESOS-G
515-01.20 WorkIng Card
EditIon 01 Lubricating l , Thermostatic Valve Page 2 (2)
23/30
92.05 - ESOS-G
Working Card
Check of Lubricating l Piping System
515-01 .90
Page 1 (2) EditIon 01
23/30
Descriplion:
Slarling posilion:
Engine running.
Relaled procedure:
Dala:
92.04 - ESOU-G
"llM,, DieseII
515-01.90 WorkIng Card
EdiIIon 01 Check of Lubricating Piping System Page 2 (2)
23/30
1) Examine Ihe piping syslem for leaks. 5) Check fle i ble conneclions for leaks and dama-
ges.
2) Retighten all boltsand nuts in the piping system.
6) Check manometers and thermometers for pos-
3) Move all valves and cocks the piping system. sible damages.
Lubricate valve spindles with graphite similar. For lubricating l condition, see section 504.
92.04 - ESOU-G
l' DieseII
Working Card 515-06.00
Page 1 (4) Lubricating CooIer Edilion 02
23/30
Stopped engine
Shut-off starting air
Plate ItemNo Note
Shut-off cooling water
Shut-off fuel l
Shut-off cooling l
Stopped lub. l circul.
Descriplion :
Related procedure:
Manpower:
96.39 - ESOS
515-06.00 Working Card
Edition 02 Lubricating CooIer Page 2 (4)
L23/30
Cleaning the cooler has take place, when the Clean the plates with a solt brush and a suitable
pressure drop the l and water side is larger detergent . case dense coating scale
than allowable and/or l the l cannot be sufficiently organic materials, the plates must be ul a bath
cooled. detergent.
Cooling and Pressure l high-pressure cleaner can be used with care, how-
, with sand oth er abrasives added.
Belore opening the plate heat ec h a n ge r, has
be cooled down below 40' C and be without
pressure! Detergents
The cooling must exceed 1 ' C per minute. detergent is suitable, l ll remove any coating
The pressure drop must eceed 1 bar per the plates without causing any damage plates
minute. and gaskets.
: 1I th ese norms are exceeded, the guarantee : It is great importance that decomposition
ll cease be valid. the protective Iilm the stainless steel
does take place - the llm preserves the
corrosion resistancy the steel.
Separation Edgeclamped Frame
use chlorine-containing agents such
Upon completion the procedure "Cooling and as hydrochloricacid (HCI)!
Pressure l l", separate th e Irame by retaining
lour diagonally placed bolts. l and lats are removed by using a water emulsify
ing l solvent, e.g. BP-system cleaner.
: Take care that the pressure plate does
l ! Organic and greasy coatings are removed by using
sodium hydroxide (NaOH):
Loosen the bolts unilormly and diagonally (ma. 1
mm at a time), then push the pressure plate towards m a.concen1ration 1.5%
the end support. When the pressure plate is tight (1.5% concentration corresponds 3.75
anymore, the plates can be removed. 130% NaOH per 100 water).
ma. temperature 85' C.
: When using plate heat echangers board
ships, th e pressure plate have be secured Stone and lme/ca lcareo us deposits are removed by
orderto avoid danger due th e movements using nitric acid (,) :
the ship.
ma. concentration 1.5%
(1.5% concentration corresponds 1.75
Cleaning 62% , per 100 water).
max. temperature 65' C.
The capacity and corrosion resistance the plate
heat echangers depend the the plates. Note:The nitric acid has an important constructi ve el-
Any coating the plates can be removed manu- lect the protective llm stainless steel.
ally.
96.39 - ESOS
Working Card 515-06.00
P_ge 3 (4) Lubricating CooIer Edilion 02
23/30
Sodium hydroxide (NaOH) solution is tritrated with Plate 51506 are stated gasket and glue quan-
0.1 n hydro-chloric acid (HCI) with methyl orange
methyl red as indicator.
Please use a degreasing agent the new gas-
Nitric acid (,) solution is titrated with 0.1 n sodium kets.
hydroxide (NaOH) with phenolphtalin as indicator.
The lirst plate alter the end cover and the connector
The concentration the cleaning Iluid % can be grid must have gaskets all grooves. The gaskets
calculated from th e titration result by means th e are be cut according th e existing gaskets.
lollowing lormula:
Loosen the glued gaskets by heating the plate
Concentration = b n m % water at 100" C. Clean the plates and remove the
ax 10 coatings, l any.
Replacemenl Plales and Gaskels Please use our cleaning Iluid, which is according
suppliers recommendations.
Marking
Alternatively, please use:
The plates are marked with material codes and reler-
ence numbers at each end, plus codes lor non-glue Trichloroethylene
gaskets, l any, and stamped with the letter V and Chlorothene VG
at either end (Fig 1). Acetone
Methyl ethyl ketone
Looking towards the gasket side, the plate is des- Ethylacetat
ignated as a lelt plate, when the letter V is turning
upwards - and a right plate when th e letler is turn- is importan t that all degreasing agen t has evapo-
ing upwards. Inlets and outlets th e V-plates are rated, belore the glue is applied. This ll normally
taking place Ihrough the corner holes Nos 1 and 4. take approx. 15 min. at 20" C.
Inlets and outlets the H-plates are taking place
through th e corner holes Nos 2 and 3. Clean the new gaskets the glue surfaces with
line-grain sandpaper instead the degreasing
agent supplied.
Replacemenl Plales
96.39 - ESQS
+ DieseI[
515-06.00 Lubricating CooIer Working Card
Edition 02 Page 4 (4)
23/30
Gluing Assembling
Pliobond 25, which is a l rubber glue solvent th e plates have been dismounted, they have
basis (25% solids). Th e glue is applied with a brush be correctly assembled according the plate item
a thin layer th e backs the gaskets and the numbers.
gaskets are dry a clean place free dust.
The fixed cover has number 1 and the serial numbers
Apply a thin layer glue the gasket grooves for the subsequent plates and intermedi ate frames,
the plates and press the gaskets down the any, have the numbers 2, 3, 4, 5 etc.
gasket grooves.
The serial number are stamped the right corner
The insertion gaskets starts at both ends the th e plates. Further, please n that the gasket
plate - and continues with the straight sections along side must face the fixed cover.
the edges.
A487G
The plates with the gaskets are mounted
the frame which is Iightly clamped. case use
rubber grooves, they are assembled the mini-
mum measure stated th e engine sign plus 0.2
mm per plate.
96.39 - ESOS
WorkIng Card 515-15.00
Page 1 (3) Centrifugal Bypass Filter EditIon 01
L23/30
De5cription:
Starting 05n:
Related procedure:
~
ro Manpower:
"~
v
~
Working time hour
~
:\
"
Data for pressure and tolerance (Page 500.35) 51515 398 1/Filter
DaIa for torque moment (Page 500.40) 51515 408 1/Filter
Declaration weight (Page 500.45) 51515 421 1/Fiiter
96.03 - ESOS
',' DieseII
515-15.00 CentrifugaI Bypass FiIter
WorkIng Card
EdiIion Q1H Page 2 (3)
23/30
Cleaning Procedure, see Plate 51515 Note: Failure do so could cause an - '
balance condition which wiII acce/erate bearing
and spindle wear.
1) Isolate the l by closing the valve for lbr
cating l inlet the I. 7) Clean nozzle with brass . Examine and
bottom bearings in tbe assembly. If damaged
2) Slacken cover clamp ring (266). Unscrew worn - re l ace tbe assembly comlete. Examine
cover fixing nut and l ! cover. O-ring (063) and renew ! damaged.
3) Lift off rotor assembly having allowed l 8) Reassemble rotor complete and tighten
drain from nozzles. The rotor should be removed and nut.
replaced on the spindle with ex treme care in order
ensure that the bearings are not damaged. 9) Examine spindle journals. If damaged worn
- relace with body assembly comlete.
4) Unscrew rotor cover nt (026) and sear ate
cover (038) from body. 1) Reassemble l com l ete checking that rotor
revolves freely. Then relace l bodycover. Tighten
cover nut and secure safety clam . The clam ring
should be securely fitted at all times and the l
026 should not b e run withot the clamp ring fi tted.
96.03 ESOS
Working Card 515-15.00
Page 3 (3) Centrifugal Bypass Filter Edition 01
23/30
Check Bearing Clearances The maximum clearances when new are 0,08 mm at
and 0,06 mm at bo tom bearing. 1I the clearance
This is most easily done by applying a dial gauge exceeds 0,25 mm 0.2 mm bo tom then check
the outside the roOr opposite each bearing in the sizes the individual components and replace
turn and measu rin g the total play thus: as necessary.
1) Apply dial gauge and measure play. Spindle journal diameter 14,98 mm Min.
Spindle bottom journal diameter 21,63 mm Min.
2) Turn rotor 900 and repeat meas ure ren. bearing bore diameter 15,06 mm Max.
Bottom bearing bore diameter 21,69 mm Max .
3) Re-apply dial gauge at 900 previ ous posi tion
and repeat. The spi ndle and body assembly and the rotor
bea ring tube assembl y are lactory assembled
4) urn 900 and repeat. items and should only be replaced wi th complete
assemblies.
The highest reading is the play in the beari ng.
96.03 - ESOS
PlaIe
Page 1 (2) Lubricating Pump (CentraI driven) 51501-01
5-6-7L23/30H 72050
L23/30H-900
079
317
067
018 - ______
163
234
175
234 199
187 305
210
209 329
330 - ----
234
~-- 043 222
~- 031
258 ~
~
:: ~
114
126
<ri
'~"
~ 092 342
'''~
~
f)I 080
i 354 102
"
------. ~
295
94.22 - ESOS
+.. DieseII
Plale
51501-01 Lubricating Pump (CentraI driven) Page 2 (2)
5-6-7L23/30H 72050
L23/30H-900
Item Item
. aly. Designatlon Benaavnelse . aly. Oesignation Bencevnels e
175 1/ l M0trik
256 / l 511ft
271 1 / Feder
When orderlng spare parts, see also page 500.50. Ved bestllling af reservedele, se ogsf slde 500.50.
94.22 ESOS
l 'l DieseII
Plate
Page 1 (2) Lubricating Pump (CentraI driven) 51501-02
8L23/30
72050
079
317
067
163
234
175
234 199
305
187 210
209 329
330 - ..../'
234
:L-- 043 222
031
258~
~
::~
114
126
.;
.; 092 342
~
'''~
~
-
080
354
102
9
~
295--4
94 .22 - ESOS
Mi'M.lfMAN DieseI!
Plate
51501-02 Lubricating Pump (CentraI driven) Page 2 (2)
823/30
72050
Item Item
. Qty. Deslgnatlon Bencevnelse . Qty. Deslgnatlon Benrevnelse
175 / Nut 0
258 1/ Stift
When orderlng spare parts, see also page 500.50. Ved bestillIng af reservedele, se ogsA side 500.50.
Only avai lable as part a spare parts kit. tiIgcengelig som en del af et reservedelssret.
QtyJE OtyJEnglne Antal/E = Antal/Motor
QtyJP OtyJPump Antal/? = AnIal/Pumpe
94 .22 ESOS
Plale
Page 1 (2) Lubricating Ol Pump (Gear driven) 51501-10
5-623/30-72050 RPM
6-7-8L23/30H-900 RPM
6L23/30H-900 RPM (High Capacily)
079 - -
163
234
175
234
: -:::..... ~
..
25 ~ ~ ~
:~: ~~ ~246
~~: ~. 283
092 342
354 ~
151 080
102
295~
07.01 ESO
+' DieseII
Plate
51501-10 Lubricating Pump (Gear driven) Page 2 (2)
5-6L23/30-72050
6-7-8L23/30H-900
6L23/30H-900 (High Capacity)
Item Item
. aty. Designation Benrevnelse . aty. Designation Bencevnelse
079 1 / ! M0trik
175 1 / ! Metrik
258 1/ Feder
329 21 ! M01rjk
When orderl ng spare parts, see also page 500.50. Ved beslilling af reseredele , se ogsf side 500.50.
; Only aval'ab'e as part of a spare parts kit. lilgcengelig som en del af eI reseIVedelssrel.
atyJE OtyJEngine Antal/E = Antal/Motor
atyJP ; OtyJPump Antal/P = Antal/Pumpe
07.01 - ESO
',:,,.( DieseI!
Plale
Page 1 (2) Lubricatig Pump (Gear drive) 51501-11
7-823/30-72050
5-623/30-72050 (High Capacity)
7-8L23/30H-900 (High Capacity)
079 - ____
067
163
234
175
234
234
401 --
222
330 -----
305
329
391
07.01 - ESO
I,,lM" MAN DieseII
Plate
51501-11 Lubricating Pump (Gear drien) Page 2 (2)
7-823/30-72050 RPM
5-623/30 -72050 RPM (High Capacity)
7-8L23/30H-900 RPM (High Capacity)
Item Item
. Oesignatlon Bencenelse . Desig natlon Benrevnelse
031 l Shaft with gear Aksel med tand- 366 / Key Feder
wheel , IO"9 hjul , lan9
391 / Gasket Pakning
043 / Shaft with gear Aksel med land-
wheel, short hjul , kort 401 / Plston , complete Trykregulerings-
stempel, komplel
055 5/ Bush 80sning
079 / MeIrik
175 / MoIrik
258 / Feder
329 21 l t r k
When orderIng spare parts, see a ls o page 500.50. Ved beslilling aI reservedele, se 09S.3 side 500.50.
= Only avai lable as p art of a spare parts klt. Kun lilgrengelig som del af l res erede l s srel.
aIyJE QtyJEnglne Anlal/ E = Anlal/Molor
aty./p = atyJPump AnlaVP = AnlaVPumpe
07.01 - ESO
Plate
Page 1 (2) Lubricating Pump (Gear driven) 515 0 1-22
079 - __
163
234
175
234
401 234
222
330 - - - -
366 \ <:N',~
258 ~
~
..
.;
a ::: 1
114
126
89'" 092 342
ro
~~
151 080
ro
354 102
295
07.01 - ESO
Plate
51501-22 High Capacity Lubricating Pump (Gear driven) Page 2 (2)
Item IIem
. Qy. Des ignati on Bencevnelse . Qy. Deslgnation BencevneIse
031 / Shaft wlth gear Aksel med land- 366 / " Feder
wheel, lo ng hjul,lang
391 / Gasket Pakning
043 / Shaft wlth gear Aksel med land-
wheel, short hjul, korl 401 / PI ston, co mplete Trykregu1erings-
sIempel, koml eI
055 5/ Bush Bsn i ng
256 / l 81ift
Wh en orderln g spare p arts, see also page 500.50. Ved bestiIling af reservedeie. se 09S8. side 500.50.
Only ava 'ab' e as par t of a spare parts klt. liIgrengeIig sorn dei af eI reservedeIsscet.
QlyJE OtyJEnglne An!aIfE = AntaIfMoIor
Qty./ P = OtyJPump AnIal/? = AnlaIfPume
07.01 - ESO
PlaIe
Page 1 (2) Lubricating Ol Filter (Type ) 51502-07
L23/30
,,
11
,,
11
,,
086+ 300
145
108
' - - - - 170 241
228
289
+ For deta/jer se / for detai/s see P/ate 5 1 502 -02
02.16 - ESO-G
1,Ji,z'lMAN DieseII
Plate
51502-07 Lubricating FiIter (Type ) Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnel se . Oty. Des ignation Bencevnelse
013 2/F Paper element Papirelement 300 1 / lub. l filter, Sm0reoliefilter, kom-
comptete ptel
025 2/F Safety element SikkerhedseIement
108 2/F Vent screw, inc!. Item Luftskrue, inkl. ilem 228
228 and 241 09241
216 5/F
228 61F l
When orderlng spare parts, see also page 500.50. Ved besli tling af reservedele, ogsA side 500.50.
= Only available as part of a spare parts kit. Iilg39:ngelig sam del af l reservedelsscel.
OtyJE QtyJEngine =
II! Anlal! Molar
OtyJF QtyJFi lter AnlaVF = Antai!Fiiler
02.16 - ESO-G
+ DieseII
Plate
Page 1 (2) Lubricating FiIter (SuppI. for PIate 51502-06/7) 51502-02
23/30
V28/32S
312 - - ,
444 - _____
~~~::;j~~-~-- 51502/037+
468
rl\0
456
397
515021050+
361
419
11
-~
~~ 385
324
420
373
\ ----- 336
407
02.16 - ESO-G
Plate
51502-02 Lubricating FiIter (Suppl. for PIate 51502-06/7) Page 2 (2)
L23/30
V28/32S
Item Item
. Qty. DesIgnation Benrevnelse . Qty. Designation Bencevnelse
When ordering s pare parts, see also page 500.50. Ved bestilling af reservedele, S0 ogsa side 500.50.
= Only available as part of a spare parts kit. Kun tilgrengelig som det af et reseredelsscet.
atylF = QtyJFiIter AntalJF = Anlal!Filter
02.16 - ESO-G
Plate
Page 1 (2) Lubricating l Thermostatic Valve 51503-01
23/30
019
~ ___ o
020
032
115
@--... 068
\L 081
103
94 .23 ESOSL
Plate
51503-01 Lubricating l Thermostatic Valve Page 2 (2)
L23/30
Item Item
. Oly. Designation Bena:vnelse . Qty. Designation Bencevnelse
When orderlng spare parts, see a lso page 500.50. Ved beslilling af reservedele, ogs~ side 500.50.
Only available as part a spare kit. Kun tilgrengelig som del af l reservedelsscet.
OlyJE Qty./Englne Antal/E = Antal/Motor
OlyJ aty.IThermostatlc a lve = Anlal(Termostalsventil
94.23 - ESOS-L
Plate
Pa ge 1 (2) Prelubricating Pump with EI-Motor 51504-02
General
349 337 362 254 325 301 291 266 374 350 278 313
421
470
445
470
408
482
386
398
457
469
528
516
94.23 - ESOS-L
Plale
51504-02 Prelubricating Pump with EI-Motor Page 2 (2)
General
Item Item
. aty. Designat ion Benaavnetse . Oty. Designation Bencevnelse
350 21 0- r in 9 0 - 9
Wh en o rdering spare parts, see also page 500.50. Ved beslilling af reservedele, se ogs<'l. side 500,50.
94.23 - ESOS-L
Plale
Page 1 (2) Prelubricating Pump with EI-Motor 51504-08
General
109 099 122 014 087 063 051 026 134 110 038 075
/'
266
-1-- -- - 183
l~!=~r== 230
_ - - 205
,~~~::==
L ' 230
171
242
hF==~~~~-- 195
:11 :=J
02.39 , ESO
PIate
51504-08 Prelubricating Pump with EI-Motor Page 2 (2)
General
Item Item
. Qty. Design atlon Benrevnelse . a ty. Desig nation Benre vnelse
110 21 O~ in g 0 -rin9
When ordering spare parts, see also page 500.50. Ved beslilling af reservedele, se ogS8. side 500. 50.
Only available as part of a sp are p arts ki tilgrengelig som en del af et reserede lssre t.
QtyJE = Oty.IEng ine Antal/E = Antal/ Motor
QtyJP Oty./Pump AntaIIP = AnIal/Pumpe
02.39 ESO
f,JII@!/fMANDieseI!
Plale
Page 1 (2) Lubricating CooIer 51506-01
L23/30
015
016
027 { 017
039 ~
040
Q
0Q
8-- 351
07.06 - ESOS-G
':'!'!I' DieseII
l
51506-01 Lubricating Cooler Pag. 2 (2)
23/30
Item Item
. Designation Benrevnelse . Deslgnatlon Benrevnelse
080 4/ Dlsta nce piece Afstandsslykke 351 Clea ning 11uid Rensevreske
~
6 cyI. englne 6 cy molor <
q
(900 rpm) (900 rpm) ~
~
~
~
i5
,
When ordering 5pare part5, 5 al50 page 500.50. Ved bestilling af reservedele, se ogsa side 500.50.
= Only avallable as part of a spare parts klt. tilgcengelig som del af l reservedelss;;el.
OtyJE = atyJEnglne AnIal/E = Antal/Motor
OtyJK QtyJCooler AnIal/K = Antal/K01er
OtyJI = Qty./lndlvidual I/I = AnIalJlndividuel
07.06 ESOSG
M+"MAN DieseII
Plate
Page 1 (2) Combined Lubricating CooIer 51506-02
23/30
218 r - 321
Gasket, model ,
mounting between
frame plate and
Plate 2.
267
321
00 279
i----- 280 Gasket, model C,
mounting between
8 - 292
8 - 363
00
96.26 - ESOS-G
'+HM'lMAN Dieserl
Plate
51506-02 Combined Lubricating CooIer Page 2 (2)
23/30
Item Item
. Qty. Deslgnation Benrevnelse . aty. Designation Bencevnel se
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogsf side 500.50.
= Only available as part of a spare parts kit. tilga3ngelig som del af reseredel ssa3t.
atyJE = Qty./Englne Antal/E = AnIal/Motor
atyJK QtyJCooler AntaVK = AntaVK01er
atyJI atyJIndlvidual l1l = AntaVlndividuel
96.26 - ESOS-G
PlaIe
Page 1 (2) Lubricating l Cooler 51506-11
L23/30
015
016
027 ( 017
039 ~
040
Q
0Q
1 00
meret er stemplet
toppen al laden l 078
h,e. (Se arbejdskort
079
515-06.00) 080
081
082
172 --~~~ 088
173 0 0 111
174
175 123
176 -----
177 Q
178
160
L 159
~r- 147
07.06 - ESOS-G
''!" DieseII
Plate
51506- 11 Lubricating CooIer Page 2 (2)
23/30
Ite m Item
. Qty. DesignatIon Benmvnelse . Qty. Deslgnation Benrevnelse
When ordering spare parts, see al50 page 500.50. Ved besIi lling af reservedele, se ogS<3 side 500.50.
Only avall able as part a spare parts kit. Iilgrengelig som en del af et reservedelssret.
QtyJE = Oty./Englne Anlal/E = Antal/Molor
QlyJK = OtyJCooler l/ = AntaVK01er
QtyJI OtyJlndlvldual AnIaVI = AntaVlndividueI
07.06 - ESOS-G
',I,I@,I,IlMANDieseI!
Plale
Page 1 (21 Lubricating CooIer 51506-12
23/30
015
027 ~
039 --------.. Q
040
0Q
I
g~~
066
399
Husk: Ved bestilling 411
r
af plader angives ./-:"""""'5;;,,-
serienummeret
pladen . Serienum- ~ /
076
meret stemplet
toppen af pladen til
h,e . (Se arbejdskort
gt~
~ r 079
d
515-06.00) 080
081
082
088
172 / 111
173 , 123
174 --
175
176
177
178 160 r-- 147
8 - 135
8-- 351
07.08 - ESO
1,:,:,'!I' DieseII
Plate
51506-12 Lubricating CooIer Page 2 (2)
23/30
Item Item
. Qty. Designation Bencevnelse . Qty. Des ign ation Bencevnelse
8
::
When ordering spare parts, see also page 500.50. Ved bestiIIing af re5ervedele, 5 Og58 side 500.50. "
"
= Only avai lable as part of a spare parts kft. lilgcengeJig som del af re5eredelssre l.
QtyJE = OtyJEnglne AnIal/E = AnIal/MoIor
QtyJK QtyJCooler AnIal/K = AnIal/K01er
QtyJI = Oty./Indlvidual l = AntaVindividuel
07.08 ESO
,+ Diesell
Plate
Page 1 (2) Combined Lubricating l Cooler 51506-13
23/30
00 321
218
Gasket, model ,
mounting between
Irame plate and
Plate 2.
Gasket, model ,
mounting between
the rest the plates.
Husk: Ved bestilling
al plader angives
serienummeret !.
pladen. Serienum-
( ~!~
meret stemplet
toppen al pladen til
0 0
he. (Se arbejdskort 258
515-06.00) 259
260
261
267
338 '
. J 11 r -- 321
339 279
340
341
------ 280
342 Gasket, model C,
mounting between
343
344
W- 302 c plate 26 and
27.
-- 292
8 - 363
00
the gaskets are delivered as model C.
Gasket and must be unreeved Irom
model C.
07.08 - ESO
1,:,!'!I' Dieserl ..
Plate
51506-13 Combined Lubricating CooIer Page 2 (2)
23/30
Item Item
. Qty. Designatlon Benrevnelse . Qty. Designatlon Ben;;ev nelse
218 l Press ure plate Trykplade 339 r Plates. 72050 rpm Plader, 7201750 rpm
6 cyl. englne 6 cyl. rnoIor
321 11 Gasket Pakning
the Gaskets de- Alle pakningerne l - 340 11 Plates, 7201750 rpm Plader, 7201750 rpm
Ilvered as model C. res som model C. 7 cyl. englne 7 cyl. motor
Gasket and mu st Pakning 09 skal
be unreeved from mo- skreres ud fra model 341 11 PIates, 7201750 rpm Plader, 720/750 rpm
del C. C. cyl. engine 8 cyl. motor
243 21 Guide bar, Slyrepjnd, 342 11 Plates, 900 rpm Plader, 900 rpm
72050 rpm 72050 rpm 6 cy. engine 6 cyl. molor
244 21 Guide bar, 6~7 cy l. Styrepind, 6-7 cyl 343 11 Plate5, 900 rpm Plader, 900 rpm
900 rpm 900 rpm 7 cyl. englne 7 cyl. molor
245 21 Guide bar, 8 cyl. Slyrepind, 8 cyl 344 11 Plates, 900 rpm Plader, 900 rpm
900 rpm 900 rpm cyl. englne 8 cyl. motor
When ordering spare parts , see al50 page 500.50. Ved beslilHng af reservedele, se ogsf sjde 500.50.
Only avaiJab/e as part a spare parts kIt. Kun IIgaangelig som en del af eI reseredelsscet.
QtyJ E = OtyJEngine AnIal!E = Antal!Motor
QtyJK = OtyJCooler = naler
QtyJI OtyJJndlvidual l = Anlal! lndjviduel
07.08 - ESO
-',$ DieseI!
Plate
Page 1 (2) Combined Lubricating CooIer 51506-14
23/30
196
321
206
218
Gasket, model ,
mounting between
Irame plate and
Plate 2.
Gasket, model ,
mounting between
the rest the plates.
Husk: Ved bestilling
al plader angives
serienummeret
pladen . Serienum-
meret er stempl et
toppen al pladen l
00
he . (Se arbejdskort
515-06.00)
267
338 ., -/1 1 . , - - - 321
339 279
340
341
----- 280
Gasket, model C,
342 mounting between
343
344
~ 302 c plate 26 and
02?
-- 292
-- 363
00
the gaskets are delivered as model C.
Gasket and must be unreeved Irom
model C.
07.08 - ESO
Plale
51506-14 Combined Lubricating l Cooler Page 2 (2)
23/30
Item Item
. Q Designation Benrevnelse . Qty. Des lgnatlon Bencevnelse
184 4/ Hexagon screw ll 338 11 Plates, 72050 rpm Plader, 720 50 rpm
5 cyl. engine 5cyl. molor
196 4/ Washer Skive
339 ; Plates, 72050 rpm Plader, 7 2050 rpm
206 4/ Washer Skive 6 cyI. e nglne 6cyl. molor
218 1/ Pressure plate Trykplade 340 11 Plates, 72050 rpm Plader, 720 50 rpm
7 cyl. e nglne 7 cyl. molor
243 2/ Guide bar, SIyrepind,
72050 rpm 72050 rpm 341 11 Plates, 72050 rpm Plader, 72050 rpm
6 cyl., 900 rpm 6 cyJ., 900 rpm cyl. engine 8cyl. molor
244 21 Gulde bar, 7~8 cyl. Styrepind, 7-8 cyl 342 11 Plates, 900 rpm Plader, 900 rpm
900 rpm 900 rpm 6 cyl. englne 6 cyl. molor
255 4/ Distance piece, Afstandsslykke, 343 11 PIates, 900 rpm Plader, 900 rpm
72050 rpm , 5 cyl. 72050 rprn, 5 cyf. 7 cyl. engine 7 cyl. motor
256 4/ Di stance piece, Afstandsstykke, 344 11 Plates, 900 rpm Plader, 900 rpm
720 5 0 rpm, 6 cyJ. 7250 rpm, 6 cyJ. 8 cyl. e nglne 8 cyl. moIor
When ordering spare p arts, see al80 page 500.50. Ved beslilling af reservedele, se ogsA side 500.50.
Only avaiIable as part a 8 parts kit. Kun lilgrengelig som del af reseredelssreI.
QtyJE OtyJEnglne AntallE = Antal/Motor
QtyJK OtyJCooler Antal/K = ntaVler
QtyJI atyJlndividu al AnlaVI = AntaVlndividuel
07.08 ESO
PlaIe
Page 1 (2) Centrifugal By-Pass Filter 51515-01
23/30
099 - .-
----- /' 038
~~ - 278
. .. ..
...... ..
... "
"
075 - 266
063
171 ~
171
109
____ 254
110
195
171
---- 337
386
1 ~- 386
~ ___ 349
374~ ~ 362
Plale
51515 -01 Centrifugal By-Pass Filter Page 2 (2)
L23/30
Item Item
. Oty. Deslgnatlon Benrevnel se . aty. Deslgnatlon Bencevnel se
014 1/1' Rotor, complete Incl. , krlet rnkl. I 291 1/F O-rIng O-flng
Item 026, 038, 063 , 026,038,063,075, 09 ,
075, 109,110, 171 , 195 110,171, 195 og 205 301 1/F Clrcllp LAsering
and 205
313 1/F Cover Da3ksel
026 1/F Cover nut Drekselm0Irrk
325 1/F Body cover, compl ete Dc:eksel. komplet inkI.
038 I/F Rotor cover HoIordreksel incl. Ilem 087,266,278, ilem087, 266,278, 291,
291 , 301 and313 301 and 313
051 1/F Body Sokkel
337 Centrifugal by-pass Cenlr f ugal by-pass
063 1/F O-rlng O-ring filter, complete filter, komple\
1 / 5-6 cyl. 5-6cyl.
075 1/F Stand tube Standr0f 2/ 7-8 cyl. 7-8cyl.
109 1/1' Rotor body Rotorsokkel 362 1/F Bracket for mountlng Kol,sol monlering
122 1/F Plug (cut ofl valve) (modtryksvenliJ) 386 1/F Gasket PaknlIlg
134 1/F Sprlng (cut off valve) Feder (modtryksventrl) 398 1/F Spare parts klt, Incl. Reservedelsscel, rnkl .
Item 087 , 278 , 291 ilem 087, 278, 291
146 1/F Gasket (cut Pakn ing (modI ryk s- and 301 og301
vatve) l)
408 1/F Spare parts kit, Incl. Reservedelsscel, lnkl.
158 1/F Shuttle (cut VenIilkegle (modtryks- Item 122, 134 , 146 122 , 134, 146
valve) I I) and 158 og 158
171 1/F Bearlng, complete Lejemontering, krlet 421 1/F Spare parts kit, Incl. Reservedelsscet. inkl.
Incl. Ile m 195 and inkl . item 19509205 Item 063, 146, 229, 230 ilem 063, 146, 229, 230
205 and 291 09291
When orderlng spare parts, see aIso page 500.50. Ved bestilllng af reservedele, se ogsA side 500.50.
= Only available as part of a spare parts kit. lilgc:engelig som en del af eI reservedelssc:el.
QlyJE Qty./Englne An1al/E = Antal/Motor
QlyJF Qty./Fl lter Antal/F = Antal/FiIIer
94.23 - ESOS
Plale
Page 1 (2) Hand Wing Pump 51525-01
23/30
019
94.20 - ESOS-G
Plate
51525-01 Hand Wing Pump Page 2 (2)
23/30
Item Ilem
. Qty. Designation Bencevnelse . aty. Designation Bencevnelse
When ordering sare parls, see a/so page 500.50. Ved bestil llng af reservedele, 5 ogsa side 500.50.
= Only avaflable as of a spare parts kit. Iilgcengellg som del reservedelssrel.
. = Qty./Englne Qty./E = Qty./Motor
94.20 - ESOS-G
Plate
Page 1 (2) Lubricating l Separator 51530-04
23/30
~ 077
053
r'~ 089
~090
041~
-1----100
161
219
220
232
07.08 - ESO
PlaIe
51530-04 Lubricating l Separator Page 2 (2)
23/30
Item Item
. Qty. Designation Ben<evnelse . aty. DesIgnation Benrevnelse
When orderlng spare parts, see also page 500.50. Ved besIilling af re5ervedele, se Og5 5ide 500.50.
= Only avai lable as part of a spare parts klt. Iilg ngelig som del af eI reservedelss
Qty.lE :: Qty./Englne Antal!E = AnIal!MoIor
QtyJF Qty.JFl lter AnIal/F = AnIal!FilIer
07.08 - ESO
Section 516
Cooling Water System
Description
Working card
Plates
23/30
V28/32S
Description High Temperature Circuit
The cooling water system consists separate The high temperature circuit is used cooling
systems. The lw temperature (L) and the high the cylinder units.
temperature () circuits.
Cooling water is led through a distributing pipe
the bottom the cooling water space between the
Temperature Circuit lner and the frame each cylinder uni!. The water
is led ! through bores in the the frame via
The lw temperature circuit is used cooling the the cooling water guide jacket the bore.
charge air and the lubricating l , and the alternator
the latter is water cooled.
96.03 - ESOU-G
DescripIion
Cooling Water Thermostatic Valve 516.04
Pagel(l)
Edilion 01
23/30
V28/32S
Thermostatic VaIe The thermostatic valve cannot be se! adjusted,
and requires maintenance.
The thermostatic valve the high temperature cir-
cuit is mainly located imediately after the outlet some plants a corresponding thermostatic valve
the engine, but alternatively the external cooling is instaIIed th e lw temperature circuil. The ther-
system near the Iresh water cooler. mostatic elements this valve have an other tem-
perature range.
The cooling water enters through the cover () under
which the thermostatic elements are located.
94.26 - ESOS-G
',j,HM'(MAN DieseII
Working Card 516-01.90
Page 1 (2) Check of CooIing Water System Edition 04
23/30
Starting position
Engine is running
Related procedure
~
Working time % hour Plate no Item no Oty/
~
Data
05.4 1 - ESO
',I,I'!" DieseI[
516-01.90 Working Card
Edilion 04 Check of CooIing Water System Page 2 (2)
23/30
3) Move all valves and cocks the piping system. For check ! the fresh water condi tion , see section
Lubricate valve spindles with graphite similar. 504.
05.41 ESO
Working Card
Cooling Water, Thermostatic Valve
516-04.00
Page 1 (2) Edilion 0 1
23/30
Stopped engine
Shut-off startIng air
Shut-off cooling water
Plate Item Note
Shut-oll luel l
Shut-off cooling l
Stopped lub. il circul.
Descriplion:
Slarling posilion:
Relaled procedure:
94.29 - ESOS-G
516-04.00 Cooling Water, Thermostatic Valve
Working Card
Edilion 01 Page 2 (2)
23/30
94.29 - ESOS-G
Plate
Page 1 (2) Cooling Water Thermostatic Valve 51604-01
23/30
018
031
_------ 043
055
~
Note: When ordering new elements,
state opening temperature
Husk! ved bestilling af nye elementer 067
at angive abningstemperaturen .
;~~
114
079
'~ 080
" - - 092
~ I02
94.23 - ESOS
,, Dieserl
Plale
51604-01 CooIing Water Thermostatic VaIve Page 2 (2)
23/30
Item Item
. Qly. Designatlon Benievnelse . aty. Designation Benmvnelse
080 16 l M01rik
When orderlng spare parts, al$o page 500.50. Ved bestilling reservedele, se ogsa side 500.50.
= Only available as part a spare parts kit. tIlgrengelig som del af e! reservedelssGet.
QlyJE QtyJEngIne I/ = Antal/Molor
QlyJT QtyJThermostatlc l Antal/T = AnlaI{Termoslatsventil
94.23 - ESOS
Plate
Page 1 (2) High Temperature Fresh Water Pump 51610-01
23/30
72050
178 - - - - -
~?'=~_
154-166 ------
010 - -_ _
046 - - - - --+-11-_.-'/
071 -
129
01 .36 - ESOS
,,'" DieseII
Plate
51610-01 High Temperature Fresh Water Pump Pag.2 (2)
L23/30
72050
Item Item
. Deslgnation Benrevnelse . Deslgnatlon Benrevnelse
129 2/ Feder
When ordering spare parts, see al50 page 500.50. Ved besIillrng af reservedele, se ogsa sIde 500.50.
Onty available as part of a spare parts klt. Kun tilgcengetig som en det af reservedelsscel.
QtyJE Qty./E nglne Anta t/E = Antal/Motor
QtyJP = QtyJPump Anlat/P = Antal/Pum pe
0 1.36 ESOS
,,I( DieseII
Plate
Page 1 (2) High Temperature Fresh Water Pump 51610-02
L23/30
900
178 -~~ / /
~ r " !
010 -__ -">V -~1-: ,; __! .J,
-~ '-i(' ~ - !
_ . -'- !
046
129 -
,- \
\
\
93.05 - ESOS
Plale
51610-02 High Temperature Fresh Water Pump Page 2 (2)
23/30
900
Item Item
. Deslgnation Bencevnelse . DesJgnation Bencevnelse
When order/ng spare parts, see a l so page 500.50. besIilling af reseNedele, se 09S;\ side 500.50.
Only avai lable as part a spare parts klt. tIlgrengelig som del af et reservedelssrel.
QtyJE = atyJEngine Antal/E = Antal/Motor
QtyJP = Q1yJPump Antal/P = Antal/Pump e
93.05 - ESOS
PiaIe
Page 1 (2) LowTemperature Fresh Water Pump 51610-05
L23/30
154-166 -===~=~~!!!
010 -----I-.~
071
129
01.36 - ESOS
PlaIe
51610-05 Temperature Fresh Water Pump Page 2 (2)
23/30
Item Item
. Deslgnatton Bencevnelse . Deslgnatlon Ben revnelse
When ordering spare parts, see a l50 page 500.50. Ved bestilllng a1 reservedele, ogsA side 500.50.
Only ava il able as part of a spare parts klt. u tilgcengelig som en del af et reservedelsscet.
/ QtyJEnglne l/ = Antal/ Moto
QtyJP = atyJPump Antal/P = Antal/Pumpe
01.36 ESOS
,,!: DieseI[
Plate
Page 1 (2) Temperature Fresh Water Pump 51610-13
23/30
071 -
129 -
046
010
178 ------
201 11 7 129 142
07_06 - ESO
,+,.f DieseI[
Plate
51610-13 LowTemperature Fresh Water Pump Page 2 (2)
23/30
Ilem Ilem
. Qy. Designation Bencevnelse . Qy. Designatlon Bencevnelse
When ordering spare parts, see al$o page 500.50. Ved besti lling af reservedele. 5 ogsA side 500.50.
On/y available as part a spare parts kit. Irlgrengelig som del af el reseredelssret.
QlyJE OtyJEnglne Antal/E = Antaf/Motor
QtyJP OtyJPump Antal/P = AnIaf/Pumpe
07.06 ESO
Plate
Page 1 (2) Pipes Cylinder Head 51625-01
23/30
132 - - - - - - - - - ,
012
~-- 144
024
036
= ~-- 085
~@ 097
061 ~
,
':::,.,,-.-- -
Cylinder Head
Plate 50501, 50502,
50508 and 505 1
94.25 ESOS
'li$1'"#MAN DieseII
Plate
51625-01 Pipes CyIinder Head Page 2 (2)
23/30
Item Item
. Deslgnation Bencene l se . aty. Designation Bencevnelse
When orderlng spare parts, see a/so page 500.50. Ved besliIling af reservedele, 5 ogS8. side 500.50.
Only avallable as part of a spare parts klt. tlgcengeJig som en del af et reservedelssret.
OtyJE QtyJEnglne './ Qty./Motor
OtyJE = QtyJCylinder O'y./C Qty./Cylinder
94.25 ESOS
Pla1e
Page 1 (2) Preheater - Fresh Water 51635-04
23/30
V28/32S
365
377
389
390 _~
400
412
424
436
353
07.46 - ESO
DieseII
Plate
51635-04 Preheater - Fresh Water Page 2 (2)
23/30
V28/32S
Item Ilem
. Designation Bencevnelse . Deslgnation Bencevnelse
When ordering spare parts, see al50 page 500.50. Ved bestifling af reservedele, se ogsc'1 side 500.50.
On ly aval/able as part of a spare parts kit. u ti lge nge li g som dei af et rese rve d e l sse t.
/ QtyJEngine AnIal/E = Anlal/Motor
/ = atyJPump AnIaVP = AntaVPumpe
07.46 - ESO
Section 519
Spec. plant
Description
Working card
PIates
23/30
Resilient Mounting of Generating Sets 1) The supporl belween Ihe bottom Ilange Ihe
conical mounling and Ihe loundalon is made
resilienlly mounled generaling sels, Ihe diesel wilh a loose sleel shim. Thi s sleel shim is ad-
engine and Ihe allernalor are placed a common jusled 10 an exacl measuremenl (min. 75 mm)
rigid base Irame mounled Ihe ship's/machine lor each conical mounling.
house's loundal o n by means resilienl supporls,
Conical Iype. 2) The supporl can also be made by means
sleel shims, at the l a loose sleel shim
conneclions Irom Ihe generaling sel 10 Ihe exlernal al leasl 75 mm and below a sleel shim al
syslems should be equipped wilh flexible conneclions least 1 mm which are adjusled loreach conical
and pipes. Gangway elc. must l be welded 10 Ihe mounling and then welded the loundation.
exlernal part Ihe inslallalion.
Resilient Support
Stcel Shm~~:;:~~~;;:;:;:;:;;:::t==!:
Foundation
Fig 2 5 conicaJs.
02. 10-ES1
' DieseI!
519.03 ResiIient Mounting of Generating Sets
Description
Edition 06 Page 2 (2)
23/30
3) Finally, Ihe support can be made by means Adjustment Engine and Alternator
chocklast. is necessary use w steel Base Frame
shims, the steel shim should be loose and
have a minimum thickness 75 mm and the The resi liently mounted generating set is normally
bottom steel shim should be cast chocklast delivered Irom the lactory with engine and alternator
with a thickness at least 1 mm. mounted the common base Irame. Eventhough
the engine and alternator have been adjusted by the
Irrespective the method support, the 75 mm lactory with the alternator rotor placed correctly
steel shim is necessary lacilitate a possible luture the stator and the crankshalt bend the engine is
replacement the conical mountings, which are within the prescribed tolerances.
always replaced pairs.
02. 10-ES1
Descrilion
Page 1 (1) ResiIient Mounting of Generating Sets 519.03
Edition 10
L23/30
Resilient Mounting of Generating Sets 1) The support between the bottom Ilange the
conical mounting and th e loundat on 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 an exact measurement (min. 1 mm)
rigid base Irame mounted on the ship's/machine lor each conical mounting.
house's loundaton by means resilient supports,
Conical type. 2) Finally, the support can be made by means
chocklast. lt is necessary use one steel shim .
connections Irom the generating set the external The steel shim should be cast in chocklast with
systems should be equipped with Ilexible connections a thickness at least 1 mm.
and pipes. Gangway etc. must not be welded the
external part the installation.
Adjustment of Engine and Alternator
Base Frame
Resilient Support
Th e resi lientl y mounted generating set is normally
Th e resilient mounting a generating set is made delivered Irom the lactory with engine and alternator
with a number conical mountings. The number mounted on the common base frame. Eventhough
and the distance between them depend on the size th e engine and alternator have been adjusted by the
the plant. The conical mountings are bolted the lactory with the alternator rotor placed correctl y in
Ilange the base Irame (see fig 1). the stator and the crankshaft bend the engine is
within the prescribed tolerances.
The setting Irom unloaded loaded condition is nor-
mally between 5-11 mm lor the conical mounting.
CONICA L
---
"
Foundation
Method 2
. NECESSARY DI STANCE
" THI CKNESS OF CHOCK 10 mm
Sleel shim
ChockIasl
-~Pt:~~~~I!~~:r;==~
Fig 1 Resilent mounting of generating sets.
04.24 - ES1
Working card 519-03.00
Page 1 (3) Fitting Instructions for ResiIient Mounting of GenSets Edition 22
23/30
Stopped engine Plate no Item no Note
Shut-off startin g air
Shut-off cooling water
Shut-oll luel l
Stopped lub. l circulation
Press button (Blocking - Reset)
Mounting and adjustmen t instru cti on lor new Ring and open-end spanner. 19 mm
GenSet and adjustment instruction lor eist i ng Rin g and open-end spanner. 24 mm
plants. Ring and open-end spanner. 41 mm
Ring and open-end spanner. 65 mm
Feeler gauge. 1-2 mm
Measurement tool
Starting position Hydraulic jack ( l necessary)
Related procedure
Manpower
Spare and wearing parts
Working hours : 2 hours
Capacity 2 men Plate no Item no Qty/
Data
04.22 - ES 1
519-03.00 Fitting Instructions for Resilient Mounting of GenSets
Working card
Edition 22 Page 2 (3)
L23/30
Mounting and Adjustment Instructions 5) Position th e fou r jacking bolts the tapped
New Generating Sets holes the bottom fl ange (6).
Make Ready Adjustment Conical Ele 6) Lowerthe generating set il rests completely
ments the foundation.
! the conical elements have been mounted by 7) Loosen the nut (1).
the factory, they must be mounted on the flange
! the base frame. In case they have been mounted 8) all the central buffers (3) by applying a
by th e factory, please start with item 4. spanner the h eago n (8 = 19) check that
they can move freely.
1) Remove nut (1) and washer (5) from th e conical
element. 9) Check with the feeler gauge that central buffer
is contact with the foundation .
2) Adjustment nut (2) has be turned down until
gets in contact with the surface ! the
casting. 1I aII internal buffers Then
3) Fit the conical element the bracket on the Can move freely Let conica l e leme nts
suspended equipment by means ! fi in g the settle for min 24 hous.
central buffer (3), the washer (5) and nut (1).
Cannot be moved Turn the jacking bolts
4) Tighten the nut (1) by hand and simultane- freely clockwise release the
ously block the central buffer (3) by applying internal buffer.
a spanner the heagon (8 = 19) on the
! the central buffer (3).
flange
7
4 3
Chockfast
Foundalion ~
.;
6
1.
"~
~
2. Adjustment
~
3. Cenlral buffer
Jacking
4.
5.
Jack-up bolt
Washer
"J:
boll
7. casting
"
8. Rubber elemenl
Mounting bolt
04.22 ES1
Working card
Page 3 (3) Fitting Instructions for Reslient Mounting of GenSets 519-03.00
Edition 22
23/30
1I Then
Mounting Conical Elements the Foun-
Difference exceeds Level the conical element dation
2mm. by adjusting the jacking
bolts - commencing with 19) Drill lor mounting holes in the londaton lor
the conical element with each con ical element, either
the largest deviation.
a) Mark the positions the mounti ng holes on
Dilference does not ex- The height between the foundation through the conical element.
ceed 2 mm bottom flange and
londaton can be (Re)move the set completely so that the mark-
meaured. ingscan be reached bydrilling with conventional
tools.
The dilference between the w sides a conical Place the set on its lormer position by aligning
mounting should not be more than 0.5 mm. with the drilled holes.
or
Height adjustment
b) Drill the mounting holes in the foundation by
11) Turn the internal bufler anticlockwise until means the drilling pattern Irom the installa-
contacts the base casting secure the loaded tion drawing.
height each conical element.
The drilling has be done on belorehand and
12) Lift the generating set with crane or hydraulic the set must be aligned with the foundation
jack. holes before the work starts avoid l urther
re moval the set.
13) Turn the adjustment nut (2) the measured
height (see point 1) max 5 mm above the 20) Fix the conical element the foundation with
casting .. lor bolts.
14) Lowerthe generating set until rests completely Note! Afte r completion all works the buffer clear-
in itself. ance must be checked, see points 15-18.
04.22 - ES1
Working card
Fitting Instructions for ResiIient Mounting of GenSets 519-03.00
Page ' (4) Edition 24
23/30
Stopped engine Plate Item Note
Shut-off starting air
Shut-off cooling water
Shut-off fuel '
Stopped lub. ' circulation
Press button (Blocking - Reset)
Relaled procedure
Dala
03.50 ES,
519-03.00 Fitting Instructions for Resilient Mounting of GenSets
Working card
Edition 24 Page 2 (4)
23/30
Mounting and Adjustment Instructions lor 5) Position the jacking bolt with a through-going
New Generating Sets (Method 1) minimum 75 mm.
Make Ready lor Adjustment ConicaI EIe 6) l owerthe generating set until rests completely
ments on the foundation.
1I the conical elements have not been mounted by 7) Check that allthe jacking bolts have ll contact
the lactory, they must be mounted on the prepared with the foundation.
brackets on the base Irame. In case they have been
mounted by the lactory, please start with item 4. 8) Loosen the nut (7).
1) Remove nut (7) and ring (6) Irom the conical 9) Turn all the internal buffers by applying a span-
elemen!. ner th e hexagon (5 = 19) check that they
can move I .
2) Fit the coni cal element th e bracket on th e
suspended equipment by means fi xing the
central buffer (2), the ring (6) and nut (7). 1I all internal buffers Then
3) Tighten the nut (7) by hand and simultane- Can move l conical elements
ously block the central buffe r (2) by appl ying settle min 24 hours.
a spanner th e hexagon (5 = 19) on the
the central buffer (2). Cannot be moved Turn the jacking bolts
l clockwise release the
4) Position the lo r jacking bolts in th e tapped internal bulfer.
holes (8) in the bottom flange.
7 - - --L.P+-I
6 ----Eff~
5
Brackel
4
3
2 _ 1=_=:f
Jacking boll
8 -t=tt---~-
Foundation
Section -
Base casting 5 casting
2 Central buffer (spindle) 6 Ring
3 Synthetic bush 7 !
4 Rubber elemen! 8 Tapped hole 1 2
Jacking boll
MounIing bolt
03.50 - ESI
DieseII
Working card
Page 3 (4) Fitting Instructions for ResiIient Mounting of GenSets 519-03.00
Edilion 24
L23/30
Adjustment Conical Elements after min 24 l1 Ihe mounling holes Ihe sleel shim according
Hours Settling 10 Ihe conical base casling dimensions.
03.50 - ES'
519-03.00 Fitting Instructions for ResiIient Mounting of GenSets
Working card
Page 4 (4)
Edition 24
L23/30
dation
b) Drill the mounting holes in the foundation by
23) l 1
four mounting holes in th e foundation for means th e drilling pattern from the installa-
each conical element, ei th er tion drawing.
a) Mark the positions the mounting holes on The drilling has to be done on beforeh and and
th e foundation through the conical element. the set must be aligned with the foundation
holes before the work starts to avoid further
(Re)move the set completely so that the mark- removal th e set.
ingscan be reached bydrilling with conventional
tools. 24) Fix the conical elemen t and the steel shim to
the foundation with bolts.
Place the set on its former position by aligning
it wi th the drilled holes. ! After completion all works the buffer clear-
ance must be checked, see points 19, 20, 21 and
22.
03.50 - ES1
Working card 519-03.00
Page 1 (4) Fitting Instructions for ResiIient Mounting of GenSets Edition 25
23/30
Slopped engine Plate no Ilem no Nole
Shut-off starling air
Shut-off cooling waler
Shut-off fuel l
Slopped lub. l circulation
Press button (Blocking - Resel)
Mounling and adjuslmenl inslruclion for new Ring and open-end spanner, 19 mm
GenSel and adjuslmenl inslruction for existing Ring and open-end spanner, 24 mm
planls. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement 1001
Hydraulic jack ( necessary)
StartIng position
Related procedure
Data
03.50 - ES1
519-03.00 Fitting Instructions for ResiIient Mounting of GenSets
Wrkng card
Page 2 (4)
Edition 25
L23/30
Mounting and Adjustment Instructions for lr l r jacking bolts and mounting holes drilled
New Generating Sets (Method 2) according conical base casting dimensions, is
req uired.
Make Ready for Adjustment of Conical Ele
ments 4) Position the supporting steel shim as per fig
1 and locate the conical element by means !
1I the conical elements have ! been mounted by dowel pins.
the lactory, they must be mounted the prepared
brackets the base Irame. case they have been 5) Position the jacking bolts the tapped holes
mounled by the lactory, please slart with item 4. the supporting steel shim as per lig 1.
1) Remove ! (7) and ring (6) Irom the conical 6) Position the jacking bolts with a through-going
element. minimum 1 mm, see lig 1.
2) Fi t the conical element the bracket the 7) Lowed generating set l ! rests completely
suspended equipment by means lixing the the loundation.
central buffer (2), the ring (6) and ! (7).
8) Check that all jacking bolts have ll contact
3) Tighten the ! (7) by hand and simultane- with the foundation.
ously block the central buffer (2) by applying
a spanner the hexagon (S = 19) the 9) Loosen the ! (7).
! the central buffer (2).
10) all the internal buffers by applying a span-
75 mm supporting steel shim, complete with holes ner the hexagon (S = 19) check that they
can move Ireely.
Brackel
7- - _ - L1DrI
Jacking 6 --_-,!;;~
SupporIing
5
steel shim 4
Steel shim r=d====t====::;:=f:-j 3
Foundation 2 -i=_~~
Section -
8 -:::;.;... _ _ _-""""'
Jacking boll
1 Base casting 5 casting
2 Central buffer (spindle) 6 Ring
3 Synthetic bush 7
4 Rubber element 8 Tapped hole 12
Mounling bolt
03.50 - ES 1
Working card
Page 3 (4) Fitting Instructions for ResiIient Mounting of GenSets 519-03.00
Edition 25
L23/30
Can move Ireely Let conical elements 12) Measure th e steel shim several points
settle lor min 24 hours. obtain the highest possible accuracy during
preparation.
Cannot be moved Turn the three jacking
Ireely bolts the supporting
steel shim clockwise, Fabricating Steel Shim
anticlockwise release
the internal bufler. 13) Make sure that the minimum height the steel
shim is 1 mm secure the l replacement
the supporting steel shim .
Adjustment Conical Elements after min 24
Hours Settling ll the mounting holes the steel shim according
the conical base casting dimensions.
After the conical elements have been dellected
der static load lor min 24 hours, the loaded height (1)
see lig 1, should be measured and compared the Mounting the Completed Steel Shim
recommended loaded height.
14) Lilt the generating set 1 mm totally be means
11) Care must be taken, during levelling the the three jacking bolts.
installation, ensure that individual mountings
are overloaded.The variation laden height 15) Position each completed steel shim.
should exceed 2 mm and should ideally
be less. Th e laden height can be measured 16) Relower the generating set by means the
between and base casting at , W three jacking bolts l rests completely
sides (see lig 1). itself.
( + 2 + 3 -----
Ex:Average = Adjustment lnternal Buffer
Number conical elements
17) the internal buflerclockwise (downwards)
Then l
makes con tact with the steel shim
loundation.
Diflerence exceeds Level the conical element
2mm. by adjusting the jacking 18) the internal bufler anticlockwise (upwards)
bolts commencing with l obtains contact with the base casting.
the conical element with
the largest deviation . This must be (, ( trns.
Diflerence does The height the steel 19) the internal bullertwo lll turns clockwise
ceed 2 mm shim can be measured . (downwards) and check with a leeler gauge
between the base casting the conical ele
ment and the steel shim that the internal bufler
Th e diflerence between th e w sides the conical (2), see lig 1, does touch the steel shim
mounting should be more than 0.5 mm. loundation.
03.50 ES1
'( DieseII
2330
Place the set on iIs lormer position by aligning Note! After completion all works, the bufler clear-
with th e drilled holes. ance must be ch ecked, see points 17, 18, 19
and 20.
03.50 - ES1
',J,i,iHi(MAN Dieserl
Working card
Fitting Instructions for ResiIient Mounting of GenSets
519-03.00
Page 1 (4) Edition 26
23/30
Stopped engine Plate Item Note
Shut-off startin g air
Shut-oll cooling water
Shut-off fuel l
Stopped lub. l circulation
Press button (Blocking - Reset)
Mounting and adjustment instru ction for Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement l
Hydraulic jack (f necessary)
Starling position
Related procedure
Data
03.50 - ESO
519-03.00 Fitting Instructions for ResiIient Mounting of GenSets
Working card
Page 2 (4)
EdiIion 26
L23/30
Mounting and Adjustment Instructions for 75 mm supporting steel shim, complete with tapped
New Generating Sets (Method 3) holes lorthree jacking bolts, lur mounting holes and
lour tapped holes, drilled according the conical
Make Ready for Adjustment Conical Ele- base casting dimension, is required see lig 1.
ments
4) Position the supporting steel shim as per lig
1I the conical elements have been mounted by 1 and locate the conical element by means
the lactory, Ihey musl be mounled Ihe prepared lour hold-down bolts.
brackels Ihe base Irame. case Ihey have been
mounled by Ihe laclory, please slarl wilh ilem 4. 5) Position the jacking bolts the tapped holes
the supporting steel shim as per lig 1.
1) Remove l (7) and ri ng (6) Irom Ihe conical
element. 6) Position the jacking bolts with a Ihrough-going
minimum 1 mm plus permitted thickness,
2) Fil Ihe conical elemenl 10 Ihe bracket Ihe as specilied Irom the chocklast supplier, see
suspended equipmenl by means lixing Ihe lig 1.
cenlral buffer (2), Ihe ring (6) and (7).
7) Lowed the generating set l rests com-
3) Tighlen Ihe l (7) by hand and simullane- pletely the loundation.
ously block Ihe cenlral buller (2) by applying
a spanner 10 Ihe hexagon (5 = 19) the 8) Check that all jacking bolts have l ull contact
the central buffer (2). with Ihe loundation.
6 ----e~~
Bracket 5
4
3
Jacking bolt~J:!~~~
Supporting
sIeel shim
2 - 1=,,--===r
SIeel shim:E~====t:====1t~
8
Chockfast
Foundalion
1 Base casting 5 casting
2 Central buffer (spindle) 6 Ri ng
3 Synthetic bush 7
4 Rubber element 8 Tapped hole 12
Jacking Fig 2 Conical element.
boll
Mounting bolt
03.50 - ES1
l' DieseII
Working card
Page 3 (4) Fitting Instructions for Reslient Mounting of GenSets 519-03.00
Editio n 26
23/30
Can move Ireely Let conical elements 1) The steel shim should be at least 1 mm
settle for min 24 hours. heigh .
Cannot be moved n the three jacking Check the minimum permitted thickness ofchock-
freely bolts n the supporting fast for the load and surface of this applcation
steel shim clockwise, or with chockfast supplier.
anticlockwise and
slacken th e lor hold-
down bolts release Fabricating Steel Shim
the internal buffer.
Make sure that the minimum height the steel shim
is 1 mm secure a luture replacement the sup-
Adjustment Conical Element after min 24 porting steel shim.
Hours Settling
11) l 1 the mounting holes the steel shim ac-
After the conical elements have been dellected cording the mounting holes the supporting
der stalic load for min 24 hours, the loaded height ( 1 ) steel shim.
see fig 1, should be measured and compared the
recommended loaded height.
Adjustment Internal Buller
9) Care must be taken, during levelling the
installation , ensure that individual mountings 12) the internal bufferclockwise (downwards)
are overloaded.The variation laden height l makes contact with th e steel shim or
should exceed 2 mm and should ideally loundati on.
be less. The laden height can be measured
between l and base casting at , w 13) the internal buffer anticlockwise (upwards)
sides (see fig 1). l obtains contact with the base casting.
The difference between the w sides the conical 16) l1 mounting holes the londat on accord-
mounli ng should l be more than 0.5 mm. ing the supporting steel shim/steel shim and
chockfast, either
03.50 - ES1
',"( Dieserl
519-03.00 Fitting Instructions for ResiIient Mounting of GenSets
Working card
Page 4 (4)
Edition 26
23/ 30
a) Mark th e positions the mounting holes b) ll Ihe mounting holes Ihe 10unda1on by
th e 10u nd a1 on Ihrough Ihe supporling sleel means Ihe drilling pattern .
shim .
The drilling has 10 be done beforehand and
(Re)move Ihe sel complelely so Ihal Ihe mark Ihe sel musl be aligned wilh Ihe foundalion
ingscan be reached by drillingwilh convenlional holes before Ihe work slarls 10 avoid fu rlher
1001s. removal ! Ihe set.
Place Ihe sel ils former posilion by aligning Make sure Ihal Ihe mounling bolls are isolaled from
l
wilh Ihe drilled holes. Ihe chockfast.
03.50 - ES1
+ .J Dieserl
Working card
RepIacement of ConicaIs
519-03.05
Page 1 (2) Edition 1
23/30
11
Stopped engine
Shut-off starting air
Plate Item Nole
Shut-off cooling l
Stopped lub. l circulation
Descriplion:
Replacement of conicals.
Hand lools:
Relaled procedure:
Dala:
96.03 - EQOS-G
"I'I,!Ni(MAN Dieserl
519-03.05 WorkIng card
EditIon 01 RepIacement of ConicaIs Page 2 (2)
L23/30
Replacement Conicals
1. Loosen all conicals side. 3. Lift the GenSet l the steel shim can be
removed. This ll give enough space for removing
damaged conical.
2. ! a jack under the base frame. see lig
1.
4. ! !he GenSet conical.
Steel shim
7. Adjust the conicals, see Working Card 519-
Foundation 03.00 "Fitting /nstructions lor Resilent Mounting
Deck Jack GenSet.
0
0
One pair
96.03 - ESOS-G
Working card 519-03.05
Page 1 (2) Replacement of Conicals Edition 04
L23/30
Starting position
SaIety precautions.
Related procedure
Data
04.22 ESO
', DieseII
519-03.05 Working card
Edilion 04 RepIacement of ConicaIs Page 2 (2)
L23/30
Replacement Conicals
04.22 - ESO
',l,l}H'lMAN DieseI!
Working Card 519-03.10
Page 1 (2) Maintenance ConicaIs EdiIion 02
23/30
Slarling posilion
Relaled procedure
Dala
98.41 50
519-03.10 Working Card
Edition 02 Maintenance of Conicals Page 2 (2)
L23/ 30
If h e n
What Check
everylhing is check is cornpleled
1) Check ' l deposits the rubber element.
everylhing is ! adjusl conicals which do !
2) Check ' loose mounting bolts. comply with Ihe clearance
demands acc. 10 iIem 510.
Recheck all conicaJs acc. 10
3) Check ' damage the rubber element. item4.
1.
2. l I buffer
2
3. Conical base caslfng
4. Steel shim
3
Fig 1 Conica/
98.41 - ESOS
Working Card
Maintenance Conicals
519-03.10
Page 1 (3) EdiIion 04
23/30
Starting position
Related procedure
Manpower
Data
04.22 - ESO
519-03.10 Working Card
Edition 04 Maintenance of Conicals Page 2 (3)
L23/30
4) Check clearance all conicals belween sleel 8) 1I devialion is l lolerance adjusl Ihe heighl
shim and inlernal buller Ihrough Ihe slol Ihe wilh Ihe adjustmenl ul (2). Use spanner 65
base casling the conical (see lig 1) wilh a mm. It may be necessary 10 l ft Ihe GenSel
leeler gauge approx. 2 mm. slighlly wilh a hydraulic jack. Make sure Ihal
all Cenlral bullers can be turned Ireely al all
lime.
1. u
2. Adjuslment ul
3. Rubber elemenl ~
4. Jacking screw ~
~
5. Base casling ~
3
6. Central buffer "
'"
4
'"
Fig 1 Conica/
04.22 ESO
Working Card 519-03.10
Page 3 (3) Maintenance of Conicals Edition 04
23/30
15) Use the jacking screws (4) lift the base casting
until the central buffer can be turned Ireely.
Make sure that there is no contact between
thread central buffer and th e base frame.
04.22 - ESO
PIate
Page 1 (2) Flexible External Connections 51902-10
L23/30
Item
Fig. Designation Connection
03.12 - ESO
PIate
51902-10 Flexible External Connections Page 2 (2)
L23/30
Item
Fig. Oesignation Connec tion
Ireshwater,inlet G1 222
freshwater, outlet G2 234
03.12 - ESO
',Ji$1'MAN DieseII
Plale
Page 1 (2) ConicaI EIement 51903-02
23/30
013
013
025
"
..
Note! When ordering be aware that conical ele- Bemrerk! Ved bestilling al conicals elementer skal
ments always should be replaced in pairs. State conicals elementer altid udskiltes parvis. Opgiv
manulacturing existi ng conical elements. labrkaton s nr. eksisterende conicals elementer.
97.49 ESO
'' DieseI[
Plale
51903-02 Conicai EIement Page 2 (2)
23/30
Item Ile m
aty Designation Bencevnelse a Design ation Ben cevnelse
When ordering spa re parts, see a/50 page 500.50. Ved bestfling af reservedeIe, 5e ogsf side 500.50.
= Only ava ilable as part of a spa re parts kit. IilgrongeJig som del af l reservedelsscet.
Qty/M = Qty/Conica l mounting. Qty/M = Qly/ConicaJ montering.
97.49 - ESO
ll DieseII
Plate
Page 1 (2) ConicaI EIement 51903-05
L23/30
013
04.22 - ESO
Plate
51903-05 Con ical Element Page 2 (2)
L23/ 30
Item Item
aty Designation Benmvnelse aty Deslgnation Ben mvne lse
When orderlng spare parts, see also page 500.50. Ved bestiliing af reservedele, se 09S:' side 500.50.
On ly avaIIable as part of a spare parts klt. Kun tilgrengelig som en del af eI reservedelsscel.
aty/M = Qty/Coni cal mounting. Qty/M = QIy/Conical monIering.
04.22 - ESO
Section 520
Tools
Description
L23/30
V28/32S
The contents these spare part plates with Iools However, some tools such as l orque spanners, hy-
are a summary STANDARD TOOLS normal draulic tools etc. may also have olher applications.
mainIenance and EXTRA TOOLS recondil ioning, InformaIion about Ihe exacl use the lools appears
which can be supplied by & Diesel A/S, from Ihe relevanI sections the inslruction book.
Holeby. Thus, the list comprises Ihe total extent
Iools available this engine type. Note: The lable the spare parl plates is marked
wilh an S an . S means thal the lools are
For each specific plant Ihe amount lools delivered supplied when ordering .8.landard lools and an
depends the contractual specificalions. means that the tools are supplied when ordering
J;:xtra tools, i.e. Tools Reconditioning (extra l ools
The l ools l sed are assembled sections corres- are slandard delivery)
ponding the chapters the inslrucIion book.
96.03 - ESO
Working Card 520-01.05
Page 1 (7) Function of the Hydraulic Tools Edition 02
General
Starting position
Related procedure
Data
99.43 ESO
,/ DieseI!
520-01.05 Working Card
Edilion 02 Function of the Hydraulic TooIs Page 2 (7)
GeneraI
Function the l Tensioning Device 8. The operation and handHng the device are
be carried by epert staft only.
order achieve an optimal result with one or
several devices, some ru les have be considered. 9. The given ma. operation pressure is
We epressly that a conscientious handling be eceeded any case and is be walched
the device as well as the accessories is high- at the manometer the pressure generalor
est importance. ignore these rules or separate during the complel e lensioning or loosening
hinls means danger 10 l le or danger injuries! See procedure. When having achieved the given
Safety Hints. pressure, stop th e pressurization immedi-
ately.
lorbdden. "'
ately.
9
<
7. Tensioning pressures or lensioning forces are
99.43 ESO
Working Card 520-01.05
Page 3 (7) Function of the Hydraulic Tools Edition 02
General
Working Hints
securing ring
order 10 achieve a boll conneclion high precision,
l is vilal 10 consider Ihe following working hinls:
seal
selling Ihe device, clean all Ihreads and
remove possible damages order 10 avoide
a "freeze on".
99 .43 ESO
520-01.05 Working Card
Edilion 02 Function of the Hydraulic Tools Pag. 4 (7)
General
drawing the hose with a manual lorce that the max. admissible stroke the device is
about 100 make sure th at the connection is exceeded. Beside that, has be ensured that the
correctly barred. cylinder and th e support sleeve remain centrically
towards each other (consider centering shoulder).
For decoupling the high-pressure hose
a pressureless condition, lirst pull back the Having made all hydraulic connections correctly,
coupling socket and then take off the hose. see lig. 2, start the pressurization lor the tensioning
procedure. 1I the necessary pressure is achieved
stop pressurizati on. The inducted lorce causes the
bolt extend an edging the components
be tensioned so th at the main is lifted Irom the
Screw connectjoo
Ilange. Screw back the flange, see (ig. 3. Check
~~ --3--:-- ---'~ by help a leeler gauge leal whether the main
really lits tight the Ilange. Afterthat, bleed hydraulic
pressure. w the connection is tensioned.
Fig. 2. Cotplng the highpressure hoses. Having brought the piston its zero position, see lig.
4, th e hydraulic hoses can be decoupled. ord er
prevent impurities, is advisable close coupling
Hoses with last-Iock coupling sockets avoid, also sockets and coupling nipples at once by protecting
when uncoupled, that l runs l. When the hoses caps. The device can be unscrewed Irom the boll.
get heated, there can be an inside pressure the
uncoupled condi tion making a coupling impossible. Always consider the salety and working
loosening screw connection (see (ig. 2) the hints!
pressure can be bleeded
Screw the device l the support sleeve the sup- nl: Th e adjusted slit measure may never exceed
port cylinder lits exactl y th e flange. The piston the admissible stroke the device! Furthermore,
the device must be at its zero position. Furthermore, take care th at the window lor the adjusting rod are
take care that th e hydraulic connectorand the window well accessible.
lor the adjustin g rod is we ll accessible. Having made all hydraulic connections correctly, see
1I necessary, turn back the device, but make sure lig.2, start the pressurization.
99.43 - ESO
. I I1 ' .f DieseII
Working Card
Function of the Hydraulic TooIs
520-01.05
Page 5 (7) Edilion 02
GeneraI
During the pressurization, a slightturn-back momen- l:
tum is applied the main nut with the adj usting rod.
th e moment, when the main can be loosened , a) Should be impossible unscrew th e device
interrupt the pressurization. Should be possible after the depressurization , ! has been turned
loosen the main when achieving the original back by a lw measure , the pres-
tensioning pressure, interrupt the pressurization im- surization. Pressurize again l the original
mediately. Find the cause with staft. tensioning pressure is reached, the main
nul and bleed the pressure again (tensioning
Having achieved the loosening pressure, turn back procedure). can turn back the device
the main by the value that the bolt and the com- lurther. (///: consider /he admissible
ponents spring back during the loosening procedure. s/roke of/he device!) repeat the loosening
The slit measure, however, must be lower than the procedure eplained above.
slit measure adjusted at the device belore, see also
hin/ b. b) Should ! be impossible loosen th e main ul
after the depressurization, ! has been turn ed
The main may never be turned back l lts back by a l measure , the pres-
the piston or the cylinder since then th e device surization. Pressurize again and turn the main
can be tensioned itsell. ul lurther back. Bleed the pressure again.
Having turned back the main , the pressure can l: Never screw the main ul back l lits
be bled. The bolt connection is loosened. Belore the piston since the device can be tensioned
unscrewing the device, bring the piston back its itsell.
position, see fig.4. Alterthat, the hydraulic hoses
can be decoupled. order prevent impurities,
is advisable close coupling sockets and coupling Adjustment and Turn Back of the Main
nipples at once by protecting caps. The device can
be unscrewed Irom the bolt. During the pressurization the device, the bolt
is being etended by the tensioning lorce and the
Make sure that operational lorces (e.g. components are being edged. The result is that the
pressure) affect the components be main nut does longer l the Ilange.
loosened since only part the bolts take
these lorces and thu s the bolts, which are Having achieved the necessary pressure, adjust th e
yet loosened, might be overburdened. main - when tensioning - l lts the Ilange
again belore bleeding the pressure, see Tensioning
The pressure when the main can be loos- Procedure. When loosening the bolts, turn back the
ened may nevereceed the tensioning pressure main ! after the pressurization according the
by help ol which the connection was tensioned ! bolt and component delormations, (see Loosening
Should be possible loosen the main Procedure.
when reachi ng the original tensioning pressure
interrupt the pressurization immediately. Find l: During the loosening procedure, never turn
the cause wi th staft. back the main l lits the piston or the
cylinder since the main sticks after th e depres-
Always consider the salety and working surization.
hints!
The main is equipped with several radial bores
where the adjusting rod can be . Th e main !
is accessible through the window the support
sleeve.
99.43 - ESO
''( DieseI!
520-01.05 Function of the HydrauIic TooIs Working Card
EdiIion 02 Page 6 (7)
GeneraI
During the piston return stroke, considerable back-
pressures can occur in the piston area the device
window device since quite large quantities l have Il back
through the small cross sections the high-pres-
sure connections.
moin nut
odjusting rod
In order noI unnecessarily increase the lorce lor
the piston return stroke turn the piston slowly. On
principle the piston the device has be pushed
back until lits the cylinder again.
99.43 - ESO
f,J,lIM DieseI!
Genera!
a) SIorage
99.43 ESO
Working Card 520-01.06
Page 1 (2) Application of Hydraulic Tools for Connecting Rod Edilion 03
23/30
Stopped engine Plate Item
Shut-off starting air
Shut-off cooling water See page 2
Shut-off fuel l
Stopped lub. l circul.
Slarling posilion
Relaled procedure
Dala
00.20 - ESO
+J DieseII
520-01.06 AppIication of HydrauIic TooIs for Connecting Rod
Working Card
Edition 03 Page 2 (2)
23/30
Hydraulic l ighlening
52021-633
Hose wilh
52021-513
Distributi on piece
-202
Pump
52021 -0 11
Hose wilh
52021-501
Tools for changing of
Pressure parl
sealing angel connection .
52021-586
52021-621
Allen key
5202 1 -263----
00.20 - ESD
Working Card Application of Hydraulic Tools 520-01.06
Page 1 (2) Edilion 04
for Cylinder Head and Main Bearing
23/30
Stopped engine
Shut-off starting air
Plate Item Note
Shut-off cooling water See page 2
Shut-off fuel l
Stopped lub. l circul.
Slarling POSiliOn
Relaled procedure
Data
00.20 ESO
. DieseII
L23/30
High press~~
hose
52021-501
Dislribulion Dislribution
piece piece
5202 1-155 52021-202
High pressure
hose
52021 -5 13
Pressure
pump
52021-608
00.20 - ESO
',ll, MAN DieseI!
GeneraI
Stopped engine Plate Item Note
Shut-off starting air
Shut-off cooling water 52000 0 11
Shut-off fuel l
Stopped lub. l circul.
Starting position
Related procedure
Data
00.45 50
520-01.07 Hand Leer Pump
Working Card
Edilion Page 2 (4)
General
Warning: Th e hand lever pump is equipped with Initial Start-up and Venting
a pressure l l valve.
Never use the pump without a mounted manometer. general and venting
Always pay attention the given pressure the
connected pressure consumers. 00 never exceed Please make sure that all parts the pump, espe-
this pressure the max. pressure the hand lever cially the manometer and the pressure , are a
pump. perfect condition. OelecI parts are be exchanged
against W ones immediately.
Important: Except lor hydraulicoil, neveruse different
liquids such as petrol , waIer, diesel l, alcohol brake Turn the carrying handle with counter-clockwise
liquid, since these can lead damages even rotation his lixing. Then turn the hand
desIrucIion the pump and/or the parts connected lever th e pump against th e stopping l ace.
with Choose a place assembling and operation
where the pump can always sIand sale and firm : 1I the carrying handle is srewed-in
a horizontal plain. There should always be sufficienI the hand lever, it can cause injuries wh ile using
space lor operating the pump. th e pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the l l ller cap and check the oil level. 1I nec-
pump great heat, lre extreme coldness, since cessary, l ll the tank with hydraulic l according
this leads damages even destruction. Protect 180 VG 32. Never ll the tank. Close the l
the pump Irom lalling objects and avoid hard blows lller cap.
pushes. Open the tank breaIher with the square wrench
(included the scope supply) by about one turn.
tt Danger 10 lle w loosen the breather screw at the pump th e
Check the manometer the pump lor the needed lel side the pump housing with an allen key 8
hydraulic pressure, given by an auIhorized person , 2,5 by abouI one turn. Close the depressurization
be exceeded. Make sure th at the pressure valve ti ghtly. 8eal the l the pump with a hose
you want generate is also admissible lor all con- and pump at the hand lever l l Ilows out the
necti on parts. breather screw bladder-Iree. Only then are al-
lowed close th e breaIher screw. The pump is w
pressure connections and connecting elemenIs vented and ready lor operation.
have be clean and undamaged. High-pressure
connections Irom the pump th e tools have be Alter each operation and lor the transport, close
established correctly any pressurization. the tank breather order avoid the hydraulic oil's
Oisregard leads danger l . Please see working running
card 520-0 1.06.
00.45 - ESO
Working Card 520-01.07
Page 3 (4) Hand Lever Pump Edilion
General
Remark: The depressurizati on valve is designed Belowolthe pressure relielvalve is an adjusting screw
lor manual operation . The use any tools at the with hexagon (wrench size 1 mm). Turning
depressurization valve could cause damages the counter-clockwisely the adjusting screw minimizes
valve the valve seat. the change-over pressure, turning clockwise ma-
ximizes the change-over pressure.
Pump at the hand lever until the wanted pres-
sure is achieved. Check the pressurization ": Inside the adjusting screw is another
at the manometer and take care possible grub screwwith innerhexagon (wrench size4 mm)
leakages. limit the stroke the change-over piston inside
the pump block. It is absolutely necessary, screw
Remark: The pump works with w stages. The the grub screw approx. 2 times belore turning
change Irom the lirst stage the second stage the adjusting screw!
happens automatical at a system pressure about
30 bar. The regulation the adjusting screw lollows gra-
dually in approx. 100 - steps. After everv adjusting
: The pump is not equipped with an internal step th e grub screw is screw l lits closely
pressure ll valve. The use a manometer and the and approx. a 1/4 turn loosen.
control the system pressure during pressurizati on
is indispensable. Check by carelully pumping l th e change-over pres-
sure wanted has been reached. 11 necessary, repeat
: Do stand directly V the moving the procedure as described above.
lne the pump lever. Under arising circumstances
the lever can "hit back". avoid accidents stand
sideways the pump.
- High-pressure hydraulic
principle, tihen leakages occurduring the pressu-
rization, immediately release the hydraulic pressure
and seal the leakage renew delect parts.
Depressurizalion
...~
a
~ Adjuslmenl of change-over pressure from
'"
~ slage 1 10 slage 2
'?
g
"' exeptional case, can be uselul adjust the
change-over pressure Irom stage 1 stage 2 (Iactory
adjusted at approx. 30 bar).
00.45 - ESO
", Dieserl
520-01 .07 Working Card
Edition Hand Lever Pump Page 4 (4)
Genera!
00.45 - ESO
',Ji$'MAN Dieserl
Working Card 520-01.10
Page 1 (2) Maintenance of HydrauIic TooIs Edition 01
L23/30
Descriplion:
Relaled procedure:
96.03 - ESOS-G
520-01.10 Working Card
EdiIion 01 Maintenance of Hydraulic Tools Page 2 (2)
23/30
----- --------
1) The hydraulic jacks require mainlenance
excepl replacemenl deleclive sealing rings, each
which consisls an oring and a back-up ring
liIIed ring grooves Ihe pislon and cylinder.
Compression 1001
Fig2.
2) The sealing rings are 10 be liIIed wilh Ihe 0- avoid working accidenls caused by emission
rings nearesl 10 Ihe pressure chamber and wilh Ihe pressure l Irom Ihe hydraulic hoses, Ihe hoses
back-up rings away Irom Ihe pressure chamber. should be pressure lesled al 1200 bar once a
year.
96.03 - ESOS-G
f,l+6H'fMAN DieseI!
Working Card 520-01.15
Page 1 (2) Tghtening with Torque Spanner Edition 0 1
23/30
Descriplion:
Hand lools:
Starling position :
Related procedure:
Dala:
96.03 - ESOS-G
520-01.15 Working Card
EdiIion 01 Tightening with Torque Spanner Page 2 (2)
23/30
1) Belore the nuts are screwed on, the threads and 7) For setting the spanner at the torque required,
the contact laces should be greased with copaslip there is a ball a small arm at the end the
similar, the tightening torques being based a handle.
coefficient l cton the threads.
8) When pulling the ball with the arm outwards,
2) The nuts should l easily the thread, and a small crank handle is formed.
should be checked that they bear the
contact lace. spring-Ioaded slide the handle provided with a
mark which, when turning the crank handle, can be
3) the case new nuts and studs, tighten and set at the required torque the scale.
loosen the nuts 2 3 times so that the thread may
assume its dilinite shape, thus obviating the risk The torque spanner lnctons are as lollows:
loose nuts.
9) The above-mentioned spring activates a pawl
4) Nuts secured with asplit are tightened the system the handle, and when using the spanner,
stated torque and then the split-pin hole. this pawl system ll be released when the pre-
set torque has been reached, at which moment a
5) The lollowing instructi ons apply the use and small jerk is l elt the spanner and a small click is
maintenance the torqu e spanner. heard.
96.03 - ESOS-G
DieseII
23/30
V28/32S
De5criplion
Operation.
Overhaul intervals.
Dismantling, overhaul and assembly. Hand 10015
Slarling 05n
Related procedure
Manpower
96.03 - ESO
520-01.25 Working Card
Edition 01 Max. Pressure Indicator Page 2 (2)
23/30
V28/32S
General
Measuring Procedure ------
For mountng and dismantling the indicator use exclusIvely
the provided hollow spanner.
1. Before screwing the peak~ pressue indica to, open the indIcator
l cock. blow any dirt, and dose 1 again.
... DANGER! The indicator ole ejects hot 9as under high
~ pressu re. Danger of sparks and burning.
2. Close the venting screw the MSI5 and mount the peak-pressure
indica tr the indicator ole using the connecto Tighten
the connector t (15) using the spanner included the scope of
3.
supply.
6. After the measuring procedure is com pleted, open the venting 1 Handle
screw (8) revolutions order let the condensed humfdity
2 Bracket for handle
.sc'p . PROCEDURE co OF HOURS. P.,k-
pressure indicators which are used should be stored with open 3 Manometer, 0- 250 bar
venting screw. 4 Profile washer for G1/4"
5 Adapter
For further measurements start again with the l rst step.
6 Pressure spring
7 Valve
Safety Instructions
8 Venti ng screw
9 Indicator valve
CATIQN: Before using indicalor, open indicalor l cock,
10 Valve guide
blow l any dusl, and close l again. ~
11 Valve baseplate
DANGER! l gas and par1icles may be ejecled.WEAR GLQVES
SAFETY GLASSES!
12
13
Cu-seaI24 1 81,0
Lower section
"'"
~
~
~
~
14 Holding ring
Connecting nut, chromeplated
15 9ro
16 Heagonal screw 5 10 DIN 6912
ro
17 lw spanner
18 Ball-point pen
19 Leather bag
20 Wooden bo
21 Set of spare parts, valve complete
22 Pad of log diagrams
96.03 - ESO
Plale
Page 1 (4) Tools for Cylinder Head 52005-04
23/30
U u :
11
95
Max. pressure indicator. S 109
S = Slandard = Extra
01.17-ESO
Plale
52005-04 Tools for Cylinder Head Page 2 (4)
L23/30
lIll
F
'=
::; -
Grinding table for cylinder head ,
with bracket for wall mounting ,
complete. 846 426 648 254
S = Standard = Extra
01.17-ESO
Plate
Page 3 (4) Tools for Cylinder Head 52005-04
23/30
Dimensions w Item
Illustration of Tools Designation
C
Spare Parts:
~ 408
spindle, complete. 408
Spare Parts:
11 ~
Stone 421
Mounting tool for valve seat rings,
complete. 078 315 457
S = Standard = Extra
01. 16-ESO
Plale
52005-04 Tools for Cylinder Head Page 4 (4)
23/30
Dimensions w lIem
Illustration Tools Designation
C U5
~6 ~
Oi*-t
v------- ~
ll
<~
S = Standard = Extra
01.17 ESO
f,l,I'M L DieseII
Plate
Page 1 (6)
TooIs for Piston , Connecting Rod and CyIinder Liner 52006-06
23/30
~.
/
'\
/
"'--
/ ~
-U
I~Q
connecting rod big-end 1 2 54 410 S 070
bearing.
C
:~
--' L
~ .-
S = Standard = Extra
08.01 - ESO
Plate
52006-06 Tools for Piston , Connecting Rod and Cylinder Liner Page 2 (6)
23/30
~
2 pieces. 280 060.3 75 S 094
;1
~
(IC
Guide ring for mounting ! - 0298 110 S 116
ston.
~ ~
-- 720 50 rpm Stati onary
t----
j
Guide ri ng for mounting ! - 0275 85 S 11 7
ston .
i'" - -
Only for 72050 rpm Marine
-- ~~
S = Standard = Exlra
08.01 - ESO
Plale
Page 3 (6) Tools for Piston , Connecting Rod and Cylnder Lner 52006-06
23/30
Dimensions w Item
Illustration Tools Designation
h A" "'B-r--:C;;-l Jj
)J
,-
~~ .1
BqL=
C
~
~v
~
~
f B
S = Standard = Exlra
08.01 - ESO
'}2' / DieseII
Plate
52006-06 TooIs for Piston , Connecting Rod and CyIinder Liner Page 4 (6)
23/30
Dimensions w Ilem
Illuslralion ! Tools Designalion
C
Socket. 24 55 :.. " S 381
l. 'L
S = SIandard = Extra
08.01 - ESO
Plate
Page 5 (6) Tools for Piston , Connecting Rod and Cylinder Lner 52006-06
23/30
Dimensions w Item
IIlustration ofTools Designation
C {;j
.i
S = Standard =
08.01 ESO
',J,t@' Desel
Plale
52006-06 TooIs for Piston , Connecting Rod and CyIinder Liner Page 6 (6)
L23/30
Inside micrometer:
Measuring range
--- _.- 225-250 mm 618
1 . IJ~--~~
UO l
S = Slandard = Extra
08.01 . ESO
Plale Tools for Operating Gear for Inlet Valves, 52008-04
Page 1 (1)
Exhaust Valves and Fuellniection Pumps
23/30
Dimensions w Item
IIlustration ofTool s DesignaIion (fj
C no
,~
""- Feeler gauge for exhaust val
ves .
0.9 1.0 S 022
.'S<
~~c,
-
C
S = Standard = Exlra
98.51 ESOS
'/ DieseII
Plate TooIs for Contro! and Safety Systems
52009-02
Page 1 (1) Automatics and Instruments
L23/30
Dimensions w lIem
Illustration Tools Designati on
C ()j
s = Standard = ExIra
01 .17 ESO
,,'( DieseII
PJaIe
Page 1 (2) TooIs for Crankshaft and Main Bearing 52010-04
23/30
-e- f!
(autolog). 210 150 S 059
cO
!~!~I~~
.1
1. b" ~
S = SIandard = Extra
D1.17 ESD
',l,HHi(MAN DieseI!
Plale
52010-04 TooIs for Crankshaft and Main Bearing Page 2 (2)
23/30
C (f)
1
Lilting straps lor main and guide
bearing cap, 2 pieces. 1000 16 15 S 155
(j
C ~~
~
214 -------
~
226 -------
S = SIandard = Extra
01.17 - ESO
Plale
Page 1 (2)
TooIs for FueI System and Injection EqUpment 52014-03
23/30
o~ ,,~
~~ .~
~~ ~~
O~~
"- /~ V
' L
1 pc. needles.
1 pc. holder.
~J_.,,_ . Ta~~ 61 -
1 pc. box.
(~~
.. -
S = Slandard = Extra
98.35 ESOS
PIale
52014-03 TooIs for FueI System and Injection EqUpment Page 2 (2)
23/30
A[rt.=::.:'"
~
Grinding 1001 for seat for fuel
= injeclion valve. 018 533 ",70 S 361
-
'
c "
.= =
"
m c
r
-'-- -
~"
J
S = Slandard =ExIra
98.35 - ESOS
PIale
Page 1 (1) Tools for Lubricating l System 52015-01
L23/30
Dimensions w Ilem
Illuslralion ofTools Designalion ~
C (j)
[]-
8-c
S = Slandard = Exlra
96.03 - ESOS
PJate
Page 1 (5) Hydraulic Tools 52021-10
L23/30
Manometer 023
/
059
1 55
Gasket 167
011
06.25 ESO
Plale
52021-10 Hydraulic Tools Page 2 (5)
23/30
Ball 645
645
Adapler 657
704 669
Slroke indicalor band
716
Hydraulic 100ls lor connecling
741 ----I;i;I~,II!
rod wilh steel box, com- S
plete 633
716
Pislon lr hydraulic jack 704
753
Sel O-rings wil h back-up
ring 716
777
$) $)
Adapter
@1 @ 728,741, 753
Quick coupling
586
790
'"
~
~
'!
Q
9
'"
'"
633
W = 350 450 250 mm
s = Standard = Extra
06.25 - ESO
f,I,,'( DieseI[
PlaIe
Page 3 (5) HydrauIic TooIs 52021-10
23/30
0'334 t--
,
263
Quick coupl ing
179
-A~ with steel box, complete S 251
~
~
Venting screw 275
,
299 --
287
Piston for hydraulic jack 287
299 , ~ 310
~
Set of O-rings w ith back-up
309 / ~ ring 299
, ~
~
~
, -
~ - 800
O-ring 309
~
~ Cylinder for hydraulic jack 310
m
/
167 179
Spacer piece
Tommy bar
800
334
1
11 ; 275, 287, 299, 309, 3 10, 645,
.... .. U; 657, 812 358
~
Ball 645
~
~ ~
Adapter 657
Stroke indicator band 812
~ @ Gasket
Quick coupling
167
179
W
2t
= 350 450 250 mm
s = Standard = Etra
06.25 ESO
lI,t,tH'lMAN DieseI!
Plate
52021-10 HydrauIic TooIs Page 4 (5)
23/30
Dimensions w lIem
Illustration ofTools Designation
C ()j
334
Venting screw 275
Ball 645
Adapter 657
Disc 586
Guide 574
4s
W = 350 450 150 mm
S = Standard = Extra
05.25 ESO
Plate
Page 5 (5) Hydraulic Tools 52021-10
L23/30
Dimensions w Item
Illustration Tools Designation ~
C (f)
~ 549
Hose for hydraulic tools, 4 -
ces compl ete 600 027 S 501
~ ~,
Hose 1 3000 537
<{
'1V 525
~
Hose 600 525
i--
'=f
836
r-'"
Air-dri ven high pressure pump
for hydraulic tool s 367 256 326 608
~ ~
J r==:.. 9"
""
C Q)@)0
~1'0 00
;'~ ~ ...
.-
S = Standard = Extra
06.25 ESO
PJate Tools for Overhaul Height,
Page 1 (2) 52050-02
Piston, Cylinder Liner and Connecting Rod
23/30
021 021
033
057
01.1 7 - ESO-G
Tools for Overhaul Height, Plale
52050-02
Piston, Cylinder Lner and Connecting Rod Page 2 (2)
23/30
Item Item
aty Designation Bencevnelse aty Oesignation Bencevnelse
When ordering spare parts, see also page 500.50. Ved bestll i ng af reservedele, 5 og s ~ side 500.50.
= On ly avai lable as part of a spare parts klt. lilgrengelig som del reservedelssret.
Qty/E = Qty/Englne. aty.lE = Qly./Molor.
01 .17 - ESOG
Volume 2
Descriptions
DOOSAN - Diesel
5 23/30 720 RPM
ll 3071
Engine Type 5 L23/30 720 RPM
Project Name: SETA3071-1,2&3
Project . DMM1-5182/5183/5184
NICE Service
~ Necessary /nformation for Customers' Exectation
Access to NICE Service via website, by e-mail
http://nice.doosanengine.com
e-mail: nice.service@doosan.com
DOOSAN ENGINE CO., LTD. 69-3, Sinchon-dong, Seongsan-gu Technical Serice : +82552606996
CUSTOMER SATlSFACTlON Changwon-si, Gyeongnam, Korea 642-370 Parts Sales : +82 55 260 6260
T e l e f a x : +82 55 260 6772
Doosan Engine
Doosan Engine
23/30 Vol. 2
02
DRAWING5
DRAWINGS
Subject:
Note:
~
Doc.
Doosan Engfne 1-5179-0
.
-
DOOSAN DIESEL age 1/ 18- '
REVISION HISTORY
REV DESCR IPTlON
ENGINE
5L23/30 PART Machinery
Doc,
DESCR IP- ,
1-5179-0
SPECIF ICAT ION OF DIESEL GENERATOR ENGINE
Ooosan Engine CO. ,Ltd.
Page 2/ 18
Engine Specification
CONTENTS
1. General 3/18
7. Alternator 17/18
Engine Specification
1. General
1-1 .
DOOSAN - DIESEL 123/30 diesel engine is be built by Doosan
Engine Co., Ltd. under Iicense Irom DIESEL & TURBo.
Model 5 123/30H(GEN)
The main parts (wear parts & maintenance parts) engine shall have
interchangeability with DIESEL & TURBO designed parts.
~ Doosan Engfne
Doc
.
1-5179-0
Page 4/18
Engine Specification
2. Principal Particulars
Number cylinders 5
Stroke mm 300
kw 650
Maximum continuous
Revolution rpm 720
rating (MCR)
Mean ellective
MPa 1.82
pressure
Maximum continuous Mean piston
mls 7.2
rating (MCR) speed
Direction rotation(Ahead) Clockwise , seen Irom Ilywheel side
~ Doosan Engfn.
Doc
.
1-5179-0
Page 5/18
Engine Specification
3. 5cope of 5upply
~ Doosan Englne
Doc
.
1-5179-0
Page 6/ 18
Engine Specification
Doc
Doosan Englne .
1-5179-0
Page 7/18
Engine Specification
I~
Doc
Doosan Engfne .
1-5179-0
Page 8/18
Engine Specification
~ Doosan EngIne
Doc
.
1-5179-0
Page 9/ 18
Engine Specification
3- 15. Tools
1) Standard tools according DOOSA N's standard (1 seship)
~ Doosan EngIne
Doc
.
1-5179-0
Page 10/18
Engine Specification
4. Shop Trial
The diesel engine shall be applied coupling test in combination with alternator
on the common bed plate as lollowing schedule.
'* Note
1) In case measurement is required by class only.
The measurements lor each load range are performed and recorded on
DOOSAN ' s test record sheets.
Instant and permanent speed variation and voltage variation shall be measured
respectively by rapidly changing the load the engine as following method.
When full load is sudden ly taken off --> 50% --> 100% load, the speed is
control within 10% momentary variation and 5% permanent variation of rated
speed.
Speed variations with load changes in accordance with aboves are return and
remain within 1 % of final steady state speed in no more than 5 seconds.
Govemor load 100% is based on 610 kWe on board conditions .
After setting frequency(speed & voltage) at the rated value , change the load as
Doc
.
1-5179-0
Page 11/18
Engine Specification
lollows .
100% - 75% - 50% - 25% - 0% - 25% - 50% - 75% - 100% - 110% - 100%
During the each load condition , Irequency and voltage value shall be recorded
without regulation.
condition 75% load alternator, the Irequency and voltage are regulated
the rated values. After regulation, parallel running test shall be applied lor three
gensets at once.
For any load between 20% and 100% the sum the rated all
generators, the load any generator is ! diller more than 15% the rated
kilowatt the largest generator.
Th is test shall be carried ! the state the engine being load lor lollowing
items.
1) Shut down test
- Over speed
- Lub. l engine l, l pressure
- Fresh water engine outlet, high temperature
2) Alarrn test
be omitted because AMS is supplied by yard.
emission measurement lor exh. Gas and certilicate according requirement, l
4-7.
requested by class.
4-8. Measurement
1) Crankshalt dellection
Engine Specification
~ Doosan Engfne
Doc
.
1-5179-0
Page 13/ 18
Engine Specification
5. Oerhaul Inspection
After the shop test, the overhaul inspection shal l be carried ! lor the lollowing
items at shop.
'* Remark
1) The scope overhaul inspection is cylinder per engine.
2) The cylinder ! lor overhaul inspection l l be determined by attendances after
the shop tesI.
~
Doc
Doosan Englne .
1-5179-0
Page 14/ 18
Engine Specification
6. Description of Engine
6-1 . General
The engine is a turbocharger, single-acting lour-stroke diesel engine the trunk
piston with a cylinder bore 225mm and a stroke 300mm. The crankshalt
speed is 720rm.
The ale spindles are made heat-resistant material and the spindle sets are
armoured with welded on hard metal.
6-7. Val e Actuating Gear
The rocker arms are actuated through roller guides and push rods. The roller
guide lor luel pump and lor inlet and exhaust al es are mounted in one common
housing lor each cylinder. This housing is bolted the engine Irame.
6-8. Fuel injection system
The engine is proided with one luel injection pump unit, an injection ale, and a
high pressure lor each cylinder.
The injection pump is mounted on the ale gear housing by means lour screws.
The pump consist a pump housing, a centrally placed pump barel and a plunger.
Engine Specification
The pump is activated by the fuel cam, and the volume injected is controlled by
turning the plunger.
6-9. Piston
The piston , which is oil-cooled and the monoblock type made nodular cast-
iron , is equipped with 3 compression rings and 1 l scraper rin g. The piston has
a cooling l space close the piston crown and the piston ring zone.
6-10. Connecting Rod
The connecting rod is die-forged . The big-end has an inclined joint in order
facilitate the piston and connecting rod assembly be withdrawn through the
cylinder liner. The joint face s on connecting rod and bearing cap are serrated
The inlet and e hau st va lves as well as the fuel pumps the engine are actuated
bya camshaft. The camshaft is placed in the engine frame at the control side.
The camshaft is driven by a gear wheel on the crankshaft through an intermediate
wheel, and rotates a speed which is half the crankshaft.
6-1 3. Governor
The engine speed is controlled by a Hydraulic woodward governor
6-14. Monitoring and Control System
media systems are equipped with thermometers and manometers local
reading and for the essential pressure the manometers are together with
tachometers centralized in an engine-mounted instrument panel .
6-15. Turbocharger System
The turbocharger system the engine , which is a constant pressure system,
consists an ehaust gas receiver, a turbocharger, a charging air cooler.
6-16. Compressed System
The engine is started by means a built-on air starter.
I~
Doc
Doosan Engfne .
1-5179-0
Page 16/18
Engine Specification
The compressed air system comprises a main starting valve , an air strainer, a
remote controlled starting valve and an emergency starti ng valve which ll make
! possible start the engine in case of a power failure.
6-17. Fuel l System
The built-on fuel il system consists of the fue l l fi lter and fuel injection system.
6-18. Lubricating l System
moving parts of the engine are lubricated with l circulating under pressure.
The lubricating l pump is of the gear wheel type with built-in pressure control
valve. The pump draws the l from the sump in the base frame , and on the
pressure side the il passes through the lubricating l cooler(plate type) and the
fi lter which both are mounted on the engine.
6-19. Cooling water System
The cooling water system consists of a lw temperature system and a high
temperature system.
The water in the l temperature system is passed through the charge air cooler
and the lubricating l cooler, and the alternator if the latter is water cooled.
6-20. Turning
The engine is equipped with a manual tuming device.
~ Doosan Engfne
Doc
.
1-5179-0
Page 17/18
Engine Specification
7. Alternator
Engine Specification
~ Doosan EngIne
Doc
.
1-5179-0
"!= D005an l
Subject :
ARRANGEMENT OF CONNECTlON
Note:
x~ ~
20101112 ~o ~ t12 t1 2 First Issued.
~
Doc.
Doosan Engine .
2-5179-0
DOOSAN - DIESEL aae 1/ 4- #
,
REVISION HISTORY
REV DESCRIPTlON
ENGINE
5L23/30 PAR T Mach inery
Doc.
DESCR IP- .
2-5179-0
1 0
ARRANGEMENT OF CONNECT ION
Doosan Engi ne CO . ,Ltd.
DOOSAN - DIESEL aae 2/4
CONTENTS
ENG INE
5L23 / 30 PART Machinery
Doc.
DESCRIP- .
2-5179-0
ARRANGEMENT OF CONNECTI ON
i
".
, ,
~ ", ,
i~ ~
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re ;' :=f~~~
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DOOSAN-MAN DIESEL Page 1/6
Client : Vangzhou Oayang Shipbuilding Co.,Ltd.
Engine Type : 5L23/30
Subject:
Note:
~
Doc.
Doosan Engine .
MR01-5179-0
DOOSAN - DIESEL aQe 1/6- #' .
REVISION HISTORY
REV DESCRIPTlON
ENGINE
5L23/30 PART Machinery
Doc.
DESCRIP- .
MR01-5179-0
OVERHAUL AREAS OF ENGINE
Doosan Engine CO. ,Ltd .
-
DOOSAN DIESEL aae 2/ 6
CONTENTS
ENGINE
5L23 /30 1 1 PART Machinery
Doc.
DESCR IP- .
MR01-5179-0
OVERHAUL AREAS OF ENGINE
Note:
2
1
20071120 iJEH ~ td ~~ O~ 'C'J First issued.
~
Drawing
Doosan Englne .
44-012748
CONTENT
~ Doosan Englne
Drawing
.
44-012748
,\ \1' ' l
.fZ'S,
C h tgCll'
\ j ~ (X'.':;>!CI
1~-r.:::...J..:>.....ri!!.
f-- --l _
CyJ. C
~ Doosan Englne
Drawing
.
44-012748
1 ll . : 139/ 03071
Tier 2 ll . :-
Subject:
Note:
~
Doc.
Doosan Engine 10-5179-0
.
DOOSAN - DIESEL age 1/ 5- # ,
REVISION HISTORY
REV DE SCR IPTlON
ENGINE
5 L23 /30 PART Machiner y
Doc.
DESCRIP- .
10-5179-0
10
T/C POSIT ION INCLUDING EXPANS ION JOINT
CONTENTS
ENGINE
5 L 23/30 PART Machiner y
Doc.
DESCRIP- .
10-5179-0
T/C POSI TI ON INCUDI NG EXPANSION JOI NT
Note:
3
2
~
Drawing
Doosan Englne .
44-012831
Doc. . : 10-5179-0
Page 4/5
At t.. _ _
-
,
~-
' --
Flange
Exhausl flange 1). malirlQ dirnensions
EngJne type 00 PCD Hole No.ofholes
7-8L2313OH
6L23/30H-900 rpnl ;00 rrrn 540mrn 16mm 4QSmm 22 rnm 16
PCO 1'4---.-
7-8l23130H-900 rpm 450 rrr 595 n1m 16mm 55Dmm 22mm ,6
~ Doosan Englne
Drawing
.
44-012831
200 320 280 222 244 205 490 8,18 16 50 75 75 15 3 2,(5-12) 21 1627934-3
250 375 335 276 294 255 350 12 ,18 16 68 28 54 37 3 2,(5-12) 18 1673441-7
250 375 335 276 298 259 545 12,18 16 50 75 75 20 3 2, ( 5 - 12) 28 1627935 - 5
&(
300 440 395 327 344 306 350 12,22 16 68 28 62 60 3 2, ( 5-12) 22 1670058-0
300 440 3 95 327 353 305 560 12 ,22 16 50 75 75 20 3 2, ( 5 - 12) 38 1627936 - 7
-
350 490 445 359 384 337 490 12,22 16 100 50 75 30 3 2, (5 - 12) 40 1627937 - 9
- 400 540 495 410 435 388 495 16,22 16 100 50 75 40 3 2, ( 5-12) 43 1627938-0
450 595 550 461 486 439 500 16,22 16 100 50 75 50 3 2, ( 5-12) 48 1627939-2
500 645 600 512 537 490 520 20,22 16 100 50 75 60 3 2, ( 5-12) 54 1627940-2
550 703 650 563 587 540 520 20,22 20 100 50 75 70 3 2, ( 5-12) 65 162794 1 4
600 754 700 614 639 592 535 20,22 20 100 50 75 80 3 2, ( 5-12) 79 1627942 6
650 805 750 665 689 64 3 535 20,22 20 100 50 75 100 3 2, ( 5-12) 88 1646653
700 856 800 716 740 693 555 24,22 20 100 50 75 1 1 3 2 ( 5 - 12) 98 1627943 8
750 907 860 767 791 736 635 2422 20 100 50 90 140 3 2, ( 5 - 12) 1 14 1644984 - 9
800 958 900 818 842 787 635 2422 20 100 50 100 180 3 2 ( 5-12) 133 1644985
-
"l~
c MATERIAL
<ra5 a - 0f -'- \\0 FLANGE : DIN- 17100 W. NR.l.0038
" " 0~ i 1)0 MEMBRANE : DIN-1744Q W.NR. 1 . 4541
L T 0
'--
- R I NG : DIN-17440 W.NR.l .454 1
1. 1
CONNECTING : DIN- 17440 W. NR . 1.4541
Flanqes occ lrdina 86044.
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, Ooc. . : Wl1o-S179-0
DOOSAN-MAN DIESEL Page 1/ 4
Client : Vangzhou Oayang Shipbuilding Co.,Ltd.
Engine Type : 5L23/30
1 Hull . : 139/ 03071
2 Hull . :_
Subject:
Note:
~
Doc.
Doosan Engine .
13-5179-0
DOOSAN - DIESEL Page 1/ 4- #
REVISION HISTORY
REV DE SCR IPTlON
ENGINE
5L23/30 PART Machiner y
Doc.
DESCR IP- .
13-5179-0
EXHAUST GAS SILENCER
Doosan Eng ine Co . ,Ltd .
DOOSAN - DIESEL age 2/4
CONTENTS
ENG INE
5L23/3D PART Machinery
Doc.
DESCR IP- .
13-5179-0
EXHAUST GAS SILENCER
Note:
~
Drawing
Doosan Englne .
34-016839
Doc. . 1 3-5179-0
1- 8 7 6 5 ;. 4 3 2
Page . 4 / 4
,
'f-:: o.D.720 ~
490
500
P.C.D 445
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DESIGN CONDITIO ~'
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Doos an Eng i n e Co . ,
SUPPORT BRACKET & [
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8 7 5 5 111' 4 3 2
Doc. . 13-5179-0_
DOQsan EngIne
Subject:
ARRANGEMENT OF HOLDING
BOLTS
Note:
~
Doc.
Doosan Engfne .
MR03-5179-0
DOOSAN - DIESEL aae 1/ 3- #
,
REVISION HISTORY
REV DESCRIPTlON
ENGINE
5L23/30 PART Machinery
Doc.
DESCRIP- .
MR03-5179-0
ARRANGEMENT OF HOLDING D BOLTS
Doosan Eng ine CO . ,Ltd .
DOOSAN - DIESEL aae 2/ 3
CONTENTS
ENG INE
523/30 PART Machi ner y
Doc.
DESCRIP- .
MR03-5179-0
ARRANGEMENT OF HOLDING D BOLTS
2] ~ !>
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Tier 1 ll . : 139/3071
Tier 2 ll . : -
Subject:
Note:
2
Corrected dimension between common bed and resilient
2011 0614 deJ* ~5~ ~ ~~
mounling (80->95) in lig.2
1
Doc.
Doosan Engine .
MR04-5179-1
DOOSAN - DIESEL age 1/ 12-"
REVISION HISTORY
DATE REV DESCR IPTlON
201 10614 1 Co rrected dimensio n betwee n common bed and resilie nt mounting (8 0->95) fig.2
ENG INE
5 L23 /30 PART Machiner y
Doc,
DESCRIP- ,
MR04-5179-1
1 0
SUPPORT ING OF RESI LIENT MOUNT ING
Doosan Engi ne CO"Ltd,
DOOSAN - DIESEL Page 2/ 12
CONTENTS
ENGINE
5L23 / 30 PART Machinery
Doc.
DESCRIP- .
MR04-5179-1
10
SUPPORTING OF RESILIENT MOUNTING
3
Corrected dimension between common bed and
201 1061 3 ~~~ ~ o l ~~ .. m n "nHn n (RO _ Qfi\ ; ?
2
20091208 fd~ 4- :d~~ o l ~~ Added procedure for engine leveIing 1
20080429 ~ EH ~ o l ~~ o l ~~ Firsl issued.
~
Drawing
Doosan Engfne .
34-017765
CONTENT
34-017765
When Ihe generaling sel s are insl alled on a Iransverse sliffened deck slructure, l is
generally recommended 10 slrenglhen Ihe deck by a longitudinal sliffener inline wilh
Ihe resilienl supporls, see Fig 1.
,, , , , , ,
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;1l -L-dl --L-
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,
d
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, , , ,
J J '~1
1;1}- ,--r -:'i r--- r - : -
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Fig , 1 Resilienl supports.
I ~
;1
1"'"),1
. __ '" -- ----
~
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~
_.- --- -- -
95
h
155 i
L
295
Iransverse and long itudinal deck :J ; 450
slructure , Fig 2, 10 oblain
SCREW 635
sufficienl sliffness in Ihe support
Ihe resIIIenl mounled Fig.2 Transverse slill deck slructure
generaling sels.
The slrenglh and Ihe slillness Ihe deck slructure has 10 be based on Ihe actual
deck load, . . weighl machinery, lanks elc. and lurthermore, resonance wilh Ihe
Iree lorces and momenls Irom especial ly Ihe propulsion syslem have 10 be avoided .
resilienl mounled generaling sel, Ihe diesef engine and Ihe generalor are pIaced
a common rigid base Irame mounled Ihe ship's/erection haII's loundalion by
means conicaI Iype resilienl supports.
connections Irom the generating sel 10 the exlernal systems shaII be equipped
with flexibIe connections, and pipes, gangway elc. musl be weIded 10 Ihe exlernaI
part Ihe instaiIation.
The exact setting can be lound Ihe caIcu lalion Ihe conicaI mounlings lor Ihe
pIant question.
The support the individual conicaI mounling can be made the 10IIowing
Ihree ways:
Method 1.
The support between the bottom flange and the loundation the con icaI mounling is
made with a Ioose steef sh im. This steef shim is adjusted an exact measurement
(min. 75mm) lor each conicaI mounting.
~ Doosan Englne
Drawing
.
34-017765
MeIhod 1
Sleel shim .
FoundaIion
Melhod 2
i!.'
Supporllng
51eel shim
Foundation
Supporling
51eel SI11m
Sleel shim
ChockIasl
Foundation
Method 2.
The support can also be made by means steel shims, at the a loose steel
shim at least 75 mm and below a steel shim at least 1 mm which are adjusted
lor each con ical mounting and then welded the loundation.
Method 3.
Irrespective the method support, the 75mm steel shim is necessary laciltate
a possible luture replacement the conical mountings, which are always replaced
pairs.
The resilient mounted generating set is normally delivered Irom the lactory with
engine and generator mounted the common base Irame. Eventhough engine and
generator have been adjusted the lactory with the generator rotor correctly placed
the stator, and the crankshaft bend the engine within the prescribed tolerances.
General
This procedure ll describe the leveling with the litting instruction conical
mounting the basis Method 1., which is common use at the shipyard. For other
methods, please contact us separately.
I~ Drawing
Doosan Englne .
34-017765
--...
..
_.~ ~""1Co'I'. _..... ... .-"'
2 3 5
,
"
.. . ~
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.
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: :
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3
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Synttotic W$M
S Topca$lii'lg
6
7
"Iin
Fig. 5 Arrangement Conical Mounting Hut:ber lmenl 8 0018 12
~ Doosan Englne
Drawing
.
34-017765
'<
~=1 9) Care must be taken, during leveling the
SecIronA-A
, Ii ideally be less. The laden heighl can be
measured between and base casting
Eample:
Average = I + 2 + 3 + ------- +
Number conical elements
The difference between the sides a conical
Fig. 7 Sitting Conical Mounting mounting should l be more than 0.5 mm.
1I Then
~ Doosan Enlne
Drawing
.
34-017765
20) Turn the internai buffer turns ciockwise (downwards) and check with a feeIer
gauge between the base casting the conicaI mounting and the steeI shim that the
internai buffer (2), see Fig . 5, does ! touch the steei shim foundation . (Mark the
position each centraI buffer.)
21) Turn the (7) with a torque 300 Nm and bIock the centrai buffer (2) with a
spanner (S=19) at the same time. (Check the marking position.)
.1.
~ Doosan Englne
Drawing
.
34-017765
b) Drill the mounting holes the lo undat o n by means the drill ing pattern Irom the
installation drawing.
The drilling has to be done bel orehand and the set must be aligned with the
loundation holes belore the work starts avoid lurther removal the se!.
23) Fi all the conical mountings and steel shims the lo un dato n with lour bolts. (Fig.
6)
Note!
After completion all works the buffer clearance must be checked again , see item
18)-2 1).
Subject:
Note :
~
Doc.
Doosan Engine .
MR05-5179-0
-
DOOSAN DIESEL age 1/ 26- '
REVISION HISTORY
DATE REV DESCR IPTlON
ENG INE
5 L 23/30 PART Machi ner y
Doc.
DESCR IP- .
MR05-5179-0
CALCULATION OF RES ILI ENT MOUNTING
Doosan Engine CO. ,Ltd .
-
DOOSAN DIESEL aae 2/ 26
CONTENTS
ENG INE
5L23/30 PART Machinery
Doc.
DESCR IP- .
MR05-5179-0
CALCULATION OF RESIL IENT MOUNTING
Note:
5. Main Engine
71) Engine Type : 6S50MC-C (2 stroke)
2) MCR : 9480 kW a1127 RPM
3) NCR : 7395 kW at 11 3.7 RP M
4) Propeller blades : 4(FPP)
3
2
1
20 101024 t!~9 id~ t!~~ First issued.
~
Drawing
Doosan Englne .
34-030909
2995 ZG HoorJensdam
the Nethe1an ds
Mainproject Doosan Engine t. +31 (0)786778778
f. +31 (0)786771 036
Description Doosan Engine Co Ltd . !ofQ@0ibbordoog
w. wwwn '!thm1m!gn
Customer 5732
Company Doosan Engine Co. Ltd.
Address 69-3, Sincheon-Dong, Changwon
Zipcode ow 641-370 Kyungnam
Country South Korea
Note:
Mountingtype 8 RD 314 - 45 Shore
Perfonance 650 kW at 720 RPM
Bellows 1 250
Main engine
MAN-B&W 6S50MC6-C7
Number of cylinders 6
wo stroke engine
Engine output MCR 9480 kW at 127 RPM
Engine output NCR 7395 kW at 113,7 RPM
Propeller blades 4 [FPP]
Doosan ,/1125/1
+1 1
Legend
Axis Frequency
= Longitudinal f1 = Longitudinal
= Lateral f2 = Lateral
= Vertical =
f3 Vertical
Rotation =
f4 Rolling
f5 = Pitching
Delta = rotation f6 = Yawing
Sigma = rotation
Mounting rees
Mounting parameters
. t}' '"
Mounting
31425"45(401
'"
-1329,00 635,00 -610,00
Sigma
0,00
Defta
4 3142545(40J ..s89.00 -635,00 -610,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
3 1 4 0 25 4540]
0
5 281,00 635.00 -610,00 0,00 0,00 4560,00 4580,00 3040,00 0,00 0 ,00 0,00
6 3142so4S0140j 261,00 -835.00 -6 10,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
7 314"25"45"[40J 1825,00 635,00 -6 10,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
6 3 14"2545"[401 1825,00 -635,00 -610,00 0,00 0,00 4580,00 4580,00 3040,00 0,00 0,00 0,00
9 NW250-TST -2033,00 -8 10,00 1575,00 0,00 0,00 140,00 140,00 60,00 0,00 0,00 0,00
,+ ,+ -1,830+05 ,+ ,+ , +
,+ ,+ ,+
Mounting number 2 3 4 5 6 7 8
Forcd defl. 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Forced defl. 0,000 0,000 0,000 0,000 0,000 0,000 0,000 0,000
Forced defI. -8,876 -8,876 -8 ,683 -8,683 -8,462 -8,462 -8,056 -8,056
Doosan Engine/1125/3
,+ ,+ ,+ 8,621+03 ,+ ,+
,+ ,+ ,+
Mounling number 2 3 5 6 7 8 9
Fced defl. 0,005 -0,005 0,005 0,005 -0,005 0,005 -0,005 -0 ,001
Forced defl. 0,018 0,018 0,012 0,005 0,005 -0,007 -0,007 -1,770
Forced defl. 0,526 -0,516 0,524 0,522 -0,520 0,518 -0,524 -0,658
DispIacements {mm]
monting number
1: 0,000 -0,001 0,000 -0,002 -0,002 -Q,002 -0,002 -0,002
1: 0,426 0,647 1,263 1,669 2,063 2,440 2,799 3,137
1: -0,556 -1,048 -1,472 -1,826 -2,107 -2,313 -2,441 -2,492
mounting number
Dlsplacements (mm}
Degfees 5 6 7 8 9 10 11 12
mounling number
Doosan Englne/1125/5 ..
I ,~1 Rubber Design
f br .tin ilnd flOIS't i;o"t fQ_ ~
F1 ,+ ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ ,+ ,+ 6,600+03
mounting number
1: 3,849-02
1: 1,450-01
1: 3,882-02
mounting number
2: 3,849-02
2: 1,450-01
2: 3,917-02
mounting number
3: 3,849-02
3: 1 , 06-01
3: 3,890-02
mounting number
5: 3,849-02
5: 5,063-02
5: 3,899-02
mounting number
6: 3,849-02
6: 5,063-02
6: 3,90 1 -02
mounting number
7: 3,849-02
7: 5,027-02
7: 3,915-02
mounting number
8: 3,849-02
8: 5,027-02
8: 3,884-02
monting number
9: 4,933-02
9: 6,249-02
9: 5 , -02
F1 ,+ ,+ O,OQOE+OO O,OQOE+OO ,+ ,+
F2 ,+ ,+ ,+ , + 1,860+04 ,+
moonting number
1: 1,742 -02
1: ,+
1: 3, 366-02
mountlng number
2: 1,742-02
2: , +
2: 3,369-02
mounting number
3: 1 , 742-02
3: ,+
3: 1 ,467-02
mounting number
5: 1,742-02
5: , +
5: 6,720-03
mounting number
6: 1, 742-02
6: ,+
6: 6,69 1 -03
mounting number
7: 1,742-02
7: , +
7: 4,644-02
mounting number
8: 1 , 742-02
6: ,+
8: 4,641-02
mounting number
9: 3,807-02
9: , +
9: 5, 157 -02
F1 ,+ ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ 2,050+04 ,+ ,+
mounting number
1: 4,34-03
1: 6, 99-02
1: 7,559-02
At mountrng number
2: 4,34-03
2: 6,99-02
2: 7,559-02
mounting number
3: 4,34-03
3: 7,410-02
3: 7,559-02
monting number
5: 4,34-03
5: 7,997-02
5: 7,559-02
At mounting number
6: 4,34-03
6: 7,997-02
6: 7,559-02
! mounting number
7: 4,34-03
7: 9,077-02
7: 7,559-02
mounting number
8: 4,34-03
: 9,077-02
: 7,559-02
monting number
9: 5,592-03
9: 1,960 -01
9: 9,642-02
F1 , + ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ 2, 0 50+04 ,+ ,+
F1 ,+ ,+ ,+ ,+ ,+ ,+
F2 ,+ ,+ ,+ 6,400+03 ,+ ,+
F[begln) = 60,00 [HzI F(end) = 60,50 [HzI F(step) = 1,00 [HzI F(F2) = 60,00 [HzI
mounting number
1: ,+
1: 4,472-03
1: 5,164-03
At mounting number
2: ,+
2: 4,472-03
2: 5,164-03
mounting number
3: ,+
3: 4,794-03
3: 5,164-03
monting number
5: ,+
5: 5,163-03
5: 5,164-03
mounting number
6: ,+
6: 5,163-03
6: 5,164-03
At monting number
7: , +
7: 5,844-03
7: 5, 1 64-03
At mounting number
8: ,+
8: 5,844-03
8: 5,164-03
At mounting number
9: ,+
9: 1 ,360 -02
9: 6,587-03
F1 ,+ , + ,+ ,+ ,+ ,+
F2 Q,OOOE+OO ,+ ,+ 6,400+03 ,+ , +
F(begln) = 60,00 [HzI F(ond) = 60 ,50 [HzI F(st. p) = 1,00 [HzI F(F2) = 60,00 []
Doosan Engine/1125/1
2344,74 [mmJ
0,00 [mmJ
811,82 [mmJ
aI moment inertia about secified xes directions but through total center of OiY
5845,42 [kgm~
35005,98 [kgm~
31991,07 [kgm~
ly 0,00 [kgm~
l -1668,01 [kgm~
0,00 [kgm~
- -- --",,---,
!
:::===tt~=-~ ===
11 ,41 -----j----' ----"-~------ - - -'--""-1--
9,78 ,-,- -t--- '" ,-, -- ~--'-'--;--------' -- -------- -------: '---'-'1--'--- _ 1st order
8,15 .. ~ ...~. .. .... .. .. .... l_, .... " .. _ .. .. "" .. - -t ......._,...."; ..'''..........,,... 2nd order
! 2,5th order
6,52 !-----\
, --;--- :::::J 5th order
! Nn , speed 720 1/mln
4,89 - - ~- -+:---1
-t=i -=
: . . ;
:::: - - ~ - - - - -- j-
----------------- +F L! - - -
, --------------
4921
------.j----- --1
-+--- -------------- - ----+ -----,-----
: ::=~~=-- ~=:--~~
j;
. , :
- ---~~-~ =~-~:--=:=~-~~~=~~-~~=-
_ 1st order
-t,:
.a 2nd order
;
!
lIIIIiII 2,5111 order
28,12 ----- ---- - ----~--- -- ' ----j -----
c:::J 5th order
----
i lIIIIiII Norn _ seed 720 11mln
i , j
27 ,5 -----1-----~------~--
, i ;
-II------J----------
\1 i
.-----!----~-------
i
~
2nd order
2,5th d
-
16,51---!, --i---+- ;\ ! --
;...!
i i '" ! '
11 -- r : -~:1--
!~:
j '~
~
,- , "'--- ,.--~.L-=-t -"~~
!
~-=
5,5 ---'--!.1!-~ \ ,--- '\:::.-- ---;-----------r----- -...+:::::
! \ -l, ~_--_:_~--....,__- -"-V "
_ .... ""'" '" , .... . --;-
88 176 264 352 440 528 616 704 792 880
Speed [1/min]
21 r--------~3
!,
:
:'
--------
!
!
j
!j
:
Doosan Englne/1125
"'' -+t--,l-~~+=
100.16 -- .... -.-+ . --.-.-..-..--.-.. -.-I-t-._--i_._.---I. _---_-i.f-- - - -- - - ~ .--:- - .- -.
87.64 ___ ~Ii
. ---. ---- _ _ _ ....
, !
'::+=+H=H=ft=
50.08
1 ---J--- -
i
--+--- --- ' --+--.. -+.--+--t
i; . i !
_
_
_
c::::::J
_
1st order
2nd order
2,5th order
5th order
Nom.speed 720 1/mln
37,56 ~~,_L
.; --- - -+ ._-~ _. +--4-----+! - ! ! !
'-t-+=T=
! ; 1 !
::+r-,. ,-~--~
" ..... _ ~"
-' - '88 - 176 264
~352_.--.
440
,. .__. ___616
__. . .,..528 ..J....._ _ _.L
704
..--1",,---:-"
792 880
Speed [1/min]
49 ,28 --+---j---1!--II-Hj_-+-~f----+--H--'-,!
i ! !
__
42,24 ----- '.---.-- ._--+_.~. -; -- -----+--+--.--j+--~--- _ 1st order
~::=~-t--- -~_t-
_ 2nd order
_ 2,5th order
c:J 5thorder
i --1\ - '
_ Nom.speed 720 11min
u
----JN
. .---~\ j -_ .:J---.'I! -- -+---_.. ------.,::::----'----::::1='::7' _~=-L
----........
. h
-..J
i
C ''' '
!
: , <, i
,.-;..----
-- :
i
!
88 176 264 352 440 528 616 704 792 880
Speed [1/min]
Subject:
CALCULATlON OF TORSIONAL
VIBRATlON
Note:
~
Doc.
Doosan Engfne .
MR06-5179-0
DOOSAN - DIESEL aae 1/24- i'~
REVISION HISTORY
REV DESCRIPTlON
ENGINE
5L23/30 PART Machinery
Doc.
DESCRIP- .
MR06-5179-0
10
CALCULATI ON OF TORSIONAL VI8RATI ON
Doosan Eng ine CO. ,Ltd.
DOOSAN - DIESEL Page 2/ 24
CONTENTS
ENG INE
5 L23/30 PART Machinery
Doc.
DESCRIP- .
MR06-5179-0
CALCULATI ON OF TORS IONAL VI BRATI ON
Note :
3. Application
1) Fly wheel with Gear rim : 273.5 kgm2
2) Generator ( ) rotor : 61 .1 kgm2
3) damper : Viscous damper 6017/1
\ .
20080509 ~*H
/ ~ ~Tt
Change the engine power & speed and
lore Ilange
1
~
Drawing
Doosan Englne .
34-017214
Torsional
Vibration CalcuIation
!mportant Notice
The enclosed calculations made with adanced computer programs.
Geislinger has rely data furnished by technical documentation of the engine builder and
cannot guarantee the correctness of these data and therefore ecludes any warranty. liability
responsibility whateer as damage. failure malfunction of the installation due incorrect
torsional data.
n receipt of this documentation is strongly recommended check the torsional data for
correctness. Geisl inger also recommends erify these calculations. especially if they for frst
installations. by torsional ibration measurements under correct operating conditions and after
temperatures hae stabilized.
Copyright GEISLlNGER 2008
Geislinger GmbH
Hallwanger Landesstrasse 3
-5300 Hallwang/Salzburg. Austria
Tel +43 662 66 999 30 -l lange@geislinger.com
Fa +43 662 66 999 40 Internet www.geislinger.com
GEISLINGER ::
Doc. . : MR06- 5179- 0
Page 5/24
Eng lne 5L23/30H Generator-curve c n stan t GR 3212
18-Jan-2009
V 19.3-0
Torsional system 8532 (08)
GSLJG ON~1 Casing ::fIiia Ring Inertia Total Mass Ambient Temperature .
kg kgrrr kg 'C
6017/1 2.5 2.91 96.6 80
-WARNING- 19.96 ;< 18. 74bar due 10 9as ecrtalion accordil1g G8 445
2
GEISLINGER-~
(O~' l rfrlG S ~1) OAI.!PEII . ~,,;T ) -S
rCTiiideij
L...:Y_._ .........
F r n9
t
Cylinder angle interal
'
1440
[?] 1440
1440
:<\1 2880
1440 2.0
[} 4320
144'
i~1 5760
1440
1.5
1.0
0.5
2 4 6 8 10 120rderk
,~------~
, ------~,--------
50 100
- - Ideal firing
3
G~ISJING~R'~
co~ It."GS !'> I)AM'<.IIi. .,,~ 1:) ,~}T
'2
TangentiaI gas pressu re [P,.k cos(ka) + P'.k sin(ka)] Torque
k=O
bar kNm
60 \
\
30
40
20
20
10
\. " ....-
'""
-10
-20
2 2
jpc/+ (Ps,k+ mk )2
jPC.k + Ps,k
bar kNm bar kNm
10 6
6
8
4 4
6
2 2
2
mkl
bar kNm Ideal firing - Gas
10 6
Excitation due to reciprocating mass 46kg
8
4 Ideal firing - Gas & Mass
6
2 4 6 8 10 12 Order k
~,------~,------~,------
50 100
4
GE!SLING~R< :?
(OU9l IG~ D A ~IPf~S _~~lt ~~T
291
VS t:(j(7!1
OAMPER ;1,
2.5 2
~
c
~
2.039 .<
Flange+Flyw.+Gear 3
~
5.84
\1} 4 -":::r"J~
:
~
-
5.84
fgj 5 ._.s:>-j ~
~
~ ~ ~
-
[~!
5 .84
~
6 . . "";. 1:'
: -
4]
5.84
~
7 -,,,>1:'
5.84
~ f!!~
-
[ 8 :;:)I~
~
1.67
~
.
~
Camdrive 9
~
:"
0.45
Flange 10
.~
c
273.5 ~
Flywheel
61.1
~
..
~
11
Aotor 12
Inertla kgf
SIiffness MNmlrad
Damplng NmSrad
1(:: '
Eq.Oa. mm
5
GISGf2R'';
CuuI'tIH;S 4Jilt
l ;! {IAIt,c ,.s . :: l~1
1 Frequency
Node 1 543 radls 86.42 5185niri'
Modeshape 11,"
ReI.AngIe 1~'~~:~=~~-----~=-~:--:--~'=~'~--~"'--1------i-~~~--~_~=~
[] [?] lJ.l [1] [~1
Energy dIstrIbutIon
6
Page : 10/24
Eng lne 5 23/30 GR 32 12
18-Jan-2009
V 19.3-0
Natural frequencies - Holzer l abulalion - Wilh oul Damping ( )
(1)1 Frequency
1
Node2 723.2rad/.< 1 1 5. 1 6906Inin-
Rel.Angle
pot ,--11 -
1 2
- -8- - -
3
8-
4
- .... - -
5
_ - __ - -
6 7
_ -_
8
--
9
-_ -_
10
--
11
- _ 12
7
Page ; 11 /24
Englne 523/30 GR 3212
18-Jan-2009
19.3-0
3 Frequency
Node3 1182 radls 188.2 I1 11290,n/n"
ModesIlape
Re l.Angle
Energy distribLltIon
pot
1
-----~---.---~--- ___ -__ ---~- ______
2 3 4 5 6 "{ 8 9
8 - _______ 8-_
10 11 12
}- --,- -- -t- --,- -- -t- ---1---- ~ ----! -- --- ---~-- -1t ---~
8
GEI~ur\jG~~':?
(iill~tfH'S AN ~ Q"M'<~S. (;Ji,T!~ (
. Frequency
Node4 1722 'C!.' 274"'2 16440tnir(
Modeshape
.... .;a.---- .....
Rel.Angle ----------
23
ft]
4 ----_--;7--
[~)
6
@
7
]
8 9
--~--_ro--_;'t- --K
12
'-., ._-.
Energ y distrlbution
9
Page : 13/24
kW
800
600
400
200
(-)
10
(~tIS~G
' ,)
c:. ll ~S ~~'" n~_~\, ,; ~s. ~ ((~
;r(.q:
\$ 1
Doc. . : MR06-5179- 0
Page 14 /24
Englne 5L23f30H Geeratcurve constant GR 3212
Ideal firing 18-Jan-2009
V 19.3-0
( LL )
kW
1.4
1.2
1.0
0.8
0.6
SlJm aII
...!:1..
1< !! [);.,r. .
-";.,rr ["';:!
(ANG)
Vibratory angle Free end at inertia . .2..
2 .0
0.10
2 1.5
1.0
0 .05
0.5
0 .05 2 4 6 10 12 Order k
50 100
11
Page : 15/24
Englne 523/3 0 Generatr-cure constant GR 32 12
Ideal firi ng 18-Jan-2009
V 19,3-0
(ACC)
1200 20
1000 2 4 6 8 10 12 Order k
50
600 40
20
400
2 4 6 8 10 12 Qrder k
200
50 100
5.
9.5
( )
0 .00 15
0.0030
0.0010
0.0005
0.0025
4 8 12 16 20 24 Ordef'*2
,
0,0020 6 200 300
kW sum O .00125kW720pnI
0.0020
0,00 15
0 .0015
0.0010
0,0010
0 ,0005
4 8 12 16 20 24 OrdCf. 2
0.0005
100 200
12
Page 16/24
Englne 523/30 Generator-curve cnstant GR 3212
Ideal firing 18-Jan-2009
V 19.3-0
()
kW sum kW HJnIO.187kW900IfJff'
~:)I~!:~ ~,,'
100
8 12
200
16 20
300
2. Ordcrt"2
0.10 0
0 .06
0 .06
0.04
0.05 0.02
100
8 12 16
2<)0
20 2. Ordcr*2
(MSC)
IMaximum stressl Crankshaft between inertia . 2-11
15
60
10
50 5
40
,
2
,
50
6
100
8 10
150
12 Order k
30 15
10
20
5
10
2
5'0
6 8
100
10 12 Orderk
13
Page : 17 /24
1.5
1.0
3 0.5
2
50
100
8 10
150
12 Order k
1.0
0.5
7 5.
.
2
.
50
8
100
10 12 Order k
(TLGVD)
.
2.0
0.4
0 .2
1.5
,00 8 12
200
l 20
300
2' Order-2
kW sumO.436kW720rm
1.0
0.6
.
0 .2
0.5
8
100
12 l
200
20 24 Ordcr. 2
-
14
Page : 18/24
EngIne 5 23/3 0 Generator-curve constant G R 32 12
IdeaI firing 18.Jan-2009
V 19.3-0
(ROTOR)
Vibratory Istressl & to rque Rotor shaft 021 mm between inertia . J.1:1l.
2
N/mm kNm synthesls Nlmm' syn 13.1 N/Y!f 865 kNm
~)~~!:~ i:', ~I~
14 8 15
25
6
10
12 4
5
20 2
10
2 4 6 8 10 12 ()(der k
8 ,
5'0 ,00 150
8 15
N/mri' SI5. 991l' 720 kNm
8 15
6 6
10 10
~-~- -- --- 4
4 5
2
5 5
2 4 6 8 10 12 Orderk
2
sO 1(~X)
15
Page : 19/24
(P-C)
IPower-curvel
kW
800
600
400
200
(-)
16
Page : 20/24
EngIne 5L23/30H Generator-cure constant GR 3212
Misfiring marked Cylinders according compression 18-Jan-2009
V 19.3-0
12 8
\ 6
0.4
0.6 4 0.2
10 2
2 4 6 8 10 12 Order k
8 2'0 4'0 6'0 io 100
4 4 0.2
0.2 2
2 2 4 6 8 10 12 Orderk
50
1200 20
1000 2 4 6 8 10 12 Order k
,
50
800 40
20
400
2 4 6 8 10 12 Orderk
200
17
Page : 21/24
Engln e 5L23/30H Generator-curve constant GR 3212
Misfiring marked Cylinders according oompression 18-Jan-2009
V 19.3-0
0.0015
0 .0010
0 .003
,:
0.0005
.,
., 4 12 16 20 24 Orde.... 2
100 200 300
0.002 kW SUIT10.00153kW720rpn
0.0015
0.0010
0.001 0.0005
, 12 16 20 2' Ordcr*2
100 200
0.10
0. 20
0.08
.,, 0 .06
0.04
0.02
0.15
4 8 12 16 20 24 Order*2
kW SrIrrt O.0848kW720rpIn
0.10 0.10
0.08
0.06
0.04
0.05 0.02
.
4 8 12 16
.
200
20 24 Orde ....2
"".,:, ....
1
18
J"
{'I~tt:I "' ;:.J.::
,,~K" .. " r" '" '"
(OVOtrN<iS / iJAM~H S. ~uitr ~;"
::r
Doc. . : MR06- 5179- 0
Page : 22/24
Englne 5L23/ 30 Generator-curve constant GR 3212
Misfiring marked Cylinders accord ing co mpression 18-Jan2009
V 19.3-0
HIGHEST EFFECT OF [i?'!.)}:\'] l DIFFERENT FIRING (HEFOC)
IMaximum stressl Crankshaft between inertia no. 2-11
60
10
5
50
2 4 6 8 10 12 Or'der k
40 50 100 150
20 5
10 2 4 6 8 10 12 Orderk
, ,
50 100
,/ 1.0
3 . .-,--i'-f' ! 0.5
:/
..,...r! . 2 4 6 8 10 12 Orderk
5'0 160 150
./ 1.0
~
0 .5
2 4 6 8 10 12 Order k
, ,
50 100
; :
.... ~! ::~:::_~L~j~[?i~:~I!6.~~~~:~~!!~f[j~~i[~~j~~jr.f.ij![f.J~~J~i_~fj~
200 300 400 500 600 700 800 900 rpm
Engine speed
.
2.0
0 .4
0.2
1.5 4 8 12 1. 20 24 O'dep2
160 200 360
kW sumO.43kW720 fplll
1.0 .
0.4
0.2
0.5
4 8 12 1. 20 24 Ordcr*2
,
100 200
Vibratory Istress & torque Rotor shaft 021 mm between ea no. 1..1.:...!.R.
8 15
14 25 10
4
12 5
2
20
10 2 4 6 8 10 12 Orderk
,
5'0
6
10
4
10
5
4 2
5 2 4 6 8 10 12 Order k
2
50
20
G~15Ir.;~,:~
COV" U'GS " DAM or~s ~;:;!O ~>r.
r
Doc. . : MR06- 5179- 0
. "~ """ ..
""
...
J'tNma Doosan Engln.
Subject:
PIPING DIAGRAMS
Note:
20110117 [!~~ t12 t12 Corrected sensor fuel l system (de leIed 40) 1
~
Doc.
Doosan Engine .
4-5179-1
DOOSAN - DIESEL aae 1/ 7- #<
REVISION HISTORY
D REV DESCRIPTlON
ENGINE
5L23/30 PART Machinery
Doc.
DESCRIP- .
4-5179-1
10
PIPING DIAGRAMS
Doosan Eng ine Co .. Ltd.
DOOSAN - DIESEL Page 2/ 7
CONTENTS
ENGINE
5L23 / 30 PART Machinery
Doc.
DESCRIP- .
4-5179-1
PIPING DIAGRAMS
- CYl .
Leak from
fue l vc l ve
'~~
, gh _ ,
~
,,
Yr.'l......-- F ue l pump
Fue
~FueI
i n l et
1111 111 return---j- Ff
~ L eak from
fue l o i lpump
J ~ ~ ~ ~ ,~, ~
l eck f rom
fuelo i lpump
l eakage a l a rm
50.
'L - 3
2 1 --~
0 0 '0
cn c:n o~
. ' - -- - '-
-- -- ,,1
-..><(,)0 -uO "00 J:or
:J C - V - ! 20H)050~ 1 ~1It' I olt1I "I \I'1.' VtIio<I .... -.gnolrolol_~.,,.,..." ......-.
c ::::J C c c - 20081017 1 ~'Il!c 1 ~1'91. 1 '!:'!.' I F ir s t i Bu e d
~!
-c:o OCO .- C<.D
0"- 0"- 0- . O ~ CM ' d Ap~'d O ,ipl ; o> R ;,;o .~ ~.
- 1:(,) -uZ -
a...-
~ Doosan EgIne
0'- Q.. .
Q)
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- cn
'"
0"-
-
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Q1-
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"
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I~
.
- :J-Z -
:t:-I....O L...L..O ~~o
=;c,
" ." ; '" ' 2330
!!~
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,..-,., FUEL IL DI AGRAM
& & /$ '
'~"Qooo"-"" :' "
( D )
H~! 42-010644 1-;- 71;
1, r
Ooc. :-': !4-5179-1
3
< -
Droin 110m (
discharge .
t5ee Combust d i ogromJ
C13 vapour
Flange connection
d i sc~arge
, DN50,PN 10 , DIN2501
Governor
V rocker
dr ve
(;J
c
C4 Lubricot i ng l
10 to seporoto r
Flange conn e ction:
a shul ! , ,
~
1
Jj! :
m"
;n
!
: "i'
10: , Doosan EgIne
ih
~i~ ~
" ~ ~ . I AGRAM
t~!! f
!.;f
~
f.!'!~ ~
F F
Qoc. . VJ)4-5179-1
, 5 6 Paoo 5/7
F3
Non-ReIurn Valve wi Ih
ResIricIion (03 m)
=:sl Vent ing 10 expans ion iank
F l ange connection:
DN1 5, 1 0 , DIN2501
- -
F
j
..-t---O
CHARGE AIR
COOLER .
r--
i \ . )
F
li
".~ ~
:~
11
Q!
PUMP
enginedri ven
G2 . . fresh a !I.!
Flonge cannec!
DN80. 0, DIN250 1
~
c
L_
f
I - - - - - _ _ _
8 . I L COOLER
~- MJ ]" ", """
Flange connect lon
DN80, FN10, DIN2501
~", ,""
~
,!
' OOOSA~ 'I~r 01\,''(.'
~
It' ! Co"ec!ed Flonge si le (ON100- >DN80J
20080410
KA~AW ;:. ,Ir~ I t:~
OOOSAN ~~'!- -I jjr ol 'l;t'
'i! 20080225
KA RA W ~ I ~i' ~~\l 1 ~ 'o';
Firt ;nucd
~;:
~i~
ift . . " '<' ..".."
fEB'" "<.,"Doosan EgIne .-_''''.0 :
; :1
. speci f icat
i!~i
components . 23/30
\\lor '< i ng pressure:
! preS$ure :
4 bor
6 bar
'.<""
G -+ 1 ~t ""
COO l lNG WA ER DI AGRAM
Dicmeter
DN80
the
excet
l ipes
wher e otherwise sIa I ed
i~i!
3.~
:!
"$<.,".-
~
NIS
.. ...
.,..,.... ( , I S TRING )
1"" '- 10; 1'~
~!~.: 0000 42- 01 299 4
F F
Doc. -:- 4-5179-1
2 3 5 P2Qe
. Desc, ipt ;on We , ," S i le
~
'
- r=-+---rn : 1 1 ~
COMPRESSED A!R I
Max. working pressure :7 bor
Flange connection:
DN40, 40. DIN250'
--l
-
C- supp ly must ! be
i nlerrupted whe n eng ine
.-< is u
.-00"
F '
<
'-0
(2) Ai r Storter Comp l eIe. F
Overspeed
'
device with bulIon
emergency ond Iest stop .
el
Ov
Yl.,
e
L
- FOR 7
-~
bor(kgf/cm~
0 . 7 MPa
,
j:,
Olt'1 I "I t'! I Fif II i IHIed
...
li
.,
c~;. o,c.,. CI'I1 d I~'d
~ Doosan EngIne
tI.,., i , i ~ R i ;o~
.. .., "'-'....
D
~1~ ..... '..' " ~ 167 1666-0. Ol~
r
!
"".
=10
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l23/3DH
"''"'C'C'C''''"'"' .,,.., !
!!fl COMPRL...J.JL..LI " "u ,, ,...."",
. ",..., ..",,,
>.
2
kf
~. '- 1;-; 7 11!
N/S
~A , ," ' ,,, ,.
!!~; ODOD 42- 4:>l
F F
Ooc . . : 1rU.(}4-5179-1
1 2 3 1 4 5 5 ;! : 717
. ::> Oro", ; ng . Desctption I '1 w.ate, ;a t l We , ght S i ze
Water WOSh Ir1 g,
tu rb i ne s id e-j nle!
Iobec?nnecIed"'!iih ExhoustgC$ Chorgeair . _
1/2" qulck couIIngCfemoleJ l i nlet C wash I n9 .
comp r essor $lde wIth
,-_____ __________ _ 7 2 1 8 qulc' coupl 109 - I-" I-'e-'.I_ _ _--,
~~
]]
,,-
~g
Q).-
\1
60
60
~I) 60
60
i~
~
-
Compressed olr-In l el .
(see Compressed l d I ogrornJ
-
bO
_ ~ \ -/ ~ f-
--g
"" _ \r - - - " -- ~
~ ___ )~\; _ _ __ '. f-
c~ EXHAUST GAS .C. _~~
8~! ,.:----~.:--- l r'c.:- --- X- - ] \ . . .
-g~ ~ lh ~ ~
'\
'-{).
~.~ fPI\. ~ .1 CHARG NG R FROM . C ""
-
~~--~
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~~
~ 31 62
' l(
- _: 1'- d roin trcp
n
c
G)
1 .
CYIInder for L cmbd contro l l er 6 : . " .
Qnd Overspeed stop ,,~ 1 . C l eon!n~ Hose set f or ~7 (1/2 -4 2 20m) 1 $ be
D f r om " ~I su pp lI ea by DOOSAN cs tool .
(1) l discorge orr. turbochorger- 2 . Press. reducl i on unit ond press. gouge are be
See l ub . l d i ogram. 0l:lt l et / 6 included C l eon i ng hose set.
222.5 Droin from chorge
- . coo e r ,
engIne bottom c h orge recei ver ond i;~
r-------------------------------------------, vopour d i scho rge ~~= OOOSAN ' 'I~ I t'! 'I '' Chcnged 7 M~ due 10
EXHAUST FLANGE 2, DIMENS I ONS (Acc. 10 I 86044) - out l et :i: 2009070! chcnge wo shI n g loo l 1
Open dro i n 2xzj8 p i pe !; OOOSAN 1;:,'t ' '1 'I'C.' . .
ENG . 00 THICKNESS PCO SIZE NO .OF HOLES end !
~,
200801 KARAM "I~o ~'I : o' 'I~ FII st , llue~ Q
5-6 L23/30H .350 m. 490 m . 16 rrm. 445 rrm . 22 rrrn. 12 e n g i ne bottom i~~ Dat. c_ . O,a... n CM"" ~'d De,<r;p\;onaIRe"" on R
Subject:
Note:
~
Doc.
Doosan Engine .
3-5179-0
DOOSAN - DIESEL aae 1/9 - #'
REVISION HISTORY
D REV DESCR IPTlON
ENGINE
5 L23 /30 PART Machinery
Doc.
DESCRIP- .
3-5179-0
FLEXIBLE HOSE LI ST FOR EXTERNAL CONNECTI ON
Ooosan Engine CO. ,Ltd .
Page 2/ 9
F3 Ven I1g Expans 011 al1l< Fl ex ible 110se DN1 5, l, D I 250 1 42-012930-0
~ Doosan En&ine
Doc
.
3--5179-0
1 2 ' 3 4 PACON ge : 3/9
. DESCRIPT ION S I ZE ' ' WT (kgJ REMARK
1 10A-SCH.40 12 1
\ 550
81 2
- ff; -J
\
'. -
'-,;>:
'\) ( -~ f-~)
'_ u
?,
~ 45'':-
1
/
1
"-
3
'"
~
'00,
-
~.
\
JJ
293
L S IZE: DN20
!i~
30 j(j~
4-:iZ5J5 L PCD75
- \ \
~ I ~~
~~
1 V;::i~
2j~
~
'i;;~i--;;
_:i3
20080117
Oote
OOOSAN
KARAM
Comp .
~~;!
;~~
Drown
"11i'~
b'1!"~
Chk'd
ol~1[!
~~
App'd
First i ssued
De s cript i on of ReY is ion ,
.
,
~
Il 7 . .8
40
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i~i
~~
Doosan Enine
-
~:~ "' l .: .. "., d,,,,, ; n<;l no .:
loIa ( K~ ): IoIater l,
-
D 105 ~~i~ P,oj e ct ;0": T,pe:
COMMON
2i=8 - ~ 11iU l:
F3,
8
Nom i n a l si ze: 15
Fi eld , c oI a. W.cr l i c ol a.
..11500253-7, 1409203-0, 1610285-3.
Fresh
Th i s i s c CADAM drowing cnd shou Id not be crrec ed hond
Di ese l lub.
Pr e ssure
r woler
Max. work l ng
93 93 45 100
lo mn 'C
Mcx. work l ng
10 10 30 5
r e s s . bot
Doosan EnIne
8
Nom in e l s i ze: DN 40
WARNING: \ \0 be used
for preheo\ed fuel
See ser vic e l e \\ er no. :SL90 - 257
Hose 10 be tested occord i ng 10 demonds acIual
clossificotion cnd l outhoril i es
Fe d f CQ t a: ne co t .
i~~i
F lEX I BLE HQSE
(D I N, PN4QJ
!"';i
: H'J
~!.!;
.r
OOt . . -; 3-5179-0
C l assificotion l . Por t .
LLOYD'$ REGI$TER QF SH IPP ING 172359 1615724-3
NORSKE VERITAS 172359 1615725-5
8UREAU VER AS 172359 1615726-7
AMERICAN BUREAU QF $HIPPING 172 359 1615727-9
~
REGISTRO
GERMANISCHER LLOYD
172359
172359
172359
1615729-2
161 5730-2
"-- ...:;;. c !..-6
USSR REGISTER QF SHIPP ING RUlES 172359 1615731-4
KOREAN REGI$TER QF $HIPPING 172359 163 6529-3
172359
172359
172359 ,
172 359
172359
Nominel size: 25
Se e s e r c e e t t e r na.: S 9 - 257
Hose 10 be tested accord i n9 10 demcnds ac tu cl
clossificoIion ond l aulhorit i es
fRESH
Th i s is CADAM drowing and shouJd nat be corrected by hond
Die~el ' l ub.
Pressure
r WA TER
. work I ng
93 93 45 100
lemD . 'C
. wark l ng
10 10 30 5
es s . b
Doosan Enlne
Fl EX l8lE HOSE
D . 1 )
Doc, . : I3-5179-0
1 2 ' 3 4 PACON ge 7/9
. DESCRIPT I S I ZE IMAT'L b'TYI WTIkg) REMARK
1
418 PCD125
r- r-
\
..
-~ ~-
/ ~
- -- - - +
3
r-
r-lm
800
m~
L- ~ v1165
~!Y
10841 Supp ; e r ... .. 1089
- 14551 . . . . . . . ..
ype Power f e , . 0112085-063.
C l amp:E l af l e SK 2/76
13001 ter ; , .. Hose :Black synthet;c ; 16891 Sharp edges be removed.
res;stant r ubber tube
, w; th canvas i nsertion.
- Clamp :Steel
Flange:Stee l R St 37-2 acc.
16191 Med;um: ;
17100.
U ; r .
"
joo
!i~
-
17 601 emperature. -30'C - +70 ' C ~~ 20080 117
~<g;! o l ~~ ol~'
Firsl issued
~!
KARA~ ~ I~ ~ ~~: ~~
_: Oote Com. Dro..-n Chk 'd App'd DII I cripl i on Rew iJi on Re .
10021 Wo r k ; ng r e s s u r e. : .0.5 BAR io;
il"!
~ Doosan EgIne ]
Hose be mounted w;th f l a nge, w; t h ma t ; ng
d;mens;on occ. 50 , 10, 2501 . ) : IoIcIt .. , ! : R"I. l ~ .... o, 11''''' ; 1>9 .:
1638334-9 ".
~o!:! -
)
.E~~ Ptoj.~ti,,": ,.:
COMMON
!~B } .. 1 J{~ r t t:
Ii ....
:=~i Sl.: 5 1.: FLEX IBLE HOS E
ClASS P ICKLING PICKL I NG AND
PARKERIZ ING GAlVAN IZING
WORK ING
PRESSURE
1[5
PRESSURE
PAINING
INSIDE OOTSIDE
WElD I NG !:i'"
&808
1/2 3 <, 0)
~!ij 1oISJI.C .: D.". I"ll . : e"i" \ " no . :
- - - Kg/Z - g/- - - - ~!'.!.D' 0079 43-013832
F
Ooc. . "~vJ-5179-0
FIE l O OF A PP l l CA I ON
COMPEN5AOR . For mo r in e l i ca! .
m Med ium: Seo fres h coo l i ng wo t er Med ium: $ and fresh coo l i ng woter
.
. INFQ . NQ . HOlE WE I GH
.
. PAR . 8 C
DI AM.
PCO (KG J
COMPEN$A TOR
(O IN, PN10J
F
Doc . . : ~517!rO
< , ."
" " ""
&(
300 44 0 395 327 344 306 350 12,22 16 68 28 62 60 3 2, ( 5- 12) 22 167 0 058-0
300 440 395 32 7 353 305 5 60 12,22 16 50 75 75 20 3 2, ( 5 - 12 ) 38 1627936 - 7
- 350 490 445 359 38 4 337 490 12,22 16 100 50 75 30 3 2,(5 -1 2 ) 40 1627937 9
40 0 5 40 495 4 10 435 38 8 49 5 16,22 16 100 50 75 40 3 2,(5 -1 2) 43 1627938 - 0 -
4 50 595 55 0 4 61 486 439 500 16,22 16 100 50 75 50 3 2, ( 5-12) 48 1627939 - 2
5 00 645 600 5 12 53 7 490 5 20 20,22 16 100 50 75 60 3 2,( 5- 12 ) 54 162794 0 - 2
5 50 70 3 650 5 63 587 5 40 5 20 20, 22 20 100 50 75 70 3 2, ( 5-1 2) 65 162794 1- 4
600 754 700 614 6 39 592 535 20,22 20 100 50 75 80 3 2 ,( 5- 12) 79 16 27 942 - 6
65 0 805 750 665 689 643 535 2 0 ,22 20 10 0 50 75 100 3 2 ,( 5 - 12) 88 16 4 6653 - 0
700 856 800 7 16 740 693 555 24,22 20 100 50 75 110 3 2 ,( 5 - 12) 98 16 27 943-8
750 907 860 767 791 736 635 24 , 22 20 100 50 90 14 0 3 2 , (5 - 12 ) 1 14 1644984-9
80 0 958 900 8 18 842 787 6 35 24,22 20 10 0 50 10 0 18 0 3 2 ,( 5-12) 13 3 1644985-0
-
[]
MATERIAL
c (( '\ 0
-
~0
<t as Q Q FlANGE : DIN- 17100 W. NR. 1.0038
MEMBRANE: OIN- 17 4 40 W.NR . 1. 4541
L, 00
'---
- R I NG : DIN-17 4 40 W.NR.l. 4 541
-
l..
- Fl onQ e s ocl dinq 10 8 6 044.
CQNNECT ING TUBE:
DIN- 174 40 W.NR 1.4541
,
I~!' DOOS AH ! ol1lt " :.''
~
(ffi] Mck e s im i lor: Ref. . 1349. 200O~13 Oe l. ! e c! DN3S0-57 6 L 1
KARAII 1111.1:. 'I t ~ I t:~
~OOSAN t;~f" 11 'l.' 'I~'
lillI !l r i s i ss u ed
Type Doub le corbin e d
"'"
.ll
,_
ooJ r ~
!, ""
1:1":
CM ,.
1:,:;
~p'" o i pl i on tt ' .~ ..
D
lillI
nom i ne l bore: 2 00mm - 800mm.
be mo r ke d with: Monuf o ctors trod e -
i
~
;1'1
:,
... " ... , ""0'"''
C03 "...Doosan
...... -
EngIne
16 182 66- 9
mo r k, ye or/month . !
~!,; COW.ON
1,0 1.. " .. t ... ,
.. , ~= ""
Compe n so to r ( e xhous t 9 0S on l y , ~= I.! "01 0, I , , CQMPENSATOR
-
, .,
i.r
. o51 j
~.liA
" ---N/S
0079
2
.'..'.....
(Q
4 2-01 24 4 1
)
1"'" -
Ooc. . : lA03-S 179-0
DOOSAN-MAN DIESEL Page 1/9
Client : Yangzhou Dayang 5hipbuilding Co.,Ltd.
Engine Type : 5L23/30
Tier 1 Hull . : DY139/DY3071
Tier 2 Hull . :_
5ubject:
Note:
~
Doc.
Doosan Engfne .
MR07 -5179-0
DOOSAN - DIESEL Page 1/ 9- #'
REVISION HISTORY
REV DESC RIPTlON
ENG INE
5L23 /30 PART Machinery
Doc.
DESCRIP- .
MR07-5179-0
SYMBOL LEGEND FOR PIP ING DIAGRAMS
Doosan Eng ine CO. ,L td.
DOOSAN - DIESEL Page 2/ 9
CONTENTS
ENGINE
5L23 / 30 PART J Machinery
Doc.
DESCR IP- .
MR07 -5179-0
10
SYMBOL LEGEND FOR PIP ING DI AGRAMS
Note:
3
2
~
Drawing
Doosan Engfne .
44-012750
CONTENT
44-012750
Doc. . : MR07-5179- 0
Page 5/9
~ Measuring device
~. Local reading
Te mperature Indicator - . 40
Measuring device
==
22 Se nsor mounle d ' / .l
engIne
Reading/idenlificalion mounled a panel
Press ure Indicalor - . 22
Ihe engine/unil
~
Measuring device
12 S ensor mounle d eng Ine
' / .l
Reading/idenlificalion outside Ihe engine/unil
Temperature Alarm High - . 12 *
~
Measuring device
22 Sensor mounle d engIne
' / l.
Read ing/idenlificalion a panel Ihe engine/ unil and
reading/indicalion outside Ihe engine/unil
Pressure Transmitting - . 22 *
: Refer 10 slandard 10 ca1on and lexl for inslrumenls Ihe following pages.
44-012750
Chargi ng SysIem
30 l
10 cooler 34 charge air conditioning 38
31 ul Irom cooler 35 surplus air l l 39
32 jet assisl system 36 l l 10 turbocharger
33 ou!let from TC f l l 10 TC comp . 37 charge air from mixer
Load Speed
80 overspced air 84 engine slop 88 index - l injeclion pump
81 overspeed 85 micro swilch for overload 89 turbocharger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine start 87 ready 10 start
Miscellaneaus
91 natural gas - l 10 engine 94 cylinder lubricaling 97 remote
92 l mist deteclor 95 voltage 98 alternator winding
93 knocking sensor 96 switch for operating localion 99 common alarm
Doc . . 07 - 5179- 0
Page 7/ 9
1. 1 -- pe 2.15
-I!f- Orifice
1.4
D Applk'tt1ces 2.1. < Snap coL pl ing
15
IndIC3ling and me3SUriIX) insIruments 2.19 V PI1QUnlJtic 110\',' &x/)3USt 10 alnlospl'lre
1.6 --- gh- re$~r r pipe $. VA.VES. GATE VALVES. COCKS AND FLAPS
1 --"--- Trilcirlg
c*: l . slraight througtl
2. PIPES .JOINTS
ifJ lV. hr- ''l a
2.2
+ CrOGSIllg pipos, co l
~ I valve () ,
' I al\'
angle
2.6
+ Joil1l. scre\',ed
h Angle saIeIy
2.9
+ Joint, quick relessing
*J Quickclosing \'!
2. 10
2 11
---
.n....
Expcnsion n viU\
Expanson
gland
rJ<
&
AeguI"ting l\'
8.111vatve cock)
2. 12 ----J] Cpr1UI
>< 1 I l
Doc. . 07 - 5179- 0
Page 8/9
Symbol
"" Symbol designaIion Symbol Synlbol,IesigooIion
3. 17
~ {)oLIbIQ-seaIGd cl'\angOvQr vaI'o'Q 4. CONTAOL D AEGULATION $
319 ~ Suc1iorl VJ,le chest wittl IlonreUrn .1I\'6$ 4.2 ( Aelnole control
3.20
c*J DoL,I)le-seaIecl chuJlQOver , sIraighI 4.3
Sng
3.21
Js:3 Dooble-seaIod chngeover wle, angle 4.4 r-D MaS5
:;
3.23 QJ Cock,on918 4.6
PisIon
3.24
~ Cock. - . -! l1 lJ 4.7 MembrnrlQ
*
3.26 Cock, -,'/ , sIrIighl Ihrougtl plug 4.9 fY\ Electromagnelic
3.28 C@J Cock. sIrltigllt IJvough. I'/~Il boIIom conn. 4.1 1 c:C PUSll bIIIon
3.29
~ Cok, angle. I'/ll1 botlom COI1 nx:lion 4.12 '~L- Spnng
3.30
~ Cock. IhreQ\vay, \vith botlonl col'1nQCIion 413 rIL Solenoid
3.31 -~
1
llslalic vale 4.14 zsL Solel'1oid < l directiolnl 1l
3.33
~ 3....vay l )':ith IlIol 0(1)1101(acUalor) 5. APPLIANCES
3.35
$ 312 sprir1g retu m vDle. no lf closed 5.2 ~ FiIIer SIr..,iner
3.36 -{C]- 2/2 spring relurrl l . normally dose{1 5.3 c;:::: MtIgrlelic lillQl
Englne 44-012750
5.7
: ~ .screw 6. FITT INGS
510
= rlOI$ rr.ce ssones {leX110 l>e O-dded, 6.3 '---r' \aS1e tray
.......,.,.
5.11
PiSIQrl plImp 6 .. 'l"flsle lray with plLIg
5.13
\l Electr;c ~~t I a.;r r 6.6
~ Flel l lll1
..J.L.
5.14 -<!>- Aitfilter 6.7 -rr ~anng
-
~
il l ...Il1 alac drflirl 6.9 o..'e~~d d",'J1ce
*
6.16
517
< V-liIter traj) with In:~ n ual conIrol 7 READING $ \OVITH O AOINAR DESIGNATlON$
5.18
-<>- , lr brica tor 7. 1 (') Sigl1t flovl indic"Ior
<
~
5. 19
...
5.21 8 Sitlg1e a::tit\9 c:ylit1det vt'ith spn t g telttnled 7.4 .; Otslance 19l indicator
5,23
~ Stmt <l
Doc , , 07 - 5179- 0
'!NRI D0058n Enaine
Tier 1 ll . : DY139/DY3071
Tier 2 ll . :-
Subject :
FUEL IL SPECIFICATlON
Note:
~
Doc.
Doosan Engine .
MR08-5179-0
DOOSAN - DIESEL aQe 1/15 - f'
REVISION HISTORY
DATE REV DESCRIPTION
ENGINE
5L23/30 PART Machinery
Doc.
DESCR IP- .
MR08-5179-0
FUEL IL SPECIFICATION
Doosan Engine CO., Ltd.
." DOOSAN - DIESEL aae 2/ 15
CONTENTS
ENGINE
5L23/30 PART Machinery
Doc.
DESCRIP- .
MR08-5179-0
FUEL IL SPECIF ICATION
Fuel l Specification
Note:
3
2
1
20071115 idEH ~ o l ~~ o l ~~ First issued.
~
Drawing
Doosan Englne .
44-012709
Fuel l Specification
CONTENT
5.0 Blends
7.0 Ash
Fuel l Specification
MGO is a medium class disti llate oil which therelore must not contain any
residual components.
The key property ratings reler to CIMAC #21 12003.
FueI Specification
CIMAC #21/2003 D DC
3
Density at 15 "C kg/m :;:; 900 :;:; 920
It means that engines can be operated the same luel oils as DOOSAN-
& two stroke lw speed diesel engines.
The data the HFO standards and specilications reler to the same luel type
as delivered to the ship, i.e. belore on-board cleaning.
order to ensure ellective and sullicient cleaning the HFO, i.e. removal
water and so lid contam inants, the luel l specilic gravity at 150 C (60 0 F)
should be be low 991 kg/m3. Higher densities can be allowed l special
treatment systems are installed.
~ _ gl. Drawing
.
44-012709
FueI Specification
Current analysis inlormation is not sullicient lor estimating the ignition and
co mbustion properties the l. This means that service resu lts depend on
il properties which cannot be known belorehand. Thi s especially app lies to
the tendency the il to l orm deposits in combustion chambers, gas
passages and turbines.
Kinematic Viscosity
2
at 40"C cSt(mm Is) :5 55
2
at50"C cSt(mm Is) :5 700
Flash Point "C > 60
Pour Point "C :5 30
Conradsen Carbon Residue % by weight :5 22
Micro Carbon Residue % by weight :5 22
Ash content % by weight :5 0.1 5
Total Sediment alter Ageing % by weight :5 0.1
Wate r content % by olume :5 1.00
Su lphur content % by weight :5 4.50
Vanadium mgIkg :5 600
Aluminium + Silicium mgIkg :5 80
CCAI - ** 2)
Asphaltenes - :5 23 carbo n residue
FIA Cetane Number - *** 3)
Drawing
.
44-012709
Fuel l Specification
1I heavy luel oils, with analysis data exceeding the besides ligures, are be
used, especially with regard viscosity and specilic gravity, the engine
builder should be contacted lor advice regarding possible changes the luel
il system.
5.0 Blends
Fuel l containing used lubricating l (ULO) has comply with the CIMAC
#21 /2003 luel l specilication.
The order letter lor the luel should expressly mention what is prohibited, as
this constraint has ! yet been incorporated the common ly applied luel
specilications.
Drawing
.
44-012709
Fuel l Specification
The admixing chemical waste materials (such as solvents) to the luel is lor
reasons enviro nmental protection prohibited by reso lution the
Marine Environmental Protection Committee 1 Jan. 92.
1I the sodium content is lower than 30% the vanadium content, the risk
high temperature corrosion will be small. It must also be prevented that
sodium in the lorm sea water enters the engine together with the intake air.
7.0 Ash
Heavy luel oils with a high ash content in the lorm loreign particles such as
sand, corrosion elements and catalyst lines (catfines) in heavy luel oi ls
coming Irom catalytic crackin g processes. In most cases, these catfines wll
be aluminium oxides, silicium oxides, which causes high wear in the injection
system and in the engine.
Fuel l Specification
For luels above 180 cStl50 C a pressureri zed luel l syslem is necessary to
avoid boiling and loaming the luel.
The viscosity leaving the heaters should be 10-15 cSt and approx. 12-18 cSI
enlering Ihe engine.
vessel heated either by steam electricily adjusls the viscosity the luel.
There are Iw means adjusling the power supply 10 Ihe vessel :
Either by measuring the lemperature Ihe media,
by measuring the viscosity the media
Fuel l Specification
Ternperature sec.
cSt Rlv.
after prel,eater ' C
7 43
170
10 52
160
12 59
150
15 69
140
20 87
130
120
30 125
110
100
90
80
70
. plImping i!
50
40 1 - - - - - 1- - .. ........- -..
30
Log scales 10 15 25 $5 45 ~ 55 CS~100" C
30 60 100 180 380 700 cSV50' C
200 400 800 1500 3500 7000 sec, R~v/1 ? F.
Vlscostty fuel
FueI Specification
The reason being that the charges the luel oils may vary considerably
properties eg. Iractions, viscosity indexes, etc.
The so lid contaminants the luel l are mainly rust, sand, dust and relinery
atalysts. Liquid contaminants are mainly water, i.e. either Iresh water salt
water.
Impurities the luel can cause damage to luel pumps and luel valves, and
can lead to increased cylinder liner wear and deterioration the exhaust
valve seats. Also increased louling gas ways and turbocharger blades may
result Irom the use inadequately cleaned luel l. Ellective cleanin g can
only be ensured by using a centriluge.
Fuel l Specification
Fuel classes DMC to RMH55 require a treatment with centriluge all cases.
~ Doosan . Drawing
.
44-012709
Note:
3
2
1
~ {f:
~ First issued.
20101007 ~ EII ~ ~ EH ~
~
Drawing
Doosan EngIne .
34-030683
, ~ ~ ~
. -., "
;.
"
,.
~
~
:1:
Q I~
~
~ ~
'"
3 ;..
;. "
;,,,\
~ ~ .
'"
":::~
, Q
~,
~
;. ~
;
;;
..
~.,
..
, ,-,
0 .'" -'"
~ "'."
".
~""
~ ;:;
" - :;J ~ " -
{
~
" -,
., .. -
~
~ ,. , -!
"
;~ ; .....
("I~
~ -
;, : >
~ ~I i ~
;; ~ ,Q
;' " 7~
"
,
Q
>,
".- "
"
t
,/>i/""'"
~ ~
"::; u ".
~
:~
"'
:':-..'
" , ~ .'
..
,
~
""
;?:
,,
"
~
, \!"~' J-~' '" " C
~" ~ ~ ~ -'J
~ ~
<1>'"
;;"
~ ~
" ;;
..,
"
,,f.
.i ~
" .t .3"
" "'
~ , '~ "
i;
.. !
; ~
-'t!- , ......-. .
~
_ .., ._
V
. ~I"~
. .1......1 ...
___L........ L _ -; i " ...
,..
.
J
Subject:
LUBRICATlNG IL SPECIFICATlON
Note:
~
Ooc.
Doosan Englne .
MR09-5179-0
DOOSAN - DIESEL age 1/10- "
REVISION HISTORY
REV DESCRIPTlON
ENG IN E
5L23/30 PART Machinery
Doc.
DESCRIP- .
MR09-5179-0
10
LUBR ICAT ING IL SPECIFICATION
CONTENTS
ENG INE
5L23/30 PART Machinery
Doc.
DESCRIP- .
MR09-5179-0
LUBRICATING IL SPECIFICATION
Lubricating l Specification
Note:
3
2
1
20071115 1dEH ~ O l {}~ O l {}~ First issued.
~
Drawing
Doosan Englne .
44-012710
Lubricating Specification
CONTENT
1.0 Requirement
Lubricating Specification
1.0 Requirement
Heavy Duty lubricating l has be used corresponding at least type CF
after serice system (http://apiep.api.org/fi lelibrary/ACF1 E1 .pdf).
Further the lubricating l should be rust and oidation inhibited.
Marine Application
SAE class 30' 105 cSt @ 40"C (For L23/30, L+V28/32H)
SAE class 40145 cSt@40 "C (For L16/24, L21 /31, L27/38, L32/40)
! cooling water temperatures above 32 0C SAE 40 l can be used.
In this case, please contact the engine builder.
Stationar Application
SAE class 40 145 cSt @ 40 "C
(For 16/24, L21 /31, L27/38, L23/3 0, L+V28/32H, V28/32S)
The selection is based on typical load proliles lor marine GenSet (50-60%
rated power) and lor stationary GenSet (50100% rated power) .
BN(mg KOH/g)
il Type
For L32/40 For other engines
Gas l 12-15 8 12
Marine diesel 1525 10-15
Heavy luel l (S < 1.5%) 25-35 1520
Heavy luel il (S > 1.5%) 30-40 20-40
Lubricating Specification
order to meet the emission regulations , more often fuel oils with different
sulphur co ntent are operation. ! harbor/coastal operation a l sulphur
fuel l ll be used and at sea operation a high sulphur fuel l ill be used.
he lubricating l value ll have to be evaluated from engine running
hours operating the two different fuel oils. Normally the value should
be evaluated from the fuel l with the highest sulphur content.
Doc. . MR09-5179- 0
Page 7/ 10
Lubricating l Specification
As a guidance, the following formula should form the basis for choosing the
required l for th e separator capacity :
Q = 1 .36 n/ t
Q = required l (I/h)
= engine output (kW)
t = actual effective separator operating time per day (hour)
n = number ! turnovers per day ! the theoretical l volume corresponding
to 1.36 l/kW 1 /
he following values for "n" are recommended:
n = 5 for HFO operating (residual)
n = 4 for operating
n = 3 for distillate fuel
he aim is to ensure that the separator is only connected with one engine at
a time. his to ensure that there is no suction and discharging from one
engine to another.
provide the above-mentioned it is recommended that inlet and outlet
valves are connected , so that they can only be changed-over simultaneously.
Lubricating l Specification
fl!J:NI~ 1
" N~'
09. c 2
1'\9. Nc $
Fig 1. Fig 2.
Principle lay-out lor direct separating Principle lay-out lor direct
on a single plant separating on a multi plant.
c. . MR09- 5179- 0
Page 9/ 10
Lubricating l Specification
he il sample should be taken after the lilter and, l possible, while the
engine is running as this ll ensure that the test ll be representative lor the
whole change in the engine.
Flash Point
Limit value : > 185'C
Possible test : Setallash test
method (cut point correlates with 204 'C, ASM 0 -92(coc))
Water Content
Limit value : < 0.5, prelerred < 0.2 (higher value is permissible in a
shor1er period)
Possible test : Patable test unit gas chromatography (or inlra red distil).
method 1I the limit value is exceeded, a supplementary test lor
chlorides (ASM 0-878) can be made.
Guiding otal Base Number (TBN -Number)
Limit value : Reler to Iresh l % : > 70%
Unit : mg KOH/g
Possible test : ASM 0-2896
method
Oue to the generating running mode, where the lub. l consumption depends
on running time and the luel il consumption and lollowing the sulphur input
the lub. l depends on the load, a lower BN-value than normal lor main
engines is needed.
Drawing
.
44-01 2710
Lubricating l 5pecification
Neutralization Number
Limit value : 0.4-1.0 above typicallevel
Unit : mg KOHIg
Possible test : 8 0-974
method
~ Doosan Drawing
.
44-012710
1 Hull . : 139/03071
2 Hull . :-
Subject :
Note:
~
Doc.
Doosan Engine .
MR10-5179-0
DOOSAN - DIESEL age 1/ 5- #"
REVISION HISTORY
REV DESCR IPTlON
ENGINE
5L 23/30 PART Machinery
Doc.
DESCRIP- .
MR10-5179-0
10
LU8R ICAT ING IL QUANTI TIES 8ASE FRAME
Doosan Eng ine CO . ,Ltd.
DOOSAN - DIESEL aae 2/5
CONTENTS
ENGINE
5L23/30 PART Machinery
Doc.
DESCR IP- .
MR10-5179-0
LUBR ICATING IL QUANT ITIES BASE FRAME
Note:
3
2
1
20071 120 fd EH ~ fd~V ol~ ~ First issued.
~
Drawing
Doosan Engfne .
44-012747
CONTENT
1.0 l Quantities
44-012747
1.0 l Quantities
The appro i mate quantities il necessary lor a new engine, bel ore starti ng
are given in the lollowing tab le.
1I there are connected eternal , lull-Ilow llters etc., the quantity l in the
eternal piping must also be taken into account.
,
, . .
Subject:
Note:
~
Doc.
Doosan Engfne .
MR11-5179-0
-
DOOSAN DIESEL aae 1/ 11 - '
REVISION HISTORY
REV OESCR IPTlON
ENGINE
5L23/30 PART Machinery
Ooc.
OESCR IP- .
MR11-5179-0
FRESHWATER SYSTEM
Doosan Eng ine CO . ,Ltd.
DOOSAN - DIESEL aQe 2/ 11
CONTENTS
ENG INE
5L23/30 PART Machi nery
Doc.
DESCR IP- .
MR11-5179-0
FRESHWATER SYSTEM
Doosan Engine CO. ,Ltd.
Page 3/11
Note:
3
2
1
20071115 ~EK ~ o l ~~ o l ~~ First issued.
~
Drawing
Doosan Engine .
44-012708
CONTENT
6.0 Degreasing
44-012708
Doc. . MR 11 - 5179- 0
Page 5/ 11
Ready- mied cleaning agents, specially made lor cleaning the cooling water
system , can be obtained Irom companies specializing coo ling water
treatment. hese companies oller assistance and control the treatment all
major ports. number these companies are mentioned the enclosed list.
We point ! that the directions given by them should be closely lollowed. It is
particular importance Ilush the system completely after cleaning.
he clean ing agents should not be directly admied, but should be dissolved
water and then added to the cooling water system.
1I deionized distilled water can not be obtained, normal drinking water can be
used eception a l cases. 1I 50, the total hardne5s the water mu st
eceed 90 dH (German hardness degrees) . The chloride, chlorine, su lphate,
and silicate contents are also be checked. These content5 should
eceed the lollowing valu es:
! shou ld be noted that softening water does ! reduce its sulphate and
ch loride contents.
Doc. . MR 11 - 5179- 0
Page 7/ 11
4.0 Checking Cooling Water System and CooIing Water during Service
the cooIing water is co ntaminated during service, sIudge deposits may
lorm. he condition the cooIing water system shouId therelore be reguIarIy
checked, especiaIIy l deionized distiIIed water is ! used. deposits are
lou nd the cooIing spaces, these spaces , l necessary, the entire system
shouId be cieaned.
According to epe ri e n ce, a zinc gaIvanized coating the Ireshwater coo Iing
system is often very susceptibIe to corrosio n, which resuIts heavy lormation
sIudge, even l the cooIing water is correctIy inhibited. he initiaI descaIing
with acid w , to a great etent, remove th e gaIvanized coating. GeneraIIy,
therelore, W advise against the use gaIvanized piping the Ireshwater
coo Ii ng system.
he quaIity th e cooIing water is to be checked reguIarIy, l possibIe once a
week. BasicaIIy the inhibitor co ncentration , the vaIue and the chIoride
concentration shouId be accordance with Iimits stated by inhibitor
manufacturer. For this purpose the inhibitor manulactures normaIIy suppIy
simpIe test kits.
~ Dtosa. .I 44-012708
The water sample lor these tests is to be taken Irom the circu lating system,
and ! Irom the epansion tank the leading to !.
clear record all measuring results should be kept, so that the actual
condition and trend the system may be currently ascertained and evaluated.
ch loride content the cooling water higher than the 50 ppm specilied might,
eceptional cases be tolerated. However, that case the upper Iimit
specilied by the individual inhibitor supplier must not be eceed.
clear record all measuring results should be kept, so that the actual
condition and trend the system may be currently ascertained and evaluated.
Every third month a cooling water sample shou ld be sent ashore lor laboratory
analysis, particular to ascertain the contents inhibitor, sulphate, and ,
as well as the total sali nity the water.
6.0 Degreasing
Use clean tap water lor filling-up. The cooling water the system can be used,
l it does not contain inhibitors.
Heat the water to 60 'C and circulate the water continuous ly.
Drain to the lowest water level epans i on tank.
Add the amount degreasing chemical specilied by the suppli er, prelerably
Irom the suction side the Ireshwater pump.
Drain to the lowest water level the epansion tank directly afterwards.
Circulate the cleaning chemical lor the period specilied by the supplier.
The cooling water system must not be kept under pressure.
For engines which have been treated belore the trial trip, the lowest
concentration recommended by the supplier ll normally be sufficient.
Drain some water Irom the system and add the acid solution via the epansion
tank.
Keep the temperature the water between 70 'C and 75 'C, and circulate !
constantly.
The duration the treatment will depend on the degree louling. Normally,
the shortest time recommended by the supplier will be sullicient lor engines
which are treated belore the trial . For untreated engines, a longer time
must be reckoned with. Check every hour, lor example with pH-paper, that the
acid in the solution has not been used up.
After completing the descaling, drain the system and Ilush with water.
Acid residues can be neutralized with clean tap water containing 1 kg soda
per ton water. Circulate the mixture lor 30 minutes, then drain and Ilush
the system. The cooling water system must not be put under pressure.
ll the engine to run lor not less than 24 hours to ensure that a stable
protection the cooling surfaces is lormed.
Subsequently, test the cooling water with a test kit(available Irom the inhibitor
supplier) ensure that an adequate inhibitor concentration has been obtained.
This should be checked every week.
The acid content the system il is to be checked directly after the descaling
with acid, and again 24 hours afterwards.
Maker's Min .
l
Company Name Inhibitor Recommended
Form
Oosage*
Castrol Limited, Swindon Castrol So lve 4 Powder 3 kg/10001
Wiltshire, England Castrol Solve 2 Liquid 201/1000 1
Orew Ameriod OEWT-NC Powder 3.2 kg/1000 1
Marine Liquidewt Liquid 81/10001
Boonton , N.J.lU.S.A M aig u a rd Liqu id 161/10001
Houseman Scandinavia Cooltreat 651 Liquid 51/10001
3660 Stenlese
Oenmark Cooltreat 652 Liquid 51/1000 1
Nalfleet Marine Chemicals Nalfleet Liq (9-108) Liquid 31/1000
Northwich ,
Cheshire CW80X, England Nalfleet 9-131 C Liquid 10 i 1 0001
Nalfleet 9-111 Liquid 1 1/1000
The list is for guidance on ly and must not be considered comp lete. We undertake no
responsibility for difficu lties that might be caused by these other water
inhibitors/chem icals.
The suppliers are lsted in alphabetical order.
Suitable cleaners can normally be supplied by these firms .
Subject:
Note:
~
Doc.
Doosan Engine .
5-5179-0
DOOSAN - DIESEL aQe 1/4- #'
REVISION HISTORY
DATE REV DESCR IPTlON
ENG INE
5L23/30 PART Machinery
Doc.
DESCRIP- .
5-5179-0
1 0
PRE- LUBRICATING PUMP l
Doosan Eng ine CO. ,Ltd.
DOOSAN - DIESEL aQe 2/4
CONTENTS
ENGINE
523/30 PART Machinery
Doc.
DESC RIP- .
5-5179-0
1 0
PRE-LUBR ICATI NG PUMP l
RO TA
210 4- _,2
"
, 3420 < 3420
( (m1jhr) 2.' FREQUENCY () 60
I---
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1 PRfSS (bar)
mIn 04 L, CURRENT{A)
1.'0-
- - j.,
i
EST PRESS (bar) 10 PROTElON '"
. . 90 ( ' 201006281C! ~~ Olt!!t O l teJ F rs ss ued
D
WEIGHT (KG) 4 \YEIGHf (KG)
;:.1;
43.9 Maker
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DOOSAN-MAN DIESEL Page : 1/ 15
Client : Vangzhou Dayang Shipbuilding Co.,Ltd.
Engine Type : 5L23/30
Tier 1 U . : 139/ 3071
2 ll . :-
Subject:
Note:
~
Doc.
Doosan Engine .
07 -5179-0
DOOSAN - DIESEL age 1/15- "
REVISION HISTORY
REV DESCRIPTlON
ENG INE
5L23 / 30 PART Machinery
Doc.
DESCR IP- .
07 -5179-0
JACKET WATER PREHEATING I
Doosan Eng ine CO . ,Ltd.
DOOSAN - DIESEL age 2/ 15
CONTENTS
ENG INE
5 L23 / 30 PART Machi nery
Doc.
DESCR IP- .
07 -5179-0
10
JACKET WATER PREHEATING I
"
Note:
1. Duty module
- 1 100% covering two(2) engines
2. Electric heater
- 10.0 kW , 1 100%1 module
3. Electric pump
, 1.0 m3/h 2.0 bar, 1 100% module
4. Unit q'ty
- One(l) set sh ip
3
2
1
20101119 ~~~ ol ~ ~ ol ~ ~ First issued.
~
Drawing
Doosan EngIne ,
34-031256
Ooc. . 07-5179-0
Page 4/ 15
1 2
3
4 5
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Doc. . 7-5179-0
Page 5/15
1 2 3 4 5
J.W.PREHEATER I
SHIPYARD CLASS
FRONT SELF SUPPORTlNG 45'C
.
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SIDE COVERS SHEET STEEL
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Doc. . 7-5179-0
Page 6/15
1 2 ~
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Doc . . 7-5179-0
Page 7/ 15
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Doc . . 7-5179-0
Page 9/15
1 2 3 1 4 5
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Ooc. . 7-5179-0
Page 1r '~5
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Doc. . 7-5179-0
Page 11 / 15
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Ooc. . 07 - 5179- 0
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DRA1IING . ; SSEOOl552
~
2010.11.18 FOR APPRO'IL CRI - 3
DWN . .
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Doc. . 7-5179-0
Page 15/15
1 2 3 4 5
-,
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2 FUSE ~ID SB-CI , 3 2 2
.
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GLOVE , 250 1 1 WHITE
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FOR
4
SIGNAL LA ~I5l? 6.3V IW 5 5
-
5 L BEARING '3() 6201
6204
2
2
C3
C3
ISET I SET
620 1 6204 C
6 SPARE
~Hl NP=SPARE 1
f-
f-
(
SHEET .
-
12
(
SCAI..E
CHK
/ S
2010.1 1.18 FR APPROVAL
REV 1 DESCRI1'1I0N DWN . .
f3--$-
ESS) @nl1iJ!n@I1iJ@ ~U@W'@ ~ @]. . ; F
Ooc . . 7-5179-0
tHIlM Doosan Englne
Subject:
Attachments : Refer 10 Ihe Revision Hislory and conlenls for drawing lisl
2
Corrected the spare of LCP (Spare .0035-3-8) and air
20110712 ~~ l!{!j ~ ~~~ 1
cooler (Spare .0092-02-04)
20101118 ~~ ~ EH ~ ~ EH ~ First issued.
Doc
Doosan Engine .
11-5179-1
DOOSAN-MAN DIESEL PAGE . 0000 - 1 / 2 - # '
REVISION HISTORY
REV DESCRIPTl ON
ENGI
NE 5 L23/30 MS/MG 0000
1-'-'-'-..::...-----------'----'--------jD c.
DESCRIP- . 11-5179-1
Li s t spar e par ts
Doosan Eng ine Co. ,Ltd.
'. DOOSAN-MAN DIESEL PAGE : 0000 - 2 2
CONTENTS
ENGINE
5 L 23/30 MS/MG 0000
Doc.
DESCRIP- .
11-5179-1
List of spare parts
Ooosan Engine Co. ,Ltd.
DOOSAN-MAN DIESEL PAGE : 0002- 1/ 1
p 'TY/ SHI
AEMAAI<S
SPAAE
e OESCAI PTI ON S <ETCH STO. .
.
I
CON
WOAI\ ING W' T(I<G)
8EAAING 51101- 157
!~, Eaill
1 AIS,,6
0002-
OOO2- 1509S
Nt1 1.600
'1.?
1
2 AIS/1
0002-
02
- p- - -J- - ~ -
1b<!7Q
0002- 162 1S
2 0 .400
'1<12 .5 2 SCM44
13~!EiI '-
0002-
03
, ,
~
ooo2- 1503S
2( Nt1 ) 4.800
0002-
- - ~ ~
2 SCM4400
04
oo02- 1523S
~7S 2(Nt1 ) 1.080
5
4
3
2
1
2010 111 2 ~2l* ~~~ ~~~ Fi rst issued.
LL . 1 39/ 03071
ENGINE
5 L 23 / 30 MS/ MG 0002
Ooc .
OESCRIP- .
11- 5179-0002-0
CRANI<CASE
1 N8R
0003-
1~7
329 . 5
0003- S624S
5 0.030
5
4
3
2
20 101 11 6 ~ I~~
== ~ ~~ ~ 8~ First issued.
:II~
\11275 1 SS400
0005- 11" ,
i
ooo5-2622S
0.050
Q-RING 50610 43
\11242 2 !fflJ
0005- ~ I'
..
02 t1I i
OOO5-062 1S
2 0.060
5
4
3
2
1
20101116 01) 101 ~~ ~8~ F i rst i ssued .
, . ., -
~
1 T13AI>F2100
~
0006- -
~ ...
- -/
424 0006-S625S
0.077
PACI< NG 50510-75
I .~
I1
+ ! 1 Tl3Al>F2100
0006-
~ --+-~--~
02
h.. i +-'
1_ 4;,>4
ooo6-S626S
0.030
L VALVE SEAT 50501-64
RING
r ~ ~
2 SCM4400
0006-
03
f%;:7
~ ~
~ 2 0. 680
0006- 1624S
L
RING
VALVE SEAT
."
50501-76
0006-
04
j
?
C
~
4 s&
.85 oo06- 1603S
2 0.680
10.681
5
4
3
2
j1} 16
8 VITCN
0006-
'~.! 1
05
OOO6-S624S
8 0.001
D-RI NG 50501- 338
1<1299 . )
0006-
06 1\, :
() 2 C512
OOO6-S623S
2 0.059
IO. C69t
ENGINE
523 / 30 MS/MG 0006
Doc .
.
11-5179-0006-0
DESCRIP-
CYLINDER D
----1-- 1 W>J<ER
0008-
1 - t~
ooo8-2505S
. ~ 196.5 , 1. 100
BEARING SHELL 50601-139
1 W>J<ER
0008-
+~
02
. ~ 196 . 5
.1 1. 100
0008-2506S
1 3
99 . !J 0008-2602S
1. 600
CONNECTING 50601-152
STUD
266 2 SN043ro
0008-
04
,
,
~
~
0008-2622S
2 1.370
5
4
3
2
1
20101 116 OIJ lof ~~~ ~~ Fi s t issued.
50601- 164
~-
~
2 SNCM43
0008-
05
~
~
~
I~ /";
." 2 0.350
0008-262 1S
ENGINE
5L 23 ! 30 MS/ MG
0008
Doc .
DESCA I- .
11 -5179-0008-0
CONNECTING ROD
Doosan Engine Co. ,Ltd.
DOOSAN-MAN DIESEL PAGE : 0010- 1/2
Q'TY/SHIF REMARI\S
R
SPARE
e
.
DESCR IPTION SI<ETCH STO. ADD. L
I
WORI<ING ' ()
PACON
PISTON 50501- 19
COMPLETE .,
-
1
00 10-
-+- + -1-1-
1 0-2502
8.800
/ ~ 2 3G,I
00 10-
02
~~
~ lo~.
OO 10-2522S
2 0.037
PISTON RING 50601-93
1 '
]
00 10-
03
[ . ''''
oo 10-2504S
0. 166
PISTON RING 50501 103
1 ~\AI<EA
]
00 10-
.
04
1122,.
00 10-2505S
0.1 66
5
4
3
2
1
20101 116 01] 101 ~~ :J~ Fir st i ssued.
1 MJ<EA
0010-
05
[ 0225 .1
00 10-2506S
0. 166
I L SCRAPER RING 50601-127
1 .MR
00 10-
06 '~I ,+
;" J
oo lO-2507S
0. 125
ENGI NE
5L23 / 30 M
S/MG
0010
Ooc .
1 1 -5179-0010-0
OESCRIP- .
PI STON/CON. ROD
Doosan Engine Co. ,Ltd.
DOOSAN-MAN DIESEL PAGE 0012- 1/ 2
Q'TYISHlf
R REMARI<S
SPARE STO. ADD .
e
.
OESCRIPTION SI <E CH
v I
\ I< 1 NG W' T(I<G) PACON
VALVE CONE 50502 512
11
6
00 12- i
"
00 12-3301S
L~ 4 0.900
COMPRESS ION SPR ING 50502-489
RIGHT
6 &r:'f3C-
0012-
02
00 12-393OS
4 0.120
10.121
6 &r:'f3C-
00 12-
03
00 12-3931S
4 0.380
IO.XI
5
4
3
2
1
20 101 116 OI J lof ~~ ~ ~ Fi rst issued.
~
4
0012-
05
...., l
--,;;;;;;-
00 12-3604S
4 0.300
,.
ENGINE
5 L 23 / 30 MS/MG 0012
Doc.
OESCR - .
11 -5 179-0012-0
VALVE GEAR ASSEMBLY
;
3
10017-
Ci
32.
00 17-3301
4 .800
5
4
3
2
1
20101 111 g~{! ~$~ ~~~ IFirst issued.
31
~
4 l
0025-
\-
0025-C621S
4 0.005
5
4
3
2
1
20101 111 ~~e ~~ ~~ First issued.
0035- ~
=
=
-
-
--
5
1
1 =
= -
-
OO35-6100S
45 0.000
ANN .CARO (For - COMMON
Local Control 80 CARO
Panel)
0035- ;;
=
=
-
-
1
1 -
2 =
= -
-
0035-6100S
3 0.010
FUSE (Fo r Loca I
Control Panel)
311
15
0035-
3
[DJ Ql 15 0.010
0035-6100S
4
[DJQl 2 0.010
OO35-6100S
5
4
20110614 :jgi=t Ol~ 011 Mod ified specification of fuse and fuse holder 3
201 10516 d~t OIQj Ol~ Modi f ied descript ion ANN.CARO(OO35- 1) 2
2011033 1 Ol~ OI~eJ OIMeJ ChangedJ~gyc . luse & luse holder due the change
of subsu 11
201011 17 0121 ~EH~ ~EH~ Fir st issued .
[]Ol
0035-
1 5
OO35-6100S
18 0.010
FUSE (For Local - l
Control Panel)
311
6 MJ<EA
[]Ol
0035-
1
6
OO35-6100S
6 0.010
FUSE (For Local - 16
Control Panel)
311
6 MJ<EA
[]Ol
0035-
1
7
OO35-6100S
6 0.010
~ 4 MJ<EA
0035- ro.
8 1
78
lk 47 0.010
-
OO35-6100S
YS8RL34-0L24-W
. L (For
Local Contro l
Pane ) 2Q
1
0035-
9 cii G-
~
~
ocxx>o
oJCX)
1 MJ<EA
OO35-6100S
3 0.010
ENGINE
5L23 /30 MS/MG 0035
Doc .
.
11-5179-0035-3
DESCRIP-
ELECTRIC
. (For - YSBRL34-0L24-G
Loca l Cont rol
Panel )
1
0035-
10
~
~
[~ 00000
00000
D= 1 f.W<IA
oo35-61ooS
3 0.010
. (For YSBRL34-0L24-Y
Local Control
Panel )
1
0035-
11 ~
~
~
00000
00000
D= 2 f.W<IR
0035-6 100S
12 0.010
. (For - YSBRL34-0L24-R
Local Cont rol
Pane l )
0035-
1 12 ~
~
~
00000
00000
D= 5 f.W<IA
OO35-61 OOS
54 0.010
MAGNETIC CONTACTOR - GMC9
(For loca l AC220V
Cont rol Pane l )
1 <
{~ ~
0035-
1 13
0035-61OOS
3 0.010
(For Local SZR 4-
Control Pane l ) OC24V
1 <
m
0035-
1 14 @@@
0035-6100S
3 0.010
ENGINE
5L23/30 S/.3 0035
Ooc.
.
11 -5179-0035-3
OESCRI P-
ELECTRIC PART
2 <
I ~~I ~[
0035-
1 15
0035-6100S
21 0.010
L (For Loca l - SZR-MY4- NI
Cont rol Panel) OC24V
10 <
~
0035-
1 16 @@"
OO35-61OOS
109 0.010
BULB (For Loca - E- 10 ,24V, IW
Control Panel)
1
0035-
17 ~I I II I
---;-
18 6 <
0035-6 ooS
6 0.010
FUSE PULLER (For PF 36
Loca l Cont rol
Panel )
~ ~
1 MJ<EA
0035-
18
OO35-6100S
0.010
I (For Local - I 5408
Control Panel)
10 MJ<EA
0035-
1 19 -==1 11 F
OO35-61OOS
39 0.010
ENGINE
5 L23!30 MS/MG 0035
Ooc .
.
11 -5179-0035-3
OESCRIP-
ELECTRIC PART
. I
v
WORI( ING W'T(KG) PACON
(For Loca -
Contro l Panel)
~
1
0035-
20
/ "-'
1 W>J<IA
". oo35-6100S
1.000
ENGINE
5L23 ! 30 MS/MG
0035
Ooc.
.
11 -5179-0035-3
OESCRIP-
ELECTRIC PART
0036- ~
~~ 1
- ::!
m~ m,
0036-3201
* 150 8 . 100
5
4
3
2
1
2010111 1 ~~e ~~ ~8~ First issued.
i1> 16
2 l
'~< r
0057-
1 - 1
0057-G623S
2 0.00 1
PACI< ING 51202-024
1HD< 1.5
~( ~- 1
NOlfoo.l
~<
0057- ~
2
."-..J~ 177 0057-G62GS
0.000
5
4
3
2
~
'="" 0072-FS08T
1. 960
5
4
3
2
1
20 1011 17 ~&~ (;1 Q (;12 Fi rsl issued.
OO77-610 1S
0.000
FILTER - HFC7
5O.FR
'Jq
8
4
OO77-610 1S
6 0.500
FI LTER - HFC7
50 .FR
re~g
4
5
0077-6101S
3 0.500
5
4
3
2
1
20101117 01~2I ~EH~ ~EH~ Fir st issued.
119 . 6
"
"; [ 1 l
0092- i
OO92-C622S
1 0.028
GASET 5120 1-054
[Q~
NON-ASffS
3
0092- TOS
02
6 10
I,2
oo92-3927S
1 0.280
GASKET 51201-137
Q]
NON-ASffS
3
0092- ( ~
TOS
03
i I~2
oo92-3927S
1 0.250
SPARE GASKET -
04 j: :1~1~~~~~"'~
oo92-3927S
2.000
5
4
3
2
20 110414 ~~{;! ~~ ~~~ ChangeQ n~he spec . and quantity spare parts 1
accordIn to manufact ur er
20101111 ~~e ~~~ ~~ First issued.
. DY139/DY307 1
ENGINE
5L23 /30 MS/MG 0092
Ooc.
OESCRIP- .
11-5179-0092-1
COMBUSTION COOLER
000
0096-\VM21
0.000
CO L L - HR705- 4P
AC220V
001 ,[ jg 1
5 0.033
002 {
50
g 2
2 0. 250
19:/'\.: 1, ""
003 {
50
g 2
2 0.250
I ~-C', :; 1
5
4
3
2
~
1
004
1 0.010
IGLOVE. 250 "/( )
{~
1
005
1 0.010
IOLUV1:.. ,6 / GAEE NI
{~
1
006
1 0 .010
161..0\1( . 250 / YELLDWI
[~
1
007
2>
1 0.010
IGLOE, 2S tP / ROI
- 2'
5 0.020
ENGINE
5L 23 / 30 MS/MG 0096
Ooc .
.
1 1 -5179-0096-0
OESCRIP-
AUXIL IARY EQUIPMENT
009
cw 6201 C3
1
1 0.350
L L BEARING - 6204
2
C3
~
1
010
620<\ C3
1 0.150
SPARE - NP-SPARE
~~
1
011
l
~~~
0.500
ENGINE 0096
5L 23/30 MS/MG
Ooc.
.
11 -5179-0096-0
OESCR IP-
AUXILIARY EQUIPMENT
Subject:
List of tools
Note:
Attachments : Refer to the Revision History and contents for drawing list
~
Doc
Doosan Engine .
12-5179-1
DOOSAN-MAN DIESEL PAGE' 0078 - 1 / 2 - #'
REVISION HISTORY
REV DESCRIPTlON
ENG INE
5L23!30 MS/MG 0078
Doc.
DESCRIP- .
12-5179-1
L i st tools
Doosan Engine Co. ,Ltd.
'\ DOOSAN-MAN DIESEL PAGE : 0078 - 2 2
CONTENTS
ENGI NE
5 L 23/3 0 MS/MG 0078
Doc.
DESCRIP- .
12-5179-1
List of tools
Doosan Engine Co .. Lt d.
DOOSAN-MAN DI ESEL PAGE 000 - 1/ 10
~ ' TY/SHI REMARI\S ,
R .
e DESCR SKETCH
POSI - STD. ADD. WEIG1T(kg) PACON
.PRESSURE
INDICATOR 95
-
000
~
~ - 1
-0 1
.~'I~0l).fS
~...,..~,.-
2.100 0078-9401
LIFT ING
SS4OO,
STPG370S ,
000
S45CN
1
-02
-
"" 5.080 0078-9701
MOUNTI NG FOR
~
000
- 03
1
3.230 0078-9821
GA INDI NG
~
r-'
SS400
000 , ~
1
,
-04
5
4
3
2
201 104 14 ~~~ ~@ Ed~ Changed ai r cooler 1001 according 10 manufaclurer
. 139 / 0307 1
ENGINE CODE
5L23 / 30 MS/MG 0078 000
.
Doc .
DESCR IP- . 12-5179-000-1
GENERALTOOL
FOR GRINOING
OF
SS400
(? ~
000 (
1
-05 j
000
-06 r~~l , 1
<
1.723 0078-9623
EXTRACTOR FOR FUEL
<
000 1
-07
1. 900 0078-9529
LIFT ING
000
(J S15CN
1
1 (
-08
IM I 2J 0.180 0078-9539
SHACI<LE
-
) SF44CAN
000 1
1 -09 ~-R--I-
~
20 0.975 0078-9521
S.W. L : 1.6 ton
ENGINE
MS/MG 0078 COOE 000
523 / 30 .
Ooc.
OESCR IP- . 12-5179-000-1
GENERALTOOL
RETAINI NG
TOOL-CYL .LINER
000 ..
,.;
.1
LJ10
STPG370S
- 10 2
L '" .
1. 940 0078-9721
L FOR RETAIN ING
RING --
S35CrVX
000
- 11
m
, 1
0.200 0078-9522
PI STON RING
000 fI
"';
- 12
Q
1
n
<
0.500 0078-9523
L L
GAUGE
3l3 1
000 1+
1
- 13
0.050 0078-9321
L LI
GAUGE
~l3 1
000 1+
1
- 14
0.050 0078-9322
ENGINE
5L23/30 M
S/MG 0078 COOE 000
.
Ooc.
OESCRIP- . 12-5179-000-1
GENERALTOOL
000
- 15
r~I)
~ I
1
<
7:r
10.210 0078-9524
LI FT NG L
000
- 16
dt-1 1
<
8.029 0078-9702
GR INOING L
000
- 17
lfr . .
1
SS400
6.000 0078-9624
HONING L
000
- 18
.e !- 1
3.000 0078-9625
FUNNEL
.258
~
<
000 8
1
- 19
W
1. 713 0078-9525
ENGINE
0078 CODE 000
5L23!30 MS/MG .
Ooc .
. 12-5179-000-1
DESCRIP-
GENERALTOOL
000
-20
-~.~ 2
S45CN
1.920 0078-9526
SCREW
000
-21
-~~!
.. ~IO 1
S45CN
0.500 7-9527
FEELER GAUGf
.... SUP4
000
-22 2
).. SUP4
000
-23 2
~t STPG370
000
-24 -8 1
0. 180 0078-9528
ENGINE
5L23 / 30 MS/MG 0078 CODE 000
.
Doc .
DESCR IP- . 12-5179- 000-1
GENERALTOOL
~ ' TY/SHI
,
DESCA IPTION SKETCH
SPANNEA FOA
OVERSPEED STOP ' 00
.,
~ ! - ..
000 1
-25 ~ !
.-
0,213 0078-9530
000 + -+--
- 26 [ '20 1 3
5,1 50 0058-2822
GAUGE
~~~~~~~
000 ~
1
- 27
21 0
RAN;;E 60-500
1,050 0078-9325
II FT NG STAAP
~~
000 ~,.
. 1000 -\
";
2
- 28
0,295 0078-9722
SUPPORT
:::::14
,- S45CN
000 2
- 29 ! ~
.~ 0,530 0078-9532
ENGINE
0078 CODE 000
5L23!30 MS/MG ,
Doc,
, 1 2-5179-000-1
DESCRIP-
GENERALTOOL
FOR
BEARING
000
- 30 ,~ 1
..!!1,
0.847 0078- 9704
TEST FOA FUEL
VALVE
000
~ '='
1
tr l ~ 4
- 32
~~ ~
ffi1
S45CN
000
- 33 1
L ~.
~
S35CrW
000 ~: '~D
. _._.- _. 1
- 34
4
000 1
-35 i A[?prox. 7q
3 , :) lO!u
0.040 0078-9730
SUPPORT
---=cTL
~,-~
000 1
-36
1.578 0078-9535
TOROUE SPANNER
lIj')I') 463
000
-37 l :) , ',Imoowl 1
STEEL
1.200 0078-9536
Ro::nge , 25- 1<:CNn
TOROUE SPANNER
"8
000
-38 l :) , IHIJ 1
STEEL
2.000 0078-9537
R->ge , 70~
SOCET SPANNER
~~
S35CrVV
000 1
-39
0.570 0078-9538
Test Torque : ~70~
COOE
ENGINE 000
5L23 / 30 MSIM
G 0078 .
Ooc .
. 12-5179-000-1
OESCRI P-
GENERALTOOL
MAGNIFIER
~ ~
000
~
- 40 )1 ~ 1
'-~
DL
'"
~~'= :..,J
000 1
-41
~~
0.500 0078-9327
WASHING
DEVICE
000
- 42
r ;:'0334
~i 1
8.500 0078-9901
-JO
c
000
1
- 43
1.000 0057-9022
CLEANING BRUSH
, STEEL
000 ;;: 11 11 111111 1
1 1
- 44
. .00
.1
0.500 0092-9921
CODE
ENGINE
5L23/30 MS/MG 0078 .
000
Doc .
DESCR IP- . 1 2-5 1 79-000- 1
GENERALTOOL
PUG
~B~
BRASS
000 30
1
-45
0 .010 0092-9921
ENGINE COOE
5L23 / 30 MS/MG 0078 .
000
Ooc .
OESffi IP- .
MA12- 5179- QQQ- 1
GENERALTOOL
L C JACI< FOR
CYL .HEAO
~ <
00 1
~ 1
-01 ~
.'"
33Q~.5Q:.Z50
12 .000 78-994
C JACI< FOR
CYL .HEAO
00 1
-02
I !j':rnJ 4
<
5.200 0078-9706
SEALING RING l
BACI<-UP R NG 90.0
1#
,
8: . 5
= ,, 1;1,
;
00 1
-03
[ 85
90
]
8
0.008 0078-9706
SEALING RING l
BACI\-UP R NG 55 . 5
.~, = , #,
4Q . ~
; ;
00 1
8
- 04
[ 50
'j!:';
J]
0.005 0078-9706
5
4
3
2
-- _.
,..
(
00 1
-05 4
!2... -.
" , 0.075 0078-9706
( FOR HEXAGON
SOCI\ET SCAEW
S(S3
00 1 2
-06
~W'b
0.030 0078-9706
1- .- - -
~ <
00 1
~ W ~- \- ~
1
-07
~
''''
0.562 0078-9706
L C JACK FOR
CO OD STlfJ
F== (
00 1 ~
1
-08
1==
L C JAC( FOR
CON STUD
00 1 _
W @
(
; ~ -. 2
-09 - , "
4. 100 0078-9707
HIGINE
5L23 / 30 M
S/M
G 0078 COOE 00 1
.
Ooc.
. 12- 5179- 00 1-0
OESCRIP-
HYD . L
<
-
,
00 1
- 10 J I . 5
1 1
0.230 0078-9707
SEALING RING l
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Doc.
DESCR IP- . 12-5179-001-0
HVO.
8-3. GENERATOR
DOOSAN-MAN DIESEL Page 1/ 14
Client : Vangzhou Oayang Shipbuilding Co.,Ltd.
Engine Type : 5L23/30
Subject:
Note:
~
Ooc.
Engine .
1-5179-0
-
DOOSAN DIESEL age 1/ 14-.,..
REVISION HISTORY
REV DESCR IPTlON
ENGINE
5L 23/30 PART lC c
Doc.
DESCR IP- .
1-5179-0
10
ENGINE AUTOMAT IC SYSTEM
Doosan Engine CO. ,Ltd.
. ~. DOOSAN - DIESEL age 2/ 14
CONTENTS
ENG INE
5L 23/30 PART El ectr iC
Doc.
DESCR IP- .
1-5179-0
1 0
ENGINE AUTOMATI C SYSTEM
GQVERNOR:
62
12 SHUTDOWN SOLENO ID & 21-22 4;3-40
SYNCHRON IE ING MQTOR
5 :: 89 PRESSURE GAUGE
5 1AR NGrB" O
:..X ,-_ _...,
L/2 8
, !, ,.
OoC. . : 00 1-5179-0
Page 4 ~
Sensor Lst
3 43-40 F.o. Filter High Diff. Press. Alarm 1 DPS 0.02-0.25 -- 0.05
6 21-22 Filter High Diff. Press. Alarm 1 DPS 0.02-0.25 0.05-0.1 0.15
10 TSH 12 . Water System Outlet High Temp. Stop 1 TS 70-120 'C 70-85 'C 95 C
--
Sensor List
Sensor Measuring Normal Alarm Autostop
Code Name Q'ty REMARKS
Type Range Range Setpoint of Eng ine
Legend
- PS : Pressure Switch - LS : Limit Switch - : Pressure Transmitter - MS : Micro Switch (Position Switch)
- DPS : Differential Pressure Switch - () : Static Pressure - TS : Temperature Sw~ch - : Temperature El ement
- RB : Temperature Sensor ( -100 ) - SE : Speed Element - : Tem perature Sensor (Thermocouple) - ZS : Position Switch
Doc. . EA01 -~ / 9- 0
Page 6/14
3
2
1
20101115 ol.gi!1 ~EH ~ ~EH ~ Firs! issued.
~
Drawing
Doosan Engine .
34-031195
000. . 0 1 -5 1 79-0
a\,jo ' ~
SHIP . DY0139!3071
PROJECT SETA0139!3071
CLASS
( 07 ) SHEETS W!COVER
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& 2010.11.12 ISSUED FOR APPROVAL S.H.SUNG
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2. . ; 45C
3. CONS1RUCTlON OF ENCOSURE
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- MATERIAL ; SHEET SEE 3.21 & 2.31
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TER~INAL ; MUNSELL .7.5 BG 7/2
- PROTECTlON DEGREE OF ENCOSURE ;
[ SARTING ; I44
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- MATERIAL ; SARTING - PHENOUC
TERMINAL - SUS 304
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Doc. . 1 5179
Page . 13/ 14
TRM INALS TERMINAL
.....,.,1"
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!: 0042 43-0139 29
F
000. . : EAD1-5179-Q
DOOSAN-MAN DIESEL Page 1/50
Client : Yangzhou Dayang Shipbuilding Co.,Ltd.
Engine Type : 5L23/30
Tier 1 ll . : DY139/DY3071
Tier 2 ll . :-
Subject:
LOCAL STARTER
Note:
2
Mod ilied the sec. luse & l use holer due the change
2011 0317 O I ~HI ~eJ ~eJ
subs u li e r
1
~
Ooc.
Doosan Engfne 2-5179-1
.
DOOSAN - DIESEL aQe 1/50- '
REVISION HISTORY
DATE REV DESCRIPTlON
Modified Ihe spec. fuse & fuse holer due 10 Ihe change subsupplier (Page 12,14,50)
- Subsupplier: S8 FUSE ~ FERRAZ
20 110317 1 - Fuse : 3 ~ 4A , 5 ~ 6A, 15 ~ 16
- Fuse holder: FH -3 0 ~ CMS101
ENGINE
5L23/30 PART Electr ic
Doc.
DESCR IP- .
2-5179-1
10
LOCAL STARTER
CONTENTS
ENGINE
5L23 / 30 PART Electri c
Doc.
DESCRIP- .
2-5179-1
10
LOCAL STARTER
, '
ReV.1
- Changed spec, of fuse & fuse holer due change the subsupplier (Sht. 09,1 , 11,47)
Subsupplier : SB FUSE -> FERRAZ
Fuse : 3 -> 4, 5 ->6, 15 -> 16
3
2
201 10315 01%21 71..2 :2: ~
o= ~ fd~~ Refer l nole, 1
20101115 0 1 %~1 t! EH ~ fd EH ~ Firsl issued.
~
Drawing
Doosan Englne .
34-031194
SHIP . DY0139!3071
PROJECT SETA0139!3071
CLASS
( 47 ) SHEETS W!COVER
&
ffi
ffi 2011.02.21 ISSUED FOR WORING ..LE
. POR. .:
l~t.tIlEt:t.
S.G.HWANG
CHK.
MACH.& ELEC.CO.,LTD.
O.S.YOON
~K. REF. . :
;. "u. .
ffi
t:MUL- :J' ( >;1' r
Page 5/ 50
GENERAL SPECIFICATlON
2. . : 45'C
3. CSTRuc OF ENCLOSURE
- MOUNlNG D : WAll & DECK MOUNlNG
- IMTERIAL : SSWO, 2.31 & 3.21
- COOR : MUNSELL . 7.5 8G 7/2
- Rc DEGREE OF ENCOSURE : I23
5. PlTE
- LETTER : ENGUSH
- IMTERIAL : PHENOUC
6. ElECTRIC SOURCE
- AC220V. 1, 60 3FEEDERS
- C44, 3, 60 3FEEDERS
(FOR C44, 1 MINIMUM FEEDER MUST CONNECED FROM EMERGENCY POWER)
- DC24V 3FEEDERS
-
7. CA8LE (INERNA)
- POWER CRCU : 66OV, SYP-2.5mn!
- CONROl CRCU : 660, SYP-O.75mrl & 1.25mn!
FW.tE RETARDANT
. S.G.HWANG &.
H8tEC:8
CHK. O.S.YOON &. GENERAL SPEClFICATION
IJII IICH.!c ELEC.CO.,LTD.
CHK. .&.
OWG. ..
~ : mm REF. . DWG. . SHT. .
2010.1 1.12 &2010.02.2 1 SCAlE: N/S KD10S220 02
uoc. 1\10. . :f1v :.-J , .,--
Page 6/ 50
FUNCTlON DESCRIPTlON
2. START
2-1. .
Engine- Local- Remote Position Selection.
3. STOP
3-1. locol Stop Push-Button . (l Stop) -
3-2. Remote Stop Push - Button . (l Stop)
3-3. Start Fail. Condition.(Auto. Stop)
3-4. Common Condition.(Overspeed, . low press., C.F.W high temp.
trip(Auto. STOP), Remote Em'cy stop)
4. BOCKING
4- 1. Engine Stop(Blocking) local & Remote Not Starting Condition
5. SHUTDOWN
5- 1. Overspeed trip.(above rating speed 112%~ 115%)
5-2. . low press. trip.
5- 3. C.F.W Outlet high temp. trip.
5-4. Remote Em'cy stop.
Page 7/50
FUNCTlON DESCRIPTlON
7. ALARM BOCKING
The Locol Control Panel is provided with output for alarm blocking,
so that ALARM is avoided during starting and stopping of the engines.
8. START FAIL.
After Engine start button is , if engine is not running during time 15 s,
the start fail. signal is activated to stop the engine stop. And start fail. Lamp is .
. S.G.HWANG &.
eIEt:8
CHK. O.S.YOON &. FUNCTION DESCRIPTION
u: IlACH.& ELEC.CO.,LTD.
CHK. &
DWG. K.H.LEE : mm REF. . DWG. . SHT. .
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&. 201 0.02.2 1 SCALE:
2010.11.12 N!S KD1OS220 04
UUli . l'4U . . CMUL- \.J 11 \1 --
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GRAPHICAL SYMBOLS
SYMBOL SYMBOL
-'I/IIV- RESISTOR
~ CONTACT(NO)
CHANGE-OVER CONTACT
- BEFORE - BREAK
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CONTACT,
-- CAPACITOR
( TIMER)
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POLARIZED CAPACITOR
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Ter 2 ll . : -
Subject:
GENERATOR
Note:
~
Doc.
Doosan Engine .
3-5179-0
DOOSAN - DIESEL ,.
Page 1/ 19-
REVISION HISTORY
REV OESCRIPTlON
ENGINE
5L23/30 PART ec t c
Ooc.
OESCRIP- .
3-5179-0
GENERATOR
Doosan Eng ine CO. ,Ltd.
., . DOOSAN - DIESEL age 2 / 19
CONTENTS
ENGINE
5L23 / 30 PART Elec tri c
Doc.
DESCRIP- .
3-5179-0
GENERATOR
Generator
3
2
1
20101115 l%~1 idEH~ idEH ~ First issued.
~
Drawing
Doosan Engine .
34-031196
Doc. . 03-5179-0
Page : 4/19
SPEC/F/CAT/ON
for
SYNCHRONOUSGENERATOR
(762.5 K VA , 1, 450V, 60 , 3SETS)
FOR APPROVAL
,'<
CONTENTS
1 CAUON
5 L OF GENERATOR 3S-000003-ReV .2
7 L SS 3G-001777 -.1
CAUTlON
. Phase Sequence
Phase seq uen ce these generators are U-> V->W regardless rotating directi on
prime mover.
Please connect all cab les as shown in below ligure 1.
U U
V V
W W
. Manual Synchronizin g
Please be carelul at synchronizing each generator during on board test normal
operating as lollows .
1) Check th at in co ming generator voltage level and Irequency in its no-Ioad cond ilion
is co rrecl.
2) After rolal ing Ihe sy nchronizing swilch 10 Ihe "" posilion . please check Ihe
condi li on Ihe sync hro scope poinler . and ad ju st Ihe speed Ih e inco min g
Engine/Generalor unlil l is rolaling slowly 10 clockw ise direclion (no more Ih an
1 revolulion / 20 seconds) .
3) Th e in co ming generalor breaker shou ld be c losed as close 10 Ihe 12 o'c lock
pos ition as possible.
Warn ing
/1 generalor breaker is clo sed al co nditions other th an the above. Ihe
generalor exc ilalion syslem (Diodes . Varislors. Translormer ... ) & rolor
sl ato r can be damaged by transi enl reacli ve currenl.
Doc. . 3-5179-0
Page 7/ 19
SPECIFICATION OF GENERATOR
USE DI ESEL ENG GENERATOR QUAN'f I Y SIlIP 3 S S II P
OF ENCOSUIlli 23 CLASS
SPECIFICATION BEARING
IIFC7 5()1 - 14 OF BEARING SLEEVE BEAlI NG
YOUR DRAWING
2 HFC7 504-14K-Rev.O
3 DESIGN CHECED CHECED APPROVED
1
Oct .09 , 2010 S.R.QIOI S.R.Choi O. S.Song D.S.Kim
5
RW- W230- 158-0 A4( 210mm 297mm)
Doc. . 3-5179-0
Page 8/19
Meas uremen l
Each winding resislance ll be
6 Winding
measured by l ! - amp ere melhod.
Resislance
Doc. . 3-5179-0
Page 9/ 19
Doc. . 3-5179-0
,---- 2 3
5
7 8
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t!!Y~~
. of
. DY3071
DOCUMENT . MSPH - 5182 - SETA3071 s
SUBJECT :
L HISTORY
- - - - - - -
~ .~ .. - _.. . -
3
L MANAGEMENT
- Medium Speed -
2
/
1 LEADER I.M . E ~
{JJf:; "
ND. 3071
. eWNE;R -SE-TAF-GAGE~Tc . .
CLASS
CERT' 10049PSN11
SPEC. . .
TEST D 28 Ju ly 2011
OWNER REPRESENTATIVE(S)
YARD REPRESENTATIVE(S)
Peter .
Jorgensen
L1CENSE REPRESENTATIVE(S)
DIES EL & TURBO SE
.
:
5182 - LlST -
1 1
1
11 " \'J:2:
PJT Name : SETA3071 -1 , 2,3 ll . DwgfTr .
3071 LlST
PJT . : 1 - 5182 5183 5184 ~ ~~ ~ ~~I~~J~
- 1-
- - - - - -.. ---------------I----If---+---I---I---I
--
Result . Salisfaclory Prepared '- ' . --'" ul.11 Approved .~~;<~'; 4.JuI'11
>iI :ill . Unsali slaclory ~ ~ A~ '--;jItJ/
S.H . G f
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Kind of inspection
Bearing Clearance (Main & Guide Bearing)
f! A~ %{f-
Witnessed Witness ed Witnessed
~ :2:1 gJ ~I A~ ~ 2.1 f
Unit: mm
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Guide bearing cJearance
Position +
F ~ F F F F
**
F , F
ClcaraIce
D.2Q' 0.20
0.20 10.20 0.20 0.20 0.20 0.20 0.20 10.20 0.20 10.20
Guide bearing clearance
Position +
Clear3JC(l F F F F F F F F F
0.20 . 0.20 0.20 10.20 02010 .20 0.20 10.20 0.20 10.20 0.20 10.20 ..
Guide bearing clearance
Position +
Clearance (0.15 - 0.44 mm) Max.0.8mm 0.19
:3 71 -, Ai .. Page .
1 of 1
llilOlxl \':!~
PJT Name : SETA3071 -1.2.3 u . Dwg r .
DY3071 302
PJT . : 1- 5182 5183 5184 ~~~~ ~~/8gI~
Shipyard
:~.:7::
. Yangzhou Dayan g
. Shipbuilding Co., Ltd
Class
i! ~ JV Engine Type
r!I~~~ ,-
5 23f30
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~ ilr . D Unsatisfactory , ~ -
Xf .. 7l. rr{YANG -Date
-
Kind of in spection
Big End Bearing Clearance
?:j At%ii-
Witnessed Witnessed Witnessed
~ ~I xf ~ ~ Xf ~ ~ xf
: mm
<:::
=
r
-
DRIVING
FREE
Doosan EngIne Co. , Ltd
Record .
5182 - 7101 - 1
INSPECTlON RECORD(A)
_: 71S}Ai ~~
: 71 ..
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1 1
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PJT Name : SETA3071 -1,2,3 . wg r .
3071 7101
PJT . : DMMI- 5182 5183 5184 ~~~~ S: ~/g~~~
Shipyard . Ya ngzhou Dayang Class Engin e Type
~~~ . ShipbuiIding Co., Ltd ~ ~ /V ~~~~
5 23/3 0
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~~
Vert ical and horizontal Def Iection BotIom 51art
Crank throws (Cold engine) lefI side
- . lor 3/100mm
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-- - AccepIable 5/100rm S Aj1I side -
Vertical Deflectioo Crank throws V 8 "
1/100 mm /Q .; at yv,!1ee
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Rigid coupl ing (}-3/1(X)nm 16=0.5 )
- f r nmJoo.Lend
~Iexible coupl ing 1 11 . --- - Hor izontal : - - S
Page
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.
7 1~ Ai ':! :[
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5182 - 7204 - 1
1 1
7204
PJT . : 1 - 5182 5183 5184 t! t3{~ ~
Shipyard Yangzhou Daya ng Shipbuilding Class Engine Type
Co., Ltd
.5 23/30
<z!!~J~ \.
Result u a " " a c <v, , Prepa red Approved ,?/'/,?r<
~ .I!.~ D Unsalislaclory . S.rl> . ~P.G CHOE . Oate
Kind of in specti on
Timing Check (NormaI Condition)
i:1A~ *
W itnessed 8 Witnessed
.. 1':1 Xf ~ ~I ~
Unit : mm
FUEL INJECTlOO TltING( BTDC) ' IESLfIEMEN
- FIRING OROER -
5 : 1 - 2 - 4 - 5 - 3
6 : 1 - 4 - 2 - 6 - 3 - 5
7 : 1 -2-4-6-7-5-3
OL . , - < . - . - - .0
L OF SHOP TEST
ENGINE 5 23/30
CLASS
i:J ~ 71 ..
-, Ai Page .
1 4
JIll ol,,1 ~~
PJT Name : SETA3071 -1,2,3 U . wgrv .
3071 7204
PJT . : DMMI- 5182 5183 5184 {:j"!~ ~ .s:~/i'I~~~
Shipyard Yangzhou Dayang Shlpbu1ldlng
Co., Ltd
Class . : /V Engine Type
5 23/30
e~ .~ /
~t:!~ '1'!~~"! "-
Result 0 Satislactory Approved . ~AJ{ ? . ;;;::;<
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Kind of inspection V
: IShODT- '
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: Safety device confirmation test
: Over speed test
I- 6: Load test
C : Governor test
D : Generator characteristic test
=
t Load(%)
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-
11
100
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1
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90 - '. - --- .. - -- - -- - ,-
,
80 -- --1- - - - ~~ - ,
_. 1-
!
'~~ 41
70 -- - -
"!
60 _. -- -2 - 1- .. ~.: .. _. -- -- -
50 - ,!
,
,
40
30
-
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.-
- ---
-
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---
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-
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-
---
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_. ---'1- -- -- - -! -----
20 ... - 1 -- . - - "1
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,~- !
-
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-
10 . - ; -1- _.
-- 6
---
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j ! ! ' ,
5 35 40 70 75 10511 1701 75 205
This test shall be carried in the state of the engine being load for following items.
(lfS'FARTlNG"FES - . - -
Emergency sIart - -
Emergency sIop - -
Turning gear inIer lock test - Interlock
Lub. l engine in leI lw press. 2.5 0.1 2.50 2.49 2.52 bar
2) LOADTEST
This test shaII be carried ! the state the engine coupIed with aIternator under rated
speed. Load test is be carried ! based engine power and testing order and durati on l or
each Ioad are as 10IIows.
GENERATOR
D ENG INE RPM DURATlON
SHOP TEST PF=1.0
The measurements lor each load range are performed and recorded Doosan's test record sheets.
3) GOVERNOR TEST
Instant and permanent speed variation and voltage variation shall be measured respectively
by rapidly changing the load the engine as lollowing method .
When lullload is suddenly taken off --- 50% --- 100% load, the speed is to control within 10%
momentary variation and 5% permanent variation rated speed.
Speed variations with load changes accordance with aboves are to return and remain within 1%
lnal
steady state speed more th an 5 seconds.
Governor load 100% is based 61 kWe board conditions.
Loa d
100%
50% -
T1me
Speed
.
110%
--------- -1\/--------------------------------- ----
~ Ir
100%
Ir
90% ---------- ~ -------- --- -------------- - ----- -- ---
--< ,max. 5 seconds
tm.
~ Ar 71 ~ Page .
i " ~ ~
4 4
100% -75% - 50% - 25% - 0% - 25% - 50% -75% -100% - 110% - 100%
During the each load condition , frequency and o l ta g e a l ue shall be recorded without regulation.
For any load between 20% and 100% of the sum of the rated of all generators, the load on any
generator is not differ more than 15% of the rated output in kilowatt of the largest generator.
6) Others
- Crankshaft defl eciton
- Torsional i bra t ion One(1) engine / project