V28-32S PowerPlantDDD

Instruction book for :
V28/32S
MAN Diesel Identification No. for Instruction Book.
Identification No for Description: 000.00
Function
Section No
Identification No for Working Card: 000 - 00.00
Sub-function
Function
Section No
Identification No for Plates: 00000 - 00 H
H for Holeby
Edition
Section No and Function
For ordering of spare parts, see page 500.50.
This book must not, either wholly or partly, be copied, reproduced, made public or in any other way made
available to any third party without the written consent to this effect from STX Engine Co.,Ltd.
TECHNICAL SERVICE
Telephone : + 82 55 280 0551
Telefax : + 82 55 282 6907
STX Engine Co., Ltd. E-mail : cs@onestx.com
80, Seongsan-dong, Changwon, Kyungnam
Republic of Korea (641-315) PART SALES
Telephone : + 82 55 280 0597
Telefax : + 82 55 282 1388
E-mail : nchwang@onestx.com
SERVICE BIZ
Telephone : + 82 55 280 0558
Telefax : + 82 55 282 1388
E-mail : simun@onestx.com
Your Notes :
MAN Diesel
GenSet Index
V28/32S
Text Index Drawing No.
Engine data 500/600
Questionnaire Description A501

Main data for engine Description 500.00 (04H)
Introduction Description 500.01 (03)
Safety Description 500.02 (02)
Cross section Description 500.05 (14)
Key for engine designation Description 500.10 (02)
Designation of cylinders Description 500.11 (04H)
Engine rotation clockwise Description 500.12 (02)
Code identification for instruments Description 500.20 (03)
Introduction to plant maintenance program Description 500.24 (03)
Planned maintenance programme Description 500.25 (31H)
Operation data & set points Description 500.30 (56H)
Green Passport Description 500.33 (02)
Data for pressure and tolerance Description 500.35 (23H)
Data for tightening torque Description 500.40 (31H)
Declaration of weight Description 500.45 (04H)
Ordering of spare parts Description 500.50 (02)
How to return spare parts Description 500.51 (05)
Service letters Description 500.55 (01)
Conversion table Description 500.60 (01)
Basic symbols for piping Description 500.65 (01)
Operation of engine 501/601
Operation Description 501.01 (08)

Operation Description 501.01 (10H)
Operation Description 501.01 (14)
Out of service Description 501.05 (05)
Starting-up after repair Description 501.10 (03)
Guidelines for longterm low-load operation on HFO Description 501.15 (03)
Guidelines regarding MAN Diesel GenSets operating on low Description 501.16 (02)
sulphur fuel oil
Operating a diesel engine at low frequency Description 501.25 (01)
Performance and condition 502/602
Engine performance and condition Description 502.01 (01H)

Evaluation of readings regarding combustion condition Description 502.02 (03H)
Condensate amount Description 502.05 (04H)
Engine performance data Working card 502-01.00 (06H)
Trouble shooting 503/603
Starting failures Description 503.01 (02)

Faults in fuel oil system Description 503.02 (05)
Disturbances during running Description 503.03 (06)
Ignition in crankcase Description 503.04 (03)
Trouble shooting guide for centrifugal by-pass filter Description 503.05 (04H)
Trouble shooting guide for air starter Description 503.06 (05H)
Trouble shooting for cooling water system Description 503.09 (08H)
Trouble shooting for lubricating cooler Description 503.10 (01)
Trouble shooting / electrical failures Description 503.20 (03H)
Media specification 504/604

MAN Diesel
Index GenSet
V28/32S
Specification for lube oil (SAE40) for heavy fuel oil operation (HFO) Description 504.01 (22)
Specification for lube oil (SAE40) for operation with gas oil, diesel oil Description 504.01 (19)
(MGO/MDO) and biofuel
Criteria for cleaning/exchange of lubricating oil Description 504.04 (07)
Lubricating points (SAE 40) Description 504.05 (02H)
Lubricating oil in base frame Description 504.06 (18H)
Specific lubricating oil consumption - SLOC Description 504.07 (03)
Specification for heavy fuel oil (HFO) Description 504.20 (20)
Specification for marine diesel oil (MDO) Description 504.20 (17)
Specification for gas oil / diesel oil (MGO) Description 504.20 (18)
Specification for biofuel Description 504.20 (14)
Fuel oil cleaning Description 504.30 (01)
Specification for engine cooling water Description 504.41 (02)
Cooling water inspecting Description 504.42 (02)
Cooling water system, cleaning Description 504.43 (02)
Quality of raw-water in cooling tower operation (additive and Description 504.44 (01)
circulating water)
Quality of water used in exhaust gas boiler plants Description 504.45 (01)
Specification for water used in fuel-water emulsions Description 504.46 (01)
Specification for intake air (combustion air) Description 504.60 (02)
Cylinder head 505/605
Cylinder head Description 505.01 (04H)

Dismantling of cylinder head Working card 505-01.00 (06H)
Inspection of inlet valve, exhaust valve and valve guide Working card 505-01.05 (05H)
Reconditioning of valve spindle seat and valve seat ring Working card 505-01.10 (05H)
Valve rotator Working card 505-01.15 (04H)
Replacement of valve guide Working card 505-01.20 (07H)
Safety valve Working card 505-01.25 (02H)
Indicator valve Working card 505-01.26 (03H)
Replacement of sleeve for fuel injector Working card 505-01.30 (02H)
Replacement of valve seat ring Working card 505-01.35 (06H)
Mounting of cylinder head Working card 505-01.40 (02H)
Cylinder head Plate 50501-06H
Valve spindles and valve gear Plate 50502-12H
Safety and indicator valve Plate 50508-02H
Cylinder head, top cover Plate 50510-04H
Piston/connecting rod 506/606
Piston, connecting rod and cylinder liner Description 506.01 (04H)

Dismounting of piston and connecting rod Working card 506-01.00 (02H)
Separation of piston and connecting rod Working card 506-01.05 (04H)
Piston (with flame ring) Working card 506-01.10 (11H)
Connecting rod Working card 506-01.15 (05H)
Criteria for replacement of connecting rod big-end and main bearing Working card 506-01.16 (03H)
shells
Mounting of piston and connecting rod Working card 506-01.20 (02H)
Hydraulic tightening of connecting rod screws Working card 506-01.25 (07H)
In-situ inspection of connecting rod big-end bearing Working card 506-01.30 (04H)
Inspection and honing of cylinder liner Working card 506-01.35 (07H)
Replacement of cylinder liner Working card 506-01.40 (02H)
Grinding of seal face on cylinder liner and cylinder head Working card 506-01.45 (04H)
Piston and connecting rod (hydraulic tightened) Plate 50601-09H
Cylinder liner and water guide jacket Plate 50610-06H
Camshaft 507/607
MAN Diesel
GenSet Index
V28/32S
Camshaft and camshaft drive Description 507.01 (04H)

Check of camshaft and camshaft drive Working card 507-01.00 (04H)
Inspection and replacement of camshaft bearing Working card 507-01.05 (06H)
Basic adjustment of camshaft Working card 507-01.20 (08H)
Intermediate wheel Plate 50701-04H
Camshaft and camshaft bearing (A-bank) Plate 50705-08H
Camshaft and camshaft bearing (B-bank) Plate 50705-09H
Operating gear 508/608
Operating gear for inlet valves, exhaust valves and fuel injection Description 508.01 (04H)
pumps
Inspection of valve roller guides Working card 508-01.00 (05H)
Inspection of fuel injection pump roller guide Working card 508-01.05 (02H)
Control and adjusting of valve clearance Working card 508-01.10 (08H)
Roller guide and push rods Plate 50801-08H
Control/safety 509/609
Safety, control and monitoring system Description 509.01 (17)

Lambda controller Description 509.10 (07H)
Communication from the GenSet Description 509.55 (12H)
Functional test and adjustment of safety, alarm and monitoring Working card 509-01.00 (04H)
equipment
Function test of shutdown Working card 509-01.05 (10)
Adjustment and test of analogous pressure transmitter Working card 509-05.03 (03)
Adjustment and test of analog temperature transmitter Working card 509-05.04 (03)
Adjustment and test of tacho and proximity sensors Working card 509-05.06 (01)
Adjustment of lambda controller, governor type, Woodward Working card 509-10.00 (12H)
Adjustment of lambda controller, governor type, Europa Working card 509-10.00 (15H)
Governor and governor drive Plate 50901-09H
Governor and governor drive Plate 50901-10H
Regulating mechanism Plate 50902-08H
Instruments Plate 50907-13H
Lambda controller Plate 50910-05H
Level switch in oil sump (LAL/LAH 28) Plate 50920-06H
Level switch in oil sump (LAL/LAH 28) Plate 50920-07H
Fuel oil leakage alarm (LAH 42) Plate 50925-07
Monitoring box Plate 50935-21H
Terminal box Plate 50936-17H
Terminal box Plate 50936-21H
Digital load sharing & speed control Plate 50945-03
Alarm panel Plate 50946-01
Output module Plate 50947-03
Output module Plate 50947-04H
APM motor control Plate 50948-01
Valve control box Plate 50949-01
Control box Plate 50949-02H
Control box Plate 50949-03H
Converter Plate 50956-01
Crankshaft 510/610
Crankshaft and main bearings Description 510.01 (04H)

MAN Diesel
Index GenSet
V28/32S
Checking of main bearings alignment (autolog) Working card 510-01.00 (16H)

Inspection of main bearing shells Working card 510-01.05 (05H)
Inspection of guide bearing shells Working card 510-01.10 (02H)
Vibration damper Working card 510-04.00 (05H)
Crankshaft Plate 51001-07H
Resilient gear wheel Plate 51002-03H
Flywheel with gear rim Plate 51003-07H
Torsional vibration damper Plate 51004-06H
Engine frame/Oil pan 511/611
Engine frame and base frame Description 511.01 (05H)

Functional test of crankcase safety relief valves Working card 511-01.00 (09H)
Frame with main bearings Plate 51101-11H
Cover with pumps Plate 51102-09H
Covers on frame Plate 51106-18H
Cover on frame Plate 51106-26H
Base frame Plate 51111-04H
Turbocharger 512/612
Turbocharger system Description 512.01 (08H)

Cleaning the turbocharger in service, water washing of compressor Description 512.05 (01)
Cleaning the turbocharger in service, dry cleaning - turbine side Description 512.10 (02H)
Cleaning the turbocharger in service, water washing - turbine side Description 512.15 (01)
Overhaul of charging air cooler Working card 512-01.00 (07H)
Exhaust pipe compensator Working card 512-01.10 (02)
Water washing of compressor side Working card 512-05.00 (01)
Cleaning the turbine, dry cleaning Working card 512-10.00 (05)
Charging air cooler Plate 51201-18
Cooler box Plate 51201-14H
Exhaust pipe arrangement Plate 51202-06H
Turbocharger arrangement Plate 51203-13H
Turbocharger arrangement Plate 51203-23H
Water washing of compressor side Plate 51205-01
Steam trap Plate 51208-01H
Blowgun for dry cleaning of turbocharger Plate 51210-01
Compressed air system 513/613
Compressed air system Description 513.01 (13H)

Air filter Working card 513-01.21 (02)
Overhaul, test and inspection of air starter Working card 513-01.30 (04H)
Check of compressed air piping system Working card 513-01.90 (03)
Electric turning gear Working card 513-25.00 (01H)
Air starter Plate 51309-09H
Main starting valve Plate 51310-04
Main stop valve Plate 51315-04H
Solenoid valve, 3/2 Plate 51318-01H
Safety valve Plate 51319-03H
ON-OFF valve for jet system Plate 51320-03
Air filter Plate 51321-03
Pressure reduction valve Plate 51322-04H
MAN Diesel
GenSet Index
V28/32S
Pressure reduction valve Plate 51322-07H

Electric turning gear Plate 51325-05H
Cover for turning gear Plate 51325-12
Manual turning gear Plate 51325-20
Pneumatic turning gear Plate 51325-21
Electric turning gear (3 x 400V) Plate 51325-22
Fuel oil system 514/614
Internal fuel oil system Description 514.01 (11)

HFO/MDO changing valves (V1 and V2) Description 514.25 (02)
Ball valve with actuator - external Description 514.25-01
Dismounting/mounting of fuel injection pump Working card 514-01.05 (10H)
Fuel injection valve Working card 514-01.10 (11H)
Check of fuel oil piping system Working card 514-01.90 (01H)
Adjustment of the maximum combustion pressure Working card 514-05.01 (02H)
Fuel injection pump Plate 51401-08H
Fuel injection valve Plate 51402-09H
Fuel injection pipe Plate 51404-09H
Safety filter Plate 51415-05
Fuel oil filter duplex Plate 51415-06
Ball valve with actuator Plate 51425-01
Butterfly valve with actuator - External Plate 51425-02H
Butterfly Valve with actuator Plate 51425-03H
Butterfly valve with actuator Plate 51425-06H
Fuel oil arrangement Plate 51430-11H
Fuel oil arrangement Plate 51430-12H
Main pipes on cylinder section Plate 51431-01H
Fuel oil inlet cylinder section Plate 51432-01H
Fuel oil inlet cylinder section Plate 51432-02H
Branch pipe on cylinder section Plate 51433-01H
Branch pipe on cylinder section Plate 51433-02H
Nozzle cooling pump Plate 51440-04H
Filter Plate 51445-01H
Installation & operation of safety filter Description 2.04.5
Lubricating oil system 515/615
Internal lubricating oil system Description 515.01 (08H)

Lubricating oil thermostatic valve - external Description 515.03 (01H)
Lubricating oil cooler - external Description 515.06 (02H)
Centrifugal by-pass filter Description 515.15 (01H)
Prelubricating pump Working card 515-01.05 (08)
Lubricating oil filter Working card 515-01.10 (05H)
Lubricating oil, thermostatic valve - external Working card 515-01.20 (06H)
Check of lubricating oil piping system Working card 515-01.90 (04H)
Centrifugal by-pass filter Working card 515-15.00 (05H)
Lubricating oil pump Plate 51501-09H
Lubricating oil filter (suppl. for plate 51502-06H/07H) Plate 51502-02H
MAN Diesel
Index GenSet
V28/32S
Lubricating oil filter (Type B) Plate 51502-06H

Lubricating oil thermostatic valve -external Plate 51503-02H
Prelubricating pump with el-motor Plate 51504-05
Prelubricating oil pump with el-motor Plate 51504-08H
Pressure regulating valve Plate 51507-01H
Centrifugal by-pass filter Plate 51515-05H
Hand wing pump Plate 51525-02H
Prelubricating pump arrangement Plate 51535-04H
Cooling water system 516/616
Cooling water system Description 516.01 (01H)

Cooling water thermostatic valve Description 516.04 (01H)
Check of cooling water system Working card 516-01.90 (01H)
Cooling water, thermostatic valve Working card 516-04.00 (05H)
HT fresh water thermostatic valve Plate 51604-02H
LT fresh water thermostatic valve Plate 51604-03H
Fresh water pump Plate 51610-06H
Fresh water pump Plate 51610-08H
Pipes on cylinder head Plate 51625-02H
Preheater - fresh water Plate 51635-04H
Special equipment 517/617
Kit for cylinder unit Kit 51704-05

Kit for renewal of piston rings Kit 51706-09
Kit for fuel injection pump Kit 51730-08
Specific plant information 519/619
Resilient mounting of generating sets Description 519.03 (09)

Fitting instructions for resilient mounting of landbased GenSets Working card 519-03.00 (23)
Flexible external connections Plate 51902-11H
Sandwich mounting Plate 51904-01
Tools 520/620
Introduction to spare part plates for tools Description 520.01 (01H)

Function of the hydraulic tools Working card 520-01.05 (02)
Application of hydraulic tools Working card 520-01.06 (07H)
Hand lever pump Working card 520-01.07 (01)
Max. pressure indicator Working card 520-01.25 (01H)
Tools for cylinder head Plate 52005-05H
Tools for piston, connecting rod and cylinder liner Plate 52006-09H
Tools for operating gear for inlet valves, exhaust valves and fuel Plate 52008-06H
injection pumps
Tools for crankshaft and main bearings Plate 52010-07H
Tools for fuel oil system and injection equipment Plate 52014-05H
Hydraulic tools Plate 52021-08H
Operating manual for testing tool (Fuel injection valve) Description GXO-D001
Engine data
500/600
Your Notes :
Description
Main Data for Engine 500.00
Page 1 (1) Edition 04H
V28/32S
Cycle : 4-stroke
Conf guration : V-built
Cyl. Nos. available : 12-16-18
Power range : 2700 - 4230 kW
Speed : 720/750 rpm
Bore : 280 mm
Stroke : 320 mm
Stroke/bore ratio : 1.14:1
Piston area per cyl. : 616 cm2
Swept volume per cyl. : 19.7 ltr.
Compression ratio : 13.9:1
Max. combustion pressure : 145 bar
Turbocharging principle : Constant pressure system and intercooling
Fuel quality acceptance : HFO up to 700 cSt/50° C (BSMA 100-M9)
Power lay-out MCR version
Speed rpm 720 750
Mean piston speed m/sec. 7.7 8.0
Mean effective pressure bar 19.0 19.1

08028-0D/H5250/94.08.12
Max. combustion pressure bar 145 145
Power per cylinder kW/cyl. 225 235
01.34 - ES1
Your Notes :
500.01
Description
Page 1 (1) Introduction Edition 03
General
Introduction Description
This instruction book provides general information The book is a basic instruction manual for the particu-
on the engine design, operation and maintenance. lar engine supplied, with plant-adapted information
It can also be used as a reference when ordering such as basic media-system drawings, electrical
spare parts. Reliable and economical operation of wiring diagrams and test bed reports.
the plant is conditional upon its correct operation
and maintenance in accordance with MAN Diesel & The first five sections (500-504) of the book serve
Turbo’s instructions. Emissions-related maintenance as a guide to engine operation, and the next fifteen
of the diesel engine shall be performed as speci- sections (505-519) contain technical descriptions,
fied in MAN Diesel & Turbo’s instructions and any spare parts illustrations with appurtenant parts lists,
additional instructions to that effect included in the as well as working cards.
Technical File. Consequently, it is essential that the
engine room personnel are fully acquainted with the The last section (520) comprises tools.
contents of this book and the Technical File.
The engine is divided into a number of main com-
Every care is taken to ensure that all information in ponents/assemblies, each of which is described in
this instruction book is present and correct. a section of this book (section 505-519).
This book must not, either wholly or partly, be copied, Each of these sections starts with technical de
reproduced, made public or in any other way made scriptions of the systems/components, followed by
available to any third party without the written consent working cards and the spare parts illustration plates
to this effect from MAN Diesel & Turbo. and parts lists.
If an instruction book is delivered in another language

than English and doubts arise concerning the trans-
lation, the English text shall prevail.
Section 505-519
Spare parts plates
Working card
Description
08028-0D/H5250/94.08.12
Fig. 1 Structure of instruction book.
10.47 - ES0
Your Notes :
Description
Safety 500.02
Page 1 (2)
Edition 02
General
General Spares
Proper maintenance, which is the aim of this book, Large spare parts should, as far as possible, be placed
is a crucial aspect of achieving optimum safety in well strapped near the area of use and should be
the engine room. The general measures mentioned accessible by crane. The spare parts should be well-
here should, therefore, be a natural routine for the preserved against corrosion and protected against
entire engine room staff. mechanical damage. Stock should be checked at
intervals and replenished in time.
Cleanliness
Light
The engine room should be kept clean above and
below the floor plates. If grit or sand blows into the Ample working light should be permanently installed
engine room while the ship is in port, the ventilation at appropriate places in the engine room, and port-
should be stopped and ventilating ducts, skylights, able working light in explosion-proof fittings should
and doors in the engine room should be closed. be available everywhere.
In particular, welding or work which causes the

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

or gases. Dismantling of parts may cause springs
If the crankcase is opened before the engine is cold, to be released.
welding and the use of naked light will involve the risk
of explosions and fire.The same applies to inspection The removal of fuel valves (or other valves in the
of oil tanks and the space below the cooler. Attention cylinder head) may cause oil to run down to the
should furthermore be paid to the danger of fire when piston crown, and if the piston is hot an explosion
using paint and solvents with a low flash point. Porous may then blow out the valve.
insulating material drenched with oil from leakages
is easily inflammable and should be renewed. See When testing fuel valves with the hand pump do not
also: "Ignition in Crankcase" in section 503. touch the spray holes, as the jet may pierce the skin.
Consider beforehand which way the liquids, gases
or flames will move, and keep clear.
08028-0D/H5250/94.08.12
Order
Hand tools should be placed to be easily accessible Crankcase Work

on tool boards. Special tools should be fastened to
tool panels (if supplied) in the engine room close Check beforehand that the starting air supply to the
to the area of use. No major objects may be left engine is shut off.
unfastened, and the floor and passages should be
kept clear.
01.32 - ES0
500.02 Safety Description
Page 2 (2)
Edition 02
General
Feeling Over Turning
Whenever repairs or alterations have been made After prolonged out-of-service periods or overhaul
to the running gear, apply the "feel-over sequence" work which may involve a risk of accumulation of liquid
until it is ensured that there is no undue heating, oil- in the combustion spaces, turning should always be
mist formation, blow-by, or failure of cooling water or effected through at least two complete revolutions.
lubricating oil systems.
Check and Maintain

Feel-over Sequence
Lubricating oil condition, filter 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 full load. See gramme".
also "Operation" in the section 501.
08028-0D/H5250/94.08.12
01.32 - ES0
Description
Cross Section 500.05
Page 1 (1) Edition 14
V28/32S
11.11 - ES1
Your Notes :
Description 500.10
Page 1 (1) Key for Engine Designation Edition 02
General
Engine Type Identification
The engine types of the MAN B&W programme are identified by the following figures:
6 L 28/32 H MCR
No of cylinders
5, 6, 7, 8, 9
12, 16, 18
Engine Type
L : In-line
V : V-built
Cyl. diam/stroke
16/24 : 160/240
21/31 : 210/310
23/30 : 225/300
27/38 : 270/380
28/32 : 280/320
32/40 : 320/400
Design Variant
08028-0D/H5250/94.08.12
Rating
MCR : Maximum continuous rating

ECR : Economy continuous rating
04.08 - ES1
Your Notes :
Description 500.11
Page 1 (1) Designation of Cylinders Edition 04H
V28/32S
Front End Flywheel end
Right Side
Left Side / Control Side
B-bank A-bank
Anti-clockwise Clockwise
Rotation Rotation
Seen from Flywheel End
89.19 - ES1
Your Notes :
Description
Page 1 (1) Engine Rotation Clockwise 500.12
Edition 02
General
Direction of rotation seen from flywheel end “Clockwise”
Engine
Alternator
10.39 - ES1
Your Notes :
Description
Code Identification for Instruments 500.20
General
Explanation of Symbols
TI Measuring device
40 Local reading
Temperature Indicator
No. 40 *
Measuring device
PI Sensor mounted on engine/unit
22 Reading/identification mounted in a panel on the engine/unit
Pressure Indicator
No. 22 *
Measuring device
TAH Sensor mounted on engine/unit
12 Reading/identification outside the engine/unit
Temperature Alarm High

No. 12 *
Measureing device
PT Sensor mounted on engine/unit
22 Reading/identification in a panel on the engine/unit and reading/indication outside
the engine/unit
Pressure Transmitting
No. 22 *
* Refer to standard location and text for instruments on the following pages.
Specification of letter code for measuring devices

1st letter Following letters
F Flow A Alarm
L Level D Differential
P Pressure E Element
08028-0D/H5250/94.08.12
S Speed, System H High

T Temperature I Indicating
U Voltage L Low
V Viscosity S Switching, Stop
X Sound T Transmitting
Z Position X Failure
V Valve, Atuator
04.36 - ES1
500.20 Code Identification for Instruments
Description
Edition 03 Page 2 (2)
General
Standard Text for Instruments
Diesel Engine/Alternator
LT Water System
01 inlet to air cooler 04 inlet to alternator 07 inlet to lub. oil cooler
02 outlet from air cooler 05 outlet from alternator 08 inlet to fresh water cooler (SW)
03 outlet from lub. oil cooler 06 outlet from fresh water cooler (SW) 09
HT Water System
10 inlet to engine 14 inlet to HT air cooler 17 outlet from fresh water cooler
10A FW inlet to engine 14A FW inlet to air cooler 18 inlet to fresh water cooler
11 outlet from each cylinder 14B FW outlet from air cooler 19 preheater
12 outlet from engine 15 outlet from HT system 19A inlet to prechamber
13 inlet to HT pump 16 outlet from turbocharger 19B outlet from prechamber
Lubricating Oil System

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

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

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

50 inlet to fuel valves 54 58 oil splash
51 outlet from fuel valves 55 valve timing 59 alternator load
52 56 injection timing
53 57
Exhaust Gas System

60 outlet from cylinder 64 68
61 outlet from turbocharger 65 69
62 inlet to turbocharger 66
63 compustion chamber 67
Compressed Air System

70 inlet to engine 74 inlet to reduction valve 78 inlet to sealing oil system
71 inlet to stop cylinder 75 microswitch for turning gear 79
08028-0D/H5250/94.08.12
72 inlet to balance arm unit 76 inlet to turning gear

73 control air 77 waste gate pressure
Load Speed
80 overspeed air 84 engine stop 88 index - fuel injection pump
81 overspeed 85 microswitch for overload 89 turbocharger speed
82 emergency stop 86 shutdown 90 engine speed
83 engine start 87 ready to start
Miscellaneous
91 natural gas - inlet to engine 94 cylinder lubricating 97 remote
92 oil mist detector 95 voltage 98 alternator winding
93 knocking sensor 96 switch for operating location 99 common alarm
04.36 - ES1
Description
Introduction to Planned Maintenance Programme 500.24
Page 1 (2)
Edition 03
General
General The front page indicates the following:
The overhaul intervals are based on operation on 1) Safety regulations, which MUST be carried out
a specified fuel oil quality at normal service output, before the maintenance work can start.
which means 70-100% of MCR.
2) A brief description of the work.
In the long run it is not possible to achieve safe and
optimum economical running without an effective 3) Reference to any work which must be carried
maintenance system. out before the maintenance work can start.
The structure and amount of information in the main- 4) Related procedures - indicates other works,
tenance programme mean that it can be integrated in depending on the present work - or works
the entire ship's/power station's maintenance system which it would be expedient to carry out.
or it can be used separately.
5) Indicates x number of men in x number of hours
The core of the maintenance system is the key dia- to accomplish the work.
gram, see pages 500.25 and 500.26, indicating the
inspection intervals for the components/systems, The stated consumption of hours is only intended
so that the crew can make the necessary overhauls as a guide.
based on the engines' condition and/or the time
criteria.
The maintenance system is divided into 2 main

groups:
a. Major overhaul / inspection (page 500.25):

These works are to be carried out during major
overhauls and inspections of the engine.
1
7
b. Duty during operation (page 500.26): indicated
the works to be carried out by the personnel
2
during the daily operation of the engine.
The stated recommended intervals are only for 3

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

6
be used to adjust the time between overhauls. It
should also be used to adjust the timetable stated
for guidance in the working cards.
Working Cards Fig. 1 Instruction guide for working cards.
Each of the working cards can be divided into two: a

front page and one or several pages describing and
illustrating the maintenance work.
98.19 - ES0
500.24 Description
Edition 03
Introduction to Planned Maintenance Programme Page 2 (2)
General
Experience with the specific station/personnel may 8) Various requisite hand tools.
lead to updating.
9) Indicates the components/parts which it is
6) Refers to data required to carry out the work. advisible to replace during the maintenance
work. Please note that this is a condition for
7) Special tools which must be used. Please note the intervals stated.
that not all tools are standard equipment.
08028-0D/H5250/94.08.12
98.19 - ES0
Description
Planned Maintenance Programme 500.25
V28/32S
Before maintenance, please see Working Card
Description Time Between Overhaul
Overhauled parts
n = Off-line check of condition (engine shutdown) Working
Observations
3th month
Card
Check new/
50
2000
after -hours
200
Weekly
8000
** 16000
*** 32000
Montly
o = On-line check of condition (engine running)
Daily
l = Off-line service / overhaul (engine shutdown) No.
m = On-line service / overhaul (engine running)
*
Operating of Engine:
Readings of data for Engine and Generator, with refe-

rence to "Engine Performance Data", section 502-1........ ❏ 502-01.00
Cylinder Head:
Inlet and exhaust valve - Overhaul and regrinding of

spindel and valve seat...................................................... ● 505-01.10
Inspection of inlet, exhaust valves and valve guide.......... ■ 505-01.05
Check of valve rotators rotation during engine rotation.... ❏ 505-01.05
Sleeve for fuel injector...................................................... ■ 505-01.30
Safety valve - Overhaul and adjustment of opening
pressure........................................................................... ● 505-01.25
Indicator valve.................................................................. ■ 505-01.26
Cylinder head cooling water space - Inspection............... ❏
Cylinder head nut - Retightening...................................... 200 ■ 505-01.40
Piston, Connecting Rod and Cylinder Liner:
Inspection of piston.......................................................... ■ 506-01.10

Piston ring, scraper ring and flame ring............................ ● 506-01.10
Piston pin and bush for connecting rod - Check of
clearance.......................................................................... ■ 506-01.15
Connecting rod - Measuring of big-end bore.................... ■ 506-01.15
Inspection of big-end bearings shells............................... ■ 506-01.16
Connecting rod - Retightening.......................................... 200 ■ 506-01.25
Cylinder liner - Cleaning, honing and measuring............. ● 506-01.35
Cylinder liner removed - Check the water space and
guide ring in frame............................................................ ■ 506-01.40
Camshaft and Camshaft Drive:
Camshaft - Inspection of gear wheels, bolt, connections

etc..................................................................................... 200 ■ 507-01.00
Camshaft bearing - Inspection of clearance..................... ■ 507-01.05
Camshaft adjustment - Check the condition..................... ■ 507-01.20
Lubrication of camshaft bearing - Check.......................... ■ 507-01.00
Overhaul to be repeated:
* Repeat 2.000 hours maintenance, with activities mentioned under 8.000 hours maintenance.
** Repeat 8.000 hours maintenance, with activities mentioned under 16.000 hours maintenance.
*** Repeat 16.000 hours maintenance, with activities mentioned under 32.000 hours maintenance.
09.48
500.25 Planned Maintenance Programme
Description
Edition 31H Page 2 (5)
V28/32S
Overhauled parts
Observations
3th month
Card
Check new/
50
2000
after -hours
200
Weekly
8000
** 16000
*** 32000
Montly
Daily
*
Operating Gear for Inlet Valves, Exhaust Valves and
Fuel Injection Pumps:
Roller guide for valve gear................................................ ■ 508-01.00

Valve gear - Valve bridge, spring, push rod, etc............... ■ 508-01.10
Roller guide for fuel injection pump.................................. ■ 508-01.05
Inlet and exhaust valve - Check and adjustment of valve

clearance.......................................................................... ■ 508-01.10
Lubricating of operating gear - Check.............................. ❏ 508-01.00

508-01.05
Control and Safety System, Automatics and

Instruments:
Safety, alarm and monitoring equipment ......................... ■ 509-01.00
Jet system - Adjustment................................................... ■ 509-01.00

Pick-up - Adjustment........................................................ ■ 509-10.00

Governor - Check oil level, see governor instruction
book, section 509............................................................. ❏
Crankshaft and Main Bearing:

Checking of main bearings alignment, (autolog).............. ■ 510-01.00
Inspection af main bearing............................................... ■ 510-01.05
Inspection of guide bearing.............................................. ■ 510-01.10
Vibration damper - Check the condition........................... ■ 510-04.00
Lubricating of gear wheel for lub. oil pump and cooling

water pump etc................................................................. ■
Counter weight - Retightening, see page 500.40............. 200 ■
Main- and guide bearing cap - Retightening.................... 200 ■ 510-01.05

510-01.10
09.48
Description
V28/32S
Overhauled parts
Observations
3th month
Card
Check new/
50
2000
after -hours
200
Weekly
8000
** 16000
*** 32000
Montly
Daily
*
Engine Frame and Bedplate:
Holding down bolts - Retightening, see page 500.40....... 200 ■

Bolts between engine frame and base frame -
Retightening, see page 500.40........................................ 200 ■
For flexible mounted engines - Check anti-vibration
mountings......................................................................... 200 ❏ 519-03.00
Safety cover - Function test.............................................. ■ 511-01.00
Turbocharger System:
Dry cleaning of turbine side.............................................. ❍ 512-10.00

Water washing of compressor side.................................. ❍ 512-05.00
Cleaning of air filter - Compressor side (see turbo-

charger instruction book)..................................................
Turbocharger complete - Dismantling, cleaning, inspec-
tion etc. (see turbocharger instruction book)....................
Charging air cooler - Cleaning and inspection................. ■ 512-01.00
Charging air cooler housing - Draining............................. ❍

Exhaust pipe - Compensator............................................ ■
Compressed Air System:
Air starter motor - Dismantling and inspection................. ■ 513-01.30

Function test - Main starting valve, starting valve, main
valves and emergency start valve.................................... ■

Dirt separator - Dismantling and cleaning........................ ●
Muffler - Dismantling and cleaning................................... ●
Compressed air system - Draining................................... ❍ 513-01.90

Compressed air system - Check of the system................ ❏ 513-01.90
Drain of bowl..................................................................... ●
(filter element to be replaced when pressure drop
exceeds 0.7 bar)...............................................................
09.48
500.25 Planned Maintenance Programme
Description
V28/32S
Overhauled parts
Observations
3th month
Card
Check new/
50
2000
after -hours
200
Weekly
8000
** 16000
*** 32000
Montly
Daily
*
Fuel Oil System and Injection Equipment:
Fuel oil filter - Dismantling and cleaning........................... ● 514-01.15

Fuel oil feed pump............................................................ ● 514-10.00
Fuel oil injection pump - Dismantling and cleaning.......... ● 514-01.05
Fuel injection valve - Adjustment of opening pressure..... ■ 514-01.10

Fuel oil high-pressure pipe - Dismantling and check........ ■ 514-01.05
Adjustment of the maximum combustion pressure........... ● 514-05.01
Fuel oil system - Check the system.................................. ■ 514-01.90

Nozzle cooling system - Check the system...................... ■ 514-01.90
Fuel oil - Oil samples after every bunkering, see sec.504.
Lubricating Oil System:
Lubricating oil pump - Engine driven................................ ■

Lubricating oil filter - Cleaning and exhange.................... ❍ 515-01.10
Lubricating oil cooler........................................................ ●
Prelubricating pump - El. driven....................................... ❏ 515-01.05

Thermostatic valve........................................................... ■ 515-01.20
Centrifugal filter - Cleaning and exhange of paper........... ❍ 515-15.00
Lubricating oil - Oil samples, see section 504.................. ❏

Lubricating oil system - Check the system....................... ❏ 515-01.90
Cooling Water System:
Cooling water pump - Engine driven (raw water and

fresh water)...................................................................... ■
Thermostatic valve........................................................... ■
Cooling water system - Check the system....................... ❏ 516-01.90
Cooling water system - Water samples, see sec. 504...... ❏ ❏
09.48
Description
V28/32S
Auxiliary equipment
The precondition of the reliability and operating economy of the GenSet will to a great extent
depend on correct operation and proper maintenance of all equipment in the Power Plant.
All auxiliary equipment in the Power Plant must be operated as described in the
operation- and maintenance instructions from the manufacturer of the components.
It is also essential that the engine room personnel is fully acquainted with the functions and
mode of operation of the auxiliary equipment.
09.48
Your Notes :
Description
Operation Data & Set Points 500.30
V28/32S
Acceptable Alarm Set point

Normal Value at Full value at shop
load Autostop of engine
test or after Delay
repair sec.
Temp. before cooler

(outlet engine) SAE 40 TI 20 65-82° C <73° C TAH 20 100° C 3
Temp. after cooler
(inlet engine) SAE 40 TI 22 50-72° C >4.5 bar TAH 22 80° C 3 TSH 22 83° C
(TSH 22) (88° C) (E)
Pressure after filter (inlet eng) PI 22 4-5 bar <0.5 bar PAL 22 3.5 bar 3 PSL 22 2.5 bar
(PSL 22) (2.2 bar) (E)
Pressure drop across filter PDAH 0.5-1 bar <1.0 bar PDAH 1.5 bar 3
21-22 21-22
Prelubricating pressure PI 25 0.12-0.3 bar PAL 25 0.10 bar (J) 60
Pressure inlet turbocharger PI 23 1.3 - 2.2 bar >1.3 bar PAL 23 0.9 bar 3
(D)
Lub. oil, level in base frame LAL 28 Low level 30
LAH 28 High level 30
Temp. main bearings SAE 40 TE 29 80-95° C TAH 29 100° C 3 TSH 29 105° C

Fuel Oil System
Pressure after filter MDO PI 40 2.5-5 bar PAL 40 1.5 bar 5

HFO PI 40 5-16 bar (A) PAL 40 4-6 bar (F) 5
Leaking oil LAH 42 leakage 5
Press. nozz. cool. oil, inlet eng. PI 50 2-3 bar PAL 50 1.5 bar
Temp. nozz. cool. oil, outlet eng. TI 51 70-80° C
75-95° C (M)
Cooling Water System
Press. LT-system, inlet engine PI 01 1-2.5 bar (C) >1.8 bar PAL 01 0.4 + (B) bar 3
Press. HT-system, inlet engine PI 10 1.5-4.6 bar >1.8-<6 bar PAL 10 0.4 + (B) bar 3
Temp. HT-system, inlet engine TI 10 60-75° C
68-78° C (M)
Temp. HT-system, outlet engine TI 12 75-85° C <85° C TAH 12 90° C 3 TSH 12 95° C
78-88° C (M) TAH 12-2 93° C 3 (TSH 12) (100° C) (E)
Temp. raise across cyl. units max. 10° C
Exhaust Gas and Charge Air
08028-0D/H5250/94.08.12
Exh. gas temp. before TC TI 62 425-475° C TAH 62 570° C 10

TAH 62-2 620° C 3
Exh. gas temp. outlet cyl. TI 60 300-400° C TAH 60 470° C 3
Diff. between individual cyl. average TAD 60 average (O) 60
±25° C ± 50° C
Exh. gastemp. after TC TI 61 275-350° C TAH 61 450° C 3
Ch. air press. after cooler PI 31 2.4-2.7 bar
Ch. air temp. after cooler TI 31 35-55° C <55° C
Compressed Air System
Press. inlet engine PI 70 8.5-10 bar >8.5-<10 bar PAL 70 8.5 bar 15
08.23 - ES1
500.30 Operation Data & Set Points Description
V28/32S
Acceptable Alarm Set point

Normal Value at Full value at shop
load Autostop of engine
test or after Delay
repair sec.
Speed Control System
Engine speed elec. SI 90 720 rpm SAH 81 815 rpm 0 SSH 81 815 rpm
(SSH 81) (828 rpm) (E)
Engine speed elec. SI 90 750 rpm SAH 81 849 rpm 0 SSH 81 850 rpm
(SSH 81) (862 rpm) (E)
Turbocharger speed SI 89 (L) SAH 89 (P) 3
Alternator
Winding temperature TI 98 100° C TAH 98 130° C 3

Bearing temperature TI 27 45-85° C TAH 27 85° C (N) 3 TSH 27 90° C (N)
Miscellaneous
Jet system failure SX32 switch 10

Monitoring system failure 24 VDC UX 95-1 switch 120
± 15%
Safety system failure 24 VDC UX 95-2 switch 120
± 15%
Turning engaged ZS75 Engaged (G) 0
Local indication ZS 96 switch 0
Remote indication ZS 97 switch 0
Common shutdown SS 86 switch (G) 0
Monitoring sensor cable failure SX 86-1 switch 120
Safety sensor cable failure SX 86-2 switch 120
Start failure SX 83 switch (H) 10
Stop signal SS 84 switch (G) 0
Stop failure SX 84 switch 30
Engine run SI 90 720/750 rpm SS 90 710 rpm (K) 0
Ready to start SS 87 switch 0
For these alarms (with underscore) there are alarm cut-out at engine standstill.
08028-0D/H5250/94.08.12
08.23 - ES1
Description
Operation Data & Set Points 500.30
V28/32S
Remarks to Individual Parameters G. Start Interlock
A. Fuel Oil Pressure, HFO-operation The following signals are used for start interlock/
blocking:
When operating on HFO, the system pressure must
be sufficient to depress any tendency to gasification 1) Turning must not be engaged
of the hot fuel. 2) Engine must not be running
3) "Remote" must be activated
The system pressure has to be adjusted according 4) No shutdowns must be activated.
to the fuel oil preheating temperature. 5) The prelub. oil pressure must be OK, 20 min.
after stop.
B. Cooling Water Pressure, Alarm Set Points 6) "Stop" signal must not be activated
As the system pressure in case of pump failure will H. Start Failure

depend on the height of the expansion tank above the
engine, the alarm set point has to be adjusted to 0.4 If remote start is activated and the engine is in block-
bar plus the static pressure. The static pressure set ing or local mode or turning is engaged the alarm
point can be adjusted on the base module SW3. time delay is 2 sec.
Start failure will be activated if revulutions are below
C. Press. LT -system, inlet engine (PI 01) 50 rpm within 5 sec. from start or revulutions are
below 210 rpm 10 sec. from start.
With two-string cooling water system the normal Start failure alarm will automatically be released after
value can be higher, max. 4.0 bar. 30 sec. of activation.
D. Lub. Oil Pressure, Offset Adjustment J. Alarm Hysterese
The read outs of lub. oil pressure has an offset On all alarm points (except prelub. oil pressure) a
adjustment because of the transmitter placement. hysterese of 0.5% of full scale are present. On prelub.
This has to be taken into account in case of test and oil pressure alarm the hysterese is 0.2%.
calibration of the transmitter.
K. Engine Run Signal
E. Software Created Signal
The engine run signal is activated when engine
Software created signal from TI 22, PI 22, TI 12, rpm >710 or lub. oil pressure >3.0 bar or TC rpm
SI 90. >5000 rpm.
If engine rpm is above 210 rpm but below 710 rpm
F. Set Points depending on Fuel Temperature within 30 sec. the engine run signal will be acti-
vated.
L. Turbocharger Speed
08028-0D/H5250/94.08.12
Normal value at full load of the turbocharger is de-

pendent on engine type (cyl. no) and engine rpm.
The value given is just a guide line. Actual values
can be found in the acceptance test protocol.
M. Temperature Level
82° C HT thermostatic valve.
Fig 1 Set point curve.
08.23 - ES1
500.30 Operation Data & Set Points Description
V28/32S
N. Alternator Bearing Temperature P. Limits for Turbocharger Overspeed Alarm

(SAH 89)
For special alternator types higher alarm and shut-
down set points may be allowed. Engine type 720 rpm 750 rpm
12V28/32S 44,700 44,700
O. Exhaust Gas Temperatures 16V28/32S 37,300 37,300
18V28/32S 37,300 37,300
The exhaust gas temperature deviation alarm is
normally ±50° C with a delay of 1 min., but at start-
up the delay is 5 min. Furthermore the deviation
limit is ±100° C if the average temperature is below
200° C.
08028-0D/H5250/94.08.12
08.23 - ES1
Description
"Green Passport" 500.33
General
In 2009 IMO adopted the „Hong Kong International
Convention for the Safe and Environmentally Sound
Recycling of Ships, 2009“
Until this convention enters into force the recommen-

datory guidelines “Resolution A.962(23)” (adopted
2003) apply. This resolution has been implemented
by some classification societies as “Green Passport”.
MAN Diesel & Turbo is able to provide a list of ha-

zardous materials complying with the requirements
of the IMO Convention. This list is accepted by
classification societies as a material declaration for
“Green Passport”.
This material declaration can be provided on request.
11.08 - ES0
Your Notes :
Description 500.35
Page 1 (1) Data for Pressure and Tolerance Edition 23H
V28/32S
Section Description mm / bar
505 Safety valve to be adjusted to 175 bar

Maximum inner diameter, valve guide 18.35 mm
For grinding of valve spindle and valve seat ring
(see also working card 505-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H" 1 6.5 mm
Maximum height of spindle above cylinder head, "H" 2 108.0 mm
506 Piston and piston ring grooves (see working card 506-01.10)
Clearance between connecting rod bush and piston pin 0.15 - 0.23 mm
Maximum ovalness in big-end bore (without bearing) 0.10 mm.
New cylinder liner, inside diameter 280.03 - 280.08 mm
Maximum inside diameter cylinder liner 280.30 mm
507 Clearance between camshaft and camshaft bearing 0.13 - 0.22 mm

Maximum clearance between camshaft and camshaft bearing 0.35 mm
Clearance between tooths on intermediate wheel 0.206 - 0.364 mm
Clearance between tooths on intermediate wheel 0.237 - 0.403 mm
508 Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm

Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.90 mm
Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm
509 Clearance between pick-up and impulse wheel (clearange to be equal

on both sides) 1 ±0.3 mm
Adjustment of Lambda controller.
(see working card 509-10.00)
510 Clearance (equal on both sides) between main bearing cap and frame,
before tightening of bracing screw (side screw) 0.06 ± 0.02 mm
Deflection of crankchaft (autolog) (see working card 510-01.00)
Clearance between crankshaft and sealing ring, (upper and lower part) 0.45 - 0.58 mm.
Clearance in main bearing 0,2-0,344 mm
Clearance in guide bearing (axial) 0.15 - 0.46 mm
Maximum clearance in guide bearing (axial) 0.8 mm
Clearance between bearing and gearwheel shaft:
Clearance when new bearings are mounted 0.125-0.200
Maximum clearance 0.250
Clearance axial 0.2-0.3
511 Opening pressure of safety relief valves (on crankcase), max: 0.20 bar
514 Maximum combustion pressure at full load 145 ± 3 bar

Maximum difference between cylinders 3 bar
A change of the height of the thrust piece spacer ring of 0.10 mm.
will change the maximum pressure by 1 bar
1° turning of camshaft gear wheel changes max. pressure by approx 3 bar
Measurement "X" between thrust piece and roller guide housing 11 ± 1.0 mm
Opening pressure of fuel valve 320 bar
Pressure testing, cooling oil sealing, on fuel valve 100 bar
05.41 - ES0
Your Notes :
Description 500.40
Page 1 (2) Data for Tightening Torque Edition 31H
V28/32S
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
505 Cylinder head stud (in frame) Stud M 39 200 Loctite 243
Nut for cylinder head stud Nut M 39 x 3 900 Oil / Molykote
(Unimol gl 82)
506 Connecting rod screw

(see working card 506-01.25) Molykote
Connecting rod screw (hydraulic Stud M 39 x 3 (Unimol gl 82)
tightening) Nut M 39 x 3 700 –
Molykote
507 Camshaft assembling Nut M 12 85 (Unimol gl 82)
Gear wheel on camshaft Screw M 12 70 –
Intermediate wheel shaft (hydraulic Nut M 39 x 3 900 –
tool from cylinder head, to be used)
Intermediate wheel assembling Nut M 12 50 –
Gear wheel on crankshaft Nut M 12 50 –
508 Rocker arm bracket Nut M 12 40 –
510 Main bearing stud (in frame) Stud M 56 200 Loctite 243
Molykote
Nut for main bearing stud Nut M 52 x 3 900 (Unimol gl 82)
Main bearing side screw Screw M 30 750 –
Counterweight on crankshaft Screw M 26 x 1.5 300 –
Vibration damper on crankshaft Nut M 30 500 –
Flywheel mounting Nut M 30 1350 –
Gear rim on flywheel Screw M 16 75 –
511 Baseframe / alternator Nut M36 2000 –

Engine / alternator Nut M 24 650 –
512 Screw for fixation of cooler Screw M 20 25 –

08028-0D/H5250/94.08.12
Screw for mounted cooler Screw M 12 55 –
514 Fuel pump connecting piece Screw M 10 60 –

Fuel pump top flange (barrel) Screw M 12 100 –
(3 x cross-tightening
Fuel pump cavitation plugs Plug M 20 x 1.5 100-120 20 - 40 - 60 Nm) –
Fuel pump mounting Screw M16 150 –
Fuel valve (nozzle nut) Nut M 26 x 1.5 100 - 120 –
Fuel valve mounting Nut M 16 30 –
Fuel valve (lock nut) Nut M 16 x 1.5 100 –
10.09 - ES0
500.40 Description
Edition 31H
Data for Tightening Torque Page 2 (2)
V28/32S
Tightening
Section Description Thread Torque Pressure Lubricant
Nm bar
Molykote
515 Gear wheel on lub. oil pump Nut M 30 x 2 400 60 (Unimol gl
82)
516 Impeller and gear wheel on fresh-

water cooling pump Nut M 33 x 2 400 –
519 Sandwich elements mounting

Upper mounting Screw M 16 165 –
Lower mounting Screw M 16 165 –
08028-0D/H5250/94.08.12
10.09 - ES0
Description
Declaration of Weight 500.45
V28/32S
Section Component Plate No. Item No. Weight in Kg.
605 Cylinder Head, complete 50501-50502 250

50508-50510
606 Piston, complete 50601 081 62

Piston Pin 50601 019 19
Connecting Rod, complete without bearing 50601 068 92
Cylinder Liner, complete 50610 018 100
Cooling Water Jacket 50610 199 33
607 Camshaft, section 50705 026, 183, 29

205
609 Governor, complete 50901 057 28
611 Main Bearing Cap 51101 108 75

Guide Bearing Cap 51101 300 85
Front cover 51102 093 164
End cover, complete 179
612 Turbocharger, complete See special

instruction
Intermediate piece 51202 9
Air Cooler 51203 470
Inlet Bend 51203 93
Charging Air Cooler Housing 51203 350
613 Air Starter 51309 160 40
614 Fuel Injection Pump 51401 972 15

Fuel Injection Valve 51402 177 5
615 Lubricating Oil Pump 51501 175 45

Prelubricating Oil Pump, incl. el-motor 51504 266 20
Centrifugal Filter 51515 362 24
616 Cooling Water Pump 51610 416 30
02.48 - ES0
Your Notes :
Description
Ordering of Spare Parts 500.50
Page 1 (2)
Edition 02
General
When spare parts are ordered (or referred to in These data are necessary to ensure supply of the
correspondence, etc.) the following data must be correct spare parts for a particular engine, even
indicated for the engine concerned: though the spare part illustrations contained in this
book may not always be in complete accordance
• Name of customer/ship with the individual components of a specific engine.
• IMO number
• Engine Type Note: For ordering of spare parts for governor,
• Engine no turbocharger and alternator, please see the special
• Built by chapter in the instruction book for these components.
• Plate number
• Item no
• Description
• Qty.
Information found on the nameplate of the engine(s)
Example: Name of customer/ship IMO no Eng. type Eng. no Built by

DANYARD 705 L9007489 5L28/32H 20433 MAN Holeby
Information found on each plate:
Plate no Edition Item no Description Qty.

50601 13H 10 Piston ring 10 pcs
Pla
Page te
1 (2)
Piston
and Co
nnectin
g Rod
60601-
13H
L/V28/
08
32H
09
10
11
12
01
02
03
04
05
7
60
8
60
9
60
06
0
61
611
08028-0D/H5250/94.08.12
13
2
61
07
3
61
4
91.4
61
6 - ES
0S
14
5
61
6
61
7
61
8
61
9
61
0
62
09.46
Description
Ordering of Spare Parts 500.50
Page 2 (2)
Edition 02
General

Name of customer/ship IMO no
Engine type Engine number Built by
Plate no Ed. no Item no Description Qty.

08028-0D/H5250/94.08.12
09.46
Description 500.51
Page 1 (1) How to Return Spare Parts and/or Tools Edition 05
General
How to return spare parts and/or tools
If the unfortunate situation occurs that your spare - If you return to Holeby instead of Frederikshavn,
parts do not fit or is damaged in any way, you need you will have to pay freight charges of minimum
to return your spare parts to us. EUR 70,-
The return procedure is as follows: Please return by cheapest mean to the below address:
Send an email to our office via - Spare Parts:

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

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

out a written agreement you will be charged a
fee for unauthorised returns.
11.09 - ES0
Your Notes :
Description
Service Letters 500.55
Page 1 (1)
Edition 01
General
Description
In order to ensure the most efficient, economical and Since new service letters might be of great impor-
up-to-date operation of our engines, we regularly send tance to the operation of the plant, we recommend
out "Service Letters" containing first-hand information that engine staff file them as supplements to the
regarding accumulated service experience. relevant chapters of this instruction book.
The service letters can either deal with specific

engine types, or contain general instructions and
recommendations for all engine types, and are used
as a reference when we prepare up-dated editions
of instruction books.
08028-0D/H5250/94.08.12
97.40 - ES0
Your Notes :
Description
Conversion Table 500.60
General
Basic Sl Units Velocity, Speed (m/s) (3.6 km/h = 1 m/s)
Quantity Name Symbol 1 kn (knot) = 1 nautical mile/h 1.852 km/h = 0.5144 m/s
Cincerning other conversions, see table for length
length metre m
mass kilogram kg
time second s Density
electric current ampere A
absolute temperature* kelvin K 1 lb/cub. ft 16.02 kg/m3
amount of substance mole mol
luminous intensity candela cd
Force (1 kg m/s2 = 1 N)
* Also named "thermodynamic temperature"
1 kp (kilopound)* 9.807 N
Supplementary SI Units 1 poundal** 138.3 x 10-3 N
1 lbf (pound force) 4.448 N
Quantity Name Symbol
* Can occasionally be found stated as kgf (kilogram force).
plane angle radian rad Standard acceleration of free fall gn = 9.80665 m/s2
solid angle steradian sr ** Unit of force in the ft-lb-s system
Additional SI Units Stress ( 1 N/m2 = 10 -6 N/mm2)
Quantity Name Symbol Definition 1 kp/mm2 = 100 kp/cm2 9.807 N/mm2

1 lbf/sq. in (psi) = 0.07031 at 6.895 x 10-3 N/mm2
time minute min 1 min = 60 s
time hour h 1h = 60 min
plane angle degree ° 1° = (p/180) rad Dynamic viscosity (N s/m2)
volume litre l 1l = 1 dm3
pressure bar bar 1 bar = 105 Pa 1 kp s/m2 9.807 N s/m2 = 98.07 P (poise)
1 poundal s/sq.ft 1.488 N s/m2
1 lbf/sq.ft 47.88 N s/m2
Length (m)
poise is a special name taken from the CGS system. 1 P = 0.1 Pa s
1 in (inch) 25.40 mm = 0.0254 m 1 cP = 1 mPa s = 10-3 Pa s
1 ft (foot) = 12 inches 0.3048 m
1 yd (yard) = 3 ft = 36 inches 0.9144 m Kinematic viscosity (m2/s)
1 statute mile = 1760 yds 1609 m
1 n mile (international nautical mile) 1852 m 1 sq.ft/s 92.90 x 10-3 m2/s = 92.90 x 103 cSt *
* 1 cSt (centi stokes) = 10-6 m2/s. Stokes is a special name

SI Prefixes taken from the CGS system. 1 St = 10-4 m2/s
Factor Prefix Symbol Factor Prefix Symbol Energy, Work (1 Nm = 1 J, Wh)
1018 exa E 10-1 deci d 1 cal I.T* 4.187 J*

1015 peta P 10-2 centi c 1 kpm 9.807 J
1012 10-3 2.648 x 106 J = 0.7355
08028-0D/H5250/94.08.12
tera T milli m 1 hph (metric) kWh

109 giga G 10-6 micro μ 1 ft. lbf 1.356 J
106 mega M 10-9 nano n 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
103 kilo k 10-12 pico p 1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
102 hecto h 10-15 femto f
10 deca da 10-18 atto a * Exact value: 4.1868 J
I.T. = International Steam Table
Area (m2)
1 sq. in (square inch) 0.6452 x 10-3 m2

1 sq. ft (square foot) 92.90 x 10-3 m2
04.37 - ES0
500.60 Conversion Table Description
General
Power (1 kg m2/s3 = 1 N m/s = 1 J/s = 1 W) Specific heat capacity (J/(kg K))
1 kpm/s 9.807 W 1 kcalI.T./(kg x °C) 4.187 x 103 J/(kg K)

1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW 1 BTU*/(lb x °F) = 1 kcalI.T. /(kg °C) 4.187 x 103 J/(kg K)
1 kcalI.T./h 1.163 W
1 ft lbf/s 1.356 W * British Thermal Unit (see table for energy conversions)
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 BTU/h 0.2931 W
Heat conductance (W/(m K))
Moment of Force, Torque (kg m2/s2 = Nm) 1 calI.T./(cm x s x °C) 418.7 W/(m K)
1 kcalI.T./(m x h x °C) 1.163 W/(m K)
Can easily be derived from the above tables. 1 BTU*/(ft x h x °F) 1.731 W/(m K)
* British Thermal Unit (see table for energy conversions)

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

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

Specific fuel consumption* (g/kWh)
Reference conditions
1 g/hph (metric) 1.360 g/kWh Specific fuel oil consumption values refer to brake power,
and the following reference conditions:
* See also table for specific fuel oil consumption values
Reference conditions (ISO)
Temperature difference (K) Blower inlet temperature 25°C 298 K

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

(see "Derived SI Units with special Names)
t °C (Celsius) tc + 273.15 = K
t°F (Fahrenheit) 5/9(tf - 32) + 273.15 = K
Celsius from Fahrenheit: tc = 5/9(tf - 32)
Fahrenheit from Celcius: tf = 9/5 x tc + 32
Derived Si Units with Special Names

08028-0D/H5250/94.08.12
Quantity Name Symbol Expressed in basic,

supplementary or
derived SI units
frequency hertz Hz 1 Hz = 1 s-1

force newton N 1N = 1 kg m/s2
pressure, stress pascal Pa 1 Pa = 1 N/m2*
energy, working quantity of heat joule J 1J = 1 Nm
power watt W 1W = 1 J/s
electric potential (DC) volt V 1V = 1 W/A
temperature Celsius °C 1°C = 1 k**
* For mechanical stresses N/mm2 is widely used. 1 N/mm2 = 106 N/m2

** t (°C) = T(K) - T0(K), where T0 = 273.15 K
04.37 - ES0
Description
Conversion Table 500.60
General
Volume (1 m3 = 1000 l)
1 cub. in (cubic inch) 16.39 x 10-6 m3

1 cub. ft (cubic foot) 28.32 x 10-3 m3 = 28.32 l
1 gallon* (imperial, UK) 4.546 x 10-3 m3 = 4.546 l
1 gallon* (US) 3.785 x 10-3 m3 = 3.785 l
1 barrel (US petroleum barrel) = 42 gallon (US) 0.1590 m3
1 bbl (dry barrel, US) 0.1156 m3
1 register ton = 100 cub. ft 2.832 m3
* 1 gallon = 4 quarts = 8 pints
Mass (kg)
1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg

1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg
1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg
1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg
1 slug* 14.59 kg
* Unit and mass in the ft-lb-s system
Pressure
(1 N/m2 = 1 Pa, 1 bar = 105 Pa, 1 mbar = 10-3 bar)
1 kp/cm2 = 1 at = 0.9678 atm 98.07 x 103 Pa = 0.9807 bar

1 at = 735.5 mm Hg* = 10 m H2O** (T = 277 K)
750 mm Hg* 105 Pa = 1 bar
1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar
1 mm H2O** (T = 277 K) 10-4 at = 9.807 Pa = 98.07 x 10-3 mbar
1 in Hg* (T = 273 K) 3386 Pa = 33.86 mbar
1 in H2O** (T = 277 K) 249.1 Pa = 2.491 mbar
1 atm (standard atmosphere) 760 mm Hg, 1.013 x 105 Pa = 1013 mbar
1 atm = 1.033 at
1 lbf/sq.in (psi) 6895 Pa = 68.95 mbar
* Mercury. 1 mm Hg = 1 Torr
Values in table provided gn = 9.80665 m/s2
** Water column (WC)
Some physical data in SI units
Nomenclature
t = temp. in °C ΔK = temperature difference
r = density in kg/m3 Cp = heat capacity in J/(kg DK)
t ρ Cp t Cp
range
08028-0D/H5250/94.08.12
Water 18 999 4.18 x 103

Lubricating oil (approx.)* 15 900 1.96 x 103
Atmospheric air (dry) (p=1 bar) 0 1.276 998 0-150 1005
Exhaust gas 200-400 1080
* Viscosity: 100-140 cSt at 40°C
750 mm Hg = 1 bar = 105 Pa
1 atm (standard pressure at sea level) = 760 mm Hg = 1013 mbar
Gas constant for air and exhaust gas = 287 J/(kg x K)
Water, heat of evaporation 100°C 1.013 bar 2.256 x 106 J/kg
Fuel oil. Lower calorific value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)
04.37 - ES0
Your Notes :
Description
Page 1 (3) Basic Symbols for Piping 500.65
Edition 01
General
No Symbol Symbol designation No Symbol Symbol designation

2.14 Spectacle flange
1. GENERAL CONVENTIONAL SYMBOLS
1.1 Pipe 2.15 Orifice
1.2 Pipe with indication of direction of flow 2.16 Orifice
1.3 Valves, gate valves, cocks and flaps 2.17 Loop expansion joint
1.4 Appliances 2.18. Snap coupling
1.5 Indicating and measuring instruments 2.19 Pneumatic flow or exhaust to atmosphere
1.6 High-pressure pipe

3. VALVES, GATE VALVES, COCKS AND FLAPS
1.7 Tracing 3.1 Valve, straight through
1.8 Enclosure for several components as-sem- 3.2 Valve, angle

bled in one unit
3.3 Valve, three-way
2. PIPES AND PIPE JOINTS
2.1 Crossing pipes, not connected 3.4 Non-return valve (flap), straight
2.2 Crossing pipes, connected 3.5 Non-return valve (flap), angle
2.3 Tee pipe 3.6 Non-return valve (flap), straight screw

down
2.4 Flexible pipe 3.7 Non-return valve (flap), angle, screw down
2.5 Expansion pipe (corrugated) general 3.8 Safety valve
2.6 Joint, screwed 3.9 Angle safety valve
2.7 Joint, flanged 3.10 Self-closing valve

08028-0D/H5250/94.08.12
2.8 Joint, sleeve 3.11 Quick-opening valve
2.9 Joint, quick-releasing 3.12 Quick-closing valve
2.10 Expansion joint with gland 3.13 Regulating valve
2.11 Expansion pipe 3.14 Ball valve (cock)
2.12 Cap nut 3.15 Butterfly valve
2.13 Blank flange 3.16 Gate valve
05.02 - ES0
500.65 Basic Symbols for Piping
Description
Page 2 (3)
Edition 01
General
No Symbol Symbol designation No Symbol Symbol designation

3.17 Double-seated changeover valve
4. CONTROL AND REGULATION PARTS
3.18 Suction valve chest 4.1 Fan-operated
3.19 Suction valve chest with non-return valves 4.2 Remote control
3.20 Double-seated changeover valve, straight 4.3 Spring
3.21 Double-seated changeover valve, angle 4.4 Mass
3.22 Cock, straight through 4.5 Float
3.23 Cock, angle 4.6 Piston
3.24 Cock, three-way, L-port in plug 4.7 Membrane
3.25 Cock, three-way, T-port in plug 4.8 Electric motor
3.26 Cock, four-way, straight through in plug 4.9 Electromagnetic
3.27 Cock with bottom connection 4.10 Manual (at pneumatic valves)
3.28 Cock, straight through, with bottom conn. 4.11 Push button
3.29 Cock, angle, with bottom connection 4.12 Spring
3.30 Cock, three-way, with bottom connection 4.13 Solenoid
3.31 Thermostatic valve 4.14 Solenoid and pilot directional valve
3.32 Valve with test flange 4.15 By plunger or tracer
3.33 3-way valve with remote control (actuator)

5. APPLIANCES
08028-0D/H5250/94.08.12
3.34 Non-return valve (air) 5.1 Mudbox
3.35 3/2 spring return valve, normally closed 5.2 Filter or strainer
3.36 2/2 spring return valve, normally closed 5.3 Magnetic filter
3.37 3/2 spring return valve contr. by solenoid 5.4 Separator
3.38 Reducing valve (adjustable) 5.5 Steam trap
3.39 On/off valve controlled by solenoid and pilot 5.6 Centrifugal pump
directional valve and with spring return
05.02 - ES0
Description
Basic Symbols for Piping 500.65
General
No. Symbol Symbol designation No. Symbol Symbol designation

5.7 Gear or screw pump
6. FITTINGS
5.8 Hand pump (bucket) 6.1 Funnel / waste tray
5.9 Ejector 6.2 Drain
5.10 Various accessories (text to be added) 6.3 Waste tray
5.11 Piston pump 6.4 Waste tray with plug
5.12 Heat exchanger 6.5 Turbocharger
5.13 Electric preheater 6.6 Fuel oil pump
5.14 Air filter 6.7 Bearing
5.15 Air filter with manual control 6.8 Water jacket
5.16 Air filter with automatic drain 6.9 Overspeed device
5.17 Water trap with manual control

7. READING INSTR. WITH ORDINARY DESIGNATIONS
5.18 Air lubricator 7.1 Sight flow indicator
5.19 Silencer 7.2 Observation glass
5.20 7.3 Level indicator

Fixed capacity pneumatic motor with direc-
tion of flow
5.21 Single acting cylinder with spring returned 7.4 Distance level indicator
5.22 Double acting cylinder with spring returned 7.5 Recorder
5.23 Steam trap

08028-0D/H5250/94.08.12
05.02 - ES0
Your Notes :
Operation of engine
501/601
Your Notes :
Description
Operation 501.01
Page 1 (4)
Edition 08
L16/24 L27/38
V28/32S L21/31
Preparations for Starting V28/32S
The following describes what to do before starting Note: The engine must be prelubricated for at least
when the engine has been out of service for a period 5 minutes prior to start-up
of time. or
check that there is oil coming out at bearings, pistons
and rocker arms.
1) Check the oil level in the base frame with the L16/24, L27/38, L21/31
dipstick.
Note: The engine must be prelubricated for at least
2) Check the oil level in the governor, see Fig 2, 30 minutes prior to start-up (at the first starting-up, or
with the level indicator on the governor. if the engine is cold, the engine must be prelubricated
for at least 60 minutes)
3) Start up the prelubricating pump. or
and rocker arms.
Synch. motor
Manuel
raise/lower speed
Droop
setting
Manuel
Oil level
emergency
stop
08028-0D/H5250/94.08.12
Compensation
Fig 1 Monitoring of temperature/pressure (MTP). Fig 2 Governor.
02.49 - ES0
501.01 Description
Edition 08
Operation Page 2 (4)
L16/24 L27/38
V28/32S L21/31
4) Check prelubricating oil pressure at inlet to
filter, inlet of the engine and inlet turbocharger
on the monitoring box display according to the
data and setpoints sheet.
5) Open the cooling water supply.
6) Check the cooling water pressure.
Note: To avoid shock effects owing to large tem-

perature fluctuations just after start, it is recom-
mended:
a) to preheat the engine. Cooling water at least

60°C should be circulated through the frame
and cylinder head for at least 2 hours before
start:
- by means of cooling water from engines which

are running or by means of a preheater (if
installed).
b) When starting without preheated cooling

Fig 3 Operation box (OB).
water, the engine may only be started on MDO
(Marine Diesel Oil).
Note: When starting on HFO (Heavy Fuel Oil), only

item a) applies. Starting Air System
9) Check the pressure in the starting air

HFO System receiver(s).
7) Open the fuel oil supply. 10) Drain the starting air system.
Starting on HFO: circulate preheated fuel through the 11) Open the starting air supply.
08028-0D/H5250/94.08.12
pumps until correct working temperatures have been

achieved. This normally takes 30-60 minutes. 12) Check the air pressure on the operating box
according to the data and setpoints sheet.
8) Regulating gear - please check:
- that all fuel injection pumps are set at index Turning of Engine (not valid for L16/24
"0" when the regulating shaft is in STOP posi- engine)
tion.
13) Open the indicator valves and turn the engine
- that each fuel injection pump can be pressed some few revolutions, check that no liquid is
by hand to full index when the regulating shaft flowing out from any indicator valves during
are in STOP position, and that the pumps return the turning.
automatically to the "0" index when the hand
is removed.
02.49 - ES0
Description
Operation 501.01
Page 3 (4)
Edition 08
L16/24 L27/38
V28/32S L21/31
14) Slow turning must always be carried out, be- 23) Test the overspeed, see Working Card
fore the engine is started after prolonged out 509-01.05.
of-service-periods and after overhauls, which
may involve a risk of liquid having collected in 24) Check that all alarms are connected.
the cylinders.
15) Close the indicator valves. Operation
The engine should not be run up to more than 50%

Starting load to begin with, and the increase to 100% should
take place gradually over 5 to 10 minutes.
16) Start the engine by activating the start button
on the operation box; push the button until the Note: When the engine is running the planned
engine ignites, see Fig 3. maintenance programme and the following should
be checked:
Note: If the engine have been without prelubrica-
tion for more than 20 min. it will not be possible 25) The lubricating oil pressure must be within the
to start the engine (either remote or local). stated limits and may not fall below the stated
The only possibility in this case is to activate minimum pressure. The paper filter cartridges
the emergency start, located directly on the must be replaced before the pressure drop
starter. across the filter reaches the stated maximum
value, or the pressure after the filter has fallen
Testing during Running below the stated minimum value. Dirty filter
cartridges cannot be cleaned for re-use.
See Description 509.05 before operating the control 26) The lubricating oil temperature must be kept
panel. within the stated limits indicated on the data
and setpoints sheet.
Check the following on the monitoring box according
to the data and setpoints sheet. 27) The fuel oil pressure must be kept at the stated
value.
17) Check the lubricating oil pressure.
28) The cylinder cooling water temperature must
18) Check the cooling water pressure. be kept within the limits indicated on the data
19) Check the fuel oil feed pressure.
29) The exhaust gases should be free of visible
20) Check that the turbocharger is running. smoke at all loads. For normal exhaust tem-
peratures, see the test report from shop and
08028-0D/H5250/94.08.12
21) Check that the prelubricating oil pump stops sea trials.
automatically.
30) Keep the charging air pressure and tempera-
22) Check that all cylinders are firing, see exhaust ture under control. For normal values, see the
gas temperatures. test report from shop and sea trials.
Note: Check the stop cylinder (Lambda controller) for 31) Recharge the starting air receivers to the de-
regulating the shaft works properly, both when stop- scribed value.
ping normally and at overspeed and shut down.
32) To ensure full operational reliability, the con-
Check that all shutdowns are connected and func- dition of the engine should be continuously
tion satisfactory. observed so that order for preventive mainte-
nance work can be carried out before serious
breakdowns occur, see also section 502.
02.49 - ES0
501.01 Description
Edition 08
L16/24 L27/38
V28/32S L21/31
Stopping Before starting on HFO the engine must be properly
preheated as described in "Preparations for Starting"
33) Before stopping, it is recommended to run the and as described below.
engine at reduced load, max. 2 min.
Stopping the engine on HFO is no problem, but it
34) The engine is stopped by activating the stop should be ensured that the temperature of fuel pipes
button on the operating box. Please note that is not reduced to a level below the pour point of the
the push button must be activated at least 3 fuel. Otherwise reestablishing the circulation might
sec. before stop will be activated. cause problems.
35) On the governor can be found a manuel emer-

gency stop botton. This can be used in case Starting on MDO
of no pilot voltage supply.
For starting on MDO there are no restrictions except
that lubricating oil viscosity may not be higher than
Starting and Stopping on HFO 1500 cSt (10°C SAE 40).
Starting and stopping of the engine should take Initial ignition may be difficult if the engine and ambient
place on HFO in order to prevent any incompatibility temperatures are lower than 5°C and 15°C cooling
problems on changeover to MDO. water temperature.
MDO should only be used in connection with mainte-

nance work on the engine or before a longer period
of engine standstill.
08028-0D/H5250/94.08.12
02.49 - ES0
Description
Operation 501.01
Page 1 (4)
Edition 10H
V28/32S
Preparations for Starting 4) Check prelubricating oil pressure at inlet to
filter, inlet of the engine and inlet turbocharger
The following describes what to do before starting on the monitoring box display according to the
when the engine has been out of service for a period data and setpoints sheet.
of time.

1) Check the oil level in the base frame with the
dipstick. 6) Check the cooling water pressure.
2) Check the oil level in the governor, see Fig 2, Note: To avoid shock effects owing to large tem-
with the level indicator on the governor. perature fluctuations just after start, it is recom-
mended:
3) Start up the prelubricating pump.
Note: The engine must be prelubricated for at least 60°C should be circulated through the frame
5 minutes prior to start-up and cylinder head for at least 2 hours before
or start:
and rocker arms. - by means of cooling water from engines which
installed).
08028-0D/H5250/94.08.12
02.49 - ES0
501.01 Description
Edition 10H
V28/32S


item a) applies.
HFO System
7) Open the fuel oil supply.
Starting on HFO: circulate preheated fuel through the

achieved. This normally takes 30-60 minutes.
- that all fuel injection pumps are set at index

"0" when the regulating shaft is in STOP posi-
tion.
- that each fuel injection pump can be pressed

by hand to full index when the regulating shaft
are in STOP position, and that the pumps return
automatically to the "0" index when the hand
is removed.
14) Slow turning must always be carried out, be-

Starting Air System fore the engine is started after prolonged out
9) Check the pressure in the starting air may involve a risk of liquid having collected in
receiver(s). the cylinders.
10) Drain the starting air system. 15) Close the indicator valves.
11) Open the starting air supply.

Starting
08028-0D/H5250/94.08.12
12) Check the air pressure on the operating box

according to the data and setpoints sheet. 16) Start the engine by activating the start button
on the operation box; push the button until the
engine ignites, see Fig 3.
Turning of Engine
Note: If the engine have been without prelubrica-
13) Open the indicator valves and turn the engine tion for more than 20 min. it will not be possible
some few revolutions, check that no liquid is to start the engine (either remote or local).
flowing out from any indicator valves during The only possibility in this case is to activate
the turning. the emergency start, located directly on the
starter.
02.49 - ES0
Description
Operation 501.01
Page 3 (4)
Edition 10H
V28/32S
Testing during Running 25) The lubricating oil pressure must be within the
stated limits and may not fall below the stated
See Description 509.05 before operating the control minimum pressure. The paper filter cartridges
panel. must be replaced before the pressure drop
across the filter reaches the stated maximum
Check the following on the monitoring box according value, or the pressure after the filter has fallen
to the data and setpoints sheet. below the stated minimum value. Dirty filter
cartridges cannot be cleaned for re-use.
26) The lubricating oil temperature must be kept
18) Check the cooling water pressure. within the stated limits indicated on the data
19) Check the fuel oil feed pressure.
27) The fuel oil pressure must be kept at the stated
20) Check that the turbocharger is running. value.
21) Check that the prelubricating oil pump stops 28) The cylinder cooling water temperature must
automatically. be kept within the limits indicated on the data
22) Check that all cylinders are firing, see exhaust
gas temperatures. 29) The exhaust gases should be free of visible
smoke at all loads. For normal exhaust tem-
Note: Check the stop cylinder (Lambda controller) for peratures, see the test report from shop and
regulating the shaft works properly, both when stop- sea trials.
Check that all shutdowns are connected and func- ture under control. For normal values, see the
tion satisfactory. test report from shop and sea trials.
23) Test the overspeed, see Working Card 31) Recharge the starting air receivers to the de-
509-01.05. scribed value.
24) Check that all alarms are connected. 32) To ensure full operational reliability, the con-
dition of the engine should be continuously
observed so that order for preventive mainte-
Operation nance work can be carried out before serious
breakdowns occur, see also section 502.
The engine should not be run up to more than 50%
08028-0D/H5250/94.08.12
load to begin with, and the increase to 100% should

take place gradually over 5 to 10 minutes. Stopping
Note: When the engine is running the planned 33) Before stopping, it is recommended to run the
maintenance programme and the following should engine at reduced load, max. 2 min.
be checked:
34) The engine is stopped by activating the stop
button on the operating box. Please note that
the push button must be activated at least 3
sec. before stop will be activated.
02.49 - ES0
501.01 Description
Edition 10H
V28/32S
Starting and Stopping on HFO Starting on MDO
Starting and stopping of the engine should take For starting on MDO there are no restrictions except
place on HFO in order to prevent any incompatibility that lubricating oil viscosity may not be higher than
problems on changeover to MDO. 1500 cSt (10°C SAE 40).
MDO should only be used in connection with mainte- Initial ignition may be difficult if the engine and ambient
nance work on the engine or before a longer period temperatures are lower than 5°C and 15°C cooling
of engine standstill. water temperature.
Before starting on HFO the engine must be properly

and as described below.

should be ensured that the temperature of fuel pipes
is not reduced to a level below the pour point of the
fuel. Otherwise reestablishing the circulation might
cause problems.
08028-0D/H5250/94.08.12
02.49 - ES0
Description
Operation 501.01
Page 1 (4)
Edition 14
L16/24 L27/38
V28/32S L21/31
Preparations for Starting L16/24, L27/38, L21/31
The following describes what to do before starting Note: The engine must be prelubricated for at least
when the engine has been out of service for a period 30 minutes prior to start-up (at the first starting-up, or
of time. if the engine is cold, the engine must be prelubricated
for at least 60 minutes)
or
Lubricating Oil System check that there is oil coming out at bearings, pistons
and rocker arms.
1) Check the oil level in the base frame with the
dipstick.
4) Check prelubricating oil pressure at inlet to
2) Check the oil level in the governor, see Fig 2, filter, inlet of the engine and inlet turbocharger
with the level indicator on the governor. on the monitoring box display according to the
data and setpoints sheet.
3) Start up the prelubricating pump.

V28/32S
Note: The engine must be prelubricated for at least
5 minutes prior to start-up 6) Check the cooling water pressure.
or
and rocker arms.
Filler cup
Oil level
UG-Actuator
08028-0D/H5250/94.08.12
06.19 - ES0
501.01 Description
Edition 14
L16/24 L27/38
V28/32S L21/31
Note: To avoid shock effects owing to large tem-
perature fluctuations just after start, it is recom-
mended:

60°C should be circulated through the frame
and cylinder head for at least 2 hours before
start:
- by means of cooling water from engines which

installed).


item a) applies.
HFO System
7) Open the fuel oil supply.
Starting on HFO: circulate preheated fuel through the

achieved. This normally takes 30-60 minutes.
11) Open the starting air supply.
12) Check the air pressure on the operating box
- that all fuel injection pumps are set at index according to the data and setpoints sheet.
"0" when the regulating shaft is in STOP posi-
tion.
Turning of Engine
- that each fuel injection pump can be pressed
by hand to full index when the regulating shaft 13) Open the indicator valves and turn the engine
are in STOP position, and that the pumps return some few revolutions, check that no liquid is
automatically to the "0" index when the hand flowing out from any indicator valves during
08028-0D/H5250/94.08.12
is removed. the turning.
14) Slow turning must always be carried out, be-

Starting Air System fore the engine is started after prolonged out
9) Check the pressure in the starting air may involve a risk of liquid having collected in
receiver(s). the cylinders.
10) Drain the starting air system. 15) Close the indicator valves.
06.19 - ES0
Description
Operation 501.01
Page 3 (4)
Edition 14
L16/24 L27/38
V28/32S L21/31
Starting Operation
16) Start the engine by activating the start button The engine should not be run up to more than 50%
on the operation box; push the button until the load to begin with, and the increase to 100% should
engine ignites, see Fig 3. take place gradually over 5 to 10 minutes.
Note: If the engine have been without prelubrica- Note: When the engine is running the planned
tion for more than 20 min. it will not be possible maintenance programme and the following should
to start the engine (either remote or local). be checked:
The only possibility in this case is to activate
the emergency start, located directly on the 25) The lubricating oil pressure must be within the
starter. stated limits and may not fall below the stated
minimum pressure. The paper filter cartridges
must be replaced before the pressure drop
Testing during Running across the filter reaches the stated maximum
value, or the pressure after the filter has fallen
See Description 509.05 before operating the control below the stated minimum value. Dirty filter
panel. cartridges cannot be cleaned for re-use.
Check the following on the monitoring box according 26) The lubricating oil temperature must be kept
to the data and setpoints sheet. within the stated limits indicated on the data
27) The fuel oil pressure must be kept at the stated
18) Check the cooling water pressure. value.
19) Check the fuel oil feed pressure. 28) The cylinder cooling water temperature must
be kept within the limits indicated on the data
20) Check that the turbocharger is running. and setpoints sheet.
21) Check that the prelubricating oil pump stops 29) The exhaust gases should be free of visible
automatically. smoke at all loads. For normal exhaust tem-
peratures, see the test report from shop and
22) Check that all cylinders are firing, see exhaust sea trials.
gas temperatures.
Note: Check the stop cylinder (Lambda controller) for ture under control. For normal values, see the
regulating the shaft works properly, both when stop- test report from shop and sea trials.
08028-0D/H5250/94.08.12

31) Recharge the starting air receivers to the de-
Check that all shutdowns are connected and func- scribed value.
tion satisfactory.
32) To ensure full operational reliability, the con-
23) Test the overspeed, see Working Card dition of the engine should be continuously
509-01.05. observed so that order for preventive mainte-
nance work can be carried out before serious
24) Check that all alarms are connected. breakdowns occur, see also section 502.
06.19 - ES0
501.01 Description
Edition 14
L16/24 L27/38
V28/32S L21/31
Stopping Before starting on HFO the engine must be properly
33) Before stopping, it is recommended to run the and as described below.
engine at reduced load, max. 2 min.
34) The engine is stopped by activating the stop should be ensured that the temperature of fuel pipes
button on the operating box. Please note that is not reduced to a level below the pour point of the
the push button must be activated at least 3 fuel. Otherwise reestablishing the circulation might
sec. before stop will be activated. cause problems.
Starting and Stopping on HFO Starting on MDO
Starting and stopping of the engine should take For starting on MDO there are no restrictions except
place on HFO in order to prevent any incompatibility that lubricating oil viscosity may not be higher than
problems on changeover to MDO. 1500 cSt (10°C SAE 40).
MDO should only be used in connection with mainte- Initial ignition may be difficult if the engine and ambient
nance work on the engine or before a longer period temperatures are lower than 5°C and 15°C cooling
of engine standstill. water temperature.
08028-0D/H5250/94.08.12
06.19 - ES0
Description
Out of Service 501.05
Page 1 (2)
Edition 05
L16/24 L27/38
V28/32S L21/31
Stand-by Mode 3) A lubricating oil sample should be sent to a
laboratory for immediate analysis.
During engine standstill in stand-by position the me-
dia cooling water and fuel oil should be continuously 4) The installed drain fasilities in the exhaust gas
circulated at temperatures similar to the operating system must be open.
conditions.
The prelubricating pump must always run in stand- Work during Repairs
by mode.
The following should be carried out during major
repairs.
Maintenance during Standstill
5) Retighten all bolts and nuts in the crankcase.
In periods during standstill of the engine (not in
stand-by position) it is recommended to start the 6) Check the various gearwheel drives for the
prelubricating oil pump for minimum 20 minutes camshafts.
once every week and to turn the engine during the
prelubricating period by 2-3 revolutions. 7) Remedy leakages of water and oil in the engine,
and blow through blocked-up drain pipes.
Laid-up Vessels 8) Drain starting air pipes of water.
During the lay-up period we recommend that our 9) Empty the oil sump of lubricating oil and check
special instructions for preservation of the engines the bottom of the oil sump for fragments of
are followed. babbitt from bearings. Remove the sludge, if
not done within a period of one year. Clean the
sump very thoroughly and subsequently coat
Work before Major Repairs with clean lubricating oil.
Follow all Working Cards carefully. Carry out all the

measuring and inspection stated on these Working Work after Repairs
Cards.
Cleaning of Lubricating Oil System
1) After stopping the engine, while the oil is still
warm, start the el-driven prelub. pump, open 10) If opening-up the engine or lubricating oil
up the crankcase and camshaft housings and system has caused the ingress of impurities,
check that the oil is flowing freely from all bear- cleaning should be carried out very carefully
ings. before starting the engine.
08028-0D/H5250/94.08.12
After overhaul of pistons, bearings, etc. this check The differential pressure across the lubricating oil
should be repeated before starting the engine. filter must be watched very carefully after cleaning
and star ting-up the engine. Be sure to replace filter
2) Open up all filters to check that filter elements cartridges in due time.
are intact. Filter cartridges in the lub. oil filter
are to be replaced before start, after repair, 11) After restoring normal prelubricating oil circula-
or after excessive differential pressure. After tion, turn the engine at least two revolutions
removal, dirty elements can be examined for by means of the turning device to check the
particles of bearing metal at the bottom of the movability of the relevant parts of the engine.
paper lamella (the elements cannot be used
again). 12) Close drain cocks in the exhaust gas system
if mounted.
02.47 - ES0
501.05 Description
Edition 05
Out of Service Page 2 (2)
L16/24 L27/38
V28/32S L21/31
Lubrication of Manoeuvering Gear b) Adjustment speed: switch in the alternator
on the switchboard and set the load to about
13) Lubricate the bearings and rod connections 40%. On reaching normal oil temperatures in
in the manoeuvering gear. Move the rod con- governor and engine increase the load instantly
nections by hand to check that the friction in to about 80% (by starting a major pump or
bearings and fuel injection pumps is sufficiently compressor).This must not cause the frequency
low. to fall by more than some 8%, and the engine
must return to a constant no. rpm after about 3
14) Checks to be made just before starting the seconds (although this rpm will be a little lower
engine are described under 501.01. than before owing to the speed drop of the
governor). If the engine is operated in parallel
with other engines, an even sharing of the load
Check of Governor must be established within about 3 seconds.
If the governor reacts too slowly, compensat-
Note: At starting-up after an overhaul the overspeed ing adjustment is effected as indicated in the
shutdown must be testet at correct setpoint after the governor's instruction manual (Compensating
following has been done: Adjustment).
a) Start the engine and keep it at no load. Note: It is a condition for this test that the engine
and turbocharger are in perfect operating condition,
b) Turn the speed setting on governor until the so that possible sources of error can be eliminated
overspeed is released. Check that it is released immediately.
at correct rpm according to "Operation data
& set points", 500.30 and working card 509- c) Hunting: run the engine at synchronous rpm,
01.05. and without load. Provided that the governor oil
is warm, the regulating lever must not perform
Note: If both overspeed shutdown (SSH 81) are ac- any major periodical movements, and neither
tivated, nuts and bolts have to be retightened before must there be any variation in the engine speed.
the engine is started, (Nuts and bolts according to the If that is the case, repeat the compensating
colomn "Check new/overhauled parts after - hours" adjustment according to the governor's instruc-
in the planned maintenance program). tion manual.
15) Check the governor as follows: start up the d) Speed drop: in case of unsatisfactory load
engine and run it at the synchronous number sharing between two or more engines this can
of revolutions. be rectified by increasing the speed drop of the
engine that is subject to the greatest load (or
a) Speed-setting: before switching-in the alterna- by reducing the setting of the other engines).
tor on the switchboard please check that the
The setting should normally not be increased be-
08028-0D/H5250/94.08.12
servomotor adjusts the rpm with a suitable

quickness after actuation of the synchronizer yond the "max" value (stated below) on the scale,
knob on the switchboard. The range from - 5% and satisfactory parallel operation can generally be
to + 5% from the synchronous rpm should be obtained at settings "normal range" (stated below).
tested. Setting "Default" stated below can be used in most
cases.
Woodward Europa
Max. 70 100
Normal range 45-60 70-90
Default 52 80
02.47 - ES0
Description
Starting-up after Repair 501.10
Page 1 (1)
Edition 03
General
The following enumerated checks are to be made im- feel-over on the surfaces of all moving parts where
mediately after starting and during load increase. friction may arise and cause undue heating.
Note: In the following it is assumed that the engine has Feel: main bearings, big-end bearings, alternator
been out of service for some time due to repairs and bearings, and camshaft bearings, cylinder liners,
that checks during out of service periods have been roller guides and gear wheels.
carried out as described in the previous chapter.
After the last feel-over, repeat check 1) on page
When starting up after repair, the following checks 501.05, see also "Ignition in Crankcase" on page
must be made, in the order stated in addition to 503.04 in section 503.
normal surveillance and recording.
After repair or renewal of cylinder liners, piston rings
or bearings, allowance must be made for a running-
To be Checked Immediately after Starting in period, i.e. the engine load should be increased
gradually as indicated in the tables below.The engine
1) Check that the turbocharger is running. output is determined on the basis of the fuel index
and the load on the electric switchboard. The turbo-
2) Check that the lubricating oil pressure is in charger speed gives some indication of the engine
order. output, but is not directly proportional to the output
throughout the service period.
3) Check that all cylinders are firing (see exhaust
temperatures). Begin the starting-up sequence at a reduced engine
speed, e.g. 400 rpm, until it can be known for cer-
4) Check that everyting is normal for the engine tain that there are no hot spots in the engine. Then
speed, fuel oil, cooling water and system oil. increase the speed to the normal rpm and connect
to the switchboard and put on load.
5) Check by simulation of the overspeed shutdown
device that the engine stops, see working card The load increase during the starting-up sequence
509-01.05. may, for instance, be:
Note: The overspeed setting should be according to 25 % load for 2 hours

"Operation data & set points", 500.30. 50 % load for 2 hours
75 % load for 2 hours
100 % load may be put on
To be Checked during Starting-up, but only
if Required after Repairs or Alterations For loads: see the fuel pump index on the testbed
figures in section 502.
6) If the condition of the machinery is not well-
08028-0D/H5250/94.08.12
known, especially after repairs or alterations, After completing the starting-up sequence, make
the "feel-over sequence" should always be sure that all fuel injection pumps are set at the same
followed, i.e.: index and that the governor can cause all fuel pumps
to move to "0" index.
After 5-15 and 30 minutes' idle running, open the
crankcase and the camshaft housing and perform
02.40 - ES0
Your Notes :
Description
Guidelines for Longterm Low-Load Operation on HFO 501.15
General
Part load/low load operation and turbocharger. HFO-operation at loads lower than
20% MCR should therefore only take place within
In certain ship and power station operation modes the certain time limitations according to the curves.
diesel generating sets are exposed to part load/low
load operation. After a certain period of HFO-operation at loads lower
than 20% MCR, a change to MDO should take place
During manoeuvring of the ship all diesel generating in order to prevent further retardation of the engine
sets are often started up for safety reasons, result- performance condition. Alternatively, the engine load
ing in low should be raised to 70% MCR over a period of 15
load operation of all the engines. During harbour stay minutes and maintained here for some time in order
one diesel generator could be low-loaded when only to burn off the carbon deposits, thus re-establishing
hotel purposes are consuming electricity. adequate performance condition. After such a "clean
burning period" low load operation on HFO can be
Island mode operation of diesel generating sets in continued.
power stations is frequently exposed to low load
operation like on a ship. However, the operator must be aware of the fact
that fouling in the combustion air inlet channels,
At part load/low load it is important to maintain if any, will not be cleaned at high load operation.
constant media temperatures, i.e. for cooling water, Extensive low load running can therefore result in
lubricating oil and fuel oil in order to ensure adequate the need for manual cleaning of the combustion air
combustion chamber temperature and thus complete inlet channels.
combustion.
If special application conditions require continuous
At loads lower than 20% MCR there is a risk of time HFO-operation at loads lower than 20% MCR and
dependant retardation of the engine performance occasionally performed "clean-burning" periods are
condition due to fouling of the exhaust gas channels inconvenient or impossible, special equipment and
and combustion air channels, combustion chambers arrangements must be established.
Load %
20
dmissible low-load operation
A Necessary operating period
(load percent/period) on HFO. with min. 70% load after low-
load operation on HFO.
15 Running-up period to 70%

load: approx. 15 min.
a b 70% load
10 HFO or MDO
5
a b
Operating period (h) Operating period (h)

Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to MDO
or b) operate engine for approx. 1.2 hours with 70% rating minimum, in order to burn off residues.
Afterwards low load operation on HFO can be continued.
Fig 1 Low-load operation.
08.20 - ES1
Your Notes :
Description Guidelines Regarding MAN Diesel & Turbo GenSets 501.16
Page 1 (1) Operating on Low Sulphur Fuel Oil Edition 02
General
Exhaust emissions from marine diesel engines have Low sulphur distillates
been the focus of recent legislation. Apart from nitrous
oxides (NOx), sulphur oxides (SOx) are considered In general our GenSet is developed for continuous
to be the most important pollution factor. A range of operation on HFO as well as on MDO/MGO. Occa-
new regulations have been implemented and others sionally changes in operation mode between HFO
will follow (IMO, EU Directive, and CARB). These and MDO/MGO are considered to be within normal
regulations demand reduction of SOx emissions operation procedures for our engine types and do
by restricting the sulphur content of the fuel. That is thus not require special precautions.
to say sulphur limits for HFO as well as mandatory
use of low sulphur distillate fuels for particular ap- Running on low sulphur fuel (< 0.1% S) will not cause
plications. This guideline covers the engine related problems, but please notice the following restrictions:
aspects of the use of such fuels.
In order to avoid seizure of the fuel oil injection pump
Low sulphur HFO components the viscosity at engine fuel oil inlet must
be > 2 cSt. In order achieve this it may be necessary
From an engine manufacturer’s point of view there to install a fuel oil cooler, when the engine is running
is no lower limit for the sulphur content of HFO. We on MGO. This is both to ensure correct viscosity and
have not experienced any trouble with the currently avoid heating up the service tank, which is important
available low sulphur HFO, that are related to the as the fuel oil injection pumps are cooled by the fuel.
sulphur content or specific to low sulphur HFO. This
may change in the future if new methods are applied When operating on MDO/MGO a larger leak oil
for the production of low sulphur HFO (desulphuriza- amount from fuel oil injection pumps and fuel oil
tion, uncommon blending components). MAN Diesel injection valves can be expected compared to op-
& Turbo will monitor developments and inform our eration on HFO.
customers if necessary.
In order to carry out a quick change between HFO
If the engine is not operated permanently on low and MDO/MGO the change over should be carried
sulphur HFO, then the lubricating oil should be se- out by means of the valve V1-V2 installed in front
lected according to the highest sulphur content of of the engine.
the fuels in operation.
For the selection of the lubricating oil the same ap-
plies as for HFO. For temporary operation on distillate
fuels including low sulphur distillates nothing has to
be considered. A lubricating oil suitable for operation
on diesel fuel should only be selected if a distillate
fuel is used continuously.
10.16 - ES1
Your Notes :
Description 501.25
Page 1 (1) Operating a Diesel Engine at Low Frequency Edition 01
General
Description Therefore it is advisable to reduce the allowable
max output of the diesel generator, in case of lower
At land-based power stations the diesel generator frequency/speed.
is often connected to a common eletrical grid with
more than one power producer. Maximum output should be lowered with the same
percentage as the frequency/speed drop.
Further the diesel engine is often small compared to
the rest of the grid. Under these circumstances the If the engine is controlled by an automatic power
diesel engine cannot control the frequency of the grid, management system, the program of the system
because the other producers are dominating. should take care of this output reduction.
If the diesel engine is delivering full 100% power at In case of no automatic power management, the
lower speed (lower frequency), this is equal to over- output reduction must be performed manually by
load on the engine. Thus, if the engine is designed the operator.
for 50 Hz at 750 rpm and the actual running condi-
tions are 100%, 45 Hz (675 rpm), this corresponds Furthermore, it is not advisable to operate the al-
to 10% overload. ternator at frequency lower than 6% under nominel
frequency.
Running the diesel engine at overload condition for
a long period is not recommendable, it will damage The alternator over/under frequency protection is
the engine and is therefore not acceptable. Such normally:
operating will immediately interrupt all guarantee ob-
ligations on the engine from MAN Diesel, Holeby. fN ± 6%, 5 sec delay
Below is illustrated a power curve for 50/60 Hz

engines.
08028-0D/H5250/94.08.12
Fig 1 Power curve for 50/60 Hz engines.
97.52 - ES1
Your Notes :
Performance and
condition
502/602
Your Notes :
Description
Engine Performance and Condition 502.01
L23/30H
V28/32S
Performance Data and Engine Condition An increase of charge air temperature involves a cor-
responding increase of the exhaust gas temperature
During operation small alterations of the engine level in a ratio of about 1:1.5, i.e. 1°C higher charge
condition continuously take place as a result of com- air temperature causes about 1.5°C higher exhaust
bustion, including fouling of airways and gasways, gas temperature.
formation of deposits, wear, corrosion, etc. If conti-
nuously recorded, these alterations of the condition Reduction of the charge air pressure results in a
can give valuable information about the operational corresponding reduction of the compression pres-
and maintenance condition of the engine. Continual sure and max. combustion pressure. When checking
observations can contribute to forming a precise the max. pressure adjustment of the engine, it is
and valuable basis for evaluation of the optimal therefore to be ensured that the existing charge air
operation and maintenance programmes for the pressure is correct.
individual plant.
The injected amount of fuel is equivalent to supplied
We recommend taking weekly records of the most energy and is thus an expression of the load and
important performance data of the engine plant. Du- mean pressure of the engine. The fuel pump index
ring recording (working card 502-01.00 can be used), can therefore be assumed to be proportional to the
the observations are to be continually compared in mean pressure. Consequently, it can be assumed
order to ascertain alterations at an early stage and that the connected values of the pump index are
before these exert any appreciable influence on the proportional to the load.
operation of the plant.
The specific fuel consumption, SFOC (measured by
As a reference condition for the performance data, weight) will, on the whole, remain unaltered whether
the testbed measurements of the engine or possibly the engine is operating on HFO or on MDO, when
the measurements taken during the sea trial at the considering the difference in calorimetric combustion
delivery of the ship can be used. If considerable value. However, when operation on HFO, the combi-
deviations from the normal condition are observed, nation of density and calorific value may result in an
it will, in a majority of cases, be possible to diagnose alteration of up to 6% in the volumetric consumption
the cause of such deviations by means of a total at a given load. This will result in a corresponding
evaluation and a set of measurements, after which alteration in the fuel pump index, and regard should
possible adjustment/overhauls can be decided and be paid to this when adjusting the overload preven-
planned. tative device of the engine.
Abrasive particles in the fuel oil result in wear of fuel

Evaluation of Performance Data pumps and fuel valve nozzles. Effective treatment
of the fuel oil in the purifier can limit the content of
For example, fouling of the air side of the air cooler abrasive particles to a minimum. Worn fuel pumps
will manifest itself in an increasing pressure drop, will result in an increase of the index on account of
lower charge air pressure and an increased exhaust an increased loss in the pumps due to leakage.
08028-0D/H5250/94.08.12
temperature level (with consequential influence on

the overhaul intervals for the exhaust valves). When evaluating operational results, a distinction
is to be made between alterations which affect the
Fouling of the turbine side of the turbocharger will, whole engine (all cylinder units) and alterations
in its first phase, manifest itself in increasing turbo- which occur in only one or a few cylinders. Deviations
charger revolutions on account of increased gas occuring for a few cylinders are, as a rule, caused
velocity through the narrowed nozzle ring area. In by malfunctioning of individual components, for
the long run, the charging air quantity will decrease example, a fuel valve with a too low opening pressure,
on account of the greater flow resistance through the blocked nozzle holes, wear, or other defects, an inlet
nozzle ring, resulting in higher wall temperatures in or exhaust valve with wrongly adjusted clearance,
the combustion chambers. burned valve seat etc.
02.47 - ES0
502.01 Engine Performance and Condition Description
L23/30H
V28/32S
The operational observations supplemented by Normally, the fuel nozzle temperature will be higher
the daily routine monitoring contribute to ensuring than the approx. 180°C, at which cold corrosion
that faulty adjustments and other deviations in the starts to occur.
performance of individual components are observed
in time to avoid operational disturbances and so Abrasive particles in the fuel oil involve a heavier wear
that normal routine overhauls can be carried out as of the fuel valve needle, seat, and fuel nozzle holes.
scheduled. Therefore, abrasive particles are, to the greatest pos-
sible extent, to be removed at the purification.
If abnormal or incomprehensible deviations in the
operation are recorded, expert assistance for the
evaluation of these should be obtained. Exhaust Valves
The overhaul intervals of exhaust valves is one of the

Turbochargers key parameters when reliability of the entire engine is
to be judged. Operation on HFO has a negative effect
Service experience has shown that the turbine side on these intervals. The performance of the exhaust
is exposed to increased fouling when operating on valves is therefore extremely informative.
HFO.
Especially under favourable conditions, fuel quali-
The rate of fouling and thereby the influence on the ties with a high vanadium and sodium content will
operation of the engine is greatest for small turbo- promote burning of the valve seats. Combinations of
chargers where the flow openings between the guide vanadium and sodium oxides with a corrosive effect
vanes of the nozzle ring are relatively small. Deposits will be formed during the combustion. This adhesive
especially occur on the guide vanes of the nozzle ring ash may, especially in the case of increased valve
and on the rotor blades. In the long run, fouling will temperatures, form deposits on the seats. An increa-
reduce the efficiency of the turbocharger and thereby sing sodium content will reduce the melting point and
also the quantity of air supplied for the combustion thereby the adhesive temperature for the ash, which
of the engine. A reduced quantity of air will result in will involve a greater risk for deposits. This condition
higher wall temperatures in the combustion spaces will be especially unfavourable when the weight ratio
of the engine. Na increases beyond 1:3.
Va
Detailed information and instructions regarding
water washing of the turbocharger are given in the The exhaust valve temperature depends on the actual
section 512. maintenance condition and the load of the engine.
With correct maintenance, the valve temperature is
kept at a satisfactory low level at all loads. The air
Fuel Valves supply to the engine (turbocharger/air cooler) and the
maximum pressure adjustment are key parameters
Assuming that the fuel oil is effectively purified and in this connection.
that the engine is well maintained, the operational
08028-0D/H5250/94.08.12
conditions for the fuel valves and the overhaul in- It is important for the functioning of the valves that the
tervals will not normally be essentially altered when valve seats are overhauled correctly in accordance
operating on HFO. with our instructions.
If, for any reason, the surface temperature of the fuel The use of rotocaps ensures a uniform distribution
valve nozzle is lower than the condensation tempe- of temperature on the valves.
rature of sulphuric acid, sulphuric acid condensate
can form and corrosion take place (cold corrosion).
The formation of sulphuric acid further depends on
the sulphur content in the fuel oil.
02.47 - ES0
Description
Engine Performance and Condition 502.01
L23/30H
V28/32S
Air Inlet Valves Engine Room Ventilation, Exhaust System
The operational conditions of the air inlet valves are Good ventilation of the engine room and a suita-
not substantially altered when using residual fuel. ble location of the fresh air intake on the deck are
important. Seawater in the intake air might involve
corrosive attack and influence the overhaul intervals
Fuel Pumps for the exhaust valves.
Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room
operation of the fuel pumps will not be very much is to correspond to approximately 1.5 times the air
affected. consumption of the engines and possible boilers
in operation. Sub-pressure in the engine room will
The occurrence of increasing abrasive wear of plun- involve an increased exhaust temperature level.
ger and barrel can be a consequence of insufficient
purification of the fuel oil, especially if using a fuel The exhaust back-pressure measured after the
which contains residues from catalytic cracking.Water turbochargers at full load should not exceed 250-
in the fuel oil involves an increased risk of cavitation 300 mm water gauge. An increase of the exhaust
in connection with pressure impulses occurring at the back-pressure will also involve an increased exhaust
cutting-off of the fuel pump. A fuel with a high asphalt valve temperature level.
content has deteriorating lubricating properties and
can, in extreme cases, result in sticking of the fuel
pump plungers.
08028-0D/H5250/94.08.12
02.47 - ES0
Your Notes :
Description Evaluation of Readings Regarding 502.02
Combustion Condition
V28/32S
PRESSURE DROP
INCREASING
(limit 50%)
Air filters
Fouled.
PRESSURE DROP
INCREASING
(limit 50%)
Air side of
cooler fouled.
ALL CYLINDERS
Exhaust temp. increasing:
TEMP. DIFFERENCE
Air system fouled
TOO LARGE
(Air filter-blower-cooler).
Water flow too small
Exhaust system fouled
(nozzle ring, turbine wheel).
TEMP. DIFFERENCE
TOO LARGE
Air cooler fouled.
ONE CYLINDER DECREASING CHARGE AIR

E x h a u s t t e m p. i n - PRESSURE:
creasing: Fuel valve Decreasing air amount.
needs overhaul. Fouled turbocharger,
Compression too low air filter or charge
owing to leakage of air cooler (air side).
exhaust valve or piston
08028-0D/H5250/94.08.12
ring blow-by.
Pcomp and Pmax ARE MEASURED by means
of max. pressure gauge.
Pcomp too low: Leaky combustion chamber,
charging air pressure too low.
See also:
Pmax too low:
P comp too low, ignition too late. Engine Performance
and Condition 502.01
02.47 - ES0
Your Notes :
Description
Condensate Amount 502.05
V28/32S
Ambient air temperature (1 bar)
(Above atmospheric)
10 20 30 40 50 60 70
0.10
of air in kg water / kg air
r
ba
1.0
r
0.08
ba
0
2.
Charge air pressure

0.06
r
ba
Max. water content
0
of atmosphere
3.
Water content
I %
%
0%
%
%
60
70
80
90
10
0.04
A B
in air tank
Pressure
0.02
II
30 bar
III
Relative 0
air humidity 30 40 50 60 70
Charge air temperature after cooler.

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

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

on the pressure and temperature of the air. 6L28/32H, 720 rpm (P) 1260 kW
Ambient air condition:
air temperature 35 °C
Amount of Condensation Water in The relative air humidity 90 %
Charge Air Receiver Charge air temperature 50 °C
Charge air pressure 2.6 bar
Both higher pressure and lower temperature reduce
the ability to absorb water. A turbocharged diesel As a guidance, an air consumption of 8.2 kg/kWh
engine takes air from outside, compresses and (Le) at full load can be used for MAN B&W Diesel
cools the air. Then, normally, the air cannot absorb A/S, Holeby engines.
the same amount of water as before.
92.06 - ES1
502.05 Condensate Amount
Description
V28/32S
Solution according to diagram: Amount of Condensate Water in Air Tanks
Water content of air (l) 0.033 kg/kg The volume of condensate in the air tank is determin-
Max. water cont. of air (ll) 0.021 kg/kg ed by means of the curve at the bottom to the right
of the diagram, representing an operating pressure
Amount of condensate in charge air recceiver. of 30 bar.
= (l - ll) x le x P Example:
= (0.033 - 0.021) x 8.2 x 1260 = 123 kg/h
Amount of condensate in air tank.
Draining of Condensation Water Volumetric capacity of tank(V) 4000 dm³

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

Max. water cont. of air (lll) 0.0015 kg/kg
Amount of condensate in air tank
= (I - III) x m.
= (0.033 - 0.0015) x 138 = 4.35 kg.
08028-0D/H5250/94.08.12
92.06 - ES1
Working Card 502-01.00
Page 1 (4) Engine Performance Data Edition 06H
V28/32S
Safety precautions Special tools
Stopped engine Plate no. Item no. Note.

Shut-off starting air
Shut-off cooling water 52005-01 10 Max. pressure
Shut-off fuel oil indicator
Shut-off nozzle cooling oil
Stopped lub. oil circul.
Press Blocking - Reset
Description Hand tools
Measurements of engine performance data.
Starting position
Engine is running.
Related procedure
08028-0D/H5250/94.08.12
Man power Replacement and wearing parts
Working time : ½ hour Plate no. Item no. Qty. /

Capacity : 1 man
Data
Data for pressure and tolerance (Page 500.35)

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
02.47 - ES0
502-01.00 Working Card
Edition 06H Engine Performance Data Page 2 (4)
V28/32S
Engine Performance Data
M/V Engine Type Engine No. Date/Year Hour Total Engine
1 2 3 4 5 6 running Hours
Engine RPM Fuel Type Turbocharger Turbocharger

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

B
18 Maximum Pressure (bar) A

B
19 Compress. Pressure (bar) A

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

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

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

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

Fuel oil temp. inlet engine (° C) Fuel oil press. before engine (bar)
46 47
Nozz. cool. oil press. inlet engine (bar) Nozz. cool. oil temp. outlet engine (°C) Sign.
48 49 50
02.47 - ES0
Page 3 (4) Engine Performance Data Edition 06H
V28/32S
The Instruction for Filling in the Diagram 13) Current (A) - can be read on the switch-
"Engine Performance Data" board.
The numbers in the instruction are commensurate 14) Cos ϕ/kVAr - can be read on the switch-
with the numbers on the diagram. board.
The automatic symbols mentioned in the instruction

TI 01, TI 03, PI 01 etc, refer to the diagrams printed Cylinder Data
in the instruction books for specified plants and
page 500.20. 15) Cylinder no. - can be read on engine plate.
A/B is used for V-engines.
Engine Performance Data 16) Average for all engine cylinders for point: 17-
18-19-20-21.
1) Name of ship, if stationary name of plant.
17) Fuel pump index - can be read on each of
2) Engine type. the high pressure fuel oil injection pumps.
3) Engine no. 18) Max pressure (bar) can be read for each
cylinder by means of indicator or Pmax gauge.
4) Date/year of observations.
19) Compression pressure (bar) - can be read for
5) Hour, time of observations. each cylinder by means of the indicator measure-
ment, which is carried out during idling by nominal
6) Total engine running hours - engineer's log- RPM.
book.
20) Exhaust temperature (°C)
7) Engine revolutions per minute (RPM) - can be - Thermometer TI 60.
read on tachometer SI 90.
21) Water outlet cylinder (°C) (jacket cooling)
8) Fuel oil type: The viscosity must be stated (in - Thermometer TI 11.
cSt) and the temperature by which the viscosity has
been measured f.inst. 180 cSt/50°C. Density must
be stated: g/cm³. Turbocharger
9) Turbocharger: Type and serial number are 22) Thermometer inlet blower (°C) can be read
stated on the rating plate of turbocharger and page by means of a thermometer placed in the engine
500.00. room near the air filter of the TC.
10) Turbocharger revolutions per minute (RPM) 23) Pressure before blower (mmWC) - can be
08028-0D/H5250/94.08.12
- can be read on the tachometer SI 89. read by means of a mmWC instrument placed in
the engine room near the TC.
Switchboard 24) Temperature after blower (°C) - can be read

by means of a thermometer TI 30.
11) Effect alternator (kW) - can be read on the
main switchboard. 25) Δ Pressure air cooler (mm/WC).
12) Voltage (V) - can be read on the switch- 26) Charge air temperature (°C). Temperature of
board. the charge air in the charge air receiver.
- Thermometer TI 31.
02.47 - ES0
Edition 06H Engine Performance Data Page 4 (4)
V28/32S
27) Pressure charge air (bar). Pressure of the 39) Pressure of the low temperature (LT) cooling
charge air in the charge air receiver. water (sea, raw or fresh) at inlet charge air cooler
- Pressure gauge PI 31. (bar)
- Pressure gauge PI 01.
28) Tempereture of the exhaust gas before TC (°C)
- Thermometer TI 62. 40) Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at inlet lub. oil cooler
29) Temperature of the exhaust gas after TC (°C) (°C)
- Thermometer TI 61. - Thermometer TI 07.
30) Pressure of the exhaust gas after the TC 41) Temperature of the low temperature (LT) cool-
(bar) ing water (sea, raw or fresh) at outlet lub. oil cooler
- Pressure gauge PI 61. °C)
Lubricating Oil System 42) Temperature of the low temperature (LT) cool-
ing water (sea, raw or fresh) at inlet alternator (°C)
31) Temperature of the lub. oil inlet cooler (°C) - Thermometer TI 04.
43) Temperature of the low temperature (LT)
32) Pressure of the lub. oil before the filter (bar) cooling water (sea, raw or fresh) at outlet alternator
- Pressure gauge PI 21. (°C)
33) Pressure of the lub. oil after the filter (bar)
- Pressure gauge PI 22. 44) Temperature of the high temperature (HT)
fresh water (FW) at inlet engine (°C)
The filter element should be replaced with a pres- - Thermometer TI 10.
sure drop across the filter of 1.5 bar (see section
515). 45) Pressure of the high temperature (HT) fresh
water (FW) of outlet engine (°C)
34) Temperature of the lub. oil inlet engine (°C) - Thermometer TI 10.
35) Pressure of the lub. oil before the turbocharger Fuel Oil System
(bar).
- Pressure gauge PI 23. 46) Temperature of the fuel oil at inlet engine
(°C)
47) Pressure of the fuel oil before engine (bar)
08028-0D/H5250/94.08.12
37) Temperature of low temperature (LT) cooling - Pressure gauge PI 40.

water (sea, raw or fresh) at inlet charge air cooler
(°C) 48) Nozzle cooling oil pressure at inlet engine
- Thermometer TI 01. (bar)
- Pressure gauge PI 50.
38) Temperature of low temperature (LT) cooling
water (sea, raw or fresh) at outlet charge air cooler 49) Nozzle cooling oil pressure at outlet engine
(°C) (bar)
- Thermometer TI 02. - Pressure gauge PI 51.
50) Signature.
02.47 - ES0
Trouble shooting
503/603
Your Notes :
Description
Starting Failures 503.01
Page 1 (1)
Edition 02
General
Trouble Possible cause Troubleshooting
Engine turns as soon as shut- Faults in electrical system. Check electrical parts.
off valve is opened, without
start button being activated.
Engine does not turn when Air pressure in starting air Start compressors, re-charge
start button is activated. receiver too low. air receiver.
Main valve(s) closed. Open valve at receiver and stop

valve interposed in line between
receiver and engine.
Pinion does not engage with Check the air starter.

the flywheel.
Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing or clutch
jaws,
see Working Card 513-01.30.
Faults in electrical system. Check electrical parts.
Engine turns too slowly or ir- Worn air motor parts. Remove and disassemble the
regularly when start button is air motor. Examine all parts
activated. and replace any that are worn
or damaged. Use the guidelines
for determining unserviceable
parts, see Working Card 513-
01.30.
Start valve is sticking in closed Check start valve.

position.
Low air pressure. Raise the air receiver pres-

sure.
Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.
08028-0D/H5250/94.08.12
04.31 - ES0
Your Notes :
Description
Faults in Fuel Oil System 503.02
Page 1 (2)
Edition 05
L16/24 L27/38
V28/32S L21/31
Engine turns, but ignition fails. Fuel Sluggish movement of manoeuvering Lubricate and mobilize rod connections
pumps are not actuated. gear. in manoeuvering gear.
Incorrect adjustment of manoeuver- Check rod connec. Check that fuel pump
ing gear. index corresponds to "Adjustments after
trials" in testbed chart.
Safety system stop activated. Reset safety system stop.
Piston in Lambda controller is ac- Check that piston is not sticking. Check
tuated. that pressure in cylinder is relieved.
Check that the shutdown trip is not
actuated.
Check pressures and temperatures.

Piston in Lambda controller cylinder Check for faults in shut-down devices:
is actuated due to stop function or Check for faults in fuel limitation de-
fuel limitation. vices.
Check adjustment according to
Working Card 509-10.00.
Incorrect adjustment of Lambda con- Adjust setting of adjustment screw, see

troller's adjustment screw. Working card 509-10.00.
Governor setting incorrect. Adjust governor, see special instruction

manual.
Failures in governor. Check that governor is working properly.

For further fault location, see special
instruction manual in section 509.
Sticking fuel pumps. Dismantle and clean.
Engine turns, but no fuel is injected Fuel oil service tank empty. Pump oil into the tank.
owing to failure in fuel system.
If Then
Air in fuel pumps. Loosen hexagon
socket screw on
fuel pumps until air
disappears.
Engine runs, but does not ignite on Air in fuel valves. Ignition fails on Vent the respective
08028-0D/H5250/94.08.12
all cylinders. one or more fuel valves.

cylinders due to
air in the fuel
valves.
Ignition fails on Change the fuel

one or more valves and check
cylinders and them for sticking
no air bubbles spindle or broken
appear. spring. Check for
collecting oil on
piston top.
Air appears in Check stuffing box

the entire system. and sealing in the
fuel system.
Cont.
02.40 - ES0
503.02 Faults in Fuel Oil System Description
L16/24 L27/38
V28/32S L21/31
Worn-out fuel pump. Change fuel pumps.
If Then
Pressure before Clean fuel filter.
pumps is too low. Check that by-pass
valve for feed pump
is not open.
Pressure is still Increase the fuel

too low. oil feed pump
pressure.
Engine turns, fuel is injected, but Water in the fuel. Drain off water and repeat venting of fuel
ignition fails. pumps by loosening the hexagonal socket
screw until air disappears.
Fuel valves or nozzles defective. Change defective fuel valves, see working
card 514-01.10.
If Then
Compression Check intake and
during start too exhaust valve for
low. tight closing.
Check piston rings.
Timing of fuel Check fuel cam-

camshaft is shaft adjustment,
incorrrect. see Working card
507-01.20.
Major alteration Adjust camshaft,

of the fuel de- see Working card
mand adjustment 507-01.20.
of the fuel pump
timing.
Oil has collected Slow turning to

on piston crown. remove oil. Locate
and change defec-
tive fuel valve.
08028-0D/H5250/94.08.12
First ignitions are too violent. Engine Sluggish movement of manoeuvering Lubricate and mobilize rod connections
runs erratically. gear. and bearings in manoeuvring gear.
Fuel pump index to high. Check rod connection in manoeuvring

gear. Check that governor is working
properly.
02.40 - ES0
Description 503.03
Page 1 (3) Disturbances During Running Edition 06
L21/31
L27/38
V28/32S
Exhaust gas temperatures Increased charging air temperature Clean air coolers, see working card 512-01.00.
increased on all cylinders. due to ineffective air coolers.
Fouling of air and gas passages. Clean air and gas passages, see working cards in section
512.
Insufficient cleaning of fuel oil or Check separator and fuel filters.

changed combustion characteristics.
Wrong maximum combustion pressure Check camshaft adjustment, see working card
/fuel injection timing 507-01.20.
Poor fuel quality. Change fuel.
Exhaust gas temperature Fuel valve or valve nozzle defective. Overhaul fuel valve, see working card 514-01.10.
increased on one cylinder.
Leaky exhaust valves. Check the valve clearance, see working card 514-01.10
or
change the leaky valve and recondition the exhaust valve,
see working card 505-01.05.
Note: This manifests itself by a rise If Then

in the exhaust temperature and faill- Stopping of the The fuel pump of the cylinder con-
ing of the compression and maximum engine is not cerned should be put out of opera-
combustion pressure of the respective possible or tion by moving the index to stop
cylinder. convenient. and locking it in this position.
Blow-by = leaky combustion cham- Check piston rings, see working card 506-01.35.
ber.
Blow-by means a serious danger of piston seizure, and
the engine must if possible be stopped and the piston in
question pulled. Leaky piston rings will normally result in
heavy excess pressure in the crankcase.
If Then
Stopping of the The fuel pump of the cylinder con-
engine is not cerned should be put out of opera-
possible or tion by moving the index to stop
convenient. and locking it in this position.
08028-0D/H5250/94.08.12
Damaged fuel pump cam. Replace camshaft section, working card 507-01.05.
Exhaust gas temperature Decreased charging air temperature. Check the thermostatic valve in the cooling water system,
decreases on all cylinders. see working card 516-04.00.
Exhaust gas temperature Spindle in fuel valve is sticking. Change and overhaul defective fuel valve, see working
decrease on one cylinder. card 514-10.00.
Fuel pump plunger is sticking or Change fuel pump plunger/barrel assembly, see working
leaking. card 514-10.00.
Cont.
05.08 - ES0
503.03 Description
Edition 06
Disturbances During Running Page 2 (3)
L21/31
L27/38
V28/32S
Engine speed decreases. Pressure before fuel pumps too low. Raise fuel oil feed pump pressure to normal.
or
check filter, see working card 514-01.15.
Fuel valve defective. Change defective valve, see working card 514-01.10.
Fuel injection pump defective. Change or overhaul.
Water in the fuel. Drain off water from service and setting tanks. Check fuel
oil centrifuge.
Governor defective. See governor manual.

Linkage adjustment wrong
Engine stops. Shut-down for overspeed. Check fuel pumps, see working card 514-10.00.
Check governor, see governor manual.
Check movement of regulating mechanism.
Shut-down for low lubricating Check pressostat, see working card 509-05.00.
oil pressure. Check lubricating oil filter, see working card 515-01.10.
Check lubricating oil pump, see working card 515-01.00.
Shut-down for high lubricating Check lub. oil flow and pressure,
oil pressure. see working card 515-01.20.
Clean lubricating oil cooler, see working card 515-06.00.
Shut-down for high HT cooling water Check HT system and pumps.

temperature.
Smoky exhaust. Turbine speed lagging behind engine Clean turbine(s), see turbocharger manual
speed.
Air supply too low. Clean air cooler, see working card 512-01.00.
Clean air filter, see working card 512-35.00.
Clean compressor, see turbocharger manual
Clean turbine, see turbocharger manual
Fuel valves or nozzles defective. Check fuel valves, see working card 514-01.10.
Exhaust valve knocking. Adjusting screw for valve setting Inspect and replace defective parts, see working card
08028-0D/H5250/94.08.12
clearance loose. Push rod thrust disc 508-01.00.

damaged.
Rising cooling water Thermostatic function Check thermostat.

temperature.
Pump defective Stop the engine and repair the pump.
Decreased flow Check valves.
If Then
The cooling water Open the test cocks (if
fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-100°C. Cont.
05.08- ES0
Description 503.03
Page 3 (3) Disturbances During Running Edition 06
L21/31
L27/38
V28/32S
Check whether steam has

developed.
Steam has developed. Stop the engine.

Leave the engine to cool
while the discharge valve
is closed.
After 15 minutes open the

discharge valve a little to
allow the water to rise
slowly in the cooling
jackets.
Check filling at test cocks.
Lubricating oil pressure Lubricating oil pump defective. Check lubricating oil pump, see working card 515-01.00.
fails.
Filters fouled. Clean filter, see working card 515-01.10.
Cooler fouled. Clean cooler, see working card 515-06.00.
If Then
The lubricating oil Stop the engine: find the
pressure drops below cause of the pressure drop
the minimum stated and remedy the defect
before
in the Data sheet. restarting the engine.
Note: Feel over 5-15-30 minutes after starting, and again

when full load is achieved.
See section 502.
Alternator (GenSet only) Short circuit Flywheel must be dismounted and guide pin replaced
08028-0D/H5250/94.08.12
05.08 - ES0
Your Notes :
Description 503.04
Page 1 (1) Ignition in Crankcase Edition 03
General
Cause 1) Stop the Engine
During running the atmosphere in the crankcase 2) Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of oil drops is slung around everywhere. If
undue friction, and thus heating, arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is otherwise transmitted to after stopping the engine. When opening up, keep
the crankcase, the heated surface will cause eva- clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed onto it. When do not smoke.
the oil vapours condense they form milky white oil
mist which can ignite. Such ignition may be caused 3) Cut off starting air.
by the same "hot spot" that produced the oil mist. Set the control panel in "Blocking Mode" see
If a large quantity of oil mist has developed before description 501.01.
ignition, the burning may cause considerable pres- Take off all doors on one side of the crank-
sure rise in the crankcase, forcing the relief valves case.
to open. In a few cases, presumably when the whole
crankcase has been filled with oil mist, a subsequent 4) Locate the hot spot. Powerful lamps should be
explosion has thrown off the crankcase doors and employed at once (in explosion-proof fittings).
caused fire in the engine room. Feel over all sliding surfaces (bearings, liners,
pistons, roller guides, etc.).
Every precaution should therefore be taken to (A)
avoid "hot spots" and (B) discover oil mist in time. Look for squeezed-out bearing metal and discol-
oration by heat (blistered paint, burnt oil, heated
steel).
"Hot spots" in Crankcase
5) Prevent further heating, preferably by making
Overheating of bearings is a result of inadequate or a permanent repair. Special attention should be
failing lubrication, possibly caused by pollution of paid to ensuring lubricating oil supply and the
the lubricating oil. satisfactory condition of the frictional surfaces
involved. It is equally important to replace filter
It is therefore important that the lubricating oil filtration elements in time.
equipment is in perfect condition. Filter cartridges may
not be used again if they have been removed from 6) Start electrically driven lubricating oil pump
the filter. Checking of the oil condition by analysis is and check oil flow from all bearings and spray
recommended. pipes in crankcase while turning the engine
through at least two revolutions.
7) Stop and feel over. Look out for oil mist.

08028-0D/H5250/94.08.12
Oil Mist in Crankcase
The presence of oil mist may be noted at the vent Especially the frictional surfaces that caused the
pipe which is usually fitted to the top of the engine heating should be felt over (5-15-30 minutes after
frame. starting, and again when full load is obtained). Sec-
tion 501.10.
Measures (in case of white oil mist).
8) If it has not been possible to locate the hot spot,
Warning: Keep away from doors and relief valves on step 7 should be intensified and repeated until
crankcase. Do not stay unnecessarily in doorways the cause of the oil mist has been found and
near the doors of the engine room casing. remedied. In very rare cases oil mist could be
due to "atomization" of lubricating oil by the
action of an air jet (for instance blow-by, or
blow-by through cracked piston).
00.12 - ES0
Your Notes :
Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 04H
V28/32S
Tabulated below are the corresponding remedial acti-
ons to be taken if the following faults are obser ved:
Trouble Possible cause Trouble shooting
Oil leakage through cover nut Missing or damaged O-ring (see Item
325, Plate 51515) Replace O-ring
Seal face damaged Replace O-ring
Excessive vibrations Rotor out of balance owing to un-even

build-up of deposit on rotor walls resul-
ting from:
Missing or damaged O-ring, allowing Replace O-ring

leakage (see Item 254, Plate 51515)
O-ring seat on rotor joint faces dama- Replace rotor assembly

ged
Rotor assembly inadequately tightened Tighten and bring to notice of main-

tenance staff
Standtube incorrectly seated or da- Re-fit or replace if damaged

maged
Dirt deposit not completely removed Clean and bring to notice of main-
tenance staff
Rotor castings distorted through mal- Replace rotor assembly

treatment
Rotor assembly components fitted in Follow sequence in Working Card

wrong sequence 515-15.00 in section 515.
Bushes loose or worn in tube assembly Fit new bearing tube assembly
02.38 - ES0
Your Notes :
Description 503.06
Page 1 (2) Trouble Shooting Guide for Air Starter Edition 05H
L27/38
V28/32S
Trouble Possible Cause, see working card Trouble Shooting
1. Air always flow through A. Relay valve improperly A. Check typical installation
exhaust installed. diagram and correct.
B. Relay valve not sealing B. Check for damaged sealing

properly. ring, replace relay valve or
damaged parts.
C. Solenoid is not sealing, C. Check solenoid potential at the

pressure remains in APP port of lead to ground should be 0. If not,
relay valve. fix ignition switch problem.
2. Starter engages but does not A. Bad relay valve A. Replace relay valve.
run
3. Starter does not run, small air A. Nozzle blockage. A. Remove blockage or obstruction
flow from turbine exhaust or from nozzles.
drive housing.
4. Starter does not run. Normal A. Excessive bends in the A. Shorten length or straighten
air flow from exhaust. supply line. supply air line.
5. Pinion does not engage A. Air pressure is too low A. Increase air pressure to 40 -
150 psig.
B. Control lines to starter ports B. Check installation diagram and

reversed. correct.
C. Solenoid valve not operating C. Check wiring and solenoid

or plugged. operation. Correct wiring, remove
blockage, or replace solenoid
valve as needed.
D. Damaged pinion teeth. D. Replace pinion or starter drive

as necessary.
6. Starter runs but engine cranks A. Air pressure too low A. Increase air pressure to 40 –
08028-0D/H5250/94.08.12
slowly or not at all. 150 psig.
B. Excessive back pressure. B. Check Exhaust Closure Plate.
C. Nozzle blocked or damaged. C. Remove blockage or replace

damaged parts.
7. Starter continues to operate A. Solenoid valve is not sealing A. See 1C above

after start button is released. correctly.
B. See 1B above
B. Relay valve is not sealing
correctly.
02.35 - ES0
503.06 Description
Edition 05H
Trouble Shooting Guide for Air Starter Page 2 (2)
L27/38
V28/32S
Trouble Possible Cause, see working card Trouble Shooting
8. Air tank pressure decays after A. Air connections are not tight. A. Tighten loose fittings. Repair or
extended shut down. replace damaged fittings.
B. Damaged air lines: crushed, B. Replace damaged lines.

frayed, and kinked.
C. Relay valve is not sealing C. See 1B above

correctly.
D. Solenoid valve is stuck open. D. A. See 1C above
08028-0D/H5250/94.08.12
02.35 - ES0
Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1)
Edition 08H
V28/32S
Description The pump bearings are lubricated automatically with

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

tank
Air cannot escape on delivery side Vent the system
Leaking shaft seal Check the shaft seal
Pump capacity drops after nor- Air leakages of shaft seal Overhaul the shaft seal
mal operation
Fouled impeller Clean the impeller
Pump does not give maximum Suction valve not fully open Open the suction valve
delivery
Defective seals Replace the seals
Worn impeller and worn wear Overhaul the pump

rings
Note: Running troubles with the pump, apart from

mechanical faults, are most often due to leaks in the
suction line. It is essential, therefore, that all packings
and gaskets are in order and that they are renewed
08028-0D/H5250/94.08.12
when necessary. Even a thiny hole in the suction line

will reduce the pump capacity.
02.38 - ES0
Your Notes :
Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01
General
Trouble Shooting Fatigue fracture will normally necessitate replace-
ment of all plates and gaskets as there may be a
It is necessary to replace damaged plates or ga- risk of fatigue fracture in all the material.
skets. In case of corrosion, all plates must be examined
carefully!
First examine the external conditions around the Concerning the work to be carried out see Working
plate heat exchanger in order to localize the cause card 515-06.00.
of the damage. Do this very carefully.
Visible Leakage
Leakage. Too high pressure. Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operating
Data & Set Points".
Leakage. Insufficient tightening. Tighten up the plate heat exchanger, but

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

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

(Even after tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension.) Replace the gaskets.
08028-0D/H5250/94.08.12

start it up again.
Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the gas- plate. Replace defective plates and gaskets,
kets.) if any.
start it up again.
98.20 - ESO
503.10 Description
Edition 01 Troubleshooting for Lubricating Oil Cooler Page 2 (2)
General
Non-Visible Leakage
Reduced heat transmission and/or Fouled plates or choked plate chan- Separate the plate heat exchanger and
increasing pressure drop. nels. check if the plates are fouled.
Clean the plates very carefully.
start it up again.
Leakage. Holes in plates. A suspected leakage can be localized in

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

(The fluids get mixed.) Corrosion or fatigue fracture. Separate the plate heat exchanger.
(Phase 2) Put all plates to dry. Suspend the plates
in the plate heat exchanger again and
tighten it.
Circulate medium at full capacity on one
plate side (every second plate channel).
Keep the other plate channels unpres-
surised and free from liquid!
Stop the circulation after a few minutes
of operation and open the plate heat ex-
changer again. Take care to avoid water
spraying onto the dry plate side!
By a careful study of the plates it will be
08028-0D/H5250/94.08.12
possible to find moist areas, if any, on the

otherwise dry plate sides.
Check these areas with a dye penetrant!
Replace defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
check to find more defective plates, if any,
by putting one side under press.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!
98.20 - ES0
Description 503.20
Page 1 (6) Trouble Shooting / Electrical Failures Edition 03H
V28/32S
Trouble Shooting Further, please remember to inform the software no
when ordering a new module.
This description is a trouble shooting guide for
the automation system on the diesel engine type
V28/32S. Safety System
The safety system is an independent system and

General consists of maker ABB PLC hardware modules and
MAN B&W software. Fig 1 describes the hardware
The following trouble shooting guide is an aid in iso- modules.
lating troubles to the engine built-on safety system
and monitoring system incl. the sensors connected For wiring of the modules and sensors a reference
to these systems. is made to the scheme which can be found in the
operation manual, section 509.
CAUTION! The control system can be damaged
with the wrong voltage. When replacing a control The safety system consists of two ABB PLC mod-
unit, check that the power supply is switched off ules. The modules named 4P1 is the CPU module
during replacement and check the power supply for and the modules named 5, 6, 7P1 are an I/O-module.
the correct voltage before switching-on. Indication of individual input and output can be found
on the modules by yellow diodes. The reference
Table 1.1 for the safety system and table 1.2 for the number for each input and output can be found in
monitoring system are general guides for isolating the scheme.
system problems. Each system check assumes that
the prior checks have been done properly. Table 1.3 On the operation box individual indication of the shut-
and 1.4 are system error messages which can be a downs (low lub. oil pressure, high cool. water temp.,
guideline to the problem. overspeed and emergency stop) can be found.
If the conclusion of a trouble shooting indicates If a replacement module is needed, the software ver-
that an exchange of a module is needed, please sion must be informed at ordering. Software version
fill-in the enclosed inspection report, and return the number is written on the module.
module together with the inspection report to the
engine maker.
08028-0D/H5250/94.08.12
Fig 1 Hardware module.
02.18 - ES0
503.20 Description
Edition 03H Trouble Shooting / Electrical Failures Page 2 (6)
V28/32S
Table 1.1
Engine will not start. Supply voltage polarity, or no sup- Check the supply voltage on the green diode on
Start motor is not engaged. ply voltage. 4P1. If it is alight the power supply for the PLC
modules are OK.
RUN/STOP change-over switch on Put the RUN/STOP change-over switch in RUN

3P1 in wrong position. position. Check RUN LED on 4P1.
No software in the module. If no diodes on 4P1, 6P1 and 7P1 are alight and err
is given on 4P1 after having switched on the power
supply, the module is without software. The module
must be replaced with a module incl. software.
Note! After switch-on of the power supply the
initialization takes app. 3 sec. Please wait these
seconds before observation.
Output relay on 5 on 7P1 is in failure Check that diode 5 on 7P1 is alight.

or loose connections. If diode 5 on 7P1 is not alight check that in 1 on
4P1 is alight and A62.07 is stable (continuous on or
continuous off) Check for loose wires on terminals
7 & C7 no on 6P1.
One or several shutdown signals are Reset the shutdowns.

activated on the monitoring box If one is still activated on the operation box, check
that out 2, 3, 4 and 5 are alight. If one is not alight,
check the sensor and wiring for short circuit.
All shutdown LED are alight on the Connector is not correctly connected Check the connector J29 on the base module. No
monitoring box. on internal failure in 4P1. LED must be alight on 4P1. Activate the change-over
switch RUN/STOP. Exchange the 4P1 module.
Low lub. oil shutdown occurs when Damaged or wrong adjustment of Check the pick-up for correct adjustment.
normal stop is activated. the rpm pick-up. Sensing distance = app. 1 mm, (for Honeywell pick-
up the latern must be placed at 3 or 9 o‘clock)
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly. Replace the pick-up.
Note! Diode 0 on 7P1 will be alight if actual speed
is above nominal speed. If actual speed is below,
it will be dark.
The alarm „System & Power failure“ The internal connection is discon- Check that the bus connection on terminals 1 +
is activated. nected or internal component 2 is OK. Check that power supply is OK. (Green
diode must be alight). Switch on the RUN/STOP
08028-0D/H5250/94.08.12
Diode 0 or 1 on 6P1 is not alight. failure.

change-over switch. The problem could be related
to an internal component failure and the module
must be replaced. Observe that no red diode is
alight on 4P1.
The shutdown functions are not Wiring or sensor problem. Check the wiring for shutdown sensors.
working. Internal component failure. Replace the module.
Overspeed set point is not correct. Missing jumper or wrong software. Check that in 7 on 4P1 is alight for 720 rpm engines,
and OFF for 750 rpm engines. Check the software
version by screwing the upper potmeter on 4P1 >
halfway, and count the flashes. It will be 7 flashes
pause x flashes pause x flashes pause x flashes,
ex. 7.2 (7 flashes pause 2 flashes)
02.18 - ES0
Description 503.20
V28/32S
The Monitoring System Interface to the alarm and monitoring system in the
control room is made by MODBUS or Interlink to the
The monitoring system monitors shows all relevant output module.
pressures, temperatures and rpm on the engine.
The software can be read on the label attached on
The monitoring system consists of four hardware the Base Module or by pushing the lamp test button
modules as standard and a module as option for for 3 seconds. The software version number will be
bearing temp. monitoring. The monitoring system displayed in the operation box display.
hardware and software is developed by MAN B&W.
Fig 2 describes the hardware. The software for engine type V28/32S will start
with 71.x, f.ex. 71.2. Please make sure that the dip
All sensors are connected to the base module and switches SW1, SW2, SW5 and SW3 are in correct
the Operation Box (OB), Monitor for Temp. and position acc. to the plant related scheme. See sec-
Pressure Module (MTP) and Monitor for Exh. Gas tion 509.
Temp. Module (MEG) are connected via interlink
bus connection.
08028-0D/H5250/94.08.12
Fig 2 Hardware modules.
02.18 - ES0
503.20 Description
V28/32S
Table 1.2
Engine will not start. Power supply is not correct, interlock Check that the power supply is correct 24 V ± 20%
Start motor is not engaged. activated or internal component on terminals J3; 132, 133.
failure Check that no interlocks are activated
– Turning gear not engaged
– No start failure activated
– No engine run signal
– Remote mode is activated
– No shutdown activated
– Stop valve not activated
– No lub. oil pressure
– Prelub. oil pressure is OK
Check that LED on base module is steadily green
alight. See also table 1.3
Check that wirings from terminals J20; 98, 99 are
correct.
Check the safety system (see table 1.1)
Check that the ON/OFF switch on the base module
is working properly.
Note! After having switched on the power supply,
the system initializes app. 3 seconds. Please wait
with observations until initializing is finished.
Replace the base module.
Start motor engaged and engine Pick-up failure on both safety- and Check monitor pick-up and safety system. If system
started but stopped again after few monitor pick-up. failure or cable failure is activated on safety system
minutes. and the monitor pick-up is out of order the engine
will be stopped again.
Data communication failure. EMC problem or loose connec- Check that the green LED on the base module is
tions. alight. See also table 1.3
Check that all cable screens are connected correctly
in the EMC cable glands.
Check that the data communiation cable (MODBUS)
is the twisted pair type.
No RPM indication Defect pick-up or incorrect adjust- Check the pick-up for correct adjustment.
ment. Sensing distance = app. 1 mm, (for Honeywell pick-
up the latern must be placed at 3 or 9 o‘clock)
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
08028-0D/H5250/94.08.12
the connector correctly.

Replace the pick-up. For the Dr. Horn pick-up the
sensing distance must be 1-1.8 mm (the thread on
the pick-up is 1 mm)
the engine suddenly starts or Two or more earth failures on the Check for earth failures on all sensors.
stops. engine and yard installation. Special attention should be made to the exh. gas sen-
sors. Check for earth failures in the yard system.
Replace the base module.
LED flashing green, yellow or red. Internal component failure or EMC See table 1.3. Switch the power ON/OFF.
problem. Exchange the base module.
Cont.
02.18 - ES0
Description 503.20
V28/32S
Cont. Table 1.2
All red diodes on the operation box No power supply or software in the Check the safety system accoding to table 1.1.
are alight. safety system.
Jet system activated under no The band steel on the lambda arm Adjust the band steel to app. 2-3 mm above the
load condition and/or jet alarm is adjusted incorrectly. jet pick-up.
activated.
„Frozen“ operation box, MTP and Internal software failure. See table 1.3. Switch the power supply on/off.
MEG box. Exchange the base module.
Instable behaviour of the output Too high voltage on the output circuit Check that the voltage is below 48 VDC.
signals for start/stop of prelubricat- terminals J20, 108, 109 120 VAC or 220 VAC is not allowed.
ing pump. Note! The voltage must be checked in the prelubri-
cating pump starter panel.
Temp. indication is too high acc. Internal component failure. Replace the base module.
to calibrated values, or values are
abnormal.
Change-over switch between LO- Internal failure in the operation See table 1.3 and 1.4. Replace the operation box.
CAL - REMOTE - BLOCKING is box.
not working. Damaged flat cable between print
card and front panel.
The alarm „System & Power failure“ This alarm consists of different alarm 1) Check diode 1 on 6P1 on the safety system
is activated. possibilities module 6P1. If it is alight, it is OK. No red LED must
1) Power & system failure in the be alight on 4P1. See also table 1.1. SUPPLY LED
safety system. and RUN LED must be alight.
2) Power supply failure to the pres- 2) Check green diode J29/J30 and fuse 2.5 AT. If
sure sensors. green diode is alight, it is OK.
3) Cable/wire failure for monitor 3) Check if any analog signals are missing. If all
sensors. signals are present, it is OK. Remember to check
4) Cable/wire failure for safety also the spare exh. gas input channels. A jumper
system sensors. must be present. See also table 1.4
5) Communication link failure. 4) Check diode 0 on 6P1. If it is alight, it is OK. If
6) Tacho failure. it is not alight, check the safety system for cable
break or loose connections.
5) Check if rpm pick-up is OK, and/or lub. oil
pressure is OK. If lub. oil pressure is normal, but
no rpm signal is present, the tacho alarm will be
08028-0D/H5250/94.08.12
activated.
6) Check the diode on the base module to table
1.3 and table 1.4.
OB display indicates OFFLN or Cable break on data communication See table 1.3. Check cable installation for sensor(s)
ERR-1 or fault. or sensor(s). and/or data communication
02.18 - ES0
503.20 Description
V28/32S
Table 1.3
Base Module LED indications
On the Base Module printed circuit board a two-coloured lamp (light diode, LED) is located , which indicates the current state of the
Base Module central processor.
The following failure LED indications are possible:
Observations Description
GREEN permanent light OK, all Interlink modules are online
GREEN flash One or more Interlink modules are offline (disconnected) or incorrect setup on SW2.
RED permanent light BM internal hardware error (or lockup caused by EMC disturbances).
YELLOW permanent light BM internal hardware error (or lockup caused by EMC disturbances).
RED flash BM software or hardware fault. The number of flashes indicates an internal error code which must be
reported when returning the module. (It may also be caused by EMC disturbances)
Yellow 4x flash MODBUS address error (SW1): Incorrectly set to an illegal address (0 or 255, all switched ON or
OFF).
Other yellow flashes BM internal software fault. The number of flashes indicates an internal error code which must be reported
when returning the module. (It may also be caused by EMC disturbances)
Table 1.4
Display indications on the Operation Box (OB)
Observations Description
Ready Shown for a few seconds when the OB module is powered on, indicating that the internal selftest of the module
was successfully passed.
OFFLN The OB module is OFFLINE. There is no communication from the base module to the OB module. This message
will appear shortly when powering on the system, indicating that the base module has been reset.
– Defective link between BM and OB module.

– No power on BM
– BM fatal hardware or software error. Indicated be red or yellow light or flashes on the BM two-coloured
08028-0D/H5250/94.08.12
LED.
ERR-1 Indicates cable break or sensor failure on the corresponding input.

Note: in case of cable break or sensor failure of the engine rpm pick-up or TC pick-up the display will change
between ERR-1 and “normal” indication.
FAULT Indicates that the BM module has entered failsafe mode either because of a fatal software or hardware fault.
Shown if the exhaust temperature is selected for an invalid cylinder number.
02.18 - ES0
Specification
504/604
Your Notes :
Description Specification for lubricating oils (SAE40) for 504.01
Page 1 (5) heavy fuel oil operation (HFO) Edition 22
L16/24, L21/31
L27/38, V28/32S
General Only lubricating oils that have been approved by
MAN Diesel & Turbo may be used. These are listed
The specific output achieved by modern diesel en- in the table entitled "Lubricating oils approved for
gines combined with the use of fuels that satisfy use in heavy fuel oil-operated MAN Diesel & Turbo
the quality requirements more and more frequently four-stroke engines".
increase the demands on the performance of the
lubricating oil which must therefore be carefully se- Specifications
lected.
Base oil
Medium alkalinity lubricating oils have a proven
track record as lubricants for the moving parts and The base oil (doped lubricating oil = base oil + addi-
turbocharger cylinder and for cooling the pistons. tives) must have a narrow distillation range and be
Lubricating oils of medium alkalinity contain addi- refined using modern methods. If it contains paraf-
tives that, in addition to other properties, ensure a fins, they must not impair the thermal stability or
higher neutralisation reserve than with fully doped oxidation stability.
engine oils (HD oils).
The base oil must comply with the limit values in
International specifications do not exist for medium the table below, particularlyin terms of its resist-
alkalinity lubricating oils. A test operation is there- ance to ageing:
fore necessary for a corresponding period in ac-
cordance with the manufacturer's instructions.
Properties/characteristics Unit Test method Limit values

Make-up   Ideally paraffin based
Low temperature behaviour, still flowable °C ASTM D 2500  15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of MAN ageing oven
 
heating up to 135 °C *
ASTM D 4055 or
insoluble nheptane Weight % < 0.2
DIN 51592
Evaporation loss Weight %  < 2
Precipitation of resins or asphalt-
MAN Diesel &
Spot test (filter paper)  like ageing products must not be
Turbo test
identifiable.
Table 1 Base oils - target values
* Works' own method
11.01 - ES1 - 3.3.6 (2011-01-04)

504.01 Specification for lubricating oils (SAE40) for Description
Edition 22 heavy fuel oil operation (HFO) Page 2 (5)
L16/24, L21/31
L27/38, V28/32S
Medium-alkaline lubricating oil For tips on selecting the base number, refer to the
table entitled “Base number to be used for various
The prepared oil (base oil with additives) must have operating conditions".
the following properties:
Evaporation tendency
Additives
The evaporation tendency must be as low as pos-
The additives must be dissolved in the oil and their sible as otherwise the oil consumption will be ad-
composition must ensure that as little ash as pos- versely affected.
sible is left over, even if the engine is provisionally
operated with distillate oil. Additional requirements
The ash must be soft. If this prerequisite is not met, The lubricating oil must not contain viscosity index
it is likely the rate of deposition in the combustion improver. Fresh oil must not contain water or other
chamber will be higher, particularly at the exhaust contaminants.
valves and at the turbocharger inlet casing. Hard
additive ash promotes pitting of the valve seats and Lubricating Oil Selection
causes the valves to burn out, it also increases me-
chanical wear of the cylinder liners.
Engine SAE Class
Additives must not increase the rate at which the 16/24, 21/31, 27/38, 28/32S, 32/40,
32/44, 40/54, 48/60, 58/64, 51/60DF 40
filter elements in the active or used condition are
blocked. Table 2 Viscosity (SAE class) of lubricating oils
Washing ability
The washing ability must be high enough to prevent Neutralisation properties (BN)
the accumulation of tar and coke residue as a result
of fuel combustion. The lubricating oil must not ab- Lubricating oils with medium alkalinity and a range
sorb the deposits produced by the fuel. of neutralisation capabilities (BN) are available on
the market. According to current knowledge, a re-
Dispersibility lationship can be established between the antici-
pated operating conditions and the BN number as
The selected dispersibility must be such that com- shown in the table entitled "Base number to be
mercially-available lubricating oil cleaning systems used for various operating conditions". However,
can remove harmful contaminants from the oil the operating results are still the overriding factor in
used, i.e. the oil must possess good filtering prop- determining which BN number produces the most
erties and separability. efficient engine operation.
Neutralisation capability
The neutralisation capability (ASTM D2896) must

be high enough to neutralise the acidic products
produced during combustion. The reaction time of
the additive must be harmonised with the process
in the combustion chamber.
11.01 - ES1 - 3.3.6 (2011-01-04)

L16/24, L21/31
L27/38, V28/32S
approx. BN of fresh Engines / Operating conditions
oil (mg KOH/g oil)
Marine diesel oil (MDO) with a lower quality (ISO-F-DMC) or heavy fuel oil with a sulphur
20
content of less than 0.5 %
generally 23/30H and 28/32H. 23/30A, 28/32A and 28/32S under normal operating
30 conditions. For engines 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64
and 51/60DF with exclusive HFO operation only with sulphur content < 1.5 %.
With unfavourable operating conditions 23/30A, 28/32A and 28/32S and also where corre-
sponding requirements in relation to the oil service life and washing ability exist. In general
40
16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 as well as 58/64 and 51/60DF with
exclusive HFO operation providing the sulphur content is greater than 1.5 %.
32/40, 32/44CR, 40/54, 48/60 and 58/64, if the oil service life or engine cleanliness is
50 insufficient with a BN number of 40 (high sulphur content of fuel, extremely low lubricating oil
consumption).
Table 3 Base number to be used for various operating conditions
Operation with low sulphur fuel Speed controller
To comply with the emissions regulations, the sul- Multigrade oil 5W40 should ideally be used in me-
phur content of fuels used nowadays varies. Fuels chanical-hydraulic controllers with a separate oil
with a low-sulphur content must be used in environ- sump. If this oil is not available when filling, 15W40
mentally-sensitive areas (SECA). Fuels with a high oil can be used instead in exceptional cases. In this
sulphur content may be used outside SECA zones. case, it makes no difference whether synthetic or
In this case, the BN number of the lubricating oil se- mineral-based oils are used.
lected must satisfy the requirements for operation
using fuel with a high-sulphur content. A lubricating The military specification for these oils is O-236.
oil with low BN number may only be selected if fuel
with a low-sulphur content is used exclusively dur- Lubricating oil additives
ing operation.
However, the results obtained in practise that dem- The use of other additives with the lubricating oil, or
onstrate the most efficient engine operation are the the mixing of different brands (oils by different man-
factor that ultimately decides which additive fraction ufacturers), is not permitted as this may impair the
is permitted. performance of the existing additives which have
been carefully harmonised with each another and
Cylinder lubricating oil also specifically tailored to the base oil.
In engines with separate cylinder lubrication, the Selection of lubricating oils / warranty
pistons and cylinder liners are supplied with lubri-
cating oil via a separate lubricating oil pump. The The majority of mineral oil companies are in close
quantity of lubricating oil is set at the factory ac- regular contact with engine manufacturers and can
cording to the quality of the fuel to be used and the therefore provide information on which oil in their
anticipated operating conditions. specific product range has been approved by the
engine manufacturer for the particular application.
Use a lubricating oil for the cylinder and lubricating Irrespective of the above, lubricating oil manufac-
circuit as specified above. turers are liable in any case for the quality and char-
acteristics of their products. If you have any ques-
tions, we will be happy to provide you with further
information.
11.01 - ES1 - 3.3.6 (2011-01-04)

504.01 Specification for lubricating oils (SAE40) for Description
Edition 22 heavy fuel oil operation (HFO) Page 4 (5)
L16/24, L21/31
L27/38, V28/32S
Oil during operation If the engine is operated provisionally with low-sul-
phur diesel fuel for more than 1000 h and is sub-
There are no prescribed oil change intervals for sequently operated once again with HFO, a lubri-
MAN Diesel & Turbo medium speed engines. The cating oil with a BN of 20 must be used. If the BN
oil properties must be regularly analysed. The oil 20 lubricating oil by the same manufacturer as the
can be used for as long as the oil properties remain lubricating oil used for HFO operation with higher
within the defined limit values (see table entitled BN (40 or 50), an oil change will not be required
"Limit values for used lubricating oil“). An oil sample when effecting the changeover. It will be sufficient
must be analysed every 1-3 months (see mainte- to use BN 20 oil when replenishing the used lubri-
nance schedule). The quality of the oil can only be cating oil.
maintained if it is cleaned using suitable equipment
(e.g. a separator or filter). If you wish to operate the engine with HFO once
again, it will be necessary to change over in good
Temporary operation with gas oil time to a lubricating oil with a higher BN (30 –
55). If the lubricating oil with higher BN is by the
Due to current and future emission regulations, same manufacturer as the BN 20 lubricating oil,
heavy fuel oil cannot be used in designated regions. the changeover can also be effected without an oil
Low-sulphur diesel fuel must be used in these re- change. In doing so, the lubricating oil with higher
gions instead. BN (30 – 55) must be used to replenish the used
lubricating oil roughly 2 weeks prior to resuming
If the engine is operated with low-sulphur diesel HFO operation.
fuel for less than 1000 h, a lubricating oil which is
suitable for HFO operation (BN 30 – 55 mg KOH/g)
can be used during this period.
Limit value Procedure
Viscosity at 40 °C 110-220 mm2/s ISO 3104 or ASTM D 445
Base Number (BN) at least 50% of fresh oil ISO 3771
Flash Point (PM) at least 185 °C ISO 2719
Water Content max. 0.2% (max. 0.5% for brief periods) ISO 3733 or ASTM D 1744
nHeptan Insoluble max. 1.5% DIN 51592 or IP 316
depends on engine type and operating

Metal Content
conditions
Guide value only

Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Table 4 Limit values for used lubricating oil
11.01 - ES1 - 3.3.6 (2011-01-04)

L16/24, L21/31
L27/38, V28/32S
Tests Note!
No liability when using these oils
We can analyse heavy fuel oil for customers at our
laboratory. A 0.5 l sample is required for the test. MAN Diesel & Turbo does not assume liability for
problems that occur when using these oils.
Manufacturer Base Number [mg KOH/g]
20 30 40 50
AGIP  Cladium 300 Cladium 400 -
BP Energol ICHFX 204 Energol ICHFX 304 Energol ICHFX 404 Energol IC-HFX 504
CASTROL TLX Plus 204 TLX Plus 304 TLX Plus 404 TLX Plus 504
CEPSA - Troncoil 3040 Plus Troncoil 4040 Plus Troncoil 5040 Plus
CHEVRON Taro 20DP40 Taro 30DP40 Taro 40XL40 Taro 50XL40

(TEXACO, CALTEX) Taro 20DP40X Taro 30DP40X Taro 40XL40X Taro 50XL40X
EXXON MOBIL - Mobilgard M430 Mobilgard M440 Mobilgard M50

EXXMAR 30 TP 40 EXXMAR 40 TP 40
PETROBRAS Marbrax CCD420 Marbrax CCD430 Marbrax CCD440 -
REPSOL Neptuno NT 2040 Neptuno NT 3040 Neptuno NT 4040 -
SHELL Argina S 40 Argina T 40 Argina X 40 Argina XL 40
TOTAL Lubmarine - Aurelia XL 4030 Aurelia XL 4040 Aurelia XL 4055

Aurelia TI 4030 Aurelia TI 4040 Aurelia TI 4055
Table 5 Approved lubricating oils for heavy fuel oil-operated MAN Diesel & Turbo fourstroke engines.
11.01 - ES1 - 3.3.6 (2011-01-04)

Your Notes :
Description Specification for lube oil (SAE40) for operation with gas 504.01
Page 1 (5) oil, diesel oil (MGO/MDO) and biofuels Edition 19
L16/24, L21/31
L27/38, V28/32S
The specific output achieved by modern diesel en- Only lubricating oils approved by MAN Diesel &
gines combined with the use of fuels that satisfy Turbo may be used. These are listed in the tables
the quality requirements more and more frequently below.
increase the demands on the performance of the
lubricating oil which must therefore be carefully se-
lected. Specifications
Doped lubricating oils (HD oils) have a proven track Base oil
record as lubricants for the drive, cylinder, turbo-
charger and also for cooling the piston. Doped lu- The base oil (doped lubricating oil = base oil + addi-
bricating oils contain additives that, amongst other tives) must have a narrow distillation range and be
things, ensure dirt absorption capability, cleaning of refined using modern methods. If it contains par-
the engine and the neutralisation of acidic combus- affins, they must not impair the thermal stability or
tion products. oxidation stability.
The base oil must comply with the following limit

values, particularly in terms of its resistance to age-
ing.
Properties/characteristics Unit Test method Limit values

Make-up   Ideally paraffin based
Low temperature behaviour, still flowable °C ASTM D 2500  15
Flash point (Cleveland) °C ASTM D 92 > 200
Ash content (oxidised ash) Weight % ASTM D 482 < 0.02
Coke residue (according to Conradson) Weight % ASTM D 189 < 0.50
Ageing tendency following 100 hours of MAN ageing oven
 
heating up to 135 °C *
ASTM D 4055 or
insoluble nheptane Weight % < 0.2
DIN 51592
Evaporation loss Weight %  < 2
Precipitation of resins or asphalt-
MAN Diesel &
Spot test (filter paper)  like ageing products must not be
turbo test
identifiable.
Table 1 Base oils - target values
* Works' own method
10.45 - ES1 - 3.3.5 (2010-11-08)

504.01 Specification for lube oil (SAE40) for operation with gas Description
Edition 19 oil, diesel oil (MGO/MDO) and biofuels Page 2 (5)
L16/24, L21/31
L27/38, V28/32S
Doped lubricating oils (HD-oils) Additional requirements
The base oil to which the additives have been add- The lubricating oil must not contain viscosity index
ed (doped lubricating oil) must have the following improver. Fresh oil must not contain water or other
properties: contaminants.
Additives Lubricating Oil Selection
The additives must be dissolved in the oil and their

Engine SAE Class
composition must ensure that as little ash as pos-
sible remains following combustion. 16/24, 21/31, 27/38, 28/32S, 32/40,
32/44, 40/54, 48/60, 58/64, 51/60DF 40
The ash must be soft. If this prerequisite is not met,

Table 2 Viscosity (SAE class) of lubricating oils
it is likely the rate of deposition in the combustion
chamber will be higher, particularly at the exhaust
valves and at the turbocharger inlet casing. Hard
additive ash promotes pitting of the valve seats and Doped oil quality
causes the valves to burn out, it also increases me-
chanical wear of the cylinder liners. We recommend doped lubricating oils (HD oils)
according to international specifications MIL-L
Additives must not increase the rate at which the 2104 or API-CD with a base number of BN 10 – 16
filter elements in the active or used condition are mgKOH/g. Military specification O-278 lubricating
blocked. oils can be used.
Washing ability The operating conditions of the engine and the

quality of the fuel determine which additive frac-
The washing ability must be high enough to prevent tions the lubricating oil contains. If marine diesel
the accumulation of tar and coke residue as a result oil with a sulphur content of up to 2.0 % by weight
of fuel combustion. according to ISO-F-DMC and coke residues of up
to 2.5 % by weight is used, you should choose a
Dispersibility base number of roughly 20. However, the operating
results that ensure the most efficient engine opera-
The selected dispersibility must be such that com- tion ultimately decide the additive content.
mercially-available lubricating oil cleaning systems
can remove harmful contaminants from the oil Cylinder lubricating oil
used, i.e. the oil must possess good filtering prop-
erties and separability. In engines with separate cylinder lubrication, the
pistons and cylinder liners are supplied with lubri-
Neutralisation capability cating oil via a separate lubricating oil pump. The
quantity of lubricating oil is set at the factory ac-
The neutralisation capability (ASTM D2896) must cording to the quality of the fuel to be used and the
be high enough to neutralise the acidic products anticipated operating conditions.
produced during combustion. The reaction time of
the additive must be harmonised with the process Use a lubricating oil for the cylinder and lubricating
in the combustion chamber. circuit as specified above.
Evaporation tendency
The evaporation tendency must be as low as pos-

sible as otherwise the oil consumption will be ad-
versely affected.
10.45 - ES1 - 3.3.5 (2010-11-08)

L16/24, L21/31
L27/38, V28/32S
Speed controller Oil during Operation
Multigrade oil 5W40 should ideally be used in me- There are no prescribed oil change intervals for
chanical-hydraulic controllers with a separate oil MAN medium speed engines. The oil properties
sump. If this oil is not available when filling, 15W40 must be regularly analysed. The oil can be used
oil can be used instead in exceptional cases. In this for as long as the oil properties remain within the
case, it makes no difference whether synthetic or defined limit values (see table entitled "Limit val-
mineral-based oils are used. ues for used lubricating oil“). An oil sample must
be analysed every 1-3 months (see maintenance
The military specification for these oils is O-236. schedule). The quality of the oil can only be main-
tained if it is cleaned using suitable equipment (e.g.
Experience with the L27/38 engine has shown that a separator or filter).
the operating temperature of the Woodward con-
troller OG10MAS and corresponding actuator for Temporary operation with gas oil
UG 723+ can be higher than 93 °C. In these cases
we recommend using asynthetic oil such as Cas- Due to current and future emission regulations,
trol Alphasyn HG150. Engines supplied after March heavy fuel oil cannot be used in designated regions.
2005 are already filled with this oil. Low-sulphur diesel fuel must be used in these re-
gions instead.
Lubricating oil additives
If the engine is operated with low-sulphur diesel
The use of other additives with the lubricating oil, or fuel for less than 1000 h, a lubricating oil which is
the mixing of different brands (oils by different man- suitable for HFO operation (BN 30 – 55 mg KOH/g)
ufacturers), is not permitted as this may impair the can be used during this period.
performance of the existing additives which have
been carefully harmonised with each another and If the engine is operated provisionally with low-sul-
also specifically tailored to the base oil. phur diesel fuel for more than 1000 h and is sub-
sequently operated once again with HFO, a lubri-
Selection of lubricating oils / warranty cating oil with a BN of 20 must be used. If the BN
20 lubricating oil by the same manufacturer as the
The majority of mineral oil companies are in close lubricating oil used for HFO operation with higher
regular contact with engine manufacturers and can BN (40 or 50), an oil change will not be required
therefore provide information on which oil in their when effecting the changeover. It will be sufficient
specific product range has been approved by the to use BN 20 oil when replenishing the used lubri-
engine manufacturer for the particular application. cating oil.
Irrespective of the above, lubricating oil manufac-
turers are liable in any case for the quality and char- If you wish to operate the engine with HFO once
acteristics of their products. If you have any ques- again, it will be necessary to change over in good
tions, we will be happy to provide you with further time to a lubricating oil with a higher BN (30 – 55).
information. If the lubricating oil with higher BN is by the same
manufacturer as the BN20 lubricating oil, the
changeover can also be effected without an oil
change. In doing so, the lubricating oil with higher
BN (30 – 55) must be used to replenish the used
lubricating oil roughly 2 weeks prior to resuming
HFO operation.
10.45 - ES1 - 3.3.5 (2010-11-08)

504.01 Specification for lube oil (SAE40) for operation with gas Description
Edition 19 oil, diesel oil (MGO/MDO) and biofuels Page 4 (5)
L16/24, L21/31
L27/38, V28/32S
Tests Approved lubricating oils SAE 40
Base Number
We can analyse heavy fuel oil for customers at our Manufacturer
10161) [mgKOH/g]
laboratory. A 0.5 l sample is required for the test.
Cladium 120  SAE 40
AGIP
Danger! Sigma S SAE 40 2)
BP Energol DS 3154
Improper handling of fuels Castrol MLC 40
CASTROL Castrol MHP 154
If fuels are improperly handled, this can pose a Seamax Extra 40
danger to health, safety and the environment. The Taro 12 XD 40
relevant safety information by the fuel supplier must CHEVRON
Delo 1000 Marine SAE 40
(Texaco, Caltex)
be observed. Delo SHP40
Exxmar 12 TP 40
Note! Mobilgard 412 / MG 1SHC
EXXON MOBIL
Mobilgard ADL 40 2)
No liability assumed if these oils are used Delvac 1640
PETROBRAS Marbrax CCD410
MAN Diesel & Turbo will not assume liability for any
Q8 Mozart DP40
problems associated with using these oils.
REPSOL Neptuno NT 1540
Gadinia 40
Gadinia AL40
SHELL
Sirius FB40 2)
Sirius/Rimula X40 2)
MarWay 1540
STATOIL
MarWay 1040
TOTAL Lubmarine Disola M4015
Table 3 Lubricating oils (SAE40) which have been ap-
proved for the use in MAN four-stroke engines running on gas
oil and Diesel oil
1)
If marine diesel oil with a low quality (ISO-F-DMC) is used,
a base number (BN) of roughly 20 should be used.
2)
with a sulphur content of less than 1%
10.45 - ES1 - 3.3.5 (2010-11-08)

L16/24, L21/31
L27/38, V28/32S
Limit value Procedure
Viscosity at 40 °C 110-220 mm /s
2
ISO 3104 or ASTM D445
Base Number (BN) at least 50% of fresh oil ISO 3771
Flash Point (PM) at least 185 °C ISO 2719
Water Content max. 0.2% (max. 0.5% for brief periods) ISO 3733 or ASTM D 1744
nHeptan Insoluble max. 1.5% DIN 51592 or IP 316
depends on engine type and operating
Metal Content
conditions
Guide value only
Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
When operating with biofuels:
max 12% FT-IR
biofuel fraction
Table 4 Limit values for used lubricating oil
10.45 - ES1 - 3.3.5 (2010-11-08)

Your Notes :
Description 504.04
Page 1 (2) Criteria for Cleaning/Exchange of Lubricating Oil Edition 07
General
Replacement of Lubricating Oil Unit : cSt (mm2/s)

The expected lubricating oil lifetime in operation is Possible test
difficult to determine. The lubricating oil lifetime is methods : ASTM D-445, DIN 51562/53018,
depending on the fuel oil quality, the lubricating oil ISO 3104
quality, the lubricating oil consumption, the lubricating
oil cleaning equipment efficiency and the engine Increasing viscosity indicates problems with inso-
operational conditions. lubles, HFO contamination, water contamination,
oxidation, nitration and low load operation. Decrea-
In order to evaluate the lubricating oil condition a sing viscosity is generally due to dilution with lighter
sample should be drawn on regular basis at least viscosity oil.
once every three month or depending on the latest
analysis result. The lubricating oil sample must be
drawn before the filter at engine in operation. The 2. Flash Point
sample bottle must be clean and dry, supplied with
sufficient indentification and should be closed im- Min. value : 185° C
mediately after filling. The lubricating oil sample
must be examined in an approved laboratory or in Possible test
the lubricating oil suppliers own laboratory. method : ASTM D-92, ISO 2719

A lubricating oil replacement or an extensive lubri- Normally used to indicate fuel dilution.
cating oil cleaning is required when the MAN Diesel
exchange criteria's have been reached.
3. Water Content

Evaluation of the Lubricating Oil Condition Max. value : 0.2 %
Based on the analysis results, the following guidance Unit : Weight %

are normally sufficient for evaluating the lubricating
oil condition. The parameters themselves can not be Possible test
jugded alonestanding, but must be evaluated together method : ASTM D4928, ISO 3733
in order to conclude the lubricating oil condition.
Water can originate from contaminated fuel oil, an
engine cooling water leak or formed as part of the
1. Viscosity combustion process. If water is detected also Sodium,
Glycol or Boron content should be checked in order
Limit value : to confirm engine coolant leaks.

Normal min. max.
value value value 4. Base Number (BN)
SAE 30 [cSt@40° C] 95 - 125 75 160
Min. value : The BN value should not be lower
SAE 30 [cSt@100° C] 11 - 13 9 15 than 50% of fresh lubricating oil
value, but minimum BN level never
SAE 40 [cSt@40° C] 135 - 165 100 220 to be lower than 10-12 at operat-
ing on HFO!
SAE 40 [cSt@100° C] 13.5 - 15.0 11 19
Unit : mg KOH/g
Possible test
method : ASTM D-2896, ISO 3771
07.11 - ES1
504.04 Description
Edition 07 Criteria for Cleaning/Exchange of Lubricating Oil Page 2 (2)
General
The neutralization capacity must secure that the acidic Unit : Weight %
combustion products, mainly sulphur originate from
the fuel oil, are neutralized at the lube oil consumption Possible test
level for the specific engine type. Gradually the BN method : ASTM D-893 procedure B in n-
will be reduced, but should reach an equilibrium. Heptane, DIN 51592
Additionally
5. Total Acid Number (TAN) test : If the level in n-Heptane insolubles
is considered high for the type of
Max. value : 3.0 acc. to fresh oil value oil and application, the test could
be followed by a supplementary
Unit : mg KOH/g determination in Toluene.
Possible test Total insolubles is maily derived from products of

method : ASTM D-664 combustion blown by the piston rings into the crank-
case. It also includes burnt lubricating oil, additive
TAN is used to monitor oil degradation and is a ash, rust, salt, wear debris and abrasive matter.
measure of the total acids present in the lubricating
oil derived from oil oxidation (weak acids) and acidic
products of fuel combustion (strong acids). 7. Metal Content
Metal content Remarks Attention limits

6. Insolubles Content
Iron Depend upon max. 50 ppm
Max. value : 1.5 % generally, depending upon Chromium engine type and max. 10 ppm
Copper operating condi- max. 15 ppm
actual dispersant value and the Lead tions max. 20 ppm
increase in viscosity. Tin max. 10 ppm
Aluminium max. 20 ppm
Silicon max. 20 ppm
07.11 - ES1
Description
Lubricating Points 504.05
Page 1 (1)
Edition 02H
General
Lubricating Oil Types Used in the Engine
Description Lub. Oil Type
Engine system lubricating oil SAE 40 oil according to lubricating oil specification on page 504.01.
Turbocharger Engine system lubricating oil.
Air lubricator SAE 10W non-detergent oil.
Governor See governor instructions in section 509.
Alternator See special instructions in section 518 or separate instructions.
Hydraulic tools Hydraulic oil or turbine oil (with a viscosity of about SAE 20).
08028-0D/H5250/94.08.12
96.02 - ES0 - G
Your Notes :
Description 504.06
Page 1 (1) Lubricating Oil in Base Frame Edition 18H
V28/32S
Engine Type V28/32S 12 cyl. 16 cyl. 18 cyl.
Min. level H2 (mm) 445 445 445

08028-0D/H5250/94.08.12
Max. level H3 (mm) 556 556 556
Min. litre H2 1766 2268 2519
Max. litre H3 2206 2833 3147
06.39 - ES1
Your Notes :
Description 504.07
Page 1 (2) Specific Lubricating Oil Consumption - SLOC Edition 03
General
Engine type RPM SLOC [g/kWh]
L16/24 1000/1200 0.4 - 0.8
L21/31 900/1000 0.4 - 0.8
L23/30H 720/750/900 0.6 - 1.0
L27/38 720/750 0.4 - 0.8
L28/32H 720/750 0.6 - 1.0
V28/32H 720/750 0.6 - 1.0
V28/32S 720/750 0.4 - 0.8
L32/40 720/750 0.8 - 1.0
Please note that only maximum continuous rating A2:

(PMCR (kW)) should be used in order to evaluate the Lubricating oil evaporation
SLOC. Lubricating oil leakages
Lubricating oil losses at lubricating oil filter
Please note, during engine running-in the SLOC may exchange
exceed the values stated.
The lubricating oil density, ρ @ 15°C must be known
The following formula is used to calculate the in order to convert ρ to the present lubricating oil
SLOC: temperature in the base frame. The following formula
is used to calculate ρ:
SLOC [g/kWh] =
ρlubricating oil [kg/m3] =
(lubricating oil added - A1 - A2 [dm ]) * ρlubricating oil [kg/m ]
3 3
run.hrs period * PMCR [kW] ρlubricating oil @15°C [kg/m3] – 0,64 * (tlubricating oil [°C] – 15)
In order to evaluate the correct engine SLOC, The engine maximum continuous design rating (PMCR)
the following circumstances must be noticed and must always be used in order to be able to compare
subtracted from the engine SLOC: the individual measurements, and the running hours
since the last lubricating oil adding must be used
A1: in the calculation. Due to inaccuracy *) at adding
08028-0D/H5250/94.08.12
Desludging interval and sludge amount from the lubricating oil, the SLOC can only be evaluated
lubricating oil separator (or automatic lubricating oil after 1,000 running hours or more, where only the
filters). The expected lubricating oil content of the average values of a number of lubricating oil addings
sludge amount is 30%. are representative.
The following does also have an influence on Note *)

the SLOC and must be considered in the SLOC A deviation of ± 1 mm with the dipstick measurement
evaluation: must be expected, witch corresponds uptill ± 0.1
g/kWh, depending on the engine type.
06.25 - ES0
Description 504.07
Page 2 (2) Specific Lubricating Oil Consumption - SLOC Edition 03
General
Plant / Ship
Lube oil consumption
Engine type:___________________ Engine # :__________________
Lube oil brand/type:__________________________________________
Density @15 C:_____________ [kg/m3]
Date Run. hrs Add. Lube oil A1 + A2 L.O.Temperature SLOC Remarks

[h] [dm³] [dm³] [°C] [g/kWh]
08028-0D/H5250/94.08.12
06.25 - ES0
Description
Specification for Heavy Fuel Oil (HFO) 504.20
General
Prerequisites Different international specifications exist for heavy

fuel oils. The most important specifications are ISO
MAN four-stroke diesel engines can be operated 8217-2010 and CIMAC-2003. These two specifica-
with any heavy fuel oil obtained from crude oil that tions are more or less equivalent. Figure 1 shows
also satisfies the requirements in Table 1, provid- the ISO 8217 specification. All qualities in these
ing the engine and fuel processing system have specifications up to K700 can be used, provided
been designed accordingly. To ensure that the re- the fuel system has been designed for these fuels.
lationship between the cost of fuel, spare parts Heavy fuel oils with a maximum density of 1,010
and repair and maintenance expenditure remains kg/m3 can only be used if modern separators are
favourable at all times, the following points should installed.
be observed.
Important
Heavy Fuel Oil (HFO) Even if the fuel characteristics listed in the table
entitled "The fuel specification and correspond-
Origin/refinery process ing characteristics for heavy fuel oil" satisfy the
above requirements, this information may still not
The quality of the heavy fuel oil largely depends be enough to determine the ignition and combus-
on the quality of the crude oil and also the refining tion characteristics, and also stability, of the fuel.
process used. This is why the properties of heavy This means that the operating performance of the
fuel oils with the same viscosity can vary consider- engine may depend on characteristics that are not
ably depending on the bunker positions. Heavy fuel defined in the specification. This particularly ap-
oil is normally a mixture of residual oil and distil- plies for the tendency of the oil to form deposits in
lates. The components of the mixture are normally the combustion chamber, fuel injection system, gas
obtained from modern refinery processes, such as channels and exhaust gas system. A number of
Catcracker or Visbreaker. These processes can ad- fuels have a tendency towards incompatibility with
versely affect the stability of the fuel as well as its lubricating oil which leads to deposits being formed
ignition and combustion properties. The processing in the fuel delivery pump that can block the pumps.
of the heavy fuel oil and the operating result of the It may therefore be necessary to avoid using spe-
engine also depend heavily on these factors. cific potentially problematic fuels.
Bunker positions with standardised heavy fuel oil Blends

qualities should preferably be used. If oils need to
be purchased from independent dealers, also en- The addition of engine oils (old lubricating oil, ULO
sure that these also comply with the international –used lubricating oil) and additives that have not
specifications. The engine operator is responsible been manufactured from mineral oils, (coal-tar oil,
for ensuring that suitable heavy fuel oils are cho- for example), and residual products of chemical
sen. or other processes such as solvents (polymers or
chemical waste) is not permitted. Some of the rea-
Specifications sons for this are as follows: abrasive and corrosive
effects, unfavourable combustion characteristics,
Fuels that are intended for use in an engine must poor compatibility with mineral oils and, last but
satisfy the specifications to ensure sufficient qual- not least, adverse effects on the environment. The
ity. The limit values for heavy fuel oils are specified order for the fuel must expressly state what is not
in Table 1. permitted as the fuel specifications that generally
apply do not include this limitation.
The entries in the last column of Table 1 provide im-
portant background information and must therefore
be observed.
10.47 - ES1 - 3.3.3 (2010-11-19)

504.20 Specification for Heavy Fuel Oil (HFO)
Description
General
If engine oils (old lubricating oil, ULO – used lubri- The addition of chemical waste products (solvents,
cating oil) are added to fuel, this does pose particu- for example) to the fuel is prohibited for environ-
lar danger as the additives in the lubricating oil act mental protection reasons according to the reso-
as emulsifiers that cause dirt, water and catfines to lution of the IMO Marine Environment Protection
be transported as fine suspension. They therefore Committee passed on 1st January 1992.
prevent the necessary cleaning of the fuel. In our
experience (and this has also been the experience Leak oil collector
of other manufacturers), this can severely damage
the engine and turbocharger components. Leak oil collectors that act as receptacles for leak
oil, and also return and overflow pipes in the lube
oil system, must not be connected to the fuel tank.
Leak oil pipes should be emptied in sludge tanks.
Viscosity (at 50 °C) max. 700 Viscosity/injection viscosity

mm2/s (cSt)
Viscosity (at 100 °C) max. 55 Viscosity/injection viscosity
Density (at 15 °C) g/ml max. 1.010 Heavy fuel oil processing
Flash point min. 60 Flash point (ASTM D 93)
Low-temperature behaviour
Pour point (summer) max. 30
°C (ASTM D 97)
Low-temperature behaviour
Pour point (winter) max. 30
(ASTM D 97)
Coke residue
20 Combustion properties
(Conradson)
weight % 5
Sulphur content Sulphuric acid corrosion
or legal requirements
Ash content max. 0.15 Heavy fuel oil processing
Vanadium content mg/kg 450 Heavy fuel oil processing
Water content Vol. % 0.5 Heavy fuel oil processing
Sediment (potential) weight % 0.1
Aluminium and silicium
mg/kg 60 Heavy fuel oil processing
content (total)
Total acid number mg KOH/g 2.5
Hydrogen sulphide mg/kg 2
The fuel must be free of
lubricating oil (ULO - used
lubricating oil, old oil). Fuel is
Used lubricating oil max. considered as contaminated with
mg/kg
(ULO) lubricating oil when the following
concentrations occur:
Ca > 30 ppm and Zn > 15 ppm or
Ca > 30 ppm and P > 15 ppm.
2/3 of coke residue
Asphaltene content weight % Combustion properties
(according to Conradson)
Sodium < 1/3 Vanadium,
Sodium content mg/kg Heavy fuel oil processing
Sodium<100
The fuel must be free of admixtures that cannot be obtained from mineral oils, such as vegetable or coal-tar oils.
It must also be free of tar oil and lubricating oil (old oil), and also chemical waste products such as solvents or
polymers.
Table 1. Table_The fuel specification and corresponding characteristics for heavy fuel oil
10.47 - ES1 - 3.3.3 (2010-11-19)

Category ISO-F-
Test method
Characteristic Unit Limit RMA RMB RMD RME RMG RMK Description
reference Page 3 (10)
10 30 80 180 180 380 500 700 380 500 700
Figure 1 & 2.
Kinematic viscosity
mm2/s max. 10.00 30.00 80.00 180.0 180.0 380.0 500.0 700.0 380.0 500.0 700.0 ISO 3104
at 50° C
ISO 3675 or
Density at 15° C kg/m3 max. 920.0 960.0 975.0 991.0 991.0 1010.0
10.47 - ES1 - 3.3.3 (2010-11-19)

ISO 12185
CCAI
– max. 850 860 860 860 870 870
ISO 8754
Sulfur mass % max. Statutory requirements
ISO 14596
Flash point
°C min. 60.0 60.0 60.0 60.0 60.0 60.0 ISO 2719
Hydrogen sulfide
mg/kg max. 2.00 2.00 2.00 2.00 2.00 2.00 IP 570
mg
Acid number max. 2.5 2.5 2.5 2.5 2.5 2.5 ASTM D664
KOH/g
Total sediment aged
mass % max. 0.10 0.10 0.10 0.10 0.10 0.10 ISO 10307-2
ISO 8217-2010 specification for heavy fuel oil

Carbon residue:
mass % max. 2.50 10.00 14.00 15.00 18.00 20.00 ISO 10370
micro method
Pour point winter quality °C max. 0 0 30 30 30 30 ISO 3016
(upper) summer quality °C max. 6 6 30 30 30 30 ISO 3016
volume
Water max. 0.30 0.50 0.50 0.50 0.50 0.50 ISO 3733
%
Ash
mass% max. 0.040 0.070 0.070 0.070 0.100 0.150 ISO 6245
IP 501, IP 470
Specification for Heavy Fuel Oil (HFO)
Vanadium mg/kg max. 50 150 150 150 350 450

or ISO 14597
IP 501
Sodium mg/kg max. 50 100 100 50 100 100
IP 470
Aluminium plus silicon IP 501, IP 470
mg/kg max. 25 40 40 50 60 60
or ISO 10478
Used lubricating oils (ULO): The fuel shall be free from ULO. A fuel shall be considered to contain ULO when either one of the IP 501 or
calcium and zinc; or mg/kg – following conditions is met: IP 470
calcium and phosphorus calcium > 30 and zinc > 15; or calcium > 30 and phosphorus > 15 IP 500
© ISO 2010 – All rights reserved ISO 8217 : 2010(E)

Edition 20
504.20
General
Description
General
Additional Information Heavy fuel oil processing
The purpose of the following information is to show Whether or not problems occur when the engine is
the relationship between the quality of heavy fuel in operation depends on how carefully the heavy
oil, heavy fuel oil processing, the engine operation fuel oil has been processed. Particular care should
and operating results more clearly. be taken to ensure that highly-abrasive inorganic
foreign matter (catalyst particles, rust, sand) are
Selection of heavy fuel oil effectively removed. It has been shown in practise
that wear as a result of abrasion in the engine in-
Economic operation with heavy fuel oil within the creases considerably if the aluminium and silicium
limit values specified in the table entitled "The fuel content is higher than 15 mg/kg.
specification and corresponding properties for
heavy fuel oil" is possible under normal operating Viscosity and density influence the cleaning effect.
conditions, provided the system is working properly This must be taken into account when designing
and regular maintenance is carried out. If these re- and making adjustments to the cleaning system.
quirements are not satisfied, shorter maintenance
intervals, higher wear and a greater need for spare Settling tank
parts is to be expected. The required maintenance
intervals and operating results determine which The heavy fuel oil is precleaned in the settling tank.
quality of heavy fuel oil should be used. The longer the fuel remains in the tank and the
lower the viscosity of the heavy fuel oil is, the more
It is an established fact that the price advantage effective the precleaning process will be (maximum
decreases as viscosity increases. It is therefore not preheating temperature of 75 °C to prevent the for-
always economical to use the fuel with the highest mation of asphalt in the heavy fuel oil). A settling
viscosity as in many cases the quality of this fuel tank is sufficient for heavy fuel oils with a viscosity
will not be the best. of less than 380 mm2/s at 50 °C. If the heavy fuel
oil has a high concentration of foreign matter or if
Viscosity/injection viscosity fuels in accordance with ISO-F-RM, G/H/K380 or
H/K700 are to be used, two settling tanks will be
Heavy fuel oils with a high viscosity may be of an required one of which must be sized for 24-hour
inferior quality. The maximum permissible viscos- operation. Before the content is moved to the ser-
ity depends on the preheating system installed and vice tank, water and sludge must be drained from
the capacity (flow rate) of the separator. the settling tank.
The prescribed injection viscosity of 12 - 14 mm2/s Separators

(for GenSets, 23/30H and 28/32H: 12 - 18 cSt) and
corresponding fuel temperature upstream of the A separator is particularly suitable for separating
engine must be observed. This is the only way to material with a higher specific density – water, for-
ensure efficient atomisation and mixture formation eign matter and sludge, for example. The separa-
and therefore low-residue combustion. This also tors must be self-cleaning (i.e. the cleaning inter-
prevents mechanical overloading of the injection vals must be triggered automatically).
system. For the prescribed injection viscosity and/
or the required fuel oil temperature upstream of the Only separators in the new generation may be
engine, refer to the viscosity temperature diagram. used. They are extremely effective throughout a
wide density range with no changeover required
and can separate water from heavy fuel oils with a
density of up to 1.01 g/ml at 15 °C.
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
General
Table "Achievable proportion of foreign matter and The manufacturer's specifications must be com-
water (following separation)" shows the prereq- plied with to maximise the cleaning effect.
uisites that must be met by the separator. These
limit values are used by manufacturers as the basis
for dimensioning the separator and ensure compli-
ance.
Application in ships and

stationary use: parallel
installation
1 separator for
100% flow rate
100% 100% 1 separator (reserve) for

100% flow rate
Figure 3 Location of heavy fuel oil cleaning equipment and/or separator
The separators must be arranged according to the If processing is carried out in accordance with the
manufacturers' current recommendations (Alpha- MAN Diesel & Turbo specifications and the correct
Laval and Westfalia). The density and viscosity of separators are chosen, it may be assumed that the
the heavy fuel oil in particular must be taken into results stated in the table entitled "Achievable pro-
account. If separators by other manufacturers are portion of foreign matter and water" for inorganic
used, MAN Diesel & Turbo should be consulted. foreign matter and water in the heavy fuel oil will be
achieved at the engine inlet.
Definition Particle size Quantity

Inorganic foreign matter including catalyst particles < 5 µm < 20 mg/kg
Al + Si content - < 15 mg/kg
Water content  < 0.2 % by vol. %
Table 2 Achievable proportion of foreign matter and water (following separation)
Results obtained during operation in practise show Water

that the wear the occurs as a result of abrasion in
the injection system and the engine will remain It is particularly important to ensure that the wa-
within acceptable limits if these values are com- ter separation process is as thorough as possible
plied with. In addition, an optimum lubricating oil as the water takes the form of large droplets, and
treatment process must be ensured. not a finely distributed emulsion. In this form, water
also promotes corrosion and sludge formation in
the fuel system and therefore impairs the supply,
atomisation and combustion of the heavy fuel oil.
If the water absorbed in the fuel is seawater, harm-
ful sodium chloride and other salts dissolved in this
water will enter the engine.
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
General
The sludge containing water must be removed from Homogeniser
the settling tank before the separation process
starts, and must also be removed from the service If a homogeniser is used, it must never be installed
tank at regular intervals. The tank's ventilation sys- between the settling tank and separator as other-
tem must be designed in such a way that conden- wise it will not be possible to ensure satisfactory
sate cannot flow back into the tank. separation of harmful contaminants, particularly
seawater.
Vanadium/Sodium
Flash point (ASTM D 93)
If the vanadium/sodium ratio is unfavourable, the
melting point of the heavy fuel oil ash may fall in National and international transportation and stor-
the operating area of the exhaust-gas valve which age regulations governing the use of fuels must be
can lead to high-temperature corrosion. Most of the complied with in relation to the flash point. In gen-
water and water-soluble sodium compounds it con- eral, a flash point of above 60 °C is prescribed for
tains can be removed by precleaning the heavy fuel diesel engine fuels.
oil in the settling tank and in the separators.
Low temperature behaviour (ASTM D 97)
The risk of high-temperature corrosion is low if the
sodium content is one third of the vanadium con- The pour point is the temperature at which the fuel
tent or less. It must also be ensured that sodium is no longer flowable (pumpable). As the pour point
does not enter the engine in the form of seawater of many low-viscosity heavy fuel oils is higher than
in the intake air. 0 °C, the bunker facility must be preheated, unless
fuel in accordance with RMA or RMB is used. The
If the sodium content is higher than 100 mg/kg, this entire bunker facility must be designed in such a
is likely to result in a higher quantity of salt depos- way that the heavy fuel oil can be preheated to
its in the combustion chamber and exhaust-gas around 10 °C above the pour point.
system. This will impair the function of the engine
(including the suction function of the turbocharger). Pumping characteristics
Under certain conditions, high-temperature corro- If the viscosity of the fuel is higher than 1000 mm2/s
sion can be prevented byusing a fuel additive that (cST), or the temperature is not at least 10 °C
increases the melting point of the heavy fuel oil above the pour point, pump problems will occur.
ash(also see "Additives for heavy fuel oils”). For more information, also refer to “Low-tempera-
ture behaviour(ASTM D 97)”.
Ash
Fuel ash consists for the greater part of vanadium

oxide and nickel sulphate (see above chapter for
more information). Heavy fuel oils containing a high
proportion of ash in the form of foreign matter, e.g.
sand, corrosion compounds and catalyst particles,
accelerate the mechanical wear in the engine. Cat-
alyst particles produced as a result of the catalytic
cracking process may be present in the heavy fuel
oils. In most cases, these are aluminium silicate
particles that cause a high degree of wear in the in-
jection system and the engine. The aluminium con-
tent determined, multiplied by a factor of between 5
and 8 (depending on the catalytic bond), is roughly
the same as the proportion of catalyst remnants in
the heavy fuel oil.
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
General
Combustion properties The ignition quality is one of the most important
properties of the fuel. This value does not appear
If the proportion of asphalt is more than two thirds of in the international specifications because a stan-
the coke residue (Conradson), combustion may be dardised testing method has only recently become
delayed which in turn may increase the formation of available and not enough experience has been
combustion residues, leading to such as deposits gathered at this point in order to determine limit
on and in the injection nozzles, large amounts of values. The parameters, such as the calculated
smoke, low output, increased fuel consumption and carbon aromaticity index (CCAI), are therefore aids
a rapid rise in ignition pressure as well as combus- that are derived from quantifiable fuel properties.
tion close to the cylinder wall (thermal overloading We have established that this method is suitable for
of lubricating oil film). If the ratio of asphalt to coke determining the approximate ignition quality of the
residues reaches the limit 0.66, and if the asphalt heavy fuel oil used.
content exceeds 8%, the risk of deposits forming
in the combustion chamber and injection system is A testing instrument has been developed based on
higher. These problems can also occur when using the constant volume combustion method (fuel com-
unstable heavy fuel oils, or if incompatible heavy bustion analyser FCA) and is currently being tested
fuel oils are mixed. This would lead to an increased by a series of testing laboratories.
deposition of asphalt (see "Compatibility”). The instrument measures the ignition delay to de-
termine the ignition quality of a fuel and this mea-
Ignition quality surement is converted into a an instrument-specific
cetane number (FIA-CN or EC). It has been estab-
Nowadays, to achieve the prescribed reference vis- lished that in some cases heavy fuel oils with a low
cosity, cracking-process products are used as the FIA cetane number or ECN number can cause op-
low viscosity ingredients of heavy fuel oils although erating problems.
the ignition characteristics of these oils may also
be poor. The cetane number of these compounds As the liquid components of the heavy fuel oil deci-
should be < 35. If the proportion of aromatic hy- sively influence the ignition quality, flow properties
dro-carbons is high (more than 35 %), this also ad- and combustion quality, the bunker operator is re-
versely affects the ignition quality. sponsible for ensuring that the quality of heavy fuel
oil delivered is suitable for the diesel engine. (Also
The ignition delay in heavy fuel oils with poor igni- see illustration entitled "Nomogram for determining
tion characteristics is longer and combustion is also the CCAI – assigning the CCAI ranges to engine
delayed which can lead to thermal overloading of types").
the oil film at the cylinder liner and also high cylin-
der pressures. The ignition delay and accompany-
ing increase in pressure in the cylinder are also in-
fluenced by the end temperature and compression
pressure, i.e. by the compression ratio, the charge-
air pressure and charge-air temperature.
The disadvantages of using fuels with poor igni-

tion characteristics can be limited by preheating
the charge air in partial load operation and reduc-
ing the output for a limited period. However, a more
effective solution is a high compression ratio and
operational adjustment of the injection system to
the ignition characteristics of the fuel used, as is
the case with MAN Diesel & Turbo piston engines.
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
General
1
16/24 32/44CR
20/27 40/54
21/31 48/60
V D CCAI 23/30 48/60B
1 800 800 27/38 48/60CR
28/32 51/60DF
32/40 58/64
820
810
840
820
2
860
830
3 880 A
840
4 900
5 850
920
940 860
10
960 870
20 2 B
980 880
30
50 1000 890
100 1020
900
200
1040
910 C
700
1000
920
5000
930
20000
50000
Figure 4 Nomogram for the determination the CCAI  assigning the CCAI ranges to engine types
V Viscosity in mm²/s (cSt) at 50° C

D Density [in kg/m³] at 15° C
CCAI Calculated Carbon Aromaticity Index
A Normal operating conditions
B Ignition properties may be poor that adjustment of engine or engine operating conditions are required.
C Problems that have been identified may lead to engine damage, even after a short period of operation
1 Engine type
2 The CCAI is obtained from the straight line through the density and viscosity of the heavy fuel oils
The CCAI can be calculated using the following formula:
CCAI = D - 141 log log (V+0.85) - 81
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
General
Sulphuric acid corrosion The use of heavy fuel oil additives during the war-
ranty period must be avoided as a basic principle.
The engine should be operated at the cooling wa-
ter temperatures prescribed in the operating hand- Additives that are currently used for diesel engines,
book for the relevant load. If the temperature of the as well as their probable effects on the engine's op-
components that are exposed to acidic combustion eration, are summarised in the table below "Addi-
products is below the acid dew point, acid corro- tives for heavy fuel oils – classification/effects" .
sion can no longer be effectively prevented, even if
alkaline lubricating oil is used.
• Dispersing agent/stabilisers
Precombustion
The BN values specified are sufficient, providing • Emulsion breakers
additives
the quality of lubricating oil and engine's cooling • Biocides
system satisfy the requirements.
Combustion • Combustion catalysts (fuel
additives savings, emissions)
Compatibility
• Ash modifiers (hot corrosion)
Postcombustion
The supplier must guarantee that the heavy fuel oil additives • Soot removers (exhaust gas
is homogeneous and remains stable, even after the system)
standard storage period. If different bunker oils are Table 3 Additives to heavy fuel oils  Classification/
mixed, this can lead to separation and the asso- effects
ciated sludge formation in the fuel system during
which large quantities of sludge accumulate in the
separator that block filters, prevent atomisation and
a large amount of residue as a result of combus- Heavy fuel oils with low sulphur content
tion.
From the point of view of an engine manufacturer, a
This is due to incompatibility or instability of the oils. lower limit for the sulphur content of heavy fuel oils
As much of the heavy fuel oil in the storage tank as does not exist. We have not identified any problems
possible should therefore be removed before bun- with the low-sulphur heavy fuel oils currently avail-
kering again to prevent incompatibility. able on the market that can be traced back to their
sulphur content. This situation may change in future
Blending the heavy fuel oil if new methods are used for the production of low-
sulphur heavy fuel oil (desulphurisation, new blend-
If heavy fuel oil for the main engine is blended with ing components). MAN Diesel & Turbo will monitor
gas oil (MGO) to obtain the required quality or vis- developments and inform its customers if required.
cosity of heavy fuel oil, it is extremely important that
the components are compatible (see "Compatibil- If the engine is not always operated with low-sul-
ity"). phur heavy fuel oil, a corresponding lubricating oil
for the fuel with the highest sulphur content must
Additives for heavy fuel oils be selected.
MAN Diesel & Turbo engines can be operated eco-

nomically without additives. It is up to the customer Danger!
to decide whether or not the use of additives is ben- Improper handling of fuels
eficial. The supplier of the additive must guarantee
that the engine operation will not be impaired by If fuels are improperly handled, this can pose a
using the product. danger to health, safety and the environment. The
relevant safety information by the fuel supplier must
be observed.
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
General
Tests Analysis of samples

Sampling
Our department for fuels and lubricating oils (Augs-
To check whether the specification provided and/ burg factory, department EQC) will be pleased to
or the necessary delivery conditions are complied provide further information on request.
with, we recommend you retain at least one sample
of every bunker oil (at least for the duration of the We can analyse fuel for customers at our labora-
engine's warranty period). To ensure that the sam- tory. A 0.5 l sample is required for the test.
ples taken are representative of the bunker oil, a
sample should be taken from the transfer line when
starting up, halfway through the operating period
and at the end of the bunker period. “Sample Tec"
by Mar-Tec in Hamburg is a suitable testing instru-
ment which can be used to take samples on a regu-
lar basis during bunkering.
10.47 - ES1 - 3.3.3 (2010-11-19)

Description
Specification for marine diesel oil (MDO) 504.20
General
Marine Diesel Oil Specification
Other designations The suitability of a fuel depends on the design of

the engine and the available cleaning options as
Marine Diesel Oil, Marine Diesel Fuel. well as compliance with the properties in the fol-
lowing table that refer to the as-delivered condition
Origin of the fuel.
Marine diesel oil (MDO) is supplied as heavy distil- The properties are essentially defined using the
late (designation ISO-F-DMB) exclusively for ma- ISO 8217-2010 standard as the basis. The proper-
rine applications. MDO is manufactured from crude ties have been specified using the stated test pro-
oil and must be free of organic acids and non-min- cedures.
eral oil products.
Properties Unit Test procedure Designation

ISO-F specification DMB
Density at 15 °C kg/m 3
ISO 3675 900
> 2.0
Kinematic viscosity at 40 °C mm2/s ≙ cSt ISO 3104
< 11
Pour point, winter quality °C ISO 3016 <0
Pour point, summer quality °C <6
Flash point (Pensky Martens) °C ISO 2719 > 60
Total sediment fraction Weight % ISO CD 10307 0.10
Water content Vol. % ISO 3733 < 0.3
Sulphur content Weight % ISO 8754 < 2.0
Ash content Weight % ISO 6245 < 0.01
Coke residue (MCR) Weight % ISO CD 10370 < 0.30
Cetane number or cetane index - ISO 5165 > 35
Hydrogen sulphide mg/kg IP 570 <2
Total acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m3 ISO 12205 < 25
Lubricity (wear scar diameter) µm ISO 12156-1 < 520
Copper strip test - ISO 2160 <1
Other specifications:
British Standard BS MA 100-1987 Class M2
ASTM D 975 2D
ASTM D 396 No. 2
Table 1 Marine Diesel Oil (MDO) – characteristic values to be observed
10.45 - ES1 - 3.3.2 (2010-11-08)

504.20 Specification for Marine Diesel Oil (MDO) Description
General
Additional Information Seawater causes the fuel system to corrode and

also leads to hot corrosion of the exhaust valves
During transshipment and transfer, MDO is handled and turbocharger. Seawater also causes insuffi-
in the same manner as residual oil. This means that cient atomisation and therefore poor mixture forma-
it is possible for the oil to be mixed with high-viscos- tion accompanied by a high proportion of combus-
ity fuel or heavy fuel oil – with the remnants of these tion residues.
types of fuels in the bunker ship, for example – that
could significantly impair the properties of the oil. Solid foreign matter increase mechanical wear and
formation of ash in the cylinder space.
The lubricity of diesel fuel is normally sufficient. The
desulphurisation of diesel fuels can reduce their lu- We recommend the installation of a separator up-
bricity. If the sulphur content is extremely low (<500 stream of the fuel filter. Separation temperature 40
ppm or 0.05%), the lubricity may no longer be suf- – 50°C. Most solid particles (sand, rust and cata-
ficient. Before using diesel fuels with low sulphur lyst particles) and water can be removed, and the
content, you should therefore ensure that their lu- cleaning intervals of the filter elements can be ex-
bricity is sufficient. This is the case if the lubricity as tended considerably.
specified in ISO 12156-1 does not exceed 520 μm.
Danger!
The fuel must be free of lubricating oil (ULO – used Improper handling of fuels
lubricating oil, old oil). Fuel is considered as con-
taminated with lubricating oil when the following If fuels are improperly handled, this can pose a
concentrations occur: danger to health, safety and the environment. The
Ca > 30 ppm and Zn > 15 ppm or Ca > 30 ppm and be observed.
P > 15 ppm.
The pour point specifies the temperature at which Analyses

the oil no longer flows. The lowest temperature
of the fuel in the system should be roughly 10 °C We can analyse fuel for customers at our labora-
above the pour point to ensure that the required tory. A 0.5 l sample is required for the test.
pumping characteristics are maintained.
A minimum viscosity must be observed to ensure

sufficient lubrication in the fuel pump. The tempera-
ture of the fuel must therefore not exceed 45 °C.
10.45 - ES1 - 3.3.2 (2010-11-08)

Description
Specification for gas oil / diesel oil (MGO) 504.20
General
Diesel Oil Specification
Other designations The suitability of the fuel depends on whether it has

the properties defined in this specification (based
Gas oil, Marine Gas Oil (MGO), Diesel Oil. on its composition in the as-delivered state).
Gas oil is a crude oil medium distillate and must The DIN EN 590 and ISO 8217-2010 (Class DMA
therefore not contain any residual materials. or Class DMZ) standards have been extensively
used as the basis when defining these properties.
The properties correspond to the test procedures
stated.
Properties Unit Test procedure Typical value

Density at 15° C ≥ 820.0
kg/m3 ISO 3675
≤ 890.0
≥2
Kinematic viscosity at 40° C mm2/s (cSt) ISO 3104
≤ 6.0
Filterability*
in summer and °C DIN EN 116 ≤0
in winter °C DIN EN 116 ≤ 12
Flash point in enclosed crucible °C ISO 2719 ≥ 60
Distillation range up to 350° C Vol. % ISO 3405 ≥ 85
Sediment content (extraction method) Weight % ISO 3735 ≤ 0.01
Water content Vol. % ISO 3733 ≤ 0.05
Sulphur content ISO 8754 ≤ 1.5
Ash Weight % ISO 6245 ≤ 0.01
Coke residue (MCR) ISO CD 10370 ≤ 0.10
Hydrogen sulphide mg/kg IP 570 <2
Total acid number mg KOH/g ASTM D664 < 0.5
Oxidation stability g/m3 ISO 12205 < 25
Lubricity (wear scar diameter) µm ISO 12156-1 < 520
Cetane number or cetane index  ISO 5165 ≥ 40
Copper strip test  ISO 2160 ≤1
Other specifications:
British Standard BS MA 1001987 M1
ASTM D 975 1D/2D
Table 1 Diesel fuel (MGO)  properties that must be complied with.
* The process for determining the filterability in accordance with DIN EN 116 is similar to the process for determining the cloud point
in accordance with ISO 3015
10.45 - ES1 - 3.3.1 (2010-11-08)

504.20 Specification for gas oil / diesel oil (MGO) Description
General
Additional Information Lubricity
Use of diesel oil The lubricity of diesel fuel is normally sufficient. The
desulphurisation of diesel fuels can reduce their lu-
If distillate intended for use as heating oil is used bricity. If the sulphur content is extremely low (<500
with stationary engines instead of diesel oil (EL ppm or 0.05%), the lubricity may no longer be suf-
heating oil according to DIN 51603 or Fuel No. 1 ficient. Before using diesel fuels with low sulphur
or no. 2 according to ASTM D 396), the ignition content, you should therefore ensure that their lu-
behaviour, stability and behaviour at low tempera- bricity is sufficient. This is the case if the lubricity as
tures must be ensured; in other words the require- specified in ISO 12156-1 does not exceed 520 μm.
ments for the filterability and cetane number must
be satisfied. You can ensure that these conditions will be met by
using motor vehicle diesel fuel in accordance with
Viscosity EN 590 as this characteristic value is an integral
part of the specification.
To ensure sufficient lubrication, a minimum viscosi-
ty must be ensured at the fuel pump. The maximum
temperature required to ensure that a viscosity of Danger!
more than 1.9 mm2/s is maintained upstream of the Improper handling of fuels
fuel pump depends on the viscosity of the fuel. In
any case the temperature of the fuel upstream of If fuels are improperly handled, this can pose a
the injection pump must not exceed 45 °C. danger to health, safety and the environment. The
be observed.
Analyses
We can analyse fuel for customers at our labora-

tory. A 0.5 l sample is required for the test.
10.45 - ES1 - 3.3.1 (2010-11-08)

Description
Specification for Biofuel 504.20
General
Biofuel Provision
Other designations Transesterified and non-transesterified vegetable

oils can be used.
Biodiesel, FAME, vegetable oil, rapeseed oil, palm
oil, frying fat. Transesterified biofuels (biodiesel, FAME) must
comply with the standard EN 14214.
Origin
Non-transesterified biofuels must comply with the
Biofuel is derived from oil plants or old cooking oil. specifications listed in Table 1.
Properties/Characteristics Unit Test method

Density at 15 °C DIN EN ISO 3675,
900-930 kg/m3
EN ISO 12185
Flash point > 60 °C DIN EN 22719
> 35 MJ/kg
Lower calorific value DIN 51900-3
(typical: 37 MJ/kg)
< 40 cSt (corresponds to a
Viscosity at 50 °C DIN EN ISO 3104
viscosity/40 °C < 60 cSt)
Cetane number > 40 FIA
Coke residue < 0.4 % DIN EN ISO 10370
Sediment content < 200 ppm DIN EN 12662
Oxidation stability (110 °C) >5h ISO 6886
Phosphorous content < 15 ppm ASTM D3231
Na and K content < 15 ppm DIN 51797-3
Ash content < 0.01 % DIN EN ISO 6245
Water content < 0.5 % EN ISO 12537
Lodine number < 125 g / 100 g DIN EN 14111
TAN (Total acid number) < 5 mg KOH/g DIN EN ISO 660
< 10 °C below the lowest temperature
Filterability EN 116
in the fuel system
Table 1 Non-transesterified biofuel - specifications.
10.45 - ES1 - 3.3.1 (2010-11-08)

504.20 Specification for Biofuel Description
General
These specifications are based on experience to Danger!

date. As this experience is limited, these must be Improper handling of fuels
regarded as recommended specifications that can
be adapted if necessary. If future experience shows If fuels are improperly handled, this can pose a
that these specifications are too strict, or not strict danger to health, safety and the environment. The
enough, they can be modified accordingly to en- relevant safety information by the fuel supplier must
sure safe and reliable operation. be observed.
When operating with bio-fuels, a lubricating oil that Analyses

would also be suitable for operation with diesel oil
must be used. We can analyse fuel for customers at our labora-
tory. A 0.5 l sample is required for the test.
10.45 - ES1 - 3.3.1 (2010-11-08)

Description 504.30
Page 1 (2) Fuel Oil Cleaning Edition 01
General
Purification Recommendations Especially for fuels above 180 cST/50°C (1500 sec.
RW/100°F) the highest possible temperature of 98°C
Fuel oils are always contaminated and should there- (208°F) should be maintained in the centrifuge oil
fore be cleaned thoroughly of solid as well as liquid preheater.
contaminants before use. The solid contami-nants
in the fuel are mainly rust, sand, dust and re-finery The fuel is kept in the centrifuge for as long as pos-
catalysts. Liquid contaminants are mainly water, i.e. sible by adjusting the flow rate through the centrifuge
either fresh water or sea water. so that it corresponds to the amount of fuel required
by the engine without excessive re-circulating. Con-
The impurities can cause damage to fuel injection sequently, the centrifuge should operate for 24 hours
pumps and fuel valves, result in increased cylinder a day except during necessary cleaning.
liner wear and cause the exhaust valve seats to
deteriorate. Increased fouling of gasways and tur- Taking today's fuel qualities into consideration the
bocharger blends may also result from the use of need to clean centrifuges ("shooting frequency")
inadequately cleaned fuel oils. should not be underestimated. Correct choice and
adjustment of the regulating screws and/or the grav-
Effective cleaning can only be ensured by means ity discs are of special importance for efficient water
of a centrifuge. We recommend that the capacity removal. The centrifuge manual states the disc or
of the centrifuges installed be at least according to screw adjustment which should be chosen on the
the centrifuge maker's recommendations. To obtain basis of the specific gravity of the fuel.
optimum cleaning it is of the utmost importance to
operate the centrifuge with as low a viscosity of the Normal practice is to have at least two centrifuges
fuel oil as possible and to allow the fuel oil to remain available for fuel cleaning. Results from experimen-
in the centrifuge bowl for as long as possible. tal work on centrifuges, treating today's qualities of
residual fuel, have shown that the best cleaning ef-
fect, especially as regards removal of catalyst fines,
is achieved when the centrifuges are operated in
Cleaning of HFO by Centrifuging
series, in purifier/clarifier mode.
Single centrifuge as purifier.
Operating Therefore series operation of centrifuges to ensure
options Two centrifuges in parallel.
Two centrifuges in series. maximum safety is a fully accepted alternative to the
previously recommended parallel operation, provided
Optimum Operating Configurations the operating capacity of each individual centrifuge
can handle the total amount of fuel required by the
Water content Parallel operation engine, without exceeding the flow rate recommended
below 1 % Purifier / Purifier by the centrifuge maker for the operating mode in
Normal question.
or
conditions
Density at 15°C Series operation
below 0.991 Purifier + Clarifier If the centrifuge capacity installed is on the low side,
corresponding to the specific viscosity of the fuel
08028-0D/H5250/94.08.12
Water content oil used, and if more than one centrifuge is avail-
below 1 % Parallel operation able, parallel operation may be considered in order
to obtain an even lower flow rate. However, in view
Extreme Density at 15°C Purifier / Purifier of the above results and recommendations serious
conditions below 0.991 consideration should be given to installing new equip-
ment in accordance with today's fuel qualities and
High content Series operation flow recommendations.
of catalyst fines Purifier + Clarifier
Table 1. Cleaning of HFO.
97.40 - ES0
504.30 Description
Edition 01 Fuel Oil Cleaning Page 2 (2)
General
To determine centrifuging capacity we generally

advise to follow the recommendations of the cen- Flow Rate
trifuge maker, but the curves in fig. 1, can be used Related to Rated Capacity of Centrifuge
as a guideline. %
100
A homogenizer may be installed in the fuel oil sys- 80

tem as a supplement to the centrifuges in order to 60
homogenize possible water and sludge still present 40
in the fuel after centrifuging. 20
Separation Temperature
°F °C
212 100
194 90
176 80
158 70
140 60
122 50
104 40
100
15 25 45 75 130 cSt/80°C
Log scales 30 60 80 180 380 600 cST/50°C
200 400 600 1500 3500 6000 sec. RI/100°F
Fig. 1 Flow rate through centrifuge related to nominal capa-

city of centrifuge.
08028-0D/H5250/94.08.12
97.40 - ES0
Description
Specification for Engine Cooling Water 504.41
General
Preliminary remarks Testing equipment
As is also the case with the fuel and lubricating oil, The MAN Diesel water testing equipment incorpo-
the engine cooling water must be carefully select- rates devices that determine the water properties
ed, handled and checked. If this is not the case, referred to above in a straightforward manner. The
corrosion, erosion and cavitation may occur at manufacturers of rust inhibitors also supply user-
the walls of the cooling system and deposits may friendly testing equipment. For information on mo-
form. Deposits obstruct the transfer of heat and can nitoring cooling water, refer to "Cooling Water In-
cause thermal overloading of the cooled parts. The specting".
system must be treated with rust inhibitor before
bringing it into operation for the first time. The con-
centrations prescribed by the engine manufacturer Additional information
must always be observed during subsequent ope-
ration. The above especially applies if a chemical Distilate
additive is added.
If distilled water (from a fresh water generator, for
example) or fully desalinated water (from ion ex-
Requirements change or reverse osmosis) is available, this should
ideally be used as the engine cooling water. These
Limit values waters are free of lime and salts which means that
deposits that could interfere with the transfer of heat
The properties of the untreated cooling water must to the cooling water, and therefore also reduce the
correspond to the following limit values: cooling effect, cannot form. However, these waters
are more corrosive than normal hard water as the
thin film of lime scale that would otherwise provide
Properties/ temporary corrosion protection does not form on
Properties Unit
Characteristic the walls. This is why distilled water must be hand-
Distillate or freshwater, free led particularly carefully and the concentration of
of foreign matter. the additive must be regularly checked.
The following are
Water type prohibited: Seawater, – Hardness
brackwater, river water,
brines, industrial waste
The total hardness of the water is the combined
water and rainwater
effect of the temporary and permanent hardness.
Total hardness max. 10 °dH* The proportion of calcium and magnesium salts
pH-value 6,5 - 8 – is of overriding importance. The temporary hard-
ness is determined by the carbonate content of
Chloride ion
Max. 50 mg/l** the calcium and magnesium salts. The permanent
content
hardness is determined by the amount of remain-
Table 1 Cooling water - properties to be observed
ing calcium and magnesium salts (sulphates). The
temporary (carbonate) hardness is the critical fac-
*) 1°dH (German hardness) tor that determines the extent of limescale deposits
in the cooling system.
≙ 10 mg CaO in 1 litre of water
Water with a total hardness of > 10°dGH must be
≙ 17.9 mg CaCO3/l
mixed with distilled water or softened. Subsequent
≙ 0.357 mval/l hardening of extremely soft water is only necessary
to prevent foaming if emulsifiable slushing oils are
≙ 0.179 mmol/l used.
**) 1 mg/l ≙ 1 ppm
10.45 - 3.3.7 (2010-11-08)

504.41 Specification for Engine Cooling Water Description
General
Damage in the cooling water system Protective films can be formed by treating the cool-
ing water with a chemical or an emulsifiable slush-
Corrosion ing oil.
Corrosion is an electrochemical process that can Emulsifiable slushing oils are used less and less
generally be avoided by selecting the correct water frequently as their use has been considerably re-
quality and by carefully handling the water in the stricted by environmental protection regulations
engine cooling system. and also because are rarely available from suppli-
ers for this and other reasons.
Flow cavitation
Treatment prior to initial commissioning of engine
Flow cavitation can occur in areas in which high
flow velocities and high turbulence is present. If the Treatment with a rust inhibitor should be carried out
steam pressure is reached, steam bubbles form before the engine is brought into operation for the
and subsequently collapse in high pressure zones first time to prevent irreparable initial damage.
which causes the destruction of materials in con-
stricted areas. Caution!
Treatment of the cooling water
Erosion The engine must not be brought into operation
without treating the cooling water first.
Erosion is a mechanical process accompanied by
material abrasion and the destruction of protective
films by solids that have been drawn in, particularly Additives for cooling water
in areas with high flow velocities or strong turbu-
lence. Only the additives approved by MAN Diesel and
listed in the tables under the section entitled "Ap-
Stress corrosion cracking proved cooling water additives“ may be used.
Stress corrosion cracking is a failure mechanism Required approval

that occurs as a result of simultaneous dynamic
and corrosive stress. This can lead to cracking and A cooling water additive can only be approved if
rapid crack propagation in water-cooled, mecha- it has been tested and approved according to the
nically-loaded components if the cooling water has current regulations of the research association
not been treated correctly. for combustion engines in Germany (FVV = For-
schungsvereinigung für Verbrennungskraftma-
schinen) entitled "Testing the suitability of cooling
Processing of engine cooling water water additives for cooling liquids in internal com-
bustion engines". The test report must be obtain-
Formation of a protective film able on request. The relevant tests can be carried
out on request in Germany at the staatliche Ma-
The purpose of treating the engine cooling water terialprüfanstalt (Federal Institute for Materials Re-
using rust inhibitors is to produce a continuous search and Testing), Abteilung Oberflächentechnik
protective film on the walls of cooling surfaces and (Surface Technology Division), Grafenstraße 2 in
therefore prevent the damage referred to above. In D-64283 Darmstadt.
order for a rust inhibitor to be 100 % effective, it is
extremely important that untreated water satisfies Once the cooling water additive has been tested by
our requirements. the FVV, the engine must be tested in the second
step before the final approval is granted.
10.45 - 3.3.7 (2010-11-08)

Description
General
Only in closed circuits be added if the concentration of the anti-freeze

solution prescribed by the user for a specific ap-
Additives may only be used in closed circuits where plication does not provide an appropriate level
no significant consumption occurs, apart from leak- of corrosion protection, or if the concentration
age or evaporation losses. of anti-freeze solution used is lower due to less
stringent frost protection requirements and does
• Chemical additives not provide an appropriate level of corrosion pro-
Sodium nitrite and sodium borate based additives tection. For information on the compatibility of the
etc. have a proven track record. Galvanised iron anti-freeze solution with the rust inhibitor and the
pipes or zinc sacrificial anodes must not be used required concentrations, contact the manufac-
in cooling systems. This corrosion protection is turer. The chemical additives listed in the table
not required due to the prescribed cooling water entitled "Chemical additives containing nitrite"
treatment and electrochemical potential reversal are known to be compatible with ethylene-glycol
can occur due to the cooling water temperatures based anti-freeze solutions. Anti-freeze solutions
which are normally present in engines nowadays. may only be mixed with one another with the con-
If necessary, the pipes must be deplated. sent of the manufacturer, even if these solutions
have the same composition.
• Slushing oil
This additive is an emulsifiable mineral oil with Before an anti-freeze agent is used, the cooling
added slushing ingredients. A thin film of oil forms system must be thoroughly cleaned.
on the walls of the cooling system. This prevents
corrosion without interfering with the transfer of If the cooling water contains an emulsifiable
heat and also prevents limescale deposits on the slushing oil, anti-freeze solution must not be add-
walls of the cooling system. ed as otherwise the emulsion would break up and
oil sludge would form in the cooling system.
The significance of emulsifiable slushing oils is
fading. Oil-based emulsions are rarely used now- Observe the applicable environmental protection
adays for environmental protection reasons and regulations when disposing of cooling water con-
also because stability problems are known to oc- taining additives. For more information, consult
cur in emulsions. the supplier of the additive.
• Anti-freeze agents • Biocides

If temperatures below the freezing point of water If you cannot avoid using a biocide because the
in the engine cannot be excluded, an anti-freeze cooling water has been contaminated by bacte-
solution that also prevents corrosion must be ria, observe the following steps:
added to the cooling system or corresponding
parts. Otherwise the entire system must be heat- • You must ensure that the biocide to be used is
ed. (Military specification: Sy-7025). suitable for the specific application.
Sufficient corrosion protection can be provided • The biocide must be compatible with the seal-
by adding the products listed in the table entit- ing materials used in the cooling water system
led "anti-freeze agents with slushing properties" and must not react with these.
while observing the prescribed concentration.
This concentration prevents freezing at tempera- • The biocide and its decomposition products
tures down to -22 °C. However, the quantity of must not contain corrosion-promoting compo-
anti-freeze agent actually required always de- nents. Biocides whose decomposition products
pends on the lowest temperatures that are to be contain chloride or sulphate ions are not permit-
expected at the place of use. ted.
Anti-freeze solutions are generally ethylene gly- • Biocides that cause foaming of the cooling
col-based. A suitable chemical rust inhibitor must water are not permitted.
10.45 - 3.3.7 (2010-11-08)

General
Prerequisite for effective use of a rust inhibitor Excessively low concentrations can promote cor-
rosion and must be avoided. If the concentration is
Clean cooling system slightly above the recommended concentration this
will not result in damage. Concentrations which are
As contamination significantly reduces the effec- more than twice the recommended concentration
tiveness of the additive, the tanks, pipes, coolers should be avoided.
and other parts outside the engine must be free of
rust and other deposits before the engine is started A cooling water sample must be sent to an inde-
up for the first time and after repairs are carried out pendent laboratory or the engine manufacturer
on the pipe system. The entire system must there- every 2 – 6 months for comprehensive analysis.
fore be cleaned with the engine switched off using
a suitable cleaning agent. Emulsifiable rust inhibitors must generally be re-
placed after roughly 12 months according to the
Loose solid matter in particular must be removed supplier's instructions. When carrying this out, the
by flushing the system thoroughly as otherwise ero- entire cooling system must be flushed and, if nec-
sion may occur in locations where the flow velocity essary, cleaned. Once filled in the system the fresh
is high. water must be treated immediately.
The cleaning agents must not corrode the seals and If chemical additives or anti-freeze agents are used,
materials of the cooling system. In most cases, the the cooling water should be replaced after 3 years
supplier of the cooling water additive will be able to at the latest.
carry out this work and, if this is not possible, will
at least be able to provide suitable products to do If there is a high concentration of solids (rust) in the
this. If this work is carried out by the engine opera- system, the water must be completely replaced and
tor, he should use the services of a specialist sup- entire system carefully cleaned.
plier of cleaning agents. The cooling system must
be flushed thoroughly following cleaning. Once this Deposits in the cooling system may be caused by
has been done, the engine cooling water must be fluids that enter the cooling water, or the break up
treated immediately with a rust inhibitor. Once the of emulsion, corrosion in the system and limescale
engine has been brought back into operation, the deposits if the water is very hard. If the concentra-
cleaned system must be checked for leakages. tion of chloride ions has increased, this generally
indicates that seawater has entered the system.
• Regular checks of the cooling water condition The maximum specified concentration of 50 mg
and cooling water system chloride ions per kg must not be exceeded as oth-
Treated cooling water may become contaminated erwise the risk of corrosion is too high. If exhaust
when the engine is in operation which causes the gas enters the cooling water this can lead to a sud-
additive to loose some of its effectiveness. It is den drop in the pH value or to an increase in the
therefore advisable to regularly check the cooling sulphate content.
system and the condition of the cooling water.
Water losses must be compensated for by filling
The additive concentration must be checked at with untreated water that meets the quality require-
least once a week using the test kits specified ments specified. The concentration of the rust in-
by the manufacturer. The results must be docu- hibitor must subsequently be checked and adjusted
mented. if necessary.
Notice! Subsequent checks of the cooling water are espe-

Concentrations of chemical additives cially required if the cooling water had to be drained
The chemical additive concentrations must not fall off in order to carry out repairs or maintenance.
below the minimum concentrations specified in the
table entitled "Chemical additives containing ni-
trite".
10.45 - 3.3.7 (2010-11-08)

Description
General
Protective measures Auxiiliary engines
Rust inhibitors contain chemical compounds that If a marine engine of type 16/24, 21/31, 23/30H,
can pose a risk to health or the environment if in- 27/38 or 28/32H uses the same cooling water sys-
correctly used. Comply with the directions in the tem as a MAN Diesel two-stroke main engine, the
manufacturer's material safety data sheets. recommendations for the cooling water of the main
engine must be observed.
Avoid prolonged direct contact with the skin. Wash
hands thoroughly after use. If larger quantities
spray and/or soak into clothing, remove and wash Analysis
clothing before wearing it again.
We analyse cooling water for our customers in our
If chemicals come into contact with your eyes, rinse chemical laboratory. A 0.5 l sample is required for
immediately with plenty of water and seek medical the test.
advice.
Rust inhibitors are generally harmful to the water

cycle. Observe the relevant statutory requirements
for disposal.
10.45 - 3.3.7 (2010-11-08)

General
Approved cooling water additives
Chemical additives containing nitrite
Minimum concentration ppm

Initial
Manufacturer Product designation dosing for
Nitrite Na-nitrite
1000 litres Product
(NO2) (NaNO2)
Drew Marine
One Drew Plaza
Liquidewt 15 l 15,000 700 1,050
Boonton
Maxigard 40 l 40,000 1,330 2,000
New Jersey 07005
USA
Wilhelmsen (Unitor)
KJEMI-Service A.S.
Rocor NB Liquid 21.5 l 21,500 2,400 3,600
P.O. Box 49
Dieselguard 4.8kg 4,800 2,400 3,600
3140 Borgheim
Norway
Nalfleet Marine
Chemicals Nalfleet EWT Liq (9-108) 3l 3,000 1,000 1,500
P.O. Box 11 Nalfleet EWT 9-111 10 l 10,000 1,000 1,500
Northwich Nalcool 2000 30 l 30,000 1,000 1,500
Cheshire CW8DX, UK
Maritech AB
P.O. Box 143
Marisol CW 12 l 12,000 2,000 3,000
29122 Kristianstad
Sweden
Uniservice
Via al Santurio di N.S. N.C.L.T. 12 l 12,000 2,000 3,000
della Guardia 58/A Colorcooling 24 l 24,000 2,000 3,000
16162 Genova, Italy
Marichem - Marigases
D.C.W.T -
64 Sfaktirias Street 48 l 48,000 2,400 –
Non-Chromate
18545 Piraeus, Greece
Vecom
Schlenzigstrasse 7
Cool treat N.C.L.T. 16 l 16,000 4,000 6,000
21107 Hamburg
Germany
Table 2 Chemical additives containing nitrite
10.45 - 3.3.7 (2010-11-08)

Description
General
Additives (chemical additives) - nitrite free
Initial dosing
Manufacturer Product designation Minimum concentration
for 1000 litres
Arteco
Technologiepark
Havoline
Zwinaarde 2 75 l 7.5 %
XLI
B-9052 Gent
Belgium
Total Lubricants
WT Supra 75 l 7.5 %
Paris, France
Table 3 Chemical additives - nitrite free
Emulsifiable slushing oils
Manufacturer Product (designation)
BP Marine
Breakspear Way Diatsol M
Hemel Hempstead Fedaro M
Herts HP2 UL, UK
Castrol Int.
Pipers Way Solvex WT 3
Swindon SN3 1RE, UK
Deutsche Shell AG
Überseering 35 Oil 9156
22284 Hamburg, Germany
Table 4 Emulsifiable slushing oils
10.45 - 3.3.7 (2010-11-08)

General
Anti-freeze solutions with slushing properties
Minimum
Manufacturer Product designation
concentration
BASF
Glysantin G48
Carl-Bosch-Str.
Glysantin 9313
67063 Ludwigshafen,
Glysantin G 05
Rhein, Germany
Castrol Int.
Pipers Way Antifreeze NF,SF
Swindon SN3 1RE, UK
BP, Brittanic Tower,

Moor Lane, Antifrost X 2270A
London EC2Y 9B, UK
35 %
Deutsche Shell AG
Überseering 35 Glycoshell
Höchst AG, Werk Gendorf Genatin extra

84508 Burgkirchen, Germany (8021 S)
Mobil Oil AG
Steinstraße 5 Antifreeze agent 500
Arteco, Technologiepark,
Zwijnaarde 2, Havoline XLC
B-9052 Gent, Belgium
50 %
Total Lubricants Glacelf Auto Supra

Paris, France Total Organifreeze
Table 5 Anti-freeze agents with slushing properties
10.45 - 3.3.7 (2010-11-08)

Description
Cooling Water Inspecting 504.42
General
Summary Tools/equipment required
Acquire and check typical values of the service me- Equipment for checking the fresh water quality
dia to prevent or limit damage.
The following equipment can be used:
The fresh water used to fill the cooling water cir-
cuits must satisfy the specifications. The cooling • MAN Diesel water testing kit or a similar testing
water in the system must be checked regularly in kit containing all the instruments and chemicals re-
accordance with the maintenance schedule. quired to determine the water hardness, pH value
and chlorine content (obtainable from MAN Diesel
The following work/steps is/are necessary: or Mar-Tec Marine, Hamburg)
Acquisition of typical values for the operating fluid,
evaluation of the operating fluid and checking the Equipment for testing the concentration of additives
concentration of the rust inhibitor.
When using chemical additives:
• Testing equipment in accordance with the sup-

plier's recommendations.
Testing kits from the supplier also include equip-
ment that can be used to determine the fresh water
quality.
Testing the typical values of water
Abbreviated specification
Water for filling and refilling

Typical value/property Circulating water (with additive)
(without additive)
Water type Fresh water, free of foreign matter Treated cooling water
Total hardness ≤ 10 °dGH 1) ≤ 10 °dGH 1)
pH-value 6.5 - 8 at 20 °C ≥ 7.5 at 20 °C
Chloride ion content ≤ 50 mg/l ≤ 50 mg/l 2)
Table 1: Quality specifications for cooling water (abbreviated version)
1)
dGH = German hardness:
1°dGH = 10 mg/l CaO
= 17.9 mg/l CaCO3
= 0.179 mmol/L
2)
1 mg/l = 1 ppm
10.12 - 000.07 (2010-02-25)

504.42 Cooling Water Inspecting Description
General
Testing the concentration of rust inhibitors
Abbreviated specification
Slushing oil Concentration
Chemical additives according to "Quality of Engine Cooling Water"
Anti-freeze according to "Quality of Engine Cooling Water"
Table 2: Concentration of the cooling water additive
Testing the concentration of chemical additives Testing the concentration of anti-freeze
The concentration should be tested every week, The concentration must be checked in accordance
and/or according to the maintenance schedule, us- with the manufacturer's instructions or the test can
ing the testing instruments, reagents and instruc- be outsourced to a suitable laboratory. If in doubt
tions of the relevant supplier . you should consult MAN Diesel.
Chemical slushing oils can only provide effective Testing

protection if the right concentration is precisely
maintained. This is why the concentrations recom- We test cooling water for customers in our labora-
mended by MAN Diesel (quality specifications) tory. To carry out the test we will need a representa-
must be observed in every case. These recom- tive sample of roughly 0.5 l.
mended concentrations may not be the same as
those specified by the manufacturer.
10.12 - 000.07 (2010-02-25)

Description
Cooling Water System, Cleaning 504.43
General
Summary This work should ideally be carried out by a spe-

cialist who can provide the right cleaning agents
Remove contamination/residue from operating fluid for the type of deposits and materials in the cooling
systems, ensure/reestablish operating reliability. circuit. The cleaning should only be carried out by
the engine operator if this cannot be carried out by
Cooling water systems containing deposits or con- a specialist.
tamination prevent effective cooling of parts. Con-
tamination and deposits must be regularly elimi- Oil sludge
nated.
Oil sludge from lubricating oil that has entered the
This comprises the following: cooling system or a high concentration of rust in-
Cleaning the system and, if required, hibitors can be removed by flushing the system
removal of limescale deposits, with fresh water to which some cleaning agent has
flushing the system. been added. Suitable cleaning agents are listed al-
phabetically in the table entitled "Cleaning agents
for removing oil sludge". Products by other manu-
Cleaning facturers can be used providing they have similar
properties. The manufacturer's instructions for use
The cooling water system must be checked for con- must be strictly observed.
tamination at regular intervals. Cleaning is required
if the degree of contamination is high.
Duration of cleaning procedure /

Manufacturer Product Concentration
temperature
Drew HDE - 777 4-5% 4 hrs at 50 - 60 °C
Nalfleet MaxiClean 2 2-5% 4 hrs at 60 °C
Unitor Aquabreak 0.05 - 0.5 % 4 hrs at ambient temperature
Ultrasonic
Vecom 4% 12 hrs at 50 - 60 °C
Multi Cleaner
Table 1 Cleaning agents for removing oil sludge
10.13 - 000.08 (2010-02-25)

504.43 Cooling Water System, Cleaning Description
General
Lime and rust deposits which tends to gather in areas where the flow ve-
locity is low.
Lime and rust deposits can form if the water is es-
pecially hard or if the slushing oil concentration is Products that remove limescale deposits are ge-
too low. A thin lime scale layer can be left on the nerally suitable for removing rust. Suitable cleaning
surface as experience has shown that this pro- agents are listed alphabetically in the table entitled
tects against corrosion. If however, the thickness of "Cleaning agents for removing lime scale and rust
limescale deposits exceeds 0.5 mm, this can ob- deposits". Products by other manufacturers can be
struct the transfer of heat and cause thermal over- used providing they have similar properties. The
loading of the components being cooled. manufacturer's instructions for use must be strict-
ly observed. Prior to cleaning, check whether the
Rust that has been flushed out may have an abra- cleaning agent is suitable for the materials to be
sive effect on other parts of the system, such as the cleaned. The products listed in the table entitled
sealing elements of the water pumps. Together with "Cleaning agents for removing lime scale and rust
the elements that are responsible for water hard- deposits" are also suitable for stainless steel.
ness, this forms what is known as ferrous sludge
Duration of cleaning procedure /

Manufacturer Product Concentration
temperature
SAF-Acid 5 - 10 % 4 hrs at 60-70 °C

Drew Descale-IT 5 - 10 % 4 hrs at 60 - 70 °C
Ferroclean 10% 4 - 24 hrs at 60 - 70 °C
Nalfleet Nalfleet 9 - 068 5% 4 hrs at 60 - 75 °C
Unitor Descalex 5 - 10 % 4 - 6 hrs at approx. 60 °C
Vecom Descalant F 3 - 10 % approx. 4 hrs at 50 - 60 °C
Table 2 Cleaning agents for removing limescale and rust deposits
In emergencies only treated with deactivated aminosulfonic acid. This

acid should be added to water in a concentration
Hydrochloric acid diluted in water or aminosulfo- of 3 - 5 %. The temperature of the solution should
nic acid may only be used in exceptional cases if be 40 - 50 °C.
a special cleaning agent that removes limescale
deposits without causing problems is not available. • Diluted hydrochloric acid may only be used to
Observe the following during application: clean steel pipes. If hydrochloric acid is used as
the cleaning agent, there is always a danger that
• Stainless steel heat exchangers must never be acid will remain in the system, even once the
treated using diluted hydrochloric acid. system has been neutralised and flushed. This
residual acid promotes pitting. We therefore re-
• Cooling systems containing non-ferrous metals commend you have the cleaning carried out by a
(aluminium, red bronze, brass, etc.) must be specialist.
10.13 - 000.08 (2010-02-25)

Description
Cooling Water System, Cleaning 504.43
General
The carbon dioxide bubbles that form when lime- Caution!

scale deposits are dissolved can prevent the clean- Only carry out the cleaning operation once the
ing agent from reaching boiler scale. It is therefore engine has cooled down
absolutely necessary to circulate the water with the Only start the cleaning operation once the engine
cleaning agent to flush away the gas bubbles and has cooled down. Hot engine components must not
allow them to escape. The length of the cleaning come into contact with cold water. Open the vent-
process depends on the thickness and composition ing pipes before refilling the cooling water system.
of the deposits. Values are provided for orientation Blocked venting pipes prevent air from escaping
in the table entitled "Detergents for removing lime which can lead to thermal overloading of the en-
scale and rust deposits“. gine.
Following cleaning Caution!

Cleaning products can cause damage
The cooling system must be flushed several times The products to be used can endanger health and
once it has been cleaned using cleaning agents. may be harmful to the environment.
Replace the water during this process. If acids are Follow the manufacturer's handling instructions
used to carry out the cleaning, neutralise the cool- without fail.
ing system afterwards with suitable chemicals then
flush. The system can then be refilled with water
that has been prepared accordingly. The applicable regulations governing the disposal
of cleaning agents or acids must be observed.
10.13 - 000.08 (2010-02-25)

Your Notes :
Description Quality of Raw-water in Cooling Tower Operation 504.44
Page 1 (2) (additive and circulating water) Edition 01
General
This guideline specifies the basic demands made Additive water

on cooling water for cooling tower operation. Should
the cooling tower manufacturer make further de- The system water losses caused by blowing down,
mands on the water quality, these requirements evaporation or leakages must be replaced by con-
must, by all means, be observed. tinuous additive water topping during operation.
The required amount of additive water depends on
Moreover, it must be taken into consideration that the quality of the additive water and the climatic site
additional demands will be made on the water qual- conditions.
ity depending on the material of the coolers, which
are applied with water. Additional requirements for Certain demands have to be made on the additive
the cooling water made by the cooler manufacturer water quality, which is based on the requirements
must also be observed. for circulating water taking the concentration de-
gree into consideration. If the required water qual-
ity cannot be achieved, the water has to be treated
General chemically (e.g. softening or hardness stabilisation)
or mechanically, if necessary. Otherwise
The raw water system with cooling tower re-cooling
concerns an open circulation system, which dissi- • deposits due to precipitation of hardly soluble
pates the heat absorbed from the water by evapora- salts,
tion into the cooling tower. This results at the same • sediments of disperse solid substances,
time in a continuous water loss due to evaporation. • corrosion,
In order to restrict the incurring salt concentration, a • growth of micro organisms
certain water amount must permanently be topped
as additive water. are to be expected.
Water losses due to evaporation and blowing down The cooling tower should, at least, be run with a
(depending on the additive water quality) may concentration by factor 2. Higher concentrations
amount up to 3 % of the circulating water quantity. are, in general, more economic. In order to permit
this, the content of substances must not exceed half
of the amount of the contents permitted for circulat-
Blowing down ing water. For the absolute minimum requirements,
please see Table 1.
An increasing evaporation loss results in a higher
concentration of the salts and the suspended sub-
stances in the water and, therefore, in an increas- Water treatment
ing tendency to corrosion and the formation of
deposits in the system. In addition, the raw water Depending on the water quality, various treatment
absorbs impurities from the ambient air. Deposits processes come into consideration:
have a negative effect on the heat dissipation in the
coolers and the control system function. • Decarbonisation, acid injection
08028-0D/H5250/94.08.12
• Desalinisation
In order to avoid excessive concentration, a part of • Cooling water conditioning (chemical treatment).
the thickened circulating water must be removed
from the circuit and be replaced by less concen- By using special chemicals, so-called stabilisers
trated additive water. Blowing down has a regulat- and conditioners, deposits and corrosion in the cool-
ing effect on the concentration constituents of the ing water circuit can largely be controlled. These
circulating water. The amount of the water to be ex- means permit operation at increased concentration
changed depends on the water quality and has to and, therefore, a reduction of the required additive
be chosen as to ensure constant compliance with water.
the limit values specified for the circulating water
(see Table 1). When using chemical additives for cooling water
conditioning, the cooling tower manufacturer is to
be contacted.
08.44
504.44 Quality of Raw-water in Cooling Tower Operation Description
Edition 01 (additive and circulating water) Page 2 (2)
General
Quality guidelines for circulating and additive Monitoring of the water quality
water
pH Value, water hardness and conductivity of the
circulating water should, at least, be measured
Circulating every 2 weeks. Based on the conductivity, it can be
Additive water 1)
water checked whether the prescribed concentration fac-
tor is kept. Regular checks must include the values
Colourless, Colourless,
stated in Table 1.
Appearance clear, no clear, no
sediments sediments
pH value 2) 7.5 - 8.5 - Utilisation of biocides
Intensive venting of the water in the cooling tower

Total salt content < 2,500 ppm < 1,250 ppm and insulation will, above all, during the warm sea-
son, cause algeas and microorganisms, which clog
Conductivity < 3,000 μS/cm - the cooling system, support corrosion and clearly
reduce the cooling efficiency.
Calcium > 20 ppm > 10 ppm
Growth by algeas, shells and bacteria colonies
Carbonate must, therefore, be eliminated by vaccination with
< 4 ûdH < 2 üdH chlorine or effective biocides.
hardness without
< 71 ppm < 35 ppm
hardness
CaCO3 CaCO3
stabilation The selection and application of biocides depends
Carbonate on the occurring microorganisms. Close coopera-
< 20 üdH < 10 üdH tion with the manufacturer, resp. supplier, would be
hardness with
< 356 ppm < 178 ppm recommendable as they dispose of suitable test
hardness
CaCO3 CaCO3
stabilisation processes for micro organism detection as well as
the necessary experience.
Chloride < 200 ppm < 100 ppm
Environmental protection, safety
Sulphate < 300 ppm < 150 ppm
The locally applicable environmental requirements
KMnO4 are, in cooling tower operation, to be taken into
< 100 g/m3 - consideration for the discharge of blow-down wa-
consumption
ter and disposal of the substances (hardness sta-
Germ number < 10,000 /ml -
bilisers, biocides, corrosion inhibitors, dispersants)
used for cooling water treatment.
Table 1 Quality guidelines for circulating and
additive water When using chemical additives, the safety regula-
tions of the manufactures must, by all means, be
08028-0D/H5250/94.08.12
1)
observed.
Minimum requirements in the case of contration factor
2. At a higher concentration the values are accordingly
lower.
2)
When using chemical additives, the pH values may be
located outside the specified range.
08.44
Description
Quality of Water used in Exhaust Gas Boiler Plants 504.45
General
Conditions
Low-salt or
Saltless feed
salt-laden
Like fuel, lube oil and engine cooling water, water water
feed water
for exhaust gas boiler plants is a consumable, which
has carefully to be chosen, treated and supervised. pH value at 25 °C >9 >9
In the case of improper water maintenance, corro-
sion and deposits may form up in the water. Depos- < 0.06 ûdH
its will on their part again result in corrosion and Hardness resp.
have an adverse effect on heat transfer. < 0.01 mmol/l
Any additional requirements for water quality speci- Conductivity at

< 0.2 μS/cm 1)
25 °C
fied in the boiler manufacturer's manual have to be
taken into consideration.
Oxygen content < 0.1 mg/l < 0.02 mg/l
Table 1 Requirements for feed water in exhaust gas

Applications boilers
Two different systems are used:

1)
After strongly acid sample drawing cation exchanger
• Exhaust gas boiler plants generate steam, which
is used as heat transfer agent in other systems.
• With regard to steam turbines, steam generated

Low-salt or
by means of the exhaust gas temperature is used Saltless
salt-laden
for energy production. circulating
circulating
water
water
Separate demands made on feed and circulating
water are valid for both application cases. pH value at 25 °C 9.5 - 10.5 10.5 - 12
Conductivity at
Exhaust gas boiler without steam turbine < 50μS/cm < 5000μS/cm
25 °C
The quality requirements for feed and circulating

Acid capacity up
water comply with TRD 611 (Technische Regeln für 1 - 12 mmol/l
to pH 8.2
Dampfkessel = technical rules for steam boilers).
Low-salt and salt-laden feed water can be used if Table 2 Requirements for circulating water in
the specifications in Table 1, are kept. The utilisa- exhaust gas boiler
tion of the salt-free feed water is possible, but not
necessary. When using saltless feed water, corre-
sponding limit values are valid for circulating water. Exhaust gas boiler with steam turbine
08028-0D/H5250/94.08.12
Only saltless feed water, which complies with the

requirements according to Table 3, may be used
for steam turbines.
08.44
504.45 Quality of Water used in Exhaust Gas Boiler Plants Description
General
Treatment
Saltfree feed water
The feed water has to be treated with suitable
chemicals. If an exhaust gas boiler without turbine
pH value at 25 °C >9
is used, the conditioning agent must contain the fol-
lowing products:
Conductivity at 25 °C < 0.2 μS/cm1)
• Residue softener
Oxygen content < 0.1 mg/l • Oxygen binder
• Alkalising medium
Iron, total Fe < 0.03 mg/l
• Steam-volatile alkalising medium for corrosion
protection in the condensate system (not compul-
Copper, total Cu < 0.005 mg/l sorily required in the case of saltless feed water)
• Possible dispersing agent (in particular, if depos-

Silicic acid, SiO2 < 0.02 mg/l its already exist in the boiler system).
Table 3 Requirements for feed water in steam
MAN Diesel recommends using combination prod-
turbines
ucts. This simplifies the treatment and ensures that
all vital points concerning water treatment are taken
1)
After strongly acid sample drawing cation exchanger into consideration.
During the warranty period and in the case of exist-

ing maintenance contracts, only the products men-
tioned in Table 5, are to be used.
Saltfree circulating water
pH value at 25 °C 9.5 - 10.5
Producer Product
Conductivity at 25 °C < 3 μS/cm
DREW Advantage 121 M

Silicic acid, SiO2 < 4 mg/l
Table 4 Requirements for circulating water in Nalco Nalco 72400

steam turbines
08028-0D/H5250/94.08.12
Unitor Liquitreat + Condensate Control
Table 5 Combination products for treatment of the

feed water in exhaust gas boilers without
steam turbine
08.44
Description
Quality of Water used in Exhaust Gas Boiler Plants 504.45
General
It is expressly pointed out that warranty for the The following values of the boiler water are to be
products used has to be taken over by the product checked and documented regularly:
manufacturer.
• pH Value, daily
The recommendations of the turbine manufacturer • Conductivity, daily
are to be taken into consideration for the treatment • Hardness, daily
of water used in steam turbines. General recom- • Iron content
mendations can, in this case, not be given. • Acid capacity of up to pH 8.2 (pH value).
• Additive concentration (according to manufactur-
er specifications)
Water maintenance
The following values of the condensate are to be
The following values of the feed water are to be checked and documented regularly:
checked and documented regularly:
• pH Value, daily
• pH Value, daily • Conductivity, daily
• Conductivity, daily • Hardness
• Hardness, daily • Iron content
• Oxygen content, resp. surplus at oxygen binder, • Additive concentration (according to manufactur-
daily er specifications).
• Concentration of additives (according to manu-
facturer specifications)
• Iron content Cleaning of the exhaust gas boiler
• Acid capacity of up to pH 8.2 (pH value)
Cleaning at the exhaust gas side is carried out with
With regard to steam turbines, the following has, in steam or water, by means of the corresponding
addition, to be checked weekly: devices. In the case of water cleaning, special re-
quirements are not to be observed, with the excep-
• Copper content, silicic acid tion that sea or brackish water must not be used.
Correct maintenance provided, water cleaning is

not necessary. Should cleaning prove to be neces-
sary, a suitable company has to be engaged, which
is able to carry out professional cleaning.
08028-0D/H5250/94.08.12
08.44
Your Notes :
Description Specification for Water 504.46
Page 1 (1)
used in Fuel-water emulsions Edition 01
General
Prerequisites Specifications
The water used for the fuel-water emulsion is an Limit values

operating fluid that must be carefully selected,
processed (if necessary) and monitored. If this is The characteristic values of the water used must be
not done, deposits, corrosion, erosion and cavita- within the following limit values:
tion may occur on components of the fuel system
that come into contact with the fuel-water emulsion.
Properties/Characteristic Characteristic value Unit
Seawater, brackwater, river water, brines, industrial waste

Water type -
water and rainwater, distilled or fresh water
Total hardness max. 10 °dH*
pH-value 6.5 - 8 -
Chloride ion content max. 50 mg/l
Table 1: Fuel-water emulsion – characteristic values to be observed
*) 1°dH (German hardness) ≙ 10 mg CaO in 1l water ≙ 17.9 mg CaCO3/l

≙ 0.357 mval/l ≙ 0.179 mmol/l
Testing instruments
The MAN Diesel water testing kit contains instru- It is largely determined by the calcium and mag-
ments that allow the water characteristics referred nesium salts. The temporary hardness depends on
to above (and others) to be easily determined. the hydrogencarbonate content in the calcium and
magnesium salts. The lasting (permanent) hard-
ness is determined by the remaining calcium and
Additional information magnesium salts (sulphates).
Destillate Water with a hardness greater than 10°dH (Ger-

man total hardness) must be blended or softened
If distillate (e.g. from the fresh water generator) or with distillate. It is not necessary to increase the
fully desalinated water (ion exchanger) is available, hardness of extremely soft water.
this should ideally be used for the fuel-water emul-
sion. These types of water are free of lime and salts. Caution!
Treatment with rust inhibitors not required
Hardness Treatment with rust inhibitors is not required and
must be omitted.
The total hardness of the water is the combined ef-
fect of the temporary and permanent hardness.
10.45 - 3.3.10 (2010-11-08)

Your Notes :
Description
Specification for Intake Air (Combustion Air) 504.60
General
General
The quality and condition of the intake air (com- When designing the intake air system, the maximum
bustion air) have a significant effect on the power permissible overall pressure drop (filter, silencer, pipe
output of the engine. In this regard, not only are the line) of 20 mbar must be taken into consideration.
atmosperic conditions extremely important, but also
contamination by solid and gaseous foreign matter. Requirements
Mineral dust in the intake air increases wear. Chemi- The concentrations downstream of the air filter and/or
cals and gases promote corrosion. upstream of the turbocharger inlet must not exceed
the following limit values:
This is why effective cleaning of the intake air (com-
bustion air) and regular maintenance/cleaning of the
air filter is required.
Properties Typical value Unit*

Particle size max. 5 µm
Dust (sand, cement, CaO, Al2O3 etc.) max. 5
Chlorine max. 1.5
Sulphur dioxide (SO2) max. 1.25 mg/m3 (SPC)
Hydrogen sulphide (H2S) max. 15
Salt (NaCl) max. 1
* m3 (SPC) Cubic metres at standard temperature and standard pressure
Table 1 Intake air (combustion air) - typical values to be observed
10.45 - 3.3.11 (2010-11-08)

Your Notes :
Cylinder head
505/605
Your Notes :
Description 505.01
Page 1 (1) Cylinder Head Edition 04H
V28/32S
Cylinder Head Air Inlet and Exhaust Valves.
The cylinder head is made of nodular cast iron, in The inlet and exhaust valve spindles are identical.
one piece. It has a central bore for the fuel injection
valve and bores for two exhaust valves, two inlet The valves are made of heat-resistant material. Hard
valves, safety valve, indicator valve and cooling metal is welded on to the valve spindle seats.
water supply.
The valve spindles are fitted with valve rotators
The cylinder head is tightened by means of 6 nuts which turn the spindles a little each time the valves
and 6 studs, which are screwed into the engine opens.
frame. The nuts are tightened by means of hydraulic
jacks. The cylinder head is equipped with replaceable seat
rings for inlet and exhaust valves.
The cylinder head has a screwed-on coaming which
encloses the valve gear. The valve seat rings for inlet and exhaust valves
are identical.
The coaming is closed with a top cover and thus
provides an oil tight enclosure for the valve gear. The seat rings are made of heat-resistant steel,
hardened on the seating surface and water cooled in
From the cooling water guide jacket, cooling water order to assure low valve temperature and increased
is led through radial bores in the bottom of the overhaul inter vals.
cylinder head. From the cooling water space and
bores in the cylinder head, the cooling water is led
to a common outlet.
08028-0D/H5250/94.08.12
02.04 - ES0
Your Notes :
Page 1 (2) Dismantling of Cylinder Head Edition 06H
V28/32S

Shut-off cooling water 52021 01 Oil injector,
Shut-off fuel oil (complete)
Shut-off cooling oil
Stopped lub. oil circul. 52021 51 1 Piece
Press Blocking - Reset 52021 15
52005 01
52021 25 Hydraulic tools
52014 15
Description
Dismantling of cylinder head for inspection

and/or overhaul.
Hand tools
Starting position Ring and open end spanner 14 mm.

Ring and open end spanner 17 mm.
Cooling water has been drained from engine. Ring and open end spanner 24 mm.
Related procedure
Dismounting of piston and connecting

rod, 506-01.00
Dismounting and inspection of inlet valve,
exhaust valve and valve guide, 505-01.05
Safety valve, 505-01.25
Dismantling, overhaul and test
pressure of fuel oil valve, 514-01.10
Replacement and wearing parts
08028-0D/H5250/94.08.12
Man power Plate no. Item no. Qty./
Working time : 1 Hour

Capacity : 2 men
Data

02.47 - ES0
Edition 06H Dismantling of Cylinder Head Page 2 (2)
V28/32S
1) Open the drain cock and vent cock for cool- 8) Remove the exhaust pipe flange screws.
ing water.
9) Remove the cylinder head nuts, as shown,
2) Take off the rocker arm top cover. by means of hydraulic jacks, see working card
520-01.05.
3) Take off the cover which gives access to the
injection pump. 10) Mount the lifting tool on the cylinder head.
4) Disconnect the fuel oil high-pressure pipe. 11) Attach the hook to the lifting tool and lift the
cylinder head away.
5) Disconnect the cooling oil pipes, (inlet and
outlet.
6) Disconnect the rocker arm lubricating oil pi-

pe.
7) Remove the thermometer attachment branch

(cooling water outlet pipe).
Fig. 2
Fig. 1
08028-0D/H5250/94.08.12
02.47 - ES0
Working Card Inspection of Inlet Valve, Exhaust Valve and 505-01.05
Page 1 (3) Valve Guide Edition 05H
V28/32S
Stopped engine Plate no Item no Note

Shut-off cooling water 52005 01
Shut-off fuel oil 52005 05
Shut-off nozzle cooling oil 52005 25/30 Extra tools
Stopped lub. oil circul. 52005 55
Description
Dismounting of inlet and exhaust valve, inspec-

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

Starting position Small screw driver.
Measuring tools.
Cylinder head, dismantled from
engine 505-01.00
Related procedure
Reconditioning of valve spindle seat

and valve seat ring, 505-01.10
Valve rotator, 505-01.15
Replacement of valve guide, 505-01.20
Replacement of valve seat ring, 505-01.35
Mounting of cylinder head, 505-01.45
08028-0D/H5250/94.08.12
Working time : 1 hour Plate no Item no Qty. /

Capacity : 1 man
50501 076 4/cyl.
Data

02.47 - ES0
505-01.05 Inspection of Inlet Valve, Exhaust Valve and Working Card
Edition 05H Valve Guide Page 2 (3)
V28/32S
Dismantling of Inlet and Exhaust Valve 3) Turn back the rocker arm and remove the spring-
Spindles loaded valve bridge over the valve spindles.
1) Land and fasten the cylinder head upon the spe- 4) After having removed the valve bridge and
cial work table and remove the lifting tool. turned the rocker arm back, the tool should
be fitted by means of the screws (A), see fig 2
tightened in the threaded holes in the cylinder
Or as an Alternative: head.
Land the cylinder head on the floor upon wooden

supports and remove the lifting tool.
2) Mount the supporting devices for the valve

spindle heads on the work table.
Or as an Alternative:
Place wooden blocks under the valve spindleheads.
Fig 2
5) Now compress the valve springs by tighten-

ing the nut (B), after which the cone rings can
be re-moved, see fig 3.
08028-0D/H5250/94.08.12
Fig 1 Fig 3
02.47 - ES0
Working Card Inspection of Inlet Valve, Exhaust Valve and 505-01.05
Valve Guide
V28/32S
6) Release the springs again. Remove the nut Inspection of valve guide
(B) and the traverse (C). Now valve rotator
and springs can be removed. 10) Too much clearance between valve spindle
and spindle guide may cause increased lub. oil
7) Remove the supporting devices under the work consumption, fouling up of the spindle guide and
table and take out the valve spindle. thus give the risk of a sticking valve spindle.
8) Repeat point 4 - 7 to remove the two other Too much clearance also means insufficient
valve spindles. guidance of the valve spindle, and thus bad
alignment between spindle head and valve
seat ring. In connection with overhaul of the
Inspection of Valves/Valve Seats cylinder head, the valve spindle guides should
be cleaned, inspected and measured for wear.
9) A slight grinding of valve/valve seat can be If the inner diameter of the valve spindle guide
carried out by means of the handle as shown, exceeds the tolerance, see page 500.35 the
see fig 4. valve spindle guide must be replaced. See
working card 505-01.20.
If the valve seat is heavily burnt or scarred, it should
be ground using the valve seat grinder according to 11) For mounting of valve spindle follow the in-
working card 505-01.10. structions in point 4 - 7 in reversed order.
08028-0D/H5250/94.08.12
Fig 4 Fig 5
02.47 - ES0
Your Notes :
Working Card Reconditioning of Valve Spindle Seat 505-01.10
and Valve Seat Ring
V28/32S

Shut-off cooling water 52005 40 Grinding machine
Shut-off fuel oil for valve spindle.
Shut-off nozzle cooling oil 52005 35 Grinding machine
Stopped lub. oil circul. for valve seat ring.
Press Blocking - Reset (Extra tools).
Description
Reconditioning of valve spindle seat and valve

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

in the tools box for grinding machine.
Starting position
Valve spindle has been removed, 505-01.05
Related procedure
Mounting of valve spindle, 505-01.05

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

Capacity : 1 man
Data

02.47 - ES0
505-01.10 Reconditioning of Valve Spindle Seat Working Card
and Valve Seat Ring
V28/32S
Reconditioning of Valve Seat Ring However when the seat "S" has been ground to such
an extent, that the recess "R" disappears, the valve
Reconditioning of valve seat rings by machining is seat ring has to be scrapped and a new one to must
carried out by means of a grinding machine, the installed, see working card 505-01.35
pilot spindle of which is to be mounted in the valve
spindle guide. For operation of the grinding machine,
see separate instructions. Reconditioning of Valve Spindle
The grinding of the valve seat ring should be carried Reconditioning by machining is carried out with the
out according to the following sequence: valve spindle being rotated in a turning lathe and a
special grinding machine mounted on the tool post
1) The seating surface itself is ground with a feed of the turning latch.
at an angle "A" of 30° ± 0,10°.
0.
For operation of the grinding machine, see separa-
The grinding should be continued until a clean and ted instructions.
uniform surface condition has been obtained.
1) The seating surface itself is ground with a feed
Carry out the final grinding with a feed in direction at an angel "A" of 30° ± 0.
from inside to outwards, as normally the best surface
quality is obtained in this way. 2) The grinding shoud be continued until a clean
and uniform surface condition has been obtained.
3) After completing the grinding, the height "H"1

of the valve head should be checked.
"A" 30 ± 0,10°
0
"H"1 has to be at least, see page 500.35.
"R"
"S" If measured to be less, the spindle has to be scrap-

ped.
08028-0D/H5250/94.08.12
"H"1
Fig. 1.
"A" 30° ± 0,25°

0
2) Normally the valve seat ring can be recondi-

tioned several times.
Fig. 2.
02.47 - ES0
Working Card Reconditioning of Valve Spindle Seat 505-01.10
and Valve Seat Ring
V28/32S
After assembling the valves, check - on account of
the valve motion - that distance "H"2 between the
upper edge of the cylinder head and the upper edge
of the valve spindle does not exceed the maximum
value, see page 500.35.
"H"2
Fig. 3.
08028-0D/H5250/94.08.12
02.47 - ES0
Your Notes :
Page 1 (2) Valve Rotator Edition 04H
V28/32S

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

rotator. Hand tools
Small screw driver.

Ring and open end spanner 24 mm.
Starting position
Valve spindles has been removed, 505-01.05
Related procedure
Mounting of valve spindles, 505-01.05

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

Capacity : 1 man
Data

02.47 - ES0
Edition 04H Valve Rotator Page 2 (2)
V28/32S
Inspection of Rotocap When inserting the balls and the tangential springs,
note that all balls on the inclined races of the ball
Dirt especially in the ball pockets due to residues in pockets point in the same direction, see fig. 1.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and hinder the
movement of the balls.
Rotocap valve rotators need no servicing under

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

ces. Rotation of the valve should be checked at the
intervals specified in the "Maintenance program".
Rotator performance is satisfactory when the valve
rotates visibly and evenly.
Fig. 1.
Dismantling of Rotocap
See working card 505-01.05, point 3 to 6. The inner ring of the spring washer should rest on
the retainer body.
Overhauls Note ! Having assembled the valve rotator in dry

condition it should be placed in clean lubricating oil
Valve rotators should be cleaned and inspected for for a short period of time.
wear and ball impressions whenever the valves are
removed. The individual parts can be disassembled
after removal of the retaining ring, by means of which Mounting of Rotocap
the seating collar is fastened to the retainer body.
See working card 505-01.05, point 3 to 6 , opposite
Parts showing wear grooves or depressions formed direction.
by the balls should be replaced.
08028-0D/H5250/94.08.12
02.47 - ESO
Page1 (2) Replacement of Valve Guide Edition 07H
V28/32S

Shut-off cooling water 52005 60 Lytra tools
Shut-off fuel oil
Description
Dismantling and mounting of valve guide, for inlet

and exhaust valve. Hand tools
Hammer.
Nitrogen (N2), or similar.
Starting position
Valve spindle has been removed, 505-01.05
Related procedure

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

Capacity : 1 man
50501 076 4/cyl.
Data 50501 088 4/cyl.

02.47 - ES0
Edition 07H Replacement of Valve Guide Page 2 (2)
V28/32S
If the clearance exceeds the shown max. limit, (see 3) Before mounting the new valve guide, it has to
page 500.35), the valve guide must be replaced. be cooled down to approx. -70°C with nitrogen
or similar.
Dismounting of valve guide When the new valve guide has been inserted
into the bore be sure that the shoulder bears
1) The valve guide is knocked out from the bottom against the cylinder head, by knocking slightly
of the cylinder head,by means of a mandrel, with the mandrel and a hammer.
which has a shoulder turning that fits into the
valve guide, see fig. 1. 4) Before mounting of the valve spindle insert a
new o-ring in the valve guide.
Valve seat ring
Mandrel
Fig 2.
Valve guide
08028-0D/H5250/94.08.12
Correct mounting can easily be done by the use of

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

2) After having knocked out the valve guide, caused for this purpose.
refully clean the bore of the cylinder head and
inspect for marks that can prvent mounting of 5) For mounting of valve spindle, see working
a new valve guide. card 505-01.05.
02.47 -ESO
Page 1 (3) Safety Valve Edition 02H
V28/32S

Shut-off cooling water 52014 01 Pressure test
Shut-off fuel oil pump.
Shut-off nozzle cooling oil 52014 04 Pipe for fuel
Stopped lub. oil circul. injector
Description
Dismantling, inspection, reassembling and

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

Small hammer.
Copaslip.
Starting position
Related procedure
Indicator valve 505-01.26
Man power
08028-0D/H5250/94.08.12
Working time : 1 hour Replacement and wearing parts

Capacity : 1 man
Plate no Item no Qty. /
50508 121 1/cyl.

Data

02.47 - ES0
Edition 02H Safety Valve Page 2 (3)
V28/32S
Maintenance and Checking 2. Reassembling
During extended periods of standstill and at general 2.1 Lubricate the threads on valve housing (2)
engine overhauls, the safety valves should be tho- with copaslip or similar.
roughly cleaned.
2.2 Reassemble the safety valve, reverse se-
Note: Do not attempt to stop a safety valve from quence of operations outlined above, point 1.1 to
leaking by increasing the spring load. 1.5.
The setting of the opening pressure is stamped onto

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

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

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

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

OK Continue with point 3.5.
below 135 bar Scrap the valve.

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

condition valve, if necessary.
02.47 - ES0
Page 3 (3) Safety Valve Edition 02H
V28/32S
Test of Opening Pressure 4. Adjustment of Opening Pressure
3.5 Increase the pressure to the opening pres- 4.1 Increase the pressure to the opening pres-
sure. sure.
4.2 Turn the cap nut (1) to the correct opening

pressure.
If the opening pressure is Then
4.3 Drill a new hole for mounting of split pin
OK The procedure is ended.
(5).
Not OK The valve must be 5. Mounting of Safety Valve

adjusted, see point 4.
5.1 Lubricate the threads on the valve housing
(2) with copaslip or similar.
5.2 Mount the safety valve on the cylinder

head.
08028-0D/H5250/94.08.12
02.47 - ES0
Your Notes :
Page 1 (2) Indicator Valve Edition 03H
V28/32S
Stopped engine Plate No Item No Note

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

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

Steel brush
Copaslip
Starting position
Related procedure
Safety valve 505-01.25

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

Capacity : 1 man
50508 37 1/Cyl.
Data

Data for torque momen (Page 500.40)
02.47 - ES0
Edition 03H Indicator Valve Page 2 (2)
V28/32S
Maintenance
By normal working conditions the indicator valve

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

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

valve is to be replaced. 1. Indicator valve, complete
2. Connecting piece
3) Clean and lubricate all components before
remounting.
Fig 1 Indicator valve.
4) Ensure that the spindle is in "OPEN" position
when assembling the valve.
NOTE: Otherwise cone and seat may be dama-

ged.
08028-0D/H5250/94.08.12
02.47 - ES0
Page 1 (2) Replacement of Sleeve for Fuel Injector Edition 02H
V28/32S

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

for fuel injector. Hand tools
Brass mandrel.
Hammer.
Lub. oil.
Starting position Two small screw driver.
Loctite 572.
The cylinder head has been dis-
mounted from engine, 505-01.00
The fuel injector has been removed, 514-01.10
Related procedure
Mounting of fuel valve, 514-01.10

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

Capacity : 1 man
50501 040 1/cyl.
Data 50501 052 1/cyl.
50501 064 1/cyl.
02.47 - ES0
Edition 02H Replacement of Sleeve for Fuel Injector Page 2 (2)
V28/32S
Dismounting of Sleeve for Fuel Injector 4) Coat the sealing ring zone in the bore with
grease or lub. oil.
1) Remove the snap ring by means of two screw
drivers.
2) The sleeve can now be driven out of the bo- Snap ring
re by use of a brass mandrel and a hammer. O-ring
Sleeve
Loctite 572
Brass mandrel
Fig 2
5) Install new sealing rings on the sleeve.
6) Coat the sealing surfaces on the sleeve with

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

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

Any marks which could prevent mounting of
the sleeve, should be gently smoothed.
08028-0D/H5250/94.08.12
02.47 - ES0
Page 1 (4) Replacement of Valve Seat Ring Edition 06H
V28/32S

Shut-off fuel oil 52005 45 Extra tools
Shut-off nozzle cooling oil 52021 46 1 piece
Description
Replacement of valve seat ring, for inlet and

exhaust valve.
Starting position Hand tools
Inlet and exhaust valves have been Ring and open end spanner 36 mm
removed, 505-01.05 Hammer.
Loctite, 648.
Lub. oil.
Related procedure

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

Capacity : 1 man
50501 172 4/cyl.
Data 50501 184 4/cyl.

02.47 - ES0
Edition 06H Replacement of Valve Seat Ring Page 2 (4)
V28/32S
Dismounting of Valve Seat Rings Procedure for Dismounting a Valve Seat
Ring
When reconditioning of a valve seat ring no longer is
possible due to dimensions exceeding the scrapping 1) By means of the guide pin (7) the guide disc
criteria, the seat ring has to be replaced. (5) is led vertically through the valve seat ring.
Then the guide disc (5) is lifted with the guide
Dismounting of a valve seat ring is carried out by pin (7) until the latter is guided by the valve
means of a special extractor tool set somprising seat ring. The stud (1) is then screwed in until
following components, see fig 1. it rests in the valve guide.
9
3
5
10
6
8
08028-0D/H5250/94.08.12
1 Stud 6 Eye screw

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

against the bottom of the cylinder head, and the
hydraulic jack is clamped with the disc (4) and
Fig 1
collar nut hexagon (2), see fig 1. The hydraulic
jack is the one used for main bearing caps.
02.47 - ES0
Page 3 (4) Replacement of Valve Seat Ring Edition 06H
V28/32S
3) By pumping up the pack, see working card 3) To facilitate mounting of the valve seat ring it is
520-01.05 for the use of hydraulic tools, the cooled down, however to no more than -25°C
valve seat is pressed out max. 6 mm, and the or the O-ring can be damaged.
pressure is released again.The collar nut hexa-
gon is tightenied and the operation is continued 4) Place the O-ring on the valve seat ring and
until the valve seat ring can be removed. coat with oil/loctite as shown in fig 4, just before
positioning it in the bore.
Mounting of Valve Seat Rings
1) Prior to mounting of a new valve seat ring, the

bore must be cleaned thoroughly and inspected
Coat with
for marks. Marks that can hinder mounting of loctite 648
the valve seat ring must be removed.
Valve seat ring
2) Tools for mounting of valve seat rings are shown
in fig 3.
O-Ring
Coat with oil
Fig 4
5) The valve seat ring is positioned in the bore,

handle with stud inserted as shown in fig 5,
1 and washer with screw is screwed tight.
3
4
08028-0D/H5250/94.08.12
1 Handle 2 Stud
3 Washers 4 Hexagon nut
with collar
Fig 5
Fig 3
02.47 - ES0
Edition 06H Replacement of Valve Seat Ring Page 4 (4)
V28/32S
6) By knocking on the handle and at the same

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

seat ring must be ground to ensure correct
centering of valve guide and valve seat ring.
This can be done according to working card
505-01.05 or 505-01.10.
08028-0D/H5250/94.08.12
02.47 - ES0
Page 1 (2) Mounting of Cylinder Head Edition 02H
V28/32S

Shut-off fuel oil 52021 51 1 Piece
Shut-off nozzle cooling oil 52021 15
52021 25
52014 15
Description
Mounting of cylinder head after inspection and/or

overhaul.
Cylinder head is completely Ring and open end spanner, 14 mm.

assembled, 505-01.05 to 505-01.35 Ring and open end spanner, 17 mm.
Valve gear of respective cylinder is in right posi- Ring and open end spanner, 24 mm.
tion (valve closed). Lub. oil and copaslip.
Control of the surface on the
cylinder liner, 506-01.45
Related procedure
Adjustment of valve clearance 508-01.10

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

Capacity : 2 men
50501 196 2/cyl.
Data 50510 014 1/cyl.
50610 102 2/cyl.
Data for pressure and tolerance (Page 500.35) 51202 335 1/cyl.
Data for torque moment (Page 500.40) 51625 132 2/cyl.
02.47 - ES0
Edition 02H Mounting of Cylinder Head Page 2 (2)
V28/32S
1) Check the jointing surfaces of the cylinder Place the spacer ring around the nuts with the slot
head/cylinder liner to see that they are clean in
and without damage marks, see working card such a position that the tommy bar can be used.
506-01.45, Fit new o-rings on the water pas-
sage, lubricate the o-rings with a little oil. Tighten the hydraulic jacks and make sure that the
cylinder of the jacks bears firmly against the spacer
2) Check all contact faces on the cylinder head ring. Tighten up all the nuts, see page 500.40. For
and nuts, including threads, and make sure that using the hydraulic tools, see working card 520-
these are plane and smooth and absolutely 01.05.
free from foreign particles.
3) Attach the lifting tool to the cylinder head that

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

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

508-01.10.
Fig 1
9) Fit the pipes for fuel oil, lub. oil, cooling oil.
cooling water and the flange for exhaust
08028-0D/H5250/94.08.12
4) Make sure that the nuts run easily on the threads pipe.
and that they bear on their entire contact sur-
faces. 10) Prior to start up check for leakages, and after
start up check for leakages and oil flow.
5) Coat threads and contact faces with copaslip
before fitting the nuts. 11) Mount the cover for rocker arm and the front
cover for fuel pump.
6) Screw nuts onto the studs and tighten lightly
with the tommy bar.
02.47 - ES0
Plate
Page 1 (2) Cylinder Head 50501-06H
V28/32S
529
495
483
040
052 064
446 076
458 088
542
471
554
483
495
566 578
505 591
601
613
517 625
172
184
196
422
08028-0D/H5250/94.08.12
637
649
06.32 - ES0
Plate
50501-06H Cylinder Head Page 2 (2)
V28/32S
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
040 1/C Snap ring Låsering 649 Cylinder head (as 637) Cylinderdæksel (som
with valve spindles 637), monteret med
052 1/C Sleeve for fuel valve Foring for br. ventil installed ventilspindler
064 1/C O-ring O-ring 422 Cylinder head (as 649) Cylinderdæksel (som
with brackets and 649) monteret med buk-
076 4/C O-ring O-ring rockerarms installed ke og vippearne.
088 4/C Valve guide, inlet and Ventilstyr, indstr. og

exhaust udstr.
172 4/C O-ring O-ring
184 4/C Valve seat ring, Ventilsædering,

(inlet and exhaust) (indstr. og udstødning)
446 2/C Nut Møtrik
458 2/C Distance pipe Afstandsrør
471 2/C Stud Tap
483 4/C Plug screw Propskrue
495 4/C Gasket Pakning
529 2/C Thrust collar Trykflange
542 8/C Nut Møtrik
554 8/C Stud Tap
566 4/C Spring pin Fjederstift
578 4/C Stud Tap
613 2/C Screw Skrue
625 2/C Coupling Kobling
637 Cylinder head with Cylinderdæksel mon-

08028-0D/H5250/94.08.12
valve guide sleeve for teret med spindelstyr,

fuel valve and valve foring for br. ventil og
seat rings ventilsæderinge
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty./C = Qty./Cylinder Antal/C = Antal/Cylinder
06.32 - ES0
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-12H
V28/32S
477
489
010 071
394
453
034
370 058
130 046
441 404 142
382
573 416
166 477
428
154
095
095
117
117
345 357
178 178
369
191
201 191
333
333
201
See plate 50501
08028-0D/H5250/94.08.12
490-500
512
524
561
262
08.28 - ES0
Plate
50502-12H Valve Spindles and Valve Gear Page 2 (2)
V28/32S
Item Item
010 2/C Rocker arm, compl. Vippearm, komplet 404 1/C Valve bridge, exhaust Ventilbro, udstødning
(Item 034, 046, 058, (Item 034, 046, 058, complete (incl. item komplet (inkl. item
071, 142, 453) 071, 142, 453) 095, 117, 154, 345, 095, 117, 154, 345,
357, 369, 370, 416, 357, 369, 370, 416,
034 2/C Thrust pin Trykskrue 428, 441) 428, 441)
046 2/C Bearing bush Lejebøsning 416 1/C Valve bridge,exhaust Ventilbro, udstødning
058 2/C Rocker arm Vippearm 428 2/C Thrust piece Trykstykke
071 2/C Nut Møtrik 441 2/C Nut Møtrik
095 4/C Circlip Fjederring 453 4/C Plug screw Propskrue
117 4/C Thrust piece Trykstykke 477 4/C Rocker arm bracket Buk for vippearm inkl
incl spring pin spændstift
130 1/C Valve bridge, inlet Ventilbro, indstrømning
complete (incl. item komplet (inkl. item 489 2/C Rocker arm shaft Aksel for vippearm
095, 117, 154, 166, 095, 117, 154, 166,
345, 357, 369, 370, 345, 357, 369, 370, 490 24/C Spring Fjeder
428, 441) 428, 441)
500 24/C Ball Kugle
142 2/C Thrust screw Trykskrue
512 4/C Spring washer Fjederskive
154 2/C Thrust screw Trykskrue
524 4/C Retainer ring Låsering
166 1/C Valve bridge, Ventilbro,
inlet indstrømning 561 2/C Valve spindle, outlet Ventilspindel,
udstødning
178 4/C Conical ring in 2/2 Konisk ring 2/2
573 /I Loctite 243 Loctite 243
191 4/C Rotocap, com- Rotationsgiver,
plete (incl. item komplet (inkl. item
490, 500, 512, 524) 490, 500, 512, 524)
201 4/C Outer spring Udvendig fjeder
262 2/C Valve spindle, inlet Ventilspindel,

indstrømning
333 4/C Inner spring Indvendig fjeder
345 2/C Spring Fjeder
357 2/C Ball guide Kuglestyr
369 2/C Securing ring Sikring
370 2/C Thrust piece Trykstykke
382 4/C Screw Skrue

08028-0D/H5250/94.08.12
Qty./ = Qty./Individual Antal/I = Antal/Individuelt
08.28 - ES0
Plate
Page 1 (2) Safety Valve and Indicator Valve 50508-02H
V28/32S
08028-0D/H5250/94.08.12
01.35 - ES0
Plate
50508-02H Safety Valve and Indicator Valve Page 2 (2)
V28/32S
Item Item
013 1/C Connecting piece Forbindelsesstykke
049 1/C Indicator valve, Indikatorventil,

complete komplet
108 1/C Safety valve, com- Sikkerhedsventil,

plete incl. (item 133, komplet (inkl. item
145, 157, 169, 170, 133,145, 157, 169,
182) 170, 182)
133* 1/C Cap nut Dækselmøtrik
145* 1/C Valve housing Ventilhus
157* 1/C Valve spindle Ventilspindel
169* 1/C Pressure spring Trykfjeder
170* 1/C Split pin Fjedernot
182* 1/C Valve cone Ventilkugle
08028-0D/H5250/94.08.12
01.35 - ES0
Plate
Page 1 (2) Cylinder Head, Top Cover 50510-04H
V28/32S
026
038
110
195
051
134
014
183
122
146
158
08028-0D/H5250/94.08.12
171
06.32 - ES0
Plate
50510-04H Cylinder Head, Top Cover Page 2 (2)
V28/32S
Item Item
026 4/C Handle Håndtag
051 1/C Top cover Topdæksel
110 4/C Nut Møtrik
122 18/C Washer Skive
134 1/C Top cover, compl. Topdæksel, kompl.

(incl. items 026, 038, (inkl. pos. nr. 026, 038,
051, 110) 051, 110)
146 6/C Spring pin Fjederstift
158 1/C Coaming Karm
183 18/C Screw Skrue
08028-0D/H5250/94.08.12
06.32 - ES0
Piston/connecting rod
506/606
Your Notes :
Description
Piston, Connecting Rod and Cylinder Liner 506.01
V28/32S
Piston The connecting rod has bored channels for supply

of oil from the big-end to the small-end eye.
The pistons, which are oil-cooled and of the mono-
bloc type made of nodular cast-iron, are equipped The big-end bearing is of the trimetal type coated
with 3 compression rings and 1 oil scraper ring. with a running layer.
By the use of compression rings with different The bearing shells are of the precision type and are
barral-shaped profiles and chrome-plated running therefore to be fitted without scraping or any other
surfaces, the piston ring package is optimized for kind of adaption.
maximum sealing effect and minimum wear rate.
The small-end bearing is of trimetal type and is
The piston has a cooling oil space close to the piston pressed into the connecting rod. The bush is equip-
crown and the piston ring zone. The heat transfer and ped with an inner circumferential groove, and a
thus the cooling effect is based on the shaker effect pocket for distribution of oil in the bush itself and for
arising during the oscillating piston movement. The supply of oil to the pin bosses.
cooling medium is oil from the engine’s lubricating
oil system.
Cylinder Liner
Oil is supplied to the cooling oil space through chan-
nels from the oil grooves in the piston pin bos-ses. Oil The cylinder liners are made of fine-grained, pearlite
is drained from the cooling oil space through ducts cast iron and fitted in a bores in the engine frame. Be-
situated diametrically to the inlet channels. tween the liner and the cylinder head and between
the liner and the frame there are fitted replaceable
The piston pin is fully floating and kept in position cast iron sealing rings. The liner is clamped by the
in axial direction by two circlips (seeger rings). The cylinder head and is guided by a bore at the bottom of
piston pin is equipped with channels and holes for the cooling water space of the engine frame. The lin-
supply of oil to lubrication of the pin bosses and for er can thus expand freely downwards when heated
supply of cooling oil to the piston. during the running of the engine. Sealing for the
cooling water is obtained by means of rubber rings
which are fitted in grooves machined in the liner.
Connecting Rod
Cooling water is supplied at the bottom of the cooling
The connecting rod is die-forged. The big-end has water space between the liner and the engine frame
an inclined joint in order to facilitate the piston and and leaves through bores in the top of the frame to
connecting rod assembly to be withdrawn up through the cooling water guide jacket.
the cylinder liner. The joint faces on connecting rod
and bearing cap are serrated to ensure precise loca-
tion and to prevent relative movement of the parts.
08028-0D/H5250/94.08.12
02.04 - ES0
Your Notes :
Page 1 (4) Dismounting of Piston and Connecting Rod Edition 02H
V28/32S

Shut-off fuel oil 52006 09 2 pieces
Shut-off cooling oil 52006 22
52006 28 140 - 760 Nm
52006 65
52010 01 (if necessary)
Description
Tool combination for dismounting of connecting
Dismounting of piston and connecting rod as- rod screw, see working card 520-01.20
sembly for inspection and/or overhaul.
The cylinder head has been dismounted Threaded pin, M16.

from the engine 505-01.00. Open end spanner, 32 mm.
Crankcase open. Wire.
Scraper or similar.
Small adjustable spanner.
Related procedure
Separation of piston and connecting

rod 506-01.05
Inspection and honing of cylinder
liner 506-01.35
Man power
Working time : 1 ½ hour
Capacity : 2 men Plate no Item no Qty. /
Data

02.34 - ES0
Edition 02H Dismounting of Piston and Connecting Rod Page 2 (4)
V28/32S
1) Clean the cylinder liner top of coking as the
piston may stick in the deposits.
If the liner is mounted with a flame ring then start

with item No a to e.
If the liner is not mounted with a flame ring then

continue with item No 2.
a) Turn the piston to the buttom.
b) Mount the tool for dismounting of the flame

ring in the cylinder at the top of the piston.
Fig 2.
Fig 1.
c) Place a used piston ring on top of the flame

ring tool.
d) Mount the tube (for holding down the cylin-

der liner during the piston withdrawal) on one of the
cylinder head studs, screw on the nut and tighten it
slightly.
e) Turn the piston in top, in order to push the

flame ring out of the cylinder by means of the tool.
Info: It is the used piston ring which pushes the

flame ring out of the cylinder, while the flame ring
tool guides the piston ring out against the cylinder
liner.
2) Dismount the crankcase cover for the cylin-

der section in question. Dismount the platform, if
any, in order to facilitate access. Fig 3.
02.34 - ES0
Page 3 (4) Dismounting of Piston and Connecting Rod Edition 02H
V28/32S
Fig 4.
3) Mount the supporting device on the crank-

Fig 6.
case's cover frame, see fig 1, with the two support-
ing grooves for the torque wrench extension turning
to the right of the middle.
6) Clean the thread hole in the piston top and
4) Place the mandrel in the guide sleeve and mount the lifting device, see fig 4.
push forward until the shoulder of the mandrel is
resting on the supporting device. The lifting eye must point at the engine's center
line.
The distance between the mandrel top and the con-
necting rod screw will then be approx. 5 mm. 7) Mount the pipe for retaining of the cylinder
liner, see fig 3, and tighten the nut on the cylinder
Thus collision between the mandrel and the con- stud.
necting rod screw is avoided when turning.
8) Grab the tackle in the lifting tool for the piston
5) Turn the crankshaft until the center of the and tighten.
connecting rod screw is on level with the mandrel
top, see fig 2.
Then the crank throw is in a position where both

upper and lower connecting rod screw can be loos-
ened, see fig 3.
Fig 7.
Fig 5.
02.34 - ES0
Edition 02H Dismounting of Piston and Connecting Rod Page 4 (4)
V28/32S
If it is necessary to turn the crank throw somewhat 16) Dismantle the remaining screws and the
to achieve a better access to the connecting rod bearing cap.
screws, the wire must be loosened before turning
the crankshaft and then tightened-up again in the Note: The purpose of the guide pin is to prevent
new position. any damage of crank journal, joint faces or bearing
surface to occur during dismounting of the bearing
9) Pull out the mandrel of the guide sleeve and cap.
dismount the supporting tool.
Furthermore, it facilitates easy handling when re-
10) Turn the supporting tool so that the two sup- moving the bearing cap from the crankcase.
porting grooves for the wrench torque extension
turns left to the middle of the supporting tool, see 17) Loosen the locking screw and release the
fig 5. forked rod tool, see fig. 8 in order for the connecting
rod to swing free of the crankpin when the piston
11) Mount the supporting tool, see fig 6. and the connecting rod are carefully pulled out.
12) Loosen and dismantle one of the upper con- 18) The upper bearing shell is carefully dismount-
necting rod screws. ed, see fig 8.
13) Mount the guide pin in the thread hole and 19) Pull out the piston and the connecting rod
tighten with a screwdriver, see fig 7. throughout the cylinder liner and out of the engine.
The connecting rod is carefully guided in order not
This is to avoid that the connecting rod swings out to damage the cylinder liner skirt, see fig 9.
and damages the liner when the bearing cap is dis-
mounted.
14) Mount the holding-up tool on the cover frame

of the crank housing on the opposite side of the
engine, see fig 7.
15) Press the forked rod tool against the connect-

ing rod and lock it in this position with the locking
screw on the tool.
Fig 9.
Fig 8.
02.34 - ES0
Page 1 (2) Separation of Piston and Connecting Rod Edition 04H
V28/32S

Description
Separation of piston and connecting rod for in-

spection or/and overhaul.
Assembly of the piston and connecting rod after
inspection or/and overhaul.
Hand tools
Starting position Open end spanner, 32 mm.

Wooden wedge, 2 pieces.
Piston and connecting rod are dismounted Wooden support.
from engine, 506-01.00 Wire.
Related procedure
Inspection or/and overhaul of piston, 506-01.10

Inspection or/and overhaul of
connecting rod, 506-01.15
Inspection of connecting rod
big-end bearing, 506-01.16

08028-0D/H5250/94.08.12
Man power Plate no. Item no. Qty./
Working time : 1/4 hour

Capacity : 1 man
Data

02.34 - ES0
Edition 04H Separation of Piston and Connecting Rod Page 2 (2)
L/V28/32H
Separation of the Piston and Connecting 6) Take out the securing ring, (seeger circlips),
Rod push out the piston pin and lift the connecting rod
away.
1) Land the piston and connecting rod carefully
on wooden support to prevent damage of piston and
scraper ring, see fig. 1. Assembly of the Piston and Connecting
Rod
7) For assembly of the piston and connecting rod,

see point 1-6 in opposite direction.
8) Lubricate the piston pin before assembling.
Fig. 1 V28/32S
2) The bearing cap should be mounted with the

screws tightened only by hand, in order to protect the
serrated joint faces during handling of the assembly,
see fig. 1.
3) Remove the shackle and eye screw/lifting tool

from the piston crown, see fig. 1.
4) Place the piston and connecting rod assembly

in upright position resting on the top face of the piston
crown, see fig. 2.
Wooden wedges should be used to prevent the con-

necting rod from swinging out and thus impact the
piston skirt during the lifting into upright position.
Fig. 2
5) Place a wire around the big-end of the con-
necting rod, attach a tackle and tighten the wire rope,
08028-0D/H5250/94.08.12
see fig. 2
02.34 - ES0
Page 1 (4) Piston (with flame ring) Edition 11H
V28/32S
Stopped engine Plate no Item no Note.

Cleaning and inspection of piston. Control of piston Tools for cleaning of piston, steel brush,
ring, scraper ring and ring grooves. scraper etc.
Starting position
Piston has been dismantlet from

connecting rod 506-01.05
Related procedure
Mounting of piston and

connecting rod 506-01.20
08028-0D/H5250/94.08.12
Working time : 1/2 Hour Plate no Item no Qty. /

Capacity : 1 man
Data

06.31 - ES0
Edition 11H Piston (with flame ring) Page 2 (4)
V28/32S
Removal of Piston Ring Inspection of Piston
For removal of piston rings, which are to be used 1) Remove the piston and scraper rings.
again, and for all mounting of rings, only the special
ring opener which prevents local over stressing of 2) Clean and examine the piston rings to deter-
the rings should be used. mine if reuse is acceptable, see page 3.
Straps to expand the ring gap or tools working on 3) Clean the piston outside and inside.
the same principle must not be used, as this would
result in permanent deformation which might cause 4) Inspect the piston ring and scraper ring grooves
blow-by or broken rings. for wear, see page 3.
08028-0D/H5250/94.08.12
06.31 - ES0
Page 3 (4) Piston (with flame ring) Edition 11H
V28/32S
The piston has to be scrapped if: Piston and oil New ring
Ring grooves.
scraper ring. grooves.
A) The wear limit on the testing mandrel is exceed- Nominal size. Tolerances.
Max. wear limit.
ed, see fig 1A
Piston ring New +0.18
or no 1 6.0 mm
6.0 mm
+0.16
6.43 mm
B) The clearance between the new piston/scraper Piston ring New +0.14
ring and ring groove is exceeded, see fig 1B. no 2 5.0 mm
5.0 mm
+0.12
5.43 mm
Piston ring New +0.14

Note: At each piston overhaul: no 3 4.95 mm
5.0 mm
+0.12
5.43 mm
- The piston and scraper ring must be ex- New +0.12

changed. Scraper ring 8.0 mm 8.43 mm
8.0 mm +0.10
- The cylinder liner must be honed according
to the instructions. Table 1 Nominal size, new ring groove tolerance and wear
limit for ring grooves
A) Testing Mandrel for Ring Grooves B) Clearance Ring/Groove
If the wear limit (2 mm mark) on the testing

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

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

with the nominal size.
08028-0D/H5250/94.08.12
Fig 1 Wear limits for ring grooves
06.31 - ES0
Edition 11H Piston (with flame ring) Page 4 (4)
V28/32S
Position of Piston and Scraper Rings
Piston Ring No 1:
marked with ident. no
"GOE CK36 TOP, 1678571-4".
Piston Ring No 2:
marked with ident.
no "GOE TOP, 1678572-6".
Piston Ring No 3:
"GOE TOP, 1678573-8".
Scraper ring:
"GOE, 1678575-1".
Marking of Piston and Scraper Rings

08028-0D/H5250/94.08.12
Marking
Identification marks to face upwards against the piston crown when mounted.
Note: The marking may include other figures than mentioned above, for instance trade mark and
production codes.
06.31 - ES0
Page 1 (4) Connecting Rod Edition 05H
V28/32S

Shut-off cooling water 52006 28 140-760 Nm
Shut-off fuel oil
Description
Cleaning, inspection and test measurement of

connecting rod.
Connecting rod has been Inside micrometer (242 mm).

dismantlet from piston, 506-01.05 Feeler gauge 0,15 - 0,20 mm.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

02.34 - ES0
Edition 05H Connecting Rod Page 2 (4)
V28/32S
Cleaning and Inspection of Big-end Bore Screws, which are damaged as mentioned above or
cannot be turned into the threaded holes by hand,
The connecting rod is cleaned on all machined must be renewed.
surfaces.
The serrated joint faces and threaded screw holes Measurement of Big-end Bore
are to be degreased with a volatile solvent and blown
dry with working air.
The serrated joint faces are inspected.
The serration on the connecting rod may, due to

relative movements between the mating surfaces,
30 mm
show damages in form of wear marks and pittings CL of serration B
or even cracks in highly loaded zones. A B

x
x C
x
x C
Observed damages should be registered in the schem
"Connecting Rod Inspection". See page 4. D
Wear marks are visible but not appreciable at a

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

Fig. 1. Point of measurement
be gently smoothed by careful, local treatment with
a file.
For check of roundness the big-end bore has to be
The serration on the connecting rod and on the measured in a condition, where the connecting rod
bearing cap can be damaged by improper handling is mounted with the bearing cap but without bearing
during dismounting, transport and overhaul work. shells, and the connecting rod screws are tightened
up with the prescribed torque, see working card
Note ! The connecting rod and bearing cap must 506-01.25.
therefore be handled with care.
Note ! The ident no. on the connecting rod and the
Single dent marks caused by impact can be rectified bearing cap, must always be the same, see fig. 3.
by gentle and careful local treatment with a file.
Measurements must be taken 30 mm from seration
In case of damage of the serration, reuse must centerline. See fig. 1.
be rejected, and a new connecting rod assembly
including new bearing shells must be mounted in The measuring is executed with an inside micro-
the engine. meter.
08028-0D/H5250/94.08.12
The connecting rod screws are to be carefully clean- Five different diameters are measured in the middle
ed. of the boring, see fig. 1 and registered in the scheme
"Connecting Rod Inspection". See page 4.
The threads are inspected for seizures and tested
in the threaded holes in the connecting rod. The test The maximum ovalnees is calculated as the dif-
must confirm, that the screws can be turned into ference between biggest and smallest diamenter
bottom position by hand. The contact surface of the measured. For maximum allowable ovalness see
screw heads is inspected for seizure and pittings. page 500.35.
02.34 - ES0
Page 3 (4) Connecting Rod Edition 05H
V28/32S
If the ovalness exceeds this value, reuse must be Please note that squares for statement of information
rejected and a new complete connecting rod, inclu- and identification, should also be properly filled in.
ding new screws and new bearing shells has to be
mounted in the engine.
Connecting Rod Bush
Inspect the surface of the piston pin and the connec-

ting rod bush. Measure the clearance between the
piston pin and bush, max. clearance between pin
and bush, see page 500.35.
In case the specified clearance is exceeded, contact

- 0,5 - 3,0 MAN B&W Diesel A/S, Holeby for replacement.
- 2,0 - 7,0
- 1,5 - 5,0
+ 5,0 + 5,5 Bearing Shells for Big-end
+ 3,0 + 3,5
7,0 12,5 Criteria for replacement of connecting rod big-end
bearing, see working card 506-01.16.
to be to be
reused rejected
Fig. 2. "Connecting rod inspection".
The example, see fig. 2 shows measurements and

damage observations for two connecting rods, on the
scheme "Connecting Rod Inspection", (In case the
specified maximum ovalness is exceeded, contact
MAN B&W Diesel A/S, Holeby for overhaul).
For connecting rod no. 1 the maximum ovalness is

Connecting rod
0,07 mm and reuse thus acceptable. Ident no.
08028-0D/H5250/94.08.12
For connecting rod no. 2 the maximum ovalness is

0,125 mm and therefore the connecting rod is being
rejected. Fig. 3.
02.34 - ES0
Edition 05H Connecting Rod Page 4 (4)
V28/32S
08028-0D/H5250/94.08.12
02.34 - ES0
Working Card Criteria for Replacement of 506-01.16
Connecting Rod Big-end and Main Bearing Shells
L27/38
V28/32S
Safety precautions: Special tools:

Shut-off fuel oil
Description:
Inspection of bearing shells.

Hand tools:
Magnifier (x30).
Starting position:
Bearing shells removed from engine:

Big-end bearing, 506-01.30
or
Main bearing and guide bearing 510-01.05
Related procedure:
Mounting af bearing shells:

Big-end bearing, 506-01.30
Main bearing and guide bearing 510-01.05
08028-0D/H5250/94.08.12
Man power: Replacement and wearing parts:

Capacity : 1 man
Data:

02.06 - ES0
506-01.16 Criteria for Replacement of Working Card
L27/38
V28/32S
This paper gives information about the evaluation of Wear of the bearings running surface starts primarily
the connecting rod big-end and main bearing shells in the soft overlay, where the overlay in the slots is
when wear appears on the running surface under reduced approx. 0.001 mm. The difference between
normal operating conditions. the light-alloy metal and the overlay is by further wear
almost constant, i.e. approx. 0.005 mm.
Bearing damages caused by incorrect running con-
ditions, like The gravity of the running surface’s wear must be
determined with a magnifier (x30), hereby the over-
- Scoring of the running surface due to foreign lay can be seen as the dark area and the light-alloy
particles in the lubricating oil. metal as the light area.
- Cavitation.
- Corrosion The ratio between the width of the light-alloy metal
- Overloading, overheating a.s.o. and the width of the slot as well as the dimension
of the worn area are important for determining the
are not described in this paper. wear of the bearing.
In these cases, the bearing shells must be exchang- The bearing can also operate although part of the
ed, of course, and in order to avoid further bearing overlay is missing in the slots. Practice has shown, that
failures, the cause of the failure must be found and bearings with partly empty slots can run without any
eliminated. negative influence on the operation of the bearing.
By determining the condition of the bearing shell,

the overlay at a minor stressed area must be used
as comparison.
Overlay
(~75%) The valuation of the bearing shell condition is divided
Light metal into 5 groups:
(~25%)
Nickel strike 1. Re-use
(max.5%) 2. Limiting case - wear
3. Limiting case - local levelling
4. Limiting case - permanent breakage on the
overlay
5. Empty slots.
In case of a combination of the above mentioned

conditions, the lowest possible limits are valid.
Fig. 1. Running surface of the bearing shell.

08028-0D/H5250/94.08.12
A new bearing shell has a running surface with approx.

75 % galvanic overlay and approx. 25 % light-alloy
metal, see fig. 1.
02.06 - ES0
L27/38
V28/32S
1.1. Bearing Shells for Re-use. 1.2. Bearing Shells for Re-use.
Condition: The slot geometry corresponds to a Condition: The overlay is equally worn, approx.
new bearing shell. The overlay in the slots is fully 0.005 mm in the slots. The light-alloy strips show
preserved, see fig. 2. no wear, see fig. 3.
Dark spots are mainly oil coke remains. Dark spots are mainly oil coke remains.
Valuation: The ratio between light-alloy metal and Valuation: Due to worn running surface the light-alloy
overlay is 75 % to 25 %. Re-use! strips are slightly widened. Re-use!
08028-0D/H5250/94.08.12
Fig. 2. Fig. 3.
02.06 - ES0
L27/38
V28/32S
1.3. Bearing Shells for Re-use. 1.4. Bearing Shells for Re-use.
Condition: Small particles all over the overlay. The Condition: The overlay has been dragged and
light- alloy metal shows no changes of importance, smudged over the light-alloy metal. These are only
see fig. 4. partly visible, see fig. 5.
Valuation: Re-use of the shell, as the particles are Valuation: Re-use of the shell.
wedged in the slots.
08028-0D/H5250/94.08.12
Fig. 4. Fig. 5.
02.06 - ES0
L27/38
V28/32S
2. Limiting Case - Wear Condition: The bearing shell is locally so worn, that
the ratio between the light-alloy metal and the overlay
is 1:1, see fig. 6. The width of the light-alloy metal has
increased from 100 % (new bearing shell) up to 175
%. In the slots some overlay is still left, see fig. 7.
Valuation: The bearing can operate with wear of the

below listed size, see fig. 8 og 9. If the wear limits
are exceeded the bearing shells must be exchanged
due to safety precausions.
max. 25%
of extent
Fig. 8.
max. 60%
Fig. 6. of width
175%
08028-0D/H5250/94.08.12
max. 30%
of extent
100%
Fig. 9.
Fig. 7.
02.06 - ES0
L27/38
V28/32S
3. Limit Case - Levelling Valuation: If the limits shown in fig. 11 and 12 are
exceeded the bearing shells must be exchanged.
Condition: The slots are locally totally levelled as
shown in fig. 10.
max. 10% of width
Fig. 10.
max. 5%
of extent
max. 10% of width or
max. 5 mm
Fig. 12.
Fig. 11.
08028-0D/H5250/94.08.12
02.06 - ES0
L27/38
V28/32S
4. Limit Case - Permanent Breakage of the Condition: Breakage in the overlay due to local
Running Surface overload, as shown in fig. 13 and 14.
Valuation: If the limits as shown below in fig. 15 and

16 below are exceeded with totally or partially empty
slots, the bearing shells must be exchanged.
max. 60%
of width
max. 30%
of extent
Fig. 15.
max. 10 mm
Fig. 13.
08028-0D/H5250/94.08.12
Fig. 14. Fig. 16.
02.06 - ES0
L27/38
V28/32S
5. Limit Case - Empty Slots Valuation: If the limits shown in the below fig. 18
and 19, are exceeded, the bearing shells must be
Condition: In some areas there is no overlay in the exchanged.
slots, see fig. 17.
max. 5 mm
Fig. 17.
max. 30% of width

extent
Fig. 19.
of
max. 15%
Fig. 18.
08028-0D/H5250/94.08.12
02.06 - ES0
Page 1 (4) Mounting of Piston and Connecting Rod Edition 02H
V28/32S

52006 28 140-760 Nm
52006 65
Description 52010 01 (If necessary)
Mounting of piston and connecting rod assembly

after overhaul and/or inspection.
Piston mounted on the connecting rod, crankshaft Open end spanner, 32 mm

turned in thecorrect position and the cylinder liner Clean lubricating oil.
is checked, see working card 506-01.35. Copaslip, molycote pasta or similar.
Related procedure
Tightening of connecting rod screws 506-01.25

Mounting of cylinder head 506-01.40
Working time : 2 hours Plate no. Item no. Qty. /

Capacity : 2 men
50601 09 1/cyl.
Data 50601 10 1/cyl.
50601 11 1/cyl.
02.34 - ES0
Edition 02H Mounting af Piston and Connecting Rod Page 2 (4)
V28/32S
1) Mount the piston lifting tool in current position, A crank throw position of approx. 105 degrees before
i.e. with the yoke at a right angle to the piston pin TDC will ensure this and also be suitable for the
axis and the lifting strap positioned in same direction further mounting procedure.
as the connecting rod, see fig. 1.
Fig. 2.
Fig. 1.
7) Lower the piston further down, lubricate the

2) Lift up the piston and connecting rod and mount ends of the bearings shells (a in fig. 3) with copaslip,
the piston and scraper rings, see point 16 and work- molycote pasta or similar and mount the upper shell
ing card 506-01.10. in the big-end bearing.
3) Remove the backstop for cylinder liner and Important: The upper shell is provided with
place the piston guide ring on top of the cylinder a hole for lubricating oil.
liner, see fig. 2.
8) Coat the crank journal with clean lubricating
4) Lower the piston and connecting rod assembly oil.
slowly down into the cylinder liner carefully guiding
the connecting rod and later on also the piston to 9) Now lower the piston and connecting rod
proper approach to the cylinder liner. assembly slowly into correct landing on the crank
journal.
5) When the piston approaches the guide ring,
stop the lowering, coat guide ring, piston, piston rings During this the connecting rod must be guided by
and scraper ring, with clean lubricating oil in order hand or with the forked tool.
to minimize friction during the subsequent lowering
of the assembly. 10) Mount the bearing cap with inserted big-end
bearing lower shell, using the guide pin to ensure
6) Make sure that the crank throw is in a posi- correct positioning, see fig. 4.
tion allowing the connecting rod to go clean of both
crank journal and cylinder liner skirt during further Note:The ident. no. on the connecting rod and on the
lowering. bearing cap, must always be the same and located
the same way, see fig. 4.
02.34 - ES0
Page 3 (4) Mounting of Piston and Connecting Rod Edition 02H
V28/32S
11) Lubricate threads and contact face of the con-
necting rod screws with copaslip, molycote pasta or
similar.
12) Mount the screws and tighten them slightly

using an open end spanner.
13) Remove the forked tool, slack up the tackle,

remove the wire rope and dismount the lifting tool
from the piston.
14) Tighten the screws according to "Tightening

Procedure for Connecting Rod Screws", see working
card 606-01.25.
a
a
Fig. 3.
Fig. 5.
During tightening of the screws the supporting piece

should be mounted on the crankcase cover frame to
act as guide for the tools.
15) After tightening ascertain that the big-end

moves easily on the journal.
Connecting rod ident no.
Fig. 4.
02.34 - ES0
Edition 02H Mounting af Piston and Connecting Rod Page 4 (4)
V28/32S
Mounting of Piston and Scraper Ring Before fitting the coil spring loaded scraper ring, the
coil spring is dismantled from the ring by removal of
16) If the rings are opened further than necessary the joint pin. The coil spring is placed and assembled
there is a risk of overstressing, which means that in the ring groov. Then the scraper ring is fitted in the
rings will become permanently distorted and will not groove in such a way that the ring joint is approxima-
conform to the cylinders inner running surface. tely 180° offset to the spring joint.
The piston rings should be installed with the identifi- Ascertain correct assembling by checking the back
cation mark, which is stamped into the ring close to clearance. The back clearance is sufficient when the
the ring joints, facing upwords. face of the ring is below the groove edge, when the
ring is pressed against the bottom of the groove.
When installed on the piston, the rings should be

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

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

the piston rings should be turned into positions off-
Ring joint setting the ring joint 180° to each other.
Fig. 6.
02.34 - ES0
Page 1 (2) Hydraulic Tightening of Connecting Rod Screws Edition 07H
V28/32S
Safety Precautions: Special Tools:

Shut-off cooling water 52021
Shut-off fuel oil
Description: Hand Tools:
Tightening procedure for connecting rod

screws.
Check of connecting rod screws, tightening
condition.
Starting Position:
Piston, connecting rod, bearing shells and bearing

cap preassembled. 506-01.20
Related Procedure:
Man Power: Replacement and Wearing Parts:

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

Capacity : 2 men
Data:

02.45 -ES0
Edition 07H Hydraulic Tightening of Connecting Rod Screws Edition 2 (2)
V28/32S
Tightening Sequence
Both studs to be tightened simultaneously.
1) Screw the studs (3) down by hand into the

connecting rod body (1).
2) Fit the upper part of the connecting rod (2) and

hold it with nuts (4).
Note. Remember to fit the bearing shells (unless

the mounting is carried out for finish-machining).
3) Check that the studs are screwed to the bottom

nd hand-tighten the nuts (4).
4) Mount the hydraulic jacks (5).
Note. Turn the thrust piece of the jack so that the

slots for the ball handle (6) are unloaded when pres-
surizing the jack.
5) Connect the jacks to the hydraulic system/

pump.
6) Load the studs with the hydraulic pressure and

tighten the nuts with the ball handle (6).
7) Relieve the tool pressure.
8) Re-apply the tool pressure.
9) Tighten the nuts again.

Fig. 1 Hydraulic tightening of connecting rod
Note. Item 8 and 9 are carried out in order to elimi-
nate any harmful stresses.
10) If any clearance is still visible and the nut can

be turned, then repeat item 7, 8 and 9.
11) The pressure to be relieved and the tool to

be dismantled.
08028-0D/H5250/94.08.12
02.45 - ES0
Page 1 (3) In Situ Inspection of Connecting Rod Big-end Bearing Edition 04H
V28/32S

Stopped lub. oil circul. 52006 28 140-760 Nm
52010 01 (If necessary)
Description
In situ inspection and/or replacement of con- Tool combination for tightening of connecting rod
nec-ting rod big-end bearing, dismounting and screws, see working card 520-01.20.
mounting.
Top cover for cylinder head removed. Open end spanner, 32 mm.
Crankcase open.
Fuel injector dismounted 514-01.00
Related procedure
Inspection of connecting rod big-end

bearing 506-01.16
Tightening and check of connecting rod
screws 506-01.25
Working time : 3 hours Plate no. Item no. Qty. /

Capacity : 2 men
Data

02.34 - ES0
Edition 04H In Situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
V28/32S
The big-end bearing shells can be inspected and/or
replaced insitu i.e. without dismounting the piston
and connecting rod from the engine.
Dismounting
1) The crankshaft of the engine is turned into a

position allowing the connecting rod screws to be
loosened, see working card 506-01.00.
Having loosened the connecting rod screws, the

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

ing rod bearing cap and bearing shell are dismounted,
see working card 506-01.00 for use of guide pin and
forked tool.
4) When connecting rod bearing cap and bearing

shell have been dismounted, the piston / connecting
rod is lifted from the bearing journal.
Piston / connecting rod should not be lifted further
than just to allow dismounting of the upper bearing
shell, see fig. 3.
For inspection of bearing shell, see working card

506-01.16.
Fig. 1. Mounting
Before remounting of inspected or new bearing, all

2) Before removing connecting rod bearing cap, components must be cleaned.
the special long eye bolt is mounted. It is inserted
through the fuel injector sleeve and is screwed into Note: See also working card 506-01.20.
the thread hole in the piston top, see fig. 2. Then by
means of a tackle it is slightly tightened. 1) Lubricate the ends of the bearing shell (a in fig.
3, working card 606-01.20) with copaslip, molycote
pasta or similar.
02.34 - ES0
Page 3 (3) In Situ Inspection of Connecting Rod Big-end Bearing Edition 04H
V28/32S
Fig. 3. Fig. 4.
Important: The upper shell is provided with 7) Lubricate threads and contact face of the con-
a hole for lubricating oil. necting rod screws with copaslip, molycote pasta or
similar.
2) The bearing shell is placed in the bore, the
contact surfaces of the shell to be in parallel to the 8) Mount the screws and tighten them slightly
contact surface of the connecting rod, the bearing using an open end spanner.
cap respectively.
9) Remove the forked tool, slacken up the tackle
3) Ascertain that the crank throw concerned is in and dismount the long eye screw.
a position of approx. 105 degrees, before TDC.
10) Tighten the screws according to "Tightening
4) Coat the crank journal with clean lubricating Procedure for Connecting Rod Screws" see working
oil. card 506-01.25.
5) Now lower the piston and connecting rod as- During tightening of the screws, the supporting piece
sembly into correct landing on the crank journal. should be mounted on the crankcase cover frame to
During this the connecting rod must be guided by act as guide for the tools.
hand or with the forked tool.
11) After tightening ascertain that the big-end
6) Mount the bearing cap with inserted big-end moves easily on the journal.
bearing lower shell, using the guide pin to ensure
correct positioning.
02.34 - ES0
Your Notes :
Page 1 (4) Inspection and Honing of Cylinder Liner Edition 07H
V28/32S

Shut-off cooling water 52006 50 Extra tools
Shut-off fuel oil 52006 51 Extra tools
Shut-off nozzle cooling oil 52006 60 Extra tools
Description
Inspection and honing of cylinder liner with ho-

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

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

removed, 506-01.00
Related procedure

Replacement of cylinder liner, 506-01.40
Grinding of seal face on cylinder
head and cylinder liner, 506-01.45
08028-0D/H5250/94.08.12

Capacity : 1 man
Data

05.28 - ES0
Edition 07H Inspection and Honing of Cylinder Liner Page 2 (4)
V28/32S
Measurement of Cylinder Diameter Prior to the honing, deposits of coke and possible
wear edges in the top of the liner must be removed
While the piston is removed from the cylinder, the by scraping.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, If the cylinder is of the flame ring type, the used
with measuring points at TDC-position for upper- flame ring has to be cleaned in water. Subsequent-
most piston ring, halfway down and at the bottom ly, the flame ring is remounted in the cylinder be-
of the cylinder liner, see fig. 1. fore carrying out the honing process.
Note: After the honing process has taken place

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

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

tool has the approximately same temperature as
the liner. When the wear of a cylinder liner exceeds
08028-0D/H5250/94.08.12
the value indicated on page 500.35, i.e. when it

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

The honing is made by means of a flex-honer with
The renovation can be made either with disman- finess grains 80-120. A revolution speed between
tled liner in the workshop or with liner mounted in 80 and 160 rpm is chosen.
the engine frame and by the use of the belonging
funnel.
05.28 - ES0
page 3 (4) Inspection and Honing of Cylinder Liner Edition 07H
V28/32S
In order to achieve the required angle between
the honing grooves, see fig. 2, the vertical speed
is adjusted to about 1 m/sec. which corresponds
to about 2 sec. for one double movement (the flex
honer is lead from below up and down in 2 sec.)
The procedure is to be continued until the cylinder 60°

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

with honing oil or cutting oil.
Fig. 3.
After the honing, the liner is carefully cleaned with
gas oil, and make sure that all abrasive particles
have been removed.
08028-0D/H5250/94.08.12
05.28 - ES0
Edition 07H Inspection and Honing of Cylinder Liner Page 4 (4)
V28/32S
Plant/ship: Engine Type: Engine No.:
Date: Sign.: Cyl. A-side B-side

no. Pos. A B C D
Running hours: 1
Fuel: cSt 1 2
Separator: Yes 3
2 2
3 2
4 2
5 2
6 2
7 2
1
08028-0D/H5250/94.08.12
8 2
Tem. of cyl. liner 25°C 3
Nom. diameter 280H8 1
Minimum 280.0 9 2
Maximum 280.60 3
05.28 - ES0
Page 1 (3) Replacement of Cylinder Liner Edition 02H
V28/32S

Shut-off fuel oil
Description
Replacement of cylinder liner.

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

mantled,working card 505-01.00 and 506-
01.00.
Related procedure

Grinding of seal face on cylinder
head and cylinder liner, 506-01.45
08028-0D/H5250/94.08.12
Working time : 2 Hours Plate no. Item no. Qty. /

Capacity : 2 men
50610 126 1/cyl.
Data 50610 138 12/cyl.
50610 031 2/cyl.
Declaration of weight (Page 500.45) See also plate 50610.
02.47 - ES0
Edition 02H Replacement of Cylinder Liner Page 2 (3)
V28/32S
Dismounting of Cylinder Liner
1) Dismount the cooling water guide jacket.
2) Prior to mounting of the lifting tool and dismoun-

ting from the frame, it must be ensured that the liner
and frame have been marked to match, for the sake
of a posible remounting of the liner, see fig. 1.
Hole for charging air
Hole for roller guide house
Marking scratch frame
Marking scratch liner
Fig. 2.
Fig. 1.
5) Attach a tackle hook to the eye nut or the wire
and the cross bar, and lift the liner out from the engine
3) Mount the lifting tool as shown, see fig. 2. frame and stand it careful onto wooden supports.
4) Turn the lifting eye nut to pull out the liner, until 6) Clean all parts and inspect for damage and
the upper edge of the liner lie aligned against the wear, according to the description. For measurement
copper protecting pieces of the cross bar. of cylinder liner, see working card 506-02.00.
08028-0D/H5250/94.08.12
02.47 - ES0
Page 3 (3) Replacement of Cylinder Liner Edition 02H
V28/32S
Mounting of Cylinder Liner 12) Mount the cooling water jacket, (for torque mo-
ment see page 500.40), piston/connecting rod and
7) Check that the sealing surfaces on engine, cylinder head according to working card 506-01.20
cylinder liner, and sealing rings are perfectly clean. and 505-01.40.
8) Mount the lifting tool, attach a tackle hook to 13) When preparing the start-up, check for possible
the eye nut or to the wire in the cross bar and lift the leakages of water and oil, including the inspection
liner. hole in the frame, see fig. 3.
9) Check that the o-ring grooves are clean. Mount

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

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

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

ing water jacket, mount new o-rings on the cooling
water connections and change air connections.
Fit a new sealing ring and mount the jacket.

Fig. 3.
08028-0D/H5250/94.08.12
02.47 - ES0
Your Notes :
Working Card Grinding of Seal Face on 506-01.45
Page 1 (2) Cylinder Liner and Cylinder Head. Edition 04H
V28/32S

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

head by hand, with grinding tools and grinding Hand tools
pasta.
Grinding pasta.
Starting position
Cylinder head has been removed

from the engine, 505-01.00
Cooling water guide jacket, removed.
Related procedure
Mounting of cylinder head, 505-01.40

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

Capacity : 1 man
50610 031 1/cyl.
Data

02.47 - ES0
506-01.45 Grinding of Seal Face on Working Card
Edition 04H Cylinder Liner and Cylinder Head Page 2 (2)
V28/32S
Note: The grinding tool is used for both grinding the
groove in the liner flange (1) and the seating surface
on the cylinder head (2), see fig. 1.
Fig. 3.
Fig. 1.
3) After grinding, remove all traces of abrasive

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

Fig. 2.
To do so, move the tool back and forth and lift it out
from time to time, to allow the grinding compound Fig. 4.
to distribute evenly.
02.47 - ES0
Plate
Page 1 (2) Piston and Connecting Rod (Hydraulic Tightened) 50601-09H
V28/32S
08028-0D/H5250/94.08.12
02.25 - ES0
Plate
50601-09H Piston and Connecting Rod (Hydraulic Tightened) Page 2 (2)
V28/32S
Item Item
No Qty. Designation Benævnelse No Qty. Designation Benævnelse
019 1/C Piston pin incl. Stempelpind inkl.

item 247 pos. nr. 247
032 2/C Retaining ring Sikringsring
056 1/C Bush for Plejlstangs-

connecting rod bøsning
068 1/C Connecting rod, com- Plejlstang, kompl.

pl. (incl. item 056, 152, inkl. (pos. nr. 056, 152,
164, 259, 260) 164, 259, 260)
081 1/C Piston Stempel
093 1/C Piston ring Stempelring
127 1/C Oil scraper ring Olieskrabering
139 1/C Connecting rod Plejlstangs-

bearing 2/2 leje 2/2
152 2/C Connecting rod stud Plejlstangstap
164 2/C Nut Møtrik
247* 8/C Socket screw Kraterskrue
259* 1/C Plug screw Propskrue
08028-0D/H5250/94.08.12
02.25 - ES0
Plate
Page 1 (2) Cylinder Liner and Water Guide Jacket 50610-06H
V28/32S
08028-0D/H5250/94.08.12
01.35 - ES0
Plate
50610-06H Cylinder Liner and Water Guide Jacket Page 2 (2)
V28/32S
Item Item
No Qty. Designation Beskrivelse No Qty Designation Beskrivelse
018 1/C Cylinder liner Cylinderforing
031 1/C Sealing ring Tætningsring
092 1/C Flame ring Flammering
114 1/C Sleeve Muffe
151 6/C Cooling water Kølevands-

connection overgang
163 4/C Hexagon screw Unbracoskrue
175 4/C Washer Skive
187 4/C Sleeve Foring
199 1/C Water guide jacket, Kølekappe, komplet

complete
08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt
01.35 - ES0
Camshaft
507/607
Your Notes :
Description
Camshaft and Camshaft Drive 507.01
V28/32S
Camshaft and Camshaft Drive
The engine is equipped with two camshafts A and B, Through intermediate wheels, the driving gear
one for each bank of cylinders. The camshafts are wheels are connected to a gear wheel fitted to the
carried in bearing bushes which are fitted in bores crankshaft. By means of the intermediate wheels a
in the engine frame, each bearing being locked by a gearing is obtained so that the camshafts are caused
screw that is inserted in the engine frame. to rotate at half the speed of the crankshaft.
The camshafts are built up of sections, one for each A guidering mounted at the flywheel end guides the
cylinder, and the sections are assembled by means camshaft in the longitudinal direction.
of bolts. Each section is equipped with fixed cams
for operation of fuel pump, air inlet valve and exhaust The lubricating oil pipes for the gear wheels are
valve, respectively. equipped with nozzles which are adjusted to apply
the oil at the points where the gear wheels are in
At the flywheel end, camshaft A is fitted with a mesh.
screwed-on driving gear wheel. At the flywheel end,
camshaft B has a screwed-on driving gear wheel and
a drive for the governor and the tachometer.
08028-0D/H5250/94.08.12
02.04 - ES0
Your Notes :
Page 1 (2) Camshaft and Camshaft Drive Edition 04H
V28/32S

Shut-off cooling water 52006 26 20 - 120 Nm.
Shut-off fuel oil
Description
Checking of gear wheels, bolted connections and Hand tools

lubricating system.
Allen key, 12 mm.
Socket spanner, 19 mm.
Starting position
Related procedure
08028-0D/H5250/94.08.12
Working time : 3 Hours Plate No Item No Qty./

Capacity : 1 man
50705 12 6/eng.
Data 50705 24 3/eng.
51106 11 1/cyl.
Data for torque moment (Page 500.40) 51106 14 1/eng.
01.41 - ES0
Edition 04H Camshaft and Camshaft Drive Page 2 (2)
V28/32S
1) Dismount the covers which give access to the 4) Examine all lubricating oil spray pipe nozz-
gear wheels, camshaft and crankcase. les.
2) Examine all gear wheels for cracks, wear and 5) Start the electrical prelubricating oil pump and
deformations. While turning the engine to ena- check the oil flow everywhere. Be particularly
ble inspection allover the circumference of the careful to check that the oil jet hits the gear
gear wheels. wheels correctly at the points where the wheels
mesh.
3) Check all screws, nuts and bolted connections,
including locking devices everywhere in the
gear wheel housing, camshaft housing and
crankcase to check that they have not worked
loose. Tightening torques, see page 500.40.
08028-0D/H5250/94.08.12
01.41 - ES0
Page 1 (2) Inspection and Replacement of Camshaft Bearing Edition 06H
V28/32S

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

shaft bearing.
Replacement of camshaft bearing. Ring and open end spanner, 19 mm.
Feeler gauge.
Big screw driver.
Starting position
Cover for camshaft and gear wheel has been

removed.
Related procedure
Camshaft and camshaft drive, 507-01.00

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

Capacity : 2 men
50705 01 1/eng.
Data 50705 03 1/cyl.
50705 21 1/cyl.
01.51 - ES0
Edition 06H Inspection and Replacement of Camshaft Bearing Page 2 (2)
V28/32S
To Check Roller Path of Cams
1) While turning the engine, examine the cam Camshaft bearing

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

of the rollers may be blocked, if so, the roller must
be replaced by a new one, see working card 508-
01.00.
To Check Camshaft Bearings
2) The wearing surface of the camshaft bearings Locating screw

cannot be checked without dismounting the cam-
Frame
shaft. However, ab-normal wear of one or more
bearings will become apparent in the form of
burrs of white metal at the circumference of the
camshaft journal, and in that case the bearing Fig 1.
will in no doubt be discoloured, as well.
The bearing clearance is measured with a Mount a new camshaft bearing in the bore
feeler gauge, see data sheet 500.35. and make sure that the hole for insertion of
the locating screw in the bearing is in a cor-
rect position. Lock the bearing by means of the
To Replace Camshaft Bearing locating screw, which is to be provided with a
new gasket.To facilitate the fitting of the bearing
3) If one or several of the camshaft bearings should it can be cooled down with Co2.
be replaced the camshaft must be wholly or
partly dismantled. Inspect the camshaft journal for seizures.
Dismount the fuel oil feed pump, if mounted If necessary, the camshaft section must be
and check that the camshaft sections are mar- entirely removed from the engine, and the
ked in relation to each other. Disassemble the journal concerned must be polished.
camshaft aft (toward flywheel) of the bearing
that is to be replaced. Dismount all roller guides Coat all the journals of the camshaft section
that are located forward of the disassembling with clean lubricating oil and push the camshaft
position, see working card 508-01.00 and into position, making sure that the marks on
08028-0D/H5250/94.08.12
508-01.05. the flanges coincide.
Pull the disconnected sections of the camshaft Assemble the sections and fit the bolts (coated
so far a head that the bearing which is to be with Molycote or similar).
replaced is free.
Tighten the nuts with a torque spanner, see
Take out the locating screw of the camshaft data sheet 500.40.
bearing concerned and push the bearing out
of the bore in the engine frame, see fig. 1. Mount all roller guides as well as the fuel oil
feed pump.
Check the lubricating oil ducts to the bearing
for free flow.
01.51 - ES0
Page 1 (3) Basic Adjustment of Camshaft Edition 08H
V28/32S

Shut-off fuel oil
Description
Basic adjustment of camshafts (adjustment of Hand tools

camshafts in relation to crankshaft)
Depth gauge
Starting position
Camshaft(s) assembled according to order of

ignition and mounted in frame.
Related procedure
Adjustment of the maximum combustion pres-

sure. 514-05.01

Capacity : 1 man
Data

01.51 - ES0
Edition 08H Basic Adjustment of Camshaft Page 2 (3)
V28/32S
If one or both intermediate wheels have been
dismantled, a basic adjustment of the camshaft in Nominal size
relation to the crankshaft (the timing) must be made.
It is done as follows:
1) Install piston/connecting rod for:
12 cyl. - 1B, 6A
16 cyl. - 1B, 8A
18 cyl. - 1B, 7A
For numbering of the cylinders see page 500.11.
2) Turn the piston in cylinder 1B to TDC (top dead

centre). To check the TDC a dial gauge could
be used.
3) Install the roller guide for fuel oil pump for the
cylinder numbers mentioned above. Install the
roller guides for the fuel oil pumps for cylinders
1A and 1B. Fig 2
6) Turn the camshaft for the B-side in the engines

direction of rotation (for direction of rotation
please see page 500.12) until the nominal size,
as described in point 5, has been reduced with
Roller guide the lead indicated under “lead of fuel pump”.
Note: The figure for “Lead of fuel pump”

is found in the chart “Adjustment after the Trail”,
Cam for the please see section 502.
fuel oil pump
7) When all above points are observed, turn the
crankshaft in the direction of engine rotation
until the following cylinders are in TDC (top
dead centre):
Seen from front edge
12 cyl. - 6A
16 cyl. - 8A
Fig 1 18 cyl. - 7A
4) Turn the camshaft to a position where the roller 8) When points 1 through 6 have been carried
guide is resting on a circular part of the cam out satisfactorily, the intermediate wheel on
(see fig 1). the B-side must be mounted and tightened
(for torque limits please see page 500.40)
5) On cylinder 1B, measure the nominal size with
a depth gauge, i.e. measure the distance from
the top level of the roller guide housing to the 9) When all above points are okay, turn the crank-
thrust piece pressed into the roller guide (see shaft in direction of engine rotation until cylinder
fig 2). 1A is in TDC, followed by another entire turn
until cylinder 1A is in TDC again.
01.51 - ES0
Page 3 (3) Basic Adjustment of Camshaft Edition 08H
V28/32S
10) Now the procedure is repeated for the A-side
as described in points 5, 6, and 7.
11) Mount and tighten the intermediate wheel for

the A-side.
For adjustment of fuel oil pumps (single or united)

please refer to working card 514-05.01.
01.51 - ES0
Your Notes :
Plate
Page 1 (2) Intermediate Wheel 50701-04H
V28/32S
08028-0D/H5250/94.08.12
02.07 - ES0
Plate
50701-04H Intermediate Wheel Page 2 (2)
V28/32S
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
012 2/E Stepped spur gear, Tandhjul, komplet

complete incl. item inkl. item 024, 048,
024, 048, 061, 144, 061, 144, 156
156
024 2/E Spur gear Tandhjul
048 2/E Spur gear Tandhjul
061 2/E Bearing bush Lejebøsning
073 2/E Bolt Bolt
097 2/E Bearing stud Lejetap
107 2/E Washer Skive
119 2/E Nut Møtrik
144 8/E Bolt Bolt
156 8/E Self locking nut Selvlåsende møtrik
168 1/E Pipe Rør
181 14/E Disc spring Fjederskive
264 5/E Packing Pakning
288 14/E Screw Skrue
311 1/E Pipe Rør
323 1/E Pipe Rør
360 4/E Screw Skrue

08028-0D/H5250/94.08.12
Qty/E = Qty/Engine Qty/E = Qty/Motor
02.07 - ES0
Plate
Page 1 (2) Camshaft and Camshaft Bearing (A-bank) 50705-08H
V28/32S
122
134
146
205
051
063 195
075
087 205
099
014 205
026
171
038
217
229
278
158
Camshaft for B-bank,

see plate 50705-09H
Styreaksel for B-side,

se plate 50705-09H
06.38 - ES0
Plate
50705-08H Camshaft and Camshaft Bearing (A-bank) Page 2 (2)
V28/32S
Item Item
014 2/E Camshaft bearing Styreakselleje

"Aft" "Agter"
026 1/A Camshaft section Styreakselssektion

"aft" "agter"
038 Camshaft bearing Styreakselleje

12/E 12 cyl. engine 12 cyl. motor
051 2/E Hub Nav
075 12/E Disc spring Tallerkenfjeder
087 2/E Guide ring Styrering
099 1/A Shaft pin Akseltap
146 2/E Gear wheel Tandhjul
158 Self locking nut Selvlåsende møtrik

171 Screw Skrue

195 10/A Screw Skrue
205 Camshaft, Styreaksel,

intermediate mellem
5/A 12 cyl. engine 12 cyl. motor
217 Gasket Pakning

229 Guide screw Styreskrue

278 1/E Flange Flange
Qty./E = Qty./Engine Antal/E = Antal/Motor
Qty./A = Qty./Camshaft mounting Antal/A = Antal/Styreakselmontering
06.38 - ES0
Plate
Page 1 (2) Camshaft and Camshaft Bearing (B-bank) 50705-09H
V28/32S
109
110
122
266
134
205
146
051
205
063 195
075
087
205
099
014
026
171 217
038 229
158
183
230
242
254
Camshaft for A-bank,
see plate 50705-08H
Styreaksel for A-side,

se plate 50705-08H
06.38 - ES0
Plate
50705-09H Camshaft and Camshaft Bearing (B-bank) Page 2 (2)
V28/32S
Item Item
014 2/E Camshaft bearing Styreakselleje 229 Guide screw Styreskrue

"Aft" "Agter" 14/E 12 cyl. engine 12 cyl. motor
026 1/A Camshaft section Styreakselssektion 20/E 18 cyl. engine 18 cyl. motor
"aft" "agter"
230 1/A Coupling flange Koblingssflange
038 Camshaft bearing Styreakselleje
12/E 12 cyl. engine 12 cyl. motor 242 3/A Locking plate Sikringsplade
18/E 18 cyl. engine 18 cyl. motor 254 6/A Screw Skrue
051 2/E Hub Nav 266 1/A Gear wheel Tandhjul
087 2/E Guide ring Styrering
099 1/A Shaft pin Akseltap
109 6/A Screw Skrue
110 3/A Locking plate Sikringsring
158 Self locking nut Selvlåsende møtrik

171 Screw Skrue

183 1/A Camshaft section Styreakselsektion

"Fore" "For"
195 10/A Screw Skrue
205 Camshaft, Styreaksel,

intermediate mellem
217 Gasket Pakning

Qty./A = Qty./Camshaft mounting Antal/A = Antal/Styreakselmontering
06.38 - ES0
Operating gear
508/608
Your Notes :
Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition 04H
V28/32S
Roller Guides The roller is pressed down on to the cam by a spring,

which is fixed between the roller guide and the foot
The fuel injection pumps and rocker arms for inlet plate of the fuel injection pump.
and exhaust valves are operated by the cams on the
camshafts through roller guides. The roller guides for
inlet and exhaust valves are located in bores in the Operating Gear for Inlet and Exhaust Val-
engine frame for each cylinder. ves
The roller runs on a bush fitted on a pin that is The movement from the roller guides for inlet and
pressed into the roller guide and secured by means exhaust is transmitted via the push rods the rocker
of a lock screw. arms and spring-loaded valve bridges to each of
the two valve sets. The bridge is placed between
the valve spindles and in the one end it is provided
Operating Gear for Fuel Injection Pumps with a pressed-on thrust shoe and in the other end
it is fitted with a thrust screw for adjustment of the
The injection pumps which is mounted directly on valve clearance.
the integrated roller guide housing is activated via
thrust pieces from the roller guide. On its top the bridge is controlled by a spherical
thrust shoe on the rocker arm and at the bottom
by a guide which rests in a spherical socket in the
cylinder head.
08028-0D/H5250/94.08.12
02.08 - ES0
Your Notes :
Page 1 (2) Inspection of Valve Roller Guides Edition 05H
V28/32S

Shut-off cooling water 52006 26 20 - 120 Nm
Shut-off fuel oil
Dismounting, inspection and/or overhaul, and Ring and open end spanner, 19 mm.
mounting of valve roller guides. Socket spanner, 19 mm.
Inspection of roller guide housing. Socket spanner, 24 mm.
Allen key, 3 mm.
Ratchet spanner.
Hammer.
Starting position Drift.
Top cover for cylinder head and cover for fuel

injection pump removed.
Related procedure
Inspection of fuel injection pump

roller guide, 508-01.05
Control and adjusting of valve
clearance, 508-01.10
08028-0D/H5250/94.08.12
Working time : 2 Hours Plate no. Item no. Qty. /

Capacity : 1 man
50801 185 4/cyl.
Data 50801 220 2/cyl.
Data for pressure and tolerance (Page 500.35) See also plate 50801.
02.47 - ES0
Edition 05H Inspection of Valve Roller Guides Page 2 (2)
V28/32S
Dismounting of Roller Guide 5) Dismount the screws (3) which secure the
roller guide top cover, take off the cover, and lift out
1) Turn the engine so that the roller, rests on the the roller guide (5).
circular part of the cam.
Disconnect any pipes that may be in the way (lub.
2) Unscrew the nuts which secure the rocket arm oil and fuel oil pipes).
brackets, and lift off the rocker arm with brackets.
6) If the event of any marks or scores from sezu-
3) Remove the push rods (1), see fig. 1. res, these must be polished away.
7) Inspect the spherical stud for deformations

(replace as necessary).
Examine the surface of the roller for marks and other

deformations.
Make sure that there is free ply between the roller

and the bush and the shaft pin, and replace the
bush, if necessary.
Replacement of Roller, Bush and Shaft Pin
8) Remove the lock screw which secures the roller

guide shaft pin and push out the shaft pin.
The roller, shaft pin, and bush can now be replaced

as required.
9) Blow through the lubricating ducts in roller guide

and roller guide housing, and clean the lubricating
grooves.
Mounting of Roller Guide
10) When assembling the parts, which is carried

out in the reverse order to the above care must be
exercised not to damage the o-rings when mounting
the proctecting tube.
08028-0D/H5250/94.08.12
11) Adjusting of valve clearance, see working card

508-01.10.
Fig. 1.
4) Loosen the lock screw for the push rod pro-

tecting tube, see plate 50801, item 07, on the roller
guide top cover and lift up and remove the protecting
tube (2).
02.47 - ES0
Page 1 (2) Inspection of Fuel Injection Pump Roller Guide Edition 02H
V28/32S

Shut-off fuel oil
Dismounting, inspection and/or overhaul, and Allen key, 3mm.

mounting af roller guide for fuel injection pump. Hammer.
Drift.
Starting position
Cover for fuel injection pump removed.

Fuel injection pump has been
removed, 514-01.05
Related procedure
Adjustment of the maximum

combustion pressure, 514-05.01
08028-0D/H5250/94.08.12

Capacity : 1 man
Data

02.47 - ES0
Edition 02H Inspection of Fuel Injection Pump Roller Guide Page 2 (2)
V28/32S
Dismounting of Roller Guide Inspection of Roller Guide
1) Remove the support ring (1) and spring (2) 2) If the event of any marks or scores from sezu-
and take up the roller guide (3), see fig. 1. res, these must be polished away.
3) Inspect the spherical stud for deformations

(replace as necessary).
Examani the surface of the roller for marks and other

deformations.
Make sure that there is free ply between the roller

and the bush and the shaft pin, and replace the bush
if necessary.
Replacement of Roller, Bush and Shaft Pin
4) Remove the lock screw which secures the roller

guide shaft pin and push out the shaft pin.
The roller, shaft pin, and bush can now be replaced

as required.
5) Blow through the lubricating ducts in roller guide

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

out in the reverse order.
7) For adaption of the thrust piece of the roller

Fig. 1. guide, see working card 514-05.01.
08028-0D/H5250/94.08.12
02.47 - ES0
Page 1 (3) Control and Adjusting of Valve Clearance Edition 08H
V28/32S

Shut-off cooling water 52008 02 Exhaust
Shut-off fuel oil 52008 01 Inlet
Description
Control and/or adjusting of valve clearance.

Hand tools

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

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

Capacity : 1 man
Data
Data for pressure and tolerance (Page 500.35) See also plate 50502.
02.47 - ES0
Edition 08H Control and Adjusting of Valve Clearance Page 2 (3)
V28/32S
Adjusting of Inlet Valve Clearance
1) Turn the engine so that the roller, rests on the

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

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

usly at both valve spindles.
Adjusting af Exhaust Valve Clearance

Fig. 1.
9) Carry out adjusment in the same way as dese-
ribed for the inlet valves, but using the feeler gauge
for exhaust valve clearance 0,90 mm.
3) Clearance between valve bridge and valve
spindle, see page 600.40.
4) Place the feeler gauge marked with "correct"

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

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

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

o,40 mm above the other valve spindle, see fig. 2.
Fig. 3.
7) Adjust the clearance between valve bridge and
valve spindle by means of the adjusment screw on
the valve bridge, and tighten the lock nut, see fig.
2.
02.47 - ES0
Page 3 (3) Control and Adjusting of Valve Clearance Edition 08H
V28/32S
10) The feeler gauges for checking the clearance

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

and valves bridge, be sure that the feeler gaugs mar-
ked "correct" can be inserted into the two clearances
simultaneously as where it must not be possible to
insert the gauges marked "incorrect".
Fig. 4.
08028-0D/H5250/94.08.12
02.47 - ES0
Your Notes :
Plate
Page 1 (2) Roller Guide and Push Rods 50801-08H
V28/32S
08028-0D/H5250/94.08.12
05.08 - ES0 - Mark 1

Plate
50801-08H Roller Guide and Push Rods Page 2 (2)
V28/32S
Item Item
no Qty. Designation Benævnelse no Qty. Designation Benævnelse
016 1/C Housing for Hus for 339 1/C Roller guide for fuel Rullestyr for brændsels-
roller guides rullestyr injection pump, com- pumpe, komplet inkl.
plete incl. item 028, item 028, 041, 053, 065,
028 1/C Roller guide Rullestyr 041, 053, 065, 077, 089, 077, 089, 112, 124
112, 124
041 3/C Pin Tap
340 3/C Cylindrical pin Cylindrisk stift
053 3/C Bush Foring
352 3/C Socket screw Stopskrue
065 3/C Roller Rulle
364 1/C Roller guide, exhaust Rullestyr, udstødning
077 3/C Stop screw Stopskrue
376 1/C Roller guide for Rullestyr for ventil-
089 1/C Thrust piece Tryktap valve gear complete, bevægelse komplet,
exhaust, incl. item udstødning, inkl. item
090 1/C Washer for spring Skive for fjeder 041, 053, 065, 077, 041, 053, 065, 077,
148, 364 148, 364
112 1/C Thrust piece Tryktap
124 1/C 1 set shims (0.5, 1.2, 1 sæt shims (0.5, 1.2,
1.4, 1.6, 1.8, 2.0, 2.2, 1.4, 1.6, 1.8, 2.0, 2.2,
2.4, 2.6 and 2.8 mm) 2.4, 2.6 and 2.8 mm)
136 4/C Screw Skrue
148 2/C Ball pin Kugletap
173 2/C Protecting tube Skærmrør
197 2/C Cover Dæksel
207 2/C Screw Skrue
219 4/C Screw Skrue
281 1/C Roller guide, inlet Rullestyr, tilgang
293* 2/C Pipe Rør
303 2/C Push rod, complete Stødstang, komplet inkl.

incl. item 268, 293 item 268, 293
327 1/C Roller guide for

08028-0D/H5250/94.08.12
Rullestyr for ventil-

valve gear complete, bevægelse komplet,
inlet, incl. item 041, tilgang, inkl. item 041,
053, 065, 077, 148, 053, 065, 077, 148,
281 281
05.08 - ES0 - Mark 1

Plate
V28/32S
268
293*
303
185 090
173 268
185
100
219
197 388
423
207
220
388 Frame, see

411 plate 51101
136
339
112
148
148 124
08028-0D/H5250/94.08.12
281
281 089
041
041 041
327
327 028
077
077 077
065
053 053
053
065 065
06.44 - ES0 - Mark 4

Plate
V28/32S
Item Item
112, 124
041 3/C Pin Tap
388 2/C Bushing Bøsning
053 3/C Bush Foring
090 1/C Washer for spring Skive for fjeder
1.4, 1.6, 1.8, 2.0, 2.2, 1.4, 1.6, 1.8, 2.0, 2.2,
2.4, 2.6 and 2.8 mm) 2.4, 2.6 and 2.8 mm)
136 4/C Screw Skrue
219 4/C Screw Skrue
281 2/C Roller guide Rullestyr
293* 2/C Pipe Rør

incl. item 268, 293 item 268, 293
327 2/C Roller guide for valve

08028-0D/H5250/94.08.12
Rullestyr for ventilbe-

gear complete, incl. vægelse komplet, inkl.
item 041, 053, 065, 077, item 041, 053, 065, 077,
148, 281 148, 281
06.44 - ES0 - Mark 4

Plate
V28/32S
268
293*
303
185
173 268
185
090
219
100
197
207
220
Frame, see
plate 51101
136
340
352
339
112
148
148 124
08028-0D/H5250/94.08.12
281
281 089
041
041 041
327
327 028
077
077 077
065
053 053
053
065 065
07.03 - ES0 - Mark 2

Plate
V28/32S
Item Item
112, 124
041 3/C Pin Tap
340 3/C Cylindrical pin Cylindrisk stift
053 3/C Bush Foring
352 3/C Socket screw Stopskrue
1.4, 1.6, 1.8, 2.0, 2.2, 1.4, 1.6, 1.8, 2.0, 2.2,
2.4, 2.6 and 2.8 mm) 2.4, 2.6 and 2.8 mm)
136 4/C Screw Skrue
207 2/C Screw Skrue
219 4/C Screw Skrue
293* 2/C Pipe Rør

incl. item 268, 293 item 268, 293
327 2/C Roller guide for

08028-0D/H5250/94.08.12
Rullestyr for ventil-

valve gear complete, bevægelse komplet,
inlet, incl. item 041, tilgang, inkl. item 041,
053, 065, 077, 148, 053, 065, 077, 148,
281 281
07.03 - ES0 - Mark 2

Plate
V28/32S
268
293*
303
185 090
173 268
185
100
219
197 388
423
207
220
388 Frame, see

411 plate 51101
136
339
112
148
148 124
08028-0D/H5250/94.08.12
281
281 089
041
041 041
327
327 028
077
077 077
065
053 053
053
065 065
07.03 - ES0 - Mark 3

Plate
V28/32S
Item Item
112, 124
041 3/C Pin Tap
053 3/C Bush Foring
1.4, 1.6, 1.8, 2.0, 2.2, 1.4, 1.6, 1.8, 2.0, 2.2,
2.4, 2.6 and 2.8 mm) 2.4, 2.6 and 2.8 mm)
136 4/C Screw Skrue
219 4/C Screw Skrue
293* 2/C Pipe Rør

incl. item 268, 293 item 268, 293
327 2/C Roller guide for valve

08028-0D/H5250/94.08.12
Rullestyr for ventilbe-

gear complete, incl. vægelse komplet, inkl.
item 041, 053, 065, 077, item 041, 053, 065, 077,
148, 281 148, 281
07.03 - ES0 - Mark 3

Control/safety
509/609
Your Notes :
Description
Safety, Control and Monitoring System 509.01
V28/32S
General Description The engine is equipped with the following main

safety, control and monitoring components:
Monitoring and instrumentation on the engine repre-
sents a tailor-made system. The system is designed ● Safety system
to fulfil the following requirements: ● Governor
● Monitoring modules
l Continuous analogue monitoring – base module A + B
l Independent safety system – operation box (OB)
l Easy installation – monitoring of temperatures/pressures
l Simple operation panel (MTP)
l Instrumentation complete – monitoring of exhaust gas temperature
l No maintenance panel (MEG)
l Prepared for CoCoS – monitoring of bearing temperature panel
l Redundant safety system (MBT), option
– oil mist detector, option
● Instrumentation (sensors, wiring, junction
In order to fulfil all classificatoin society requirements boxes)
the engine is equipped with monitoring sensors for ● Manometers and thermometers
all medias as standard. Also a built-on safety system ● Output module (OM), option
is standard. ● Alarm panel (AP), option
0 1400 0 16
START AIR
ENGINE RPM SI 90 PRESSURE PT 70
0 60000 0 60000
TC 1 RPM SI 89 TC 2 RPM SI 89
Operating Operating
0 4 0 4
LUB. OIL LUB. OIL

PT 23 PRESS. TC 2 PT 23
PRESS. TC 1
MBD-H
HOUR BAR BAR
Module Module
°C °C
ALT. RPM RPM
Supply
HIGH BEARING
OVERSPEED TEMP. STOP
LOW LUB. DIFF./EARTH
OIL PRESS. PROTECTION
HIGH FRESH- EMERGENCY
WATER TEMP. STOP
HIGH LUB.
GenSet
OIL TEMP.
HIGH BEARING
TEMP ALARM
START STOP LAMP TEST LAMP TEST
Control Panel
3 Secretary Delay
Monitoring
BLOCKING
REMOTE LOCAL
RESET
exhaust gas 200 400 600 200 400 600
temperature
E CYL. 1A TI 60
E CYL. 1B TI 60
X X
H H
A CYL. 2A TI 60 A CYL. 2B TI 60
U U
Safety
S CYL. 3A TI 60
S CYL. 3B TI 60
T T
G CYL. 4A TI 60 G CYL. 4B TI 60
A A
S S
System
CYL. 5A TI 60 CYL. 5B TI 60
T T
E CYL. 6A TI 60 E CYL. 6B TI 60
Base
M M
P P
R R
T T
Module
°C U U
R CYL. 9A TI 60 R CYL. 9B TI 60
E E
cS
t TC 1 INLET TI 62 TC 2 INLET TI 62
Monitoring
TC 1 OUTLET TI 61 TC 2 OUTLET TI 61
temperature & HT WATER TEMP.

OUTLET ENGINE
TI 12
pressure
HT WATER PRESS.
PI 10
INLET ENGINE
LT WATER TEMP.
TI 01
INLET AIR COOL.
LT WATER PRESS.
PI 01
Monitoring
INLET AIR COOL.
LUB. OIL TEMP.

TI 22
INLET FILTER
LUB. OIL PRESS. PI 21

INLET FILTER
exhaust gas
LUB. OIL PRESS.
PI 22
INLET ENGINE
FUEL OIL TEMP.

TI 40
INLET ENGINE
temperature
FUEL OIL PRESS.
PI 40
INLET ENGINE
NOZZ COOL PRESS.

PI 50
INLET ENGINE
0 80
CHARGE AIR TEMP.
TI 31
OUTLET COOL.
0 4
CHARGE AIR PRESS.
PI 31
OUTLET COOL.
Modbus, Monitoring & Alarm

Cable, Safety System
Fig 1 Monitoring and safety system.
06.39 - ES1
509.01 Safety, Control and Monitoring System Description
V28/32S
Safety System The spring-loaded pull rod permits the governor to

give full deflection even if the stop cylinder of the
The safety system is an independent system for manoeuvering system keeps the fuel injection pump
monitoring and controlling the GenSet’s shutdown at "no fuel" position.
functions.
Each fuel injection pump is connected to the com-
The safety system is based on a programme logic mon, longitudinal regulating shaft by means of a
controller (PLC) which automatically controls the spring-loaded arm.
following:
Should a fuel plunger seize in its barrel, thus blocking
Shutdown the regulating guide, governing of the remaining fuel
injection pumps may continue unaffected owing to
1) Overspeed the spring-loaded linkage between the blocked pump
2) Low lube oil pressure and the regulating shaft.
3) High HT water temp.
4) Emergency stop
5) High bearing temp. (option) Monitoring System
6) Oil mist stop (option)
7) Differential protection / earth connection (op- All media systems are equipped with temperature
tion) sensors and pressure sensors for local and remote
reading.
Set points and special conditions can be found in the
"Operation Data & Set Points, B 19 00 0" The sensors for monitoring and alarming are con-
nected to the base module.
Connection to and from the power management
system is hard wire connection.
Base Module
Indication of each shutdown can be found on the
operation box and directly on the PLC module. The base module is the centre of the monitoring
system.
Governor The base module, the OB-module, the MTP-mod-

ule and the MEG-module are designed by MBD-H
The engine speed is controlled by a hydraulic governor specifically for this engine type.
or electronic controller with hydraulic actuator.
Apart from the electrical main connection to the al-
Information about the design, function and opera- ternator the contractor has to perform the following
tion of the governor is found in the special governor electrical connection:
instruction book.
– 24 VDC supply to the safety system.
The governor is mounted on the flywheel end of the – Cable connection to/from power management
engine and is driven from the camshaft via a cylindri- system.
cal gear wheel and a set of bevel gears. – 24 VDC supply to the base module.
– Modbus communication or interlink to output
module.
Regulating Shaft
The alarm and monitoring system in the main switch
The governor's movements are transmitted through board can be connected to the base module by
a spring-loaded pull rod to the fuel injection pump means of a 3-wire MODBUS communication link.
regulating shaft which is fitted along the engine. For further information, please see the description
"Communication from the GenSet".
06.39 - ES1
Description
V28/32S
In situations where the alarm system cannot oper- ● Shutdowns indication:
ate a MODBUS communication unit, MBD-H offers – overspeed
an output module (OM) to be installed in the control – low lub. oil pressure
room. – high fresh water temp.
– high lub. oil. temp.
By means of the OM it is possible to connect all
digital and analogue signals to the alarm system in
a conventional manner.
Communication between the base module (BM) and

the output module (OM) takes place via a 3-wire
interlink bus (RS485).
The Base Module do also include redundant safety

stop function for:
1) Overspeed
2) Low lube oil pressure
3) High cooling water temperature
The set points for above redundant safety stop are

adjusted to a higher/lower point as the safety system.
This will secure that the safety system will normally
stop the engine in a critical situation. Only in case
that the safety system is out of order the redundant
safety stop will be needed.
Fig 2 Operation box module (OB - A).

Operating Box Module (OB - A)
This module includes the following possibilities:

Operating Box Module (OB - B)
● Operation of:
– engine start ● Indication of:
– engine stop – engine rpm
– remote mode – TC 2 rpm
– local mode – lub. oil pressure TC 2
– blocking/reset mode – display for digital read out
– lamp test – indication of software version
– arrow up - shift upwards through measure-
ments for display ● Shutdowns indication:
– arrow down - shift downwards through – high bearing temp. stop
measurements for display – diff. / earth protection
– emergency stop
● Indication of:
– engine rpm Please note that the local stop push button must be
– TC 1 rpm activated at least 3 sec. before the engine will stop.
– lub. oil pressure TC 1
– display for digital read out
– indication of software version
06.39 - ES1
V28/32S
If the lamp test button is activated for more than 3
sec. the software version will be displayed.
Monitoring of Temp./Pressure Panel (MTP)
All temperatures and pressures shown on the MTP

module's bargraph are indicated with illuminated
segments. When the temperatures and pressures
are within the stated limits, two segments are il-
luminated in the middle forming a straight line. This
means that it is easy to check the engines' systems,
even at distance.
Fig 3 Operation box module (OB - B).
The manual start button must be activated until ig-

nition, takes place. If the engine have been without
prelubrication in more than 20 minutes the engine
can not be electrical started.
The push buttons REMOTE - LOCAL - BLOCKING is

only related to the start function. In case of BLOCK-
ING the engine can not be started from local or from
Fig 4 Monitoring of temperature/pressure module (MTP).
remote (switchboard).
The stop function is not depended of the REMOTE

- LOCAL - BLOCKING position. If there is a deviation, the bargraph in question will
start to illuminate the segments upwards or down
On the local operating box module the pressure, wards, depending on rising or falling measurements,
temperature and rpm are illustrated by means of a see fig 5.
display: an LED indicates whether it is the working
hours, alternator, pressure, temperature or rpm It must be mentioned that the latter does not apply to
which is measured. the charge air temperature and charge air pressure,
because they will vary with the engine load.
The display of the operation box module is used to
read each individual measurement chosen by us-
ing "arrow up" or "arrow down" incl. MTP and MEG
measurements. All rpm, pressures and temperatures
are indicated in full values. The value displayed is
indicated by flashing of the last segment of the bar-
graph on the OB, MTP or MEG module.
06.39 - ES1
Description
V28/32S
and thermometers for:
– Cooling water temp.

– Fuel oil temp.
Fig 5 Monitor temp./press. (MTP)
Monitoring of Exhaust Gas Temperature

Panel (MEG)
Fig 7 Monitor exh. gas temperature (MEG - A).
The temperature shown on the MEG module is indi-
cated with segments illuminated from the left to the
right. The number of segments illuminated depends
on the actual temperature of the exhaust gas.
Fig 6 Monitoring of exhaust gas temperature module (MEG).
For emergency operation in case of totally black-out

on the 24 V DC supply the engine is equipped with
manometers for:
– Lub. oil pressure Fig 8 Monitor exh. gas temperature (MEG - B).
– Cooling water pressure
– Fuel oil pressure
06.39 - ES1
V28/32S
Equaliser Function for Exhaust Gas Tem- Monitoring of Bearing Temperature, MBT
perature (option)
An equaliser function has been introduced to take The temperature shown on the MBT module is
into consideration the old learning that the exhaust indicated with segments illuminated from the left
temperature values must be identical on a four-stroke to the right. The number of segments illuminated
diesel engine. depends on the actual temperature of the bearing
temperature.
On the engine type L16/24, L27/38, V28/32S and
especially L21/31 it is observed that the temperature
are not identical althrough the engine combustion
is adjusted correctly. This fact may involve that the
operator will adjust the fuel pumps improperly to
obtain identical exhaust temperature values for each
cylinder and this is of course not desirable.
By performing an offset adjustment equalisation of the

temperature when the engine is adjusted correctly the
operator will get the impression that the temperatures
then are identical when the pumps etc are adjusted
correctly. If a deviation of the temperatures occurs,
it is because of problems with the combustion or the
fuel pumps just as the operator is used to.
The equaliser function is activated by pressing the

arrow push buttons on the OB panel for minimum
three seconds. A menu occurs and by pressing ar-
row push buttons up/down the following options are
available:
"NO"
● (Nothing happens and you return to Fig 9 Monitoring of bearing temperature (MBT), option.
normal mode)
● "YES" (Equalisation is completed if pos-
sible. New offsets are calculated)
● "RESET" (All offset values are re-zeroed) Output Module (option)
The chosen option is accepted by pressing "BLOCK- For alarm systems which cannot be communicated
ING" or "lamp test". If equalisation cannot be com- through the MODBUS protocol, an output module
pleted, "Err-2" will show up for two seconds and has been designed. This module includes conven-
afterwards it returns to normal mode again. In case tional output signals (4-20 mA) for all analogue
that a temperature deviation is above 40o C it will not measuring values, signals for limit values, and infor-
be possible to complete an equalisation and "Err-2" mation signals from the safety system. The output
will be indicated. The 40o C deviation is from the "real" module will be delivered in a separate box (IP56) with
readings, and not from the "manipulated" readings. the dimensions (H/L/W): 380 x 380 x 155 mm.
If the equaliser is activated on the OB panel without

choosing an option, it will automatically return to
normal OB display again after 15 seconds.
06.39 - ES1
Description
V28/32S
Alarm Panel (option) Instrumentation
An alarm panel with 24 alarm points can be connect- Pressure measurements are generated from the
ed to the system. The alarm panel can be installed pressure transmitters.
on the engine or in the engine control room, see fig
10. The dimensions for the panel are (H/L/W): 144 The exhaust gas temperatures are generated by
x 96 x 35 mm. NiCr/Ni thermo sensors.
Temperatures are generated by PT100 sensors.
The above transmitters and sensors are specially

designed for installation on diesel engines.
The pressure sensors are placed centrally at the

front of the engine, facilitating easy access for
maintenance and overhauls, and minimizing wire
connections.
The temperature sensors are placed at the measur-

ing point.
Data
Power supply : 24 VDC -20 to +30%

Power consumption : < 2 amp
Ambient temp. : -20oC to 70oC
External
communication links : MODBUS ASCII / RTU or
Fig 10 Alarm panel. interlink (RS485)
06.39 - ES1
Your Notes :
Description
Lambda Controller 509.10
Page 1 (1)
Edition 07H
L16/24
V28/32S
Purpose If the system is activated more than 10 seconds,
the solenoid valve will be shut off and there will be
The purpose with the lambda controller is to prevent a remote signal for "jet system failure".
injection of more fuel in the combustion chamber than
can be burned during a momentary load increase. The jet system is blocked when engine speed is
This is carried out by controlling the relation between below 50 rpm.
the fuel index and the charge air pressure.
During the start procedure the jet system is used as
The Lambda controller is also used as stop cylinder. a charge air booster.
Hereby heavy smoke formation is prevented during

Advantages start procedure.
The lambda controller has the following advantages:
- Reduction of visible smoke in case of sud-

den momentary load increases.
- Improved load ability.
- Less fouling of the engine's exhaust gas ways.
- Limitation of fuel oil index during starting

procedure.
Principles for Functioning
Figure 1 illustrates the controller's operation mode. In

case of a sudden load increase, the regulating device
will increase the index on the injection pumps and
hereby the regulator arm (1) is turned, the switch (2)
will touch the piston arm (3) and be pushed down-
wards, whereby the electrical signal is sent to base
module (BM).
Thus the solenoid valve (4) controlled by the BM is

activated, the turbocharger accelerates and increases
the charge air pressure, thereby pressing the piston
(3) backwards in the lambda cylinder (5). When the
lambda ratio is satisfactory, the solenoid valve will
be de-activated.
Above system is also called jet system.

At a 50% load change the system will be activated
for about 3-8 seconds. Fig 1 Principle drawing of lambda controller
02.41 - ES0
Your Notes :
Description
Communication from the GenSet 509.55
V28/32S
System Layout All signals can be wired up from the OM-mod-
ule to the alarm & monitoring system in the
Fig 1 shows the system layout. The modules BM-A, control room.
BM-B, OB, MTP, MEG and safety system are all
placed on the engine. More detailed information on 3) Two simple alarm panels (AP) with each 24
each module and sensors can be read in the descrip- LED channels can be installed in the con-
tion "Safety, Control and Monitoring System". trol room. This solution only serves digital
alarms.
Communication If the alarm system can communicate with MODBUS

ASCII or RTU, there is no need for the OM-module
Communication from the BM-modules to the alarm & or AP. All signals can be communicated by the
monitoring system in the control room can be done MODBUS.
in three ways:
In the following please find a description of the MOD-
1) In the BM-module there is a MODBUS ASCII BUS protocol and addressing of the signals.
or RTU interface communication.
2) An output module (OM) can be placed in MODBUS Protocol (BM)

the control room switchboard or alarm disk.
Communication from the BM-modules to the The BM has a standard MODBUS ASCII and RTU
OM-modules is made via the 3 wire module interface which may be selected, by means of a DIP
interlink bus. switch on the BM, to be either:
In the OM-module all the signals are converted – RS485 3 wire (Rx+/Tx+, Rx-/Tx-, GND)
into 4-20 mA signals and digital outputs.
DO = Digital output
1 MODBUS ASCII or RTU DI = Digital input
Interface (Slave) RS485 AI = Analog input
2 DO 1 DI 2 DI 6 DO AO = Analog output
Diesel engine
31 AO, 31 AO,
4-20 mA 30 DO 4-20 mA 30 DO
Option Option
4 DI 11 AI NiCrNi 11 AI NiCrNi
8 AI Pt100 5 AI Pt100 OM-A OM-B
8 AI 4-20 mA 5 AI 4-20 mA Output Output
Safety BM-A BM-B module module Option Option
7 DI 6 DI
system Base Base
1 DI PNP 2 DO module 1 DI PNP module
AP-A AP-B
4 DI 1 DI Magn Isolated Isolated Alarm Alarm
DC/DC DC/DC
1 DO 2 DI PNP
converter converter panel panel
1 DI Magn
4 DO 3 DO
Module interlink bus

08028-0D/H5250/94.08.12
Option
11 AI NiCrNi (RS485)
2 AI Pt100
1 DI
7 DO BSM
Bearing
Surveillance OB-A MTP MEG-A OB-B MEG-B
module Opera- Monitor Monitor Opera- Monitor
ting Temp. & Exh. ting Exh.
box Press. Gas box Gas
24V DC*
24V DC*
* must be from separate sources (UPS)
Fig 1 System overview: "monitoring system & safety system"
09.36 - ES0
509.55 Communication from the GenSet Description
V28/32S
The communication setup is: 9600 baud, 8 databits, The general „message frame format“ has the fol-
1 stopbit, no parity. lowing outlook:
The BM MODBUS protocol accept one command [:] [SLAVE] [FCT] [DATA] [CHECKSUM] [CR] [LF]
(Function Code 03) for reading analog and digital
input values one at a time, or as a block of up to – [:] 1 char. Begin of frame
32 inputs. – [SLAVE] 2 char. Modbus slave address
Selected on DIP-switch at BM
MODBUS is defined by the company AEG Modicon print
and the implementated protocol in the BM is de- – [FCT] 2 char. Function code
signed to observe the relevant demands in the latest – [DATA] n X 2 chars data.
protocol description from AEG Modicon: – [CHECKSUM] 2 char checksum (LRC)
– [CR] 1 char CR
MODBUS was originally defined by EAG Modicon, – [LF] 1 char LF (end of frame)
but is now adminstered by the MODBUS-IDA group.
The MODBUS protocol implemented for the BM is Notice: The MODBUS address [SLAVE] should
defined in the document "MODBUS over serial line be adjusted on the DIP-switch (SW 1) on the BM.
specification and implementation V1.0", available at Allowed addresses are 1..63 (address 0 is not al-
http://www.modbus.org/ lowed). Broadcast packages will not be accepted
(to be ignored), see fig 2.
The following chapter describes the commands in
the MODBUS protocol, which are implementated, The following function codes (FCT) is accepted:
and how they work.
– 03H: Read n words at specific address.
– 10H: Write n words at specific address.
Protocol Description
In response to the message frame, the slave (BM)
The ASCII and RTU version of the MODBUS proto- must answer with appropriate data. If this is not pos-
col is used, where the BM works as MODBUS slave. sible, a package with the most important bit in FCT
All data bytes will be converted to 2-ASCII charac- set to 1 will be returned, followed by an exception
ters (hex-values). Thus, when below is referred to code, where the following is supported:
„bytes“ or „words“, these will fill out 2 or 4 characters,
respectively in the protocol. – 01: Illegal function
– 02: Illegal data address
– 03: Illegal data value
– 06: BUSY. Message rejected
SW 1: MODBUS address
08028-0D/H5250/94.08.12
Switch no 1 2 3 4 5 6
Address:
0 OFF OFF OFF OFF OFF OFF Not allowed
1 ON OFF OFF OFF OFF OFF
2 OFF ON OFF OFF OFF OFF
63 ON ON ON ON ON ON Not allowed
Fig 2 Modbus address
09.36 - ES0
Description
V28/32S
FCT = 03H: Read n words MODBUS addressing
The master transmits an inquiry to the slave (BM) In order to be able to read from the different I/O
to read a number (n) of datawords from a given and data areas, they have to be supplied with an
address. The slave (BM) replies with the required „address“.
number (n) of datawords. To read a single register
(n) must be set to 1. To read block type register (n) In the MODBUS protocol each address refers to a
must be in the range 1...32. word or „register“. For the GenSet there are follow-
ing I/O registers:
Request (master):
[DATA] = [ADR][n] – Block (multiple) I/O registers occupying up to
[ADR]=Word stating the address in 32 word of registers (see table 3 - 9).
HEX.
[n]=Word stating the number of words to Block I/O registers hold up to 32 discrete I/O's placed
be read. at adjacent addresses, so it is possible to request
any number of I/O's up to 32 in a single MODBUS
Answer (slave-BM): command. Please refer to table 3 - 9 which speci-
[DATA] = [bb][1. word][2. word]....[n. word] fies the block I/Os registers addresses and how the
[bb]=Byte, stating number of subsequent individual I/O's are situated within the „block".
bytes.
[1. word]=1. dataword
[2. word]=2. dataword Data Format
[n. word]=No n. dataword
The following types of data format have been cho-
FCT = 10H: Write n words sen:
The master sends data to the slave (BM) starting Digital: Consists of 1 word (register):
from a particular address. The slave (BM) returns the 1 word: [0000H]=OFF
written number of bytes, plus echoes the address. [FFFFH]=ON
Write data (master): Integer: Consists of 1 word (register):

[DATA] = [ADR][n] [bb][1. word][2. word]....[n 1 word: 12 bit signed data
word] (second complement):
[ADR] = Word that gives the address in [0000H]=0
HEX. [0FFFH]=100% of range
[n] = Word indicating number of words to [F000H]=-100% of range
be written.
[bb] = Byte that gives the number of bytes Notice: 12 bit data format must be used no matter
to follow (2*n) what dissolution a signal is sampled with. All mea-
Please note that 8bb9 is byte size! suring values will be scaled to 12 bit signed.
08028-0D/H5250/94.08.12

[2. word]=2. dataword Example 1:
PI10, range 0-6 bar
Answer (slave-BM): The value 2.3 bar will be represented as 38.33% of
[DATA] = [ADR][bb*2] 6 bar = 0621H
[ADR]= Word HEX that gives the address
in HEX
[bb*2]=Number of words written.
09.36 - ES0
V28/32S
MODBUS Timeout Index Explanation for Tables below
To prevent lock up of the protocol, ie. a breakdown In the tables below each signal has a importance
on the connection, a number of timeouts are to statement with following meaning:
be built in, as specified in the MODBUS protocol
specification: Required by MAN B&W.
Recommended by MAN B&W.
MODBUS specification max. time between charac- "Nice to have".
ters in a frame: 10 ms
In the tables below some signals have a remark with
MODBUS specification max. time between receipt following meaning:
of frame and answer: 1 second g) "Common shutdown" consists of following
signals: PSL22, TSH12, SSH81, ZS82 and
However the implementation of the protocol in the TSH29/27, LSH 92 (optionals). Furthermore
GenSet Base Module is able to handle much smaller it consist also of the redundant shutdowns
timeouts (response times), which may be required performed in the Base Module.
in order to obtain an acceptable worst-case I/O h) "Safety system failure" consists of following
scan time: signals: Power supply failure and internal watch
dog alarm.
Base Module, max. time between characters in a i) "Safety sensor cable failure" means cable fail-
frame:5 ms ure on one or more of following sensors: lub.
oil pressostate PSL22, cool. water thermostate
Base Module, max. time between receipt of frame TSH12, speed pick-up SE90-2, emergency
and answer: 100 ms stop switch ZS82 or bearing temperature shut-
down TSH29/27.
j) "Local shutdown" only consists of the shut-
downs (PSL22, TSH, SSH81, and ZS82) in the
safety system.
l) Oil mist (LSH/LAH92) is an option.
p) For GenSets with high voltage alternators.
General) All alarm signals are already performed

with necessary time delay. F.ex. lub. oil level
alarms (LAL/LAH28) includes 30 sec. alarm
delay. Start air alarm (PAL70) includes 15 sec.
alarm delay. No further delay are needed.
08028-0D/H5250/94.08.12
09.36 - ES0
Description
V28/32S
Table 3 (Block scanning) Module A

Signal Name/description Address Data format Importance Remark Meas. range
oLAH42 Drain box high level 4002 Digital Required

oPAL25 Prelub. oil low press. 4003 Digital Required
oSX32 Jet system failure 4004 Digital Required
oUX95-2 Safety system failure 4005 Digital Required h)
oSS86 Common shutdown 4006 Digital Required g)
oTAH98 Alternator winding temp. high 4007 Digital Required
oPAL10 HT water press. inlet low 4008 Digital Required
oPDAH21-22 Diff. press. high, lub. oil filter 400A Digital Required
oPAL 22 Lub. oil press. inlet low 400B Digital Required
oPAL40 Fuel press. low 400C Digital Required
oTAH12 HT water temp. high 400D Digital Required
oTAH21 Lub. oil temp. inlet high 400E Digital Required
oLAL28 Low oil level base frame 400F Digital Recommended
oLAH28 High oil level base frame 4010 Digital Recommended
iZS75 Microswitch, turning gear engaged 4011 Digital Recommended
oSAH81 Overspeed alarm 4012 Digital Recommended
oTAD60 Exh. gas temp. high or low (A-side) 4013 Digital Recommended
oTAH61 TC temp. outlet, high (A-side) 4014 Digital Recommended
oTAH62 TC temp. inlet, high (A-side) 4015 Digital Recommended
iTI12 HT water temp. outlet 4016 Integeter 12 Bit Recommended 0-200° C
iTI21/22 Lub. oil temp. inlet 4017 Integeter 12 Bit Recommended 0-200° C
iTI40 Fuel oil temp. inlet 4018 Integeter 12 Bit Recommended f) 0-200° C
iTI98-1 Alternator winding temp. 1 4019 Integeter 12 Bit Recommended 0-200° C
iTI98-2 Alternator winding temp. 2 401A Integeter 12 Bit Recommended 0-200° C
iTI98-3 Alternator winding temp. 3 401B Integeter 12 Bit Recommended 0-200° C
iPI10 HT water press. inlet 401C Integeter 12 Bit Recommended 0-6 bar
iPI22 Lub. oil press inlet engine 401D Integeter 12 Bit Recommended 0-10 bar
iPI40 Fuel oil press. inlet 401E Integeter 12 Bit Recommended 0-16 bar
oSX86-2 Safety sensor cable failure 4020 Digital Recommended i)
oSX83 Start failure 4021 Digital Recommended
Table 3 MODBUS block 1 on Base Module A (multiple i/o) register addressing.

iPSL22 Lub. oil inlet low pressure, stop 4042 Digital Nice to have
iTSH12 HT water outlet high temp., stop 4043 Digital Nice to have
iZS82 (LSH92) Emergency shutdown (oil mist) 4044 Digital Nice to have
08028-0D/H5250/94.08.12
iSSH81 Overspeed stop 4045 Digital Nice to have

oZS96 Local indication 4046 Digital Nice to have
oZS97 Remote indication 4047 Digital Nice to have
oSA99A (Spare) 4048 Digital
oSS90A Engine running 4049 Digital Nice to have
iTE60-1A Exh. gas temp., cylinder 1 (A-side) 404A Integer 12 Bit Nice to have 0-800° C
iTE60-2A Exh. gas temp., cylinder 2 (A-side) 404B Integer 12 Bit Nice to have 0-800° C
iTE60-3A Exh. gas temp., cylinder 3 (A-side) 404C Integer 12 Bit Nice to have 0-800° C
iTE60-4A Exh. gas temp., cylinder 4 (A-side) 404D Integer 12 Bit Nice to have 0-800° C
iTE60-5A Exh. gas temp., cylinder 5 (A-side) 404E Integer 12 Bit Nice to have 0-800° C
iTE60-6A Exh. gas temp., cylinder 6 (A-side) 404F Integer 12 Bit Nice to have 0-800° C
Cont.
09.36 - ES0
V28/32S
Table 4 cont.
iTE60-7A Exh. gas temp., cylinder 7 (A-side) 4050 Integer 12 Bit Nice to have 0-800° C
iTE61-1 Exh. gas temp. outlet TC 1 4053 Integer 12 Bit Nice to have 0-800° C
iTE62-1 Exhaust gas temp. inlet TC 1 4054 Integer 12 Bit Nice to have 0-800° C
iTI01 LT water temp. inlet 4055 Integer 12 Bit Nice to have 0-200° C
iTI31 Charge air temp. 4056 Integer 12 Bit Nice to have 0-200° C
iPI01 LT water press. inlet 4057 Integer 12 Bit Nice to have 0-6 bar
iPI21 Lub. oil press. inlet filter 4058 Integer 12 Bit Nice to have 0-10 bar
iPI23 Lub. oil press. TC 1 4059 Integer 12 Bit Nice to have 0-4 bar
iPI31 Charge air press. 405A Integer 12 Bit Nice to have 0-4 bar
oSE90 Engine RPM pickup 405B Integer 12 Bit Nice to have 0-1600 rpm
oSE89-1 TC speed-1 405C Integer 12 Bit Nice to have 0-60000 rpm
oUX95-2_Dly (Spare) 405D Digital
oSX84 Stop failure 405E Digital Nice to have
iSS86-3 Shutdown from safety system 405F Digital Nice to have j)
oPAL01 LT water press. inlet 4060 Digital Nice to have
oPAL23 Lub. oil press. TC 1, low 4061 Digital Nice to have
Table 4 MODBUS block 2 on Base Module A (multiple i/o) register addressing.

oSAH89 High rpm TC 1 40C2 Digital Nice to have

oTAH62-2 High exh. gas temp. before TC 1 40C3 Digital Nice to have
oTAH12-2 High cooling water temp. 40C4 Digital Nice to have
oTAH60-1A High exh. gas temp cyl. 1 40C5 Digital Nice to have
oTAH60-6A High exh. gas temp cyl. 6 40CA Digital Nice to have
oTAH60-7A High exh. gas temp cyl. 7 40CB Digital Nice to have
oTAH60-8A High exh. gas temp cyl. 8 40CC Digital Nice to have
oTAH60-9A High exh. gas temp cyl. 9 40CD Digital Nice to have
oUX95-1 Monitoring system failure 40CE Digital Recommended
oSX86-1 Monitoring sensor failure 40CF Digital Recommended
iLAH92 High oil mist alarm (oil splash) 40D0 Digital Nice to have
08028-0D/H5250/94.08.12
Table 5 MODBUS block 3 on Base Module A (mutiple i/o) register addressing.

oZS57 Earth connector & diff. protection 4090 Digital Nice to have p)
PAL 50 Nozzle oil press. low 4091 Digital Recommended
TSH 22 High lub. oil shutdown 4092 Digital Nice to have
PT 50 Nozzle oil press. 4093 Analog Recommended 0-6 bar
Table 6 MODBUS block 4 on Base Module A (mutiple i/o) register addressing.
09.36 - ES0
Description
V28/32S
Table 7 (Block scanning) Module B

oZT59 Power generator (optional) 4097 Integer 12 Bit Nice to have

oUX95-B UX95 (B-side) (UX95-B) 4005 Digital Required h)
oPAL70 Starting air press. low 4009 Digital Required
oTAD60-B Exh. gas temp high or low (B-side) 4013 Digital Recommended
oTAH61-B TC temp. outlet, high (B-side) 4014 Digital Recommended
oTAH62-B TC temp. inlet, high (B-side) 4015 Digital Recommended
iPT70 Start air pressure 401F Integer 12 Bit Recommended 0-40 bar
oSA99-B Common alarm (B-side) 4048 Digital
oSS90-B Engine running (NC) (B-side) 4049 Digital
iTE60-1B Exh. gas temp., cylinder 1 (B-side) 404A Integer 12 Bit Nice to have 0-800° C
iTE60-2B Exh. gas temp., cylinder 2 (B-side) 404B Integer 12 Bit Nice to have 0-800° C
iTE60-3B Exh. gas temp., cylinder 3 (B-side) 404C Integer 12 Bit Nice to have 0-800° C
iTE60-4B Exh. gas temp., cylinder 4 (B-side) 404D Integer 12 Bit Nice to have 0-800° C
iTE60-5B Exh. gas temp., cylinder 5 (B-side) 404E Integer 12 Bit Nice to have 0-800° C
iTE60-6B Exh. gas temp., cylinder 6 (B-side) 404F Integer 12 Bit Nice to have 0-800° C
iTE60-7B Exh. gas temp., cylinder 7 (B-side) 4050 Integer 12 Bit Nice to have 0-800° C
iTE61-2 Exh. gas temp. outlet TC 2 4053 Integer 12 Bit Nice to have 0-800° C
iTE62-2 Exhaust gas temp. inlet TC 2 4054 Integer 12 Bit Nice to have 0-800° C
iPT23-2 Lub. oil press. TC 2, low 4059 Integer 12 Bit Nice to have 0-4 bar
oSE89-2 TC speed-2 405C Integer 12 Bit Nice to have 0-60000 rpm
oPAL23-2 Lub. oil press. TC 2, low 4061 Digital Nice to have
oZS57 Earth 4095 Digital Nice to have
oZT45 Actuator index (optional) 4096 Integer 12 Bit Nice to have
oTE02 LT water temp. outlet engine 4098 Integer 12 Bit Nice to have 0-200° C
oTE10 HT water temp. inlet engine 4099 Integer 12 Bit Nice to have 0-200° C
oTE14 HT water temp. inlet cooler 409A Integer 12 Bit Nice to have 0-200° C
oTE20 Lub. temp. after engine 409B Integer 12 Bit Nice to have 0-200° C
oTE51 Nozzle oil temp. 409C Integer 12 Bit Nice to have 0-200° C
oPT02 LT water press. outlet engine 409D Integer 12 Bit Nice to have 0-6 bar
0PT14 HT water press. inlet cooler 409E Integer 12 Bit Nice to have 0-6 bar
Table 7 MODBUS block 2 on Base Module B (multiple i/o) register addressing.
Table 8 (Block scanning) Module B

08028-0D/H5250/94.08.12
oSAH89 High rpm TC 2 40C2 Digital Nice to have

oTAH62-2 High exh. gas temp. before TC 2 40C3 Digital Nice to have
oTAH12-2 High cooling water temp. 40C4 Digital Nice to have
oTAH60-1B High exh. gas temp cyl. 1 (B-side) 40C5 Digital Nice to have
oTAH60-6B High exh. gas temp cyl. 6 (B-side) 40CA Digital Nice to have
oTAH60-7B High exh. gas temp cyl. 7 (B-side) 40CB Digital Nice to have
Cont.
09.36 - ES0
V28/32S
Table 8 cont.
oTAH60-8B High exh. gas temp cyl. 8 (B-side) 40CC Digital Nice to have
oTAH60-9B High exh. gas temp cyl. 9 (B-side) 40CD Digital Nice to have
oUX95-2 Monitoring system failure 40CE Digital Recommended
oSX86-2 Monitoring sensor failure 40CF Digital Recommended
iLAH92 High oil mist alarm (oil splash) 40D0 Digital Nice to have l)
Table 8 MODBUS block 3 on Base Module B (mutiple i/o) register addressing.
Table 9 (Block scanning) BSM Module

iTI29-1 Main bearing temp. 4005H Integer 12 Bit Nice to have 0-800° C
iTI29-9 Main bearing temp. 400AH Integer 12 Bit Nice to have 0-800° C
iTI29-10 Main bearing temp. 400BC Integer 12 Bit Nice to have 0-800° C
iTI29-11 Guide bearing temp. 400CH Integer 12 Bit Nice to have 0-800° C
oTI29-1 Cable break 400DH Digital Nice to have
oTI29-2 Cable break 400EH Digital Nice to have
oTI29-3 Cable break 400FH Digital Nice to have
oTI29-4 Cable break 4010H Digital Nice to have
iTI27-1 Alternator bearing temp. 4018H Integer 12 Bit Nice to have 0-200° C
iTI27-2 Alternator bearing temp. 4019H Integer 12 Bit Nice to have 0-200° C
iTI INTERNT. Compensation resistor 401AH Integer 12 Bit Nice to have 0-200° C
oTSH29/27 High bearing temp. shutdown 401BH Digital Nice to have
oTSH29/27 Common alarm main bearing temp. 401DH Digital Nice to have
08028-0D/H5250/94.08.12
oUX29/27 Common cable failure 401FH Digital Nice to have
Table 9 MODBUS block 1 on BSM Module (mutiple i/o) register addressing.
In fig 8 some examples of wiring are illustrated. See Comment: Always connect each engine with
also description "Guidelines for cable and wiring" for separate serial cable to the alarm system. Do not
further information. connect all auxiliary engines on one serial cable
connection.
09.36 - ES0
08028-0D/H5250/94.08.12
09.36 - ES0
Page 9 (9)
Description
Communication method is RS-485. To communicate with the each module, the slave address must be set
different for each module! The slave address can be changed on SW1 directly on the base module.
For example slave add. on module A to 1 and slave add. 2 to the B module, and for the BSM module add. 3.
Engine type V28/32S
Fig 8 MODBUS communication (RS 485).

A4 A3 A2 A1
20U1 SW3 17U1 SW3 12U1 SW3

24VDC 400mA 0V 24V C 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 CO 1 C1 2 C2 2 3 C3 3 0 CO 1 C1 2 C2 2 3 C3 3
SENSOR SUPPLY DC INPUT DC INPUT 0V 24V DC INPUT
POWER RUN ERR 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 SUPPLY 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7

SUPPLY SUPPLY
IN IN OUT OUT
OUT IN
8 9 10 11 12 13 14 15
0 1 2 3 4 5
MAX
07CR41 XI16E1 X0-08R2 X0-08R2

0
MAX
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
14P1
0
2S 4P1
Advant Controller 31
Basic Unit
5P1
EXTENSION
6P1
EXTENSION
7P1
EXTENSION
11K1
4 RELAY OUTPUT 2A 4 RELAY OUTPUT 2A
8 24VDC INPUTS
S 16 24VDC INPUTS 4 RELAY OUTPUT NO/NC 3A 4 RELAY OUTPUT NO/NC 3A
6 RELAY OUTPUTS
8/3 2Sle 2Sle
du du
POWER SUPPLY RELAY OUTPUT DC INPUT 0V 24V DC INPUT
VBe2aringillance Mo
28se/3
VBa Mo
28se/3
VBa 120/230VAC 20VA L1 N 0 C 1 2 3 C 4 5 8 9 10 11 12 13 14 15
4 C4 5 C5 6 C6 6 7 C7 7 4 C4 5 C5 6 C6 6 7 C7 7
survedule
mo
SW1 SW1 SW1

SW5 SW5 SW5
SW2 SW2 SW2
J14 J20 J21 J19 J5 J1 J3 J14 J20 J21 J19 J5 J1 J3 J14 J20 J21 J19 J5 J1 J3
J32 J13 J15 J29 J30 J11 J12 J32 J13 J15 J29 J30 J11 J12 J32 J13 J15 J29 J30 J11 J12
J17 J31 J33 J17 J31 J33 J17 J31 J33 4F1 12F1
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
91
92
93
94
95
96
97
98
99
100
101
102
The end of the string is normal in

terminal X3, but it can be different
Communication from the GenSet
from plant to plant, please see the

correct terminal no. in the electrical
schematic.
127
128
129
130
131
127
128
129
130
131
127
128
129
130
131
J19 J5 J1 J3 J19 J5 J1 J3 J19 J5 J1 J3

68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
91
92
93
94
95
96
97
98
99
100
101
102
120 Ohm
120 Ohm 120 Ohm
J29 J30 J11 J12 J29 J30 J11 J12 J29 J30 J11 J12
J33 J33 J33

Edition 12H
509.55
V28/32S
Your Notes :
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2)
Alarm and Monitoring Equipment Edition 04H
V28/32S
Stopped engine Plate no Item no Note.

Shut-off cooling water See "Related procedure".
Shut-off fuel oil
Function test and adjustment of safety, alarm and See "Related procedure".
monitoring equipment.
Starting position
Related procedure
Functional test of shutdown trip 509-01.05

Analoge pressure transmitter 509-05.03
Analoge temperature transmitter 509-05.04
Manpower Replacement and wearing parts
Working time : - hours Plate no Item no Qty/

08028-0D/H5250/94.08.12
Capacity : - man
Data

02.08 - ES0
509-01.00 Functional Test and Adjustment of Safety, Working Card
Alarm and Monitoring Equipment
V28/32S
Maintenance of Monitoring and Safety

Systems
One of the most important parameters of preventive three months according to the mentioned working
work is that the alarm system, as well as the shutdown cards.
and overspeed devices, are functioning 100%.
To check these functions, use the working cards
If some of these functions are out of operation, they mentioned under related procedure on page 1.
must be repaired immediately. If this is not possible
because of the current working situation, the engine
has to be under constant observation until it can be
stopped.
It is recommended that all functions are tested every
08028-0D/H5250/94.08.12
02.08 - ES0
Page 1 (4) Function Test of Shutdown Edition 10
General

Shut-off fuel oil
Press button (Blocking - Reset)
Functional test of overspeed trip. Allen key, 4 mm

Functional test of low lubricating oil pressostate Allen key, 2 mm
trip. Manometer or test pump
Functional test of high fresh water thermostat. Large spanner
Small screwdriver
Starting position
Functional test and adjustment of safety

alarm and monitoring equipment 509-01.00
Related procedure
Working time : 1 hour Plate no Item no Qty/

08028-0D/H5250/94.08.12
Capacity : 1 man
Data

08.44 - ES0
Edition 10 Function Test of Shutdown Page 2 (4)
General
It is of the utmost importance that the shutdown Note: If safety pick-up is defective, engine will not
function is working properly.Therefore, the shutdown trip on overspeed as only a number of pulscounts
function must be tested at regular intervals according will be added to the measured pulscount from the
to the planned maintenance programme 500.25. flywheel.
Function Test of Overspeed Shutdown f. Turn both potmeters back to min.
1) Start the engine locally and keep it at no load, For functional test of redundant overspeed in Moni-
at nominal rpm: toring and alarm system:
a. Turn the engine speed to minimum.

Engine Type rpm
b. Stop the engine.
L16/24 1000 or 1200
c. Set dip switch sw5:3 on and reboot the mo-
L27/38 720 or 750
dule.
L21/31 900 or 1000
V28/32S 720 or 750
d. Start the engine and increase the speed until
engine trips
e. After engine has stopped set sw5:3 back to off

2.1) Take a large spanner and put it on the link bet- position and reboot.
ween fuel-rack and governor. Slowly force the
engine rpm over the setpoint, see Description Same methods can be used at conventional gover-
500.30 and the overspeed will release. (For nors as well.
conventional govering systems, not CR)
Warning: Do not raise the speed over 120% of no-
2.2) There are two overspeed protection functions minal speed because this could damage the valves
at this engines. and pistons.
• Overspeed protection in safety system.
• Redundant overspeed protection in Engine The engine must stop.
control and monitoring system.
3) Reset the overspeed shutdown on the operation
For functional test of overspeed in safety system box.
do as follows:
Adjustment
a. Start the engine and idle at nominal speed
900/1000 rpm. Correct detection of RPM (counting of teeths) de-
pends on the size of the gap between the movable
b. Check that both potmeters at PLC (3P1) is flywheel and the front of the pick-up sensor. If no or
turned to minimum. (left) wrong signal is detected by the sensor, the measuring
gap must be adjusted or cleaned.
08028-0D/H5250/94.08.12
c. Turn the lower potmeter on the PLC (3P1) to

max. (right) The gap is expected to be 2.0 mm ± 0.3 mm (the
pitch of the thread on the pick-up is 1.0 mm). The
d. Then turn the upper potmeter slowly up. number of teeth relative speed values/limits can be
found in the Engine Automatic diagram, section 509
e. The engine will eventually trip. and description 500.30 in section 500.
08.44 - ES0
Page 3 (4) Function Test of Shutdown Edition 10
General
The overspeed shutdown limits can not be adjusted Note: If adjustment is needed, turn the screw clock-
by the user. wise or anticlockwise, see fig 2.
8) Disconnect the manometer/test pump.
9) Open the oil pressure valve on the pressure

block.
10) Reset the low lubricating oil pressure shutdown

on the operation box.
Function Test of High Fresh Water

Temperature Shutdown
The functional test of the thermostat, is to be carried

out according to the following procedure.
11) Take the sensor out of the pocket.
Fig 1 Pressure controller
Function Test of Low Lubricating Oil Pres- Fig 2 Adjustment of pressostate and thermostate
sure Shutdown
4) Start the engine and keep it at no load.

12) Test the sensor in a water bath, which is con-
5) Mount the manometer/test pump on the test trolled by the temperature or a special testing
valve outlet, situated right under the pressostate device.
PSL 22, fig 1.
08028-0D/H5250/94.08.12
13) Start the engine and keep it at no load.

6) Close oil pressure valve, fig 1.
14) Raise the temperature until the switch chan-
7) Relieve the pressure slowly and check that the ges and check that it happens at the stated
switch changes back to the pressure stated as shutdown point, see 500.30.
the shutdown point, see 500.30.
The engine must stop.
The engine must stop.
08.44 - ES0
Edition 10 Function Test of Shutdown Page 4 (4)
General
Note: If adjustment is needed, remove the thermostat 15) The sensor is mounted again.
cover. Locking screw pos. 5, fig 3, is loosened, and
the range can be set with the spindle, pos. 1, while 16) Reset the high H.T. water temperature shut-
the scale, pos. 2, is read at the same time. down on the operation box.
Alarm System
Protection
cap
It is important that all alarms lead to prompt investi-
gation and remedy of the error.
No alarm is insignificant. It is therefore important

that all engine crew members are familiar with and
Temp. well trained in the use and importance of the alarm
sensor system.
The most serious alarms are equipped with slowdown

and/or shutdown functions.
Fig 3 Thermostate
08028-0D/H5250/94.08.12
08.44 - ES0
Working Card
Adjustment and Test of Analog Pressure Transmitter 509-05.03
General

Shut-off fuel oil
Adjustment and test of analog pressure trans- Testing pump.

mitter.
Starting position

Related procedure
Working time : ½ hour Plate no Item no Qty/

Capacity : 1 man
08028-0D/H5250/94.08.12
Data

02.20 - ES0
509-05.03 Adjustment and Test of Analog Pressure Transmitter
Working Card
General
The pressure transmitter registers the actual pressure
and converts the pressure to an electrical signal.
Adjustment
It is possible to adjust the pressure transmitter by

means of the „zero“ screw and the „span“ screw.
1) Adjust the „zero“ screw, see fig 1, to change

the pressure measurement area. zero screw
span screw
2) Adjust the „span“ screw, see fig 1, to change
the value of the electrical signal acc. to the
pressure measurement area.
Fig 1 Adjustment of pressure transmitter
Test
It is possible to make a functional test of the pres-

sure transmitter. This is carried out according to the
following procedure:
3) Shut of system pressure with the valve, see

fig 2, pos. 1.
4) Remove the screw, see fig 2, pos. 2
5) Mount the testing apparatus to the connection 2

and pump on a pressure within the working
area of the transmitter.
1
6) Read the pressure at the operating box on the
engine and check it according to the pressure
on the testing apparatus.
7) Remove the testing apparatus. Fig 2 Test of pressure transmitter
8) Mount the screw, see fig 2, pos. 2.
9) Open the valve, see fig 2, pos. 1, for the system

pressure.
08028-0D/H5250/94.08.12
02.20 - ESO
Working Card Adjustment and Test of 509-05.04
Page 1 (2)
Analog Temperature Transmitter Edition 03
L21/31
L27/38
V28/32S

Shut-off fuel oil
Adjustment and test of analog temperature trans- Special testing devices.

mitter, (PT 100 sensor).
Starting position
Related procedure


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

Capacity : 1 man
Data

04.06 - ES0
509-05.04 Adjustment and Test of Working Card
Analog Temperature Transmitter
L21/31
L27/38
V28/32S
The nickel-chrome-nickel (NiCr/Ni) sensor, which is sensor in the water bath, which is controlled
used for measurement of the exhaust gas tempera- by a special testing apparatus producing a
tures and bearing temperatures, generates a mV constant temperature.
signal depending on the temperature.
If the alarm system has an analog indication, the
The PT 100 sensor consists of a resistance wire temperature can also be read on this.
which changes resistance depending on the tem-
perature. Test of setpoint can be carried out by observing
whether the alarm system gives an alarm when the
Look and design vary depending on the place of alarm limit stated on page 500.30 is exceeded.
measurement and manufacture.
5) Check that the measuring value indicated on
the operation box on the engine is equal to the
Adjustment testing apparatus measuring valve.
1) The NiCr/Ni sensor and the PT 100 sensor 6) The sensor is mounted again.
cannot be adjusted. The alarm limit is set in
the alarm system according to the set points, Note: The test can also be made by special simulation
see page 500.30. instruments for NiCr/Ni sensors and PT 100 sensors.
The instruments can measure the sensor value and
simulate a sensor signal for the Base Module and
Test alarm system.
2) Functional test of the PT 100 sensor and NiCr/

Ni sensor can be carried out according to the
following procedure.
3) Take the sensor out of the pocket.
4) Test the measuring value by submerging the
08028-0D/H5250/94.08.12
Fig 1 PT 100 sensor
04.06 - ES0
Page 1 (2) Adjustment and test of tacho and proximity sensors Edition 01
L16/24 L27/38
V28/32S L21/31

Shut off starting air
Shut off cooling water
Shut off fuel oil
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : 1/4 hour Plate no Item no Qty/

Capacity : 1 man
Data

04.04 - ES0
Edition 01
Adjustment and test of tacho and proximity sensors Page 2 (2)
L16/24 L27/38
V28/32S L21/31
Adjustment
Correct detection of position or counting of teeth

depends on the size of the gap between the mo-
vable mechanical part and the front of the sensor. If
no signal is detected by the sensor, the measuring
gap must be adjusted. The gap is expected to be
2.0 mm ± 0.3 mm.
Test
It is possible to test the functioning of the tacho Fig 1 Tacho and proximity sensors
and proximity sensors. This is done in the following
manner:
1) Start rotation of the shaft on which the tacho

sensor is measuring.
2) Adjust shaft speed to a well-known rpm, if

necessary use a hand tachometer for refe-
rence measurement. Alternatively, a frequency
generator can be used for test of speed limits
set in the system.
3) Read and check the measured parameter in

the local operator panel and/or in the remote
control system.
4) Increase the speed slowly and check the limits

for alarm, control and overspeed stop specified
for the tested parameter.
08028-0D/H5250/94.08.12
04.04 - ES0
Working Card Adjustment of Lambda Controller 509-10.00
Page 1 (2) Governor Type, Woodward Edition 12H
V28/32S

Shut-off fuel oil
Hand tools
Description
Adjustablle spanner, 8"
Adjustment of lambda controller.
Starting position
Related procedure

Manpower
08028-0D/H5250/94.08.12

Capacity : 1 man
Data

02.41 - ES0
509-10.00 Adjustment of Lambda Controller Working Card
Edition 12H Governor Type, Woodward Page 2 (2)
V28/32S
Adjustment of the Lambda Controller
All adjustments are made when the engine is in

standstill position.
Point 1-5 has to be done for both A-side and B-

side.
Fig 3 Removal of pipe for charge air pressure.
1) Check that the free space between the pick-up

and the band steel on the regulating arm is min
1 mm, see fig 1.
2) Set the "load limit" control knob at max.
Fig 1 Check of free space. 3) Set the pump index to 27 mm by an adjustable

spanner on fuel rack arm.
4) Fit the adjustment screw (4), fig. 2, until the

piston has contact with the spring without
com-pressing it.
5) Fasten the adjustment screw.
6) Adjustment completed.
08028-0D/H5250/94.08.12
Adjustment of the Stop Screw.
7) Set the pump index to 27 mm (spring on gov-

ernor full pressed) by an adjustable spanner
on fuel rack arm.
8) Adjust the stop screw, see fig 2, to 105% load

according to the test bed.
Use the index arm on the fuel injection pump
nearest to the lambda controller as the control
for the index.
Fig 2 Fit the adjustment screw. 9) Adjustment completed.
02.41 - ES0
Working Card Adjustment of Lambda Controller 509-10.00
Page 1 (2)
Governor Type, Europa Edition 15H
V28/32S

Shut-off fuel oil
Hand tools
Description
Adjustablle spanner, 8"
Adjustment of lambda controller.
Starting position
Related procedure

Manpower
08028-0D/H5250/94.08.12

Capacity : 1 man
Data

07.44 - ES0
509-10.00 Adjustment of Lambda Controller Working Card
Page 2 (2)
Edition 15H Governor Type, Europa
V28/32S
Adjustment of the Lambda Controller
All adjustments are made when the engine is in

standstill position.
1) Check that the free space between the pick-up

and the band steel is minimum 2 mm, see fig.
1. (no light in the pick-up LED)
1. Band steel
2. Pick-up
3. Regulating arm
1
Fig 3 Removal of pipe for charge air pressure.

Min. 2 mm free space
across pick-up
3 2) Turn the governor output shaft so that fuel

pump index average is 18 mm at both A-side
2
and B-side.
3) Turn the lambda arm, fig. 3 pos. 5, on the

Fig 1 Check of free space. regulating shaft to contact with the piston rod,
fig. 3 pos. 4, on both A-side and B-side and
tighten the screws.
4) Force the output shaft on the governor with a

spanner to 100% actuator index so that the
spring loaded pull rod is activated.
5) Re-adjust the adjustment screw, fig. 2 pos. 4,

so that you reach 18 mm fuel pump index with
governor output on 100% (if not, repeat the
adjustment until the 18 mm is reached).
08028-0D/H5250/94.08.12
6) Lambda controller adjustment is completed.
7) Adjust the max. load stop screw (on both A-side

and B-side) so that max. index corresponds to
105% engine load. (Apply compressed air to
the lower pipe connection on both cylinders
so that the piston has compressed the internal
spring to upper position).
8) Max. load adjustment is completed.
Fig 2 Fit the adjustment screw.
07.44 - ES0
Plate
Page 1 (2) Governor and Governor Drive 50901-09H
392 404 V28/32S

For governor, see special
instruction book
057
344
069
104
070
045
082
190
319 094
177
128
224
116
236
141+
153 332
368
033
356
177
212 165
248
261
200
189
045
273
285
297 307
021 320
07.01 - ES0
Plate
50901-09H Governor and Governor Drive Page 2 (2)
V28/32S
Item Item
021 1/E Plug screw Propskrue 320 1/E Plug screw Propskrue
033 7/E Screw Skrue 332 1/E Plug screw Propskrue
045 2/E Slef locking nut Selvlåsende møtrik 344 4/E Plug screw Propskrue
057 1/E Governor Regulator 356 1/E Disc Skive
069 1/E Shim (set 0.1 - 0.3 - 0.5 Mellemlæg (sæt 0,1 - 368 1/E Nut Møtrik
- 1.0 mm) 0,3 - 0,5 - 1,0 mm)
392 1/E Synchronizing motor Synkroniseringsmotor
070 1/E Disc Skive
404 1/E Shutdown solenoid Shutdown solenoid
082 1/E Ball bearing Kugleleje
094 1/E Bevel gear wheel Konisk tandhjul

+ Item 141 require an + Item 141 kræver en
104 1/E Key Feder individual matching individuel tilpasning før
before mounting, con- montering, kontakt MAN
116 1/E Castle nut Kronemøtrik tact MAN Diesel A/S Diesel A/S
128 1/E Split pin Split
141+ 1/E Housing Hus
153 2/E Cylindrical pin Cylindrisk stift
165 1/E Shaft Aksel
177 2/E Bush Foring
200 1/E Thrust washer Trykskive
212 1/E Key Feder
224 1/E Stud with thread Tap med gevind
236 1/E Nut Møtrik
248 1/E Key Feder
261 1/E Key Feder
273 1/E Impulse wheel Impulshjul
285 1/E Locking ring Låsering
297 1/E Cover Dæksel
307 8/E Screw Skrue
319 2/E Plug screw Propskrue
Qty./E = Qty./Engine. Qty./E = Qty./Motor.
07.01 - ES0
Plate
Page 1 (2) Governor and Governor Drive 50901-10H
404
V28/32S
392
For governor, see special
instruction book
057
344
069
104
070
045
082
190
094
319
177
128
224
116
236
141+
153 332
368
033
356
177
212 165
248
261
200
189
045
273
285
297 307
021 320
07.01 - ES0
Plate
50901-10H Governor and Governor Drive Page 2 (2)
V28/32S
Item Item
021 1/E Plug screw Propskrue 320 1/E Plug screw Propskrue
033 7/E Screw Skrue 332 1/E Plug screw Propskrue
045 2/E Slef locking nut Selvlåsende møtrik 344 4/E Plug screw Propskrue
057 1/E Governor Regulator 356 1/E Disc Skive
069 1/E Shim (set 0.1 - 0.3 - 0.5 Mellemlæg (sæt 0,1 - 368 1/E Nut Møtrik
- 1.0 mm) 0,3 - 0,5 - 1,0 mm)
392 1/E Synchronizing motor Synkroniseringsmotor
070 1/E Disc Skive
404 1/E Shutdown solenoid Shutdown solenoid
094 1/E Bevel gear wheel Konisk tandhjul + Item 141 require an + Item 141 kræver en
individual matching individuel tilpasning før
104 1/E Key Feder before mounting, con- montering, kontakt MAN
tact MAN Diesel A/S Diesel A/S
116 1/E Castle nut Kronemøtrik
141+ 1/E Housing Hus
165 1/E Shaft Aksel
177 2/E Bush Foring
200 1/E Thrust washer Trykskive
212 1/E Key Feder
224 1/E Stud with thread Tap med gevind
236 1/E Nut Møtrik
248 1/E Key Feder
261 1/E Key Feder
273 1/E Impulse wheel Impulshjul
285 1/E Locking ring Låsering
307 8/E Screw Skrue
Qty./E = Qty./Engine. Qty./E = Qty./Motor.
07.01 - ES0
Plate
Page 1 (3) Regulation Mechanism 50902-08H
V28/32S
505, 733, 757

458
446
495
483
422
314
434 351
471
745 375 280
769 338
363
267
314 387 160
483 326
495 399
471
409
280 422 280
279
446 410
314 280
302
458 292
338
338 517
267
160 530
280
326 554 160
231
495
206 542 267
280 279
218 338
314 625
708 721
280 578 591
302 637
338 698
613
292
649 159
601
517 280 159
027
554 650 280
529
206 662
495 218 601
674 Governor see,
267 578
542 027 special instruction book
160 578 231
159
566 159 255
08028-0D/H5250/94.08.12
206 196
338 218
027 184
243 231 188
160 686
267 231
338 218 172
206 123 027
064 015
147
159
160 039
027 052 040
111 076 088 135
06.33 - ES0
Plate
50902-08H Regulation Mechanism Page 2 (3)
V28/32S
Item Item
015 1/E Split pin Split 280 Bearing bush Lejebøsning

027 5/E Ball Joint Kugle forbindelse 21/E 16 cyl. engine 16 cyl. motor
039 1/E Pull rod end Trækstangsende
292 4/E Screw Skrue
040 1/E Cylindrical pin Cylindrisktift
302 4/E Serrated washer Stjerneskive
052 1/E Spring housing Fjederhus
314 Spring pin Fjederstift
064 2/E Screw Skrue 28/E 12 cyl. engine 12 cyl. motor
076 1/E Outer spring Ydre fjeder 40/E 18 cyl. engine 18 cyl. motor
088 1/E Inner spring Indre fjeder 326 2/E Lever Arm
111 1/E Pull rod Trækstang 338 7/E Spring pin Fjederstift
123 1/E Cylindrical pin Cylindriskstift 351 1/C Linkage Lænkeled
135 1/E Guide ring Styrering 363 1/C Pin Stift
147 1/E Guide ring Styrering 375 1/C Spring Fjeder
159 5/E Nut Møtrik 387 1/C Spring lever Fjederarm
160 6/E Locking plate Låseplade 399 3/C Spring pin Fjederstift
172 1/E Spring loaded pull Fjederbelasted træk- 409 1/C Armholder, Armholder,
rod, complete incl. stang, komplet inkl. incl. item 399 inkl. item 399
item 015, 027, 039, item 015, 027, 039,
040, 052, 064, 076, 040, 052, 064, 076, 410 1/C Screw Skrue
088, 111, 123, 135, 147, 088, 111, 123, 135,
159, 160 147, 159, 160 422 1/C Spring loaded lever, Fjederbelastet arm,
complete incl. item komplet inkl. item 351,
184 1/E Governor arm Regulatorarm 351, 363, 375, 387, 409, 363, 375, 387, 409, 410,
Woodward Woodward 410, 446, 458 446, 458
188 1/E Governor arm Regulatorarm 434 1/E Regulating shaft, Reguleringsaksel,
Europa Europa (B-bank) (B-side)
12 cyl. engine 12 cyl. motor
196 1/E Screw Skrue
446 2/C Split pin Split
458 1/C Pin Stift
471 1/C Bearing bracket, Lejebuk,
231 6/E Pin for ball head Skrue for kuglehoved incl. item 280 inkl. item 280
243 1/E Lever Arm 483 2/C Screw Skrue
255 1/E Locking plate Låseplade 495 Washer Skive

08028-0D/H5250/94.08.12

267 5/E Screw Skrue 36/E 16 cyl. engine 16 cyl. motor
279 2/E Bearing housing Lejehus,
incl. item 280 inkl. item 280
Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme
06.33 - ES0
Plate
Page 3 (3) Regulation Mechanism 50902-08H
V28/32S
Item Item
505 1/E Regulating shaft, Reguleringsaksel, 757 1/E Regulating shaft, Reguleringsaksel,
(A-bank) (A-side) (A-bank) (A-side)
12 cyl. engine 12 cyl. motor 18 cyl. engine 18 cyl. motor
517 2/E Stop ring Stopring 769 1/E Regulating shaft, Reguleringsaksel,
(B-bank) (B-side)
529 1/E Bearing bracket, Lejebuk, 18 cyl. engine 18 cyl. motor
530 1/E Bearing bracket, Lejebuk,

542 4/E Screw Skrue
554 4/E Spring pin Fjederstift
566 1/E Lever Arm
591 1/E Ball joint Kugleforbindelse
601 2/E Pull rod, Trækstang,

613 1/E Adjusting screw Justeringsskrue
625 1/E Lever, incl. item 721 Arm, inkl. item 721
637 1/E Serrated washer Stjerneskive
649 1/E Bearing stud Lejetap
650 1/E Lever, incl. item 280 Arm, inkl. item 280
686 1/E Shield (Woodward Skærm (Woodward

governor) regulator)
698 1/E Counter nut Møtrik
721 1/E Screw Skrue
733 1/E Regulating shaft, Reguleringsaksel,

(A-bank) (A-side)
08028-0D/H5250/94.08.12
745 1/E Regulating shaft, Reguleringsaksel,

(B-bank) (B-side)
Qty./R = Qty./Regulation mechanism Antal/R = Antal/Reguleringsmekanisme
06.33 - ES0
Your Notes :
Plate
Page 1 (5) Instruments 50907-13H
V28/32S
Length Item
Fig. Range Code
L mm L1 mm no
70 - 120°C 99 TSH 12 012

TSH 22
Capacity
length
2m
Thermostat
(Female plug - see item 288)
1 - 10 bar 90 30 PSL 22 036
L
08028-0D/H5250/94.08.12
L1
Pressure control
07.43 - ES0
Plate
50907-13H Instruments Page 2 (5)
V28/32S
Length Item
Fig. Range Code
L mm L1 mm no
0 - 4 bar 90 30 PT 23-1 048

PT 23-2
PT 31
0 - 6 bar 90 30 PT 10 085
PT 01
L PT 02
PT 14
PT 50
0 - 10 bar 90 30 PT 21 132
PT 22
L1 0 - 16 bar 90 30 PT 40 156
0-40 bar 90 30 PT 70 168
Pressure transmitter
0 - 20 kHz 110 SE 90-1 181

SE 90-2
Pick-up
0 - 1 kHz 55 SE 89-1 203

SE 89-2
08028-0D/H5250/94.08.12
Pick-up
07.43 - ES0
Plate
V28/32S
Length Item
Fig. Range Code
L mm L1 mm no
0 - 1 kHz 22 ZT 88 227
Pick-up
0 - 160°C 63 110 TE/TI 12 240

L1
Thermometer
0-200°C 100 TE 01 335

TE 02
TE 10
TE 14
TE 20
TE 21
TE 31
08028-0D/H5250/94.08.12
TE 51
L
Temperature sensor
07.43 - ES0
Plate
50907-13H Instruments Page 4 (5)
V28/32S
Length Item
Fig. Range Code
L mm L1 mm no
0 - 800°C 127 14000 TE 60 418

L1
TE 61
TE 62
Temperature sensor
12000 TE 29 455
Temperature sensor
0-6 bar 52.5 ø57 PI 10 467
0-16 bar 52.5 ø57 PI 22 479

PI 40
08028-0D/H5250/94.08.12
Manometer
07.43 - ES0
Plate
V28/32S
Length Item
Fig. Range Code
L mm L1 mm no
54 118 US 25 492
US 50
US 75
L1
Safety cut-out
26.5 50 288
L1
Female plug with cabel relief
0-160°C 63 174 TE/TI 40 264

L1
08028-0D/H5250/94.08.12
Thermometer
07.43 - ES0
Your Notes :
Plate
Page 1 (2) Lambda Controller 50910-05H
V28/32S
03.06 - ES0
Plate
50910-05H Lambda Controller Page 2 (2)
V28/32S
Item Item
019 2/E Regulating arm, Reguleringsarm,

complete komplet
020 1/E Pick-up Pick-up
032 2/E Lambda cylinder, Lambdacylinder,

complete komplet
03.06 - ES0
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-06H
V28/32S
08028-0D/H5250/94.08.12
02.10 - ES0
Plate
50920-06H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
V28/32S
Item Item
430 4/E Nut Møtrik
442 1/E Pipe for level switch Rør for niveaualarm
454 1/E Level switch Niveaualarm

incl. cable inkl. kabel
491 2/E Red. adaptor Red. adapter
501 4/E Screw Skrue
525 1/E Gasket Pakning
549 1/E Level switch, Niveaualarm,

complete komplet

777 1/E Dipstick, complete Pejlestok, komplet
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Antal/Motor
Qty./I = Qty./Individual Qty./I = Antal/Individuel
02.10 - ES0
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-07H
V28/32S
049 050
098 013 062

074
133
025
145
145
133
108
037
086
08028-0D/H5250/94.08.12
02.50 - ES0
Plate
50920-07H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
V28/32S
Item Item
013 4/E Nut Møtrik

049 2/E Reduction Reduktion
050 4/E Screw Skrue
086 1/E Level switch, Niveaualarm,

complete komplet

121 1/E Dipstick, complete Pejlestok, komplet
145 2/E Reduction Reduktion
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Antal/Motor
Qty./I = Qty./Individual Qty./I = Antal/Individuel
02.50 - ES0
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-07
L21/31, L27/38
V28/32S
A-A 058
022 010
034
416
046
404
C C
333 178
345 333
286 357
C-C
382 369
08028-0D/H5250/94.08.12
394 370
06.47 - ES0
Plate
50925-07 Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L21/31, L27/38
V28/32S
Item Item
010 1/E Fuel oil leakage Br.olielækagealarm

alarm
046 1/E Level switch Niveaukontakt
058 1/E Hose connection Slangeforbindelse
178 1/E Repair kit for Reparationssæt for

running in filter indkørselsfilter
286 4/E Screw Skrue
333 2/E O-ring O-ring
345 1/E Packing ring Pakningsring
416 /I Glue Lim
08028-0D/H5250/94.08.12
06.47 - ES0
Plate
Page 1 (2) Monitoring Box 50935-21H
V28/32S
279 0 1400 0 16
ENGINE RPM
0 60000
SI 90
START AIR
PRESSURE
0 60000
PT 70
280
TC 1 RPM SI 89 TC 2 RPM SI 89
0 4 0 4
LUB. OIL LUB. OIL
PRESS. TC 1 PT 23 PRESS. TC 2 PT 23
HOUR BAR BAR
°C °C
ALT. RPM RPM

HIGH BEARING
OVERSPEED TEMP. STOP
LOW LUB. DIFF./EARTH
OIL PRESS. PROTECTION
HIGH FRESH- EMERGENCY
WATER TEMP. STOP
HIGH LUB.
OIL TEMP.
255
START STOP LAMP TEST LAMP TEST
3 Seconds Delay
BLOCKING
REMOTE LOCAL
RESET
039
530
200 400 600 200 400 600
E E
X
H
CYL. 1A TI 60
X
H
CYL. 1B TI 60
196
A A
U U
S CYL. 3A TI 60 S CYL. 3B TI 60
T T
G G
S S
T T
E E
M M
P P
R R
T T
U U
R TC 1 INLET TI 62 R TC 2 INLET TI 62
E E
TC 1 OUTLET TI 61 TC 2 OUTLET TI 61
160
027
HT WATER TEMP.
TI 12
OUTLET ENGINE
HT WATER PRESS.
PI 10
INLET ENGINE
196 LT WATER TEMP.

INLET AIR COOL.
LT WATER PRESS.
TI 01
PI 01
INLET AIR COOL.
542 LUB. OIL TEMP.

INLET FILTER
TI 22
08028-0D/H5250/94.08.12
LUB. OIL PRESS. PI 21

INLET FILTER
LUB. OIL PRESS.

PI 22
INLET ENGINE
FUEL OIL TEMP.

TI 40
INLET ENGINE
FUEL OIL PRESS.

PI 40
INLET ENGINE
NOZZ COOL PRESS.

PI 50
INLET ENGINE
0 80
CHARGE AIR TEMP.
TI 31
OUTLET COOL.
0 4
CHARGE AIR PRESS.
PI 31
OUTLET COOL.
08.03 - ES0
Plate
50935-21H Monitoring Box Page 2 (2)
V28/32S
Item Item
027 1/E Monitor temp./press. Monitor temp./tryk

(MTP) (MTP)
039 Monitor exh. gas Monitor udst.gastemp.

temp. A (MEG) A (MEG)
160 1/E Panel (MB) Panel (MB)
196 2/E Resistor 120R Modstand 120R
255 3/E Cable union M16 Kabelforskruning M16
279 1/E Operation box A Operation box A

(OB) (OB)
280 1/E Operation box B Operation box B

(OB) (OB)
530 1/E Monitor exh. gas Monitor udst.gastemp.

temp. B (MEG) B (MEG)
542 1/E Monitor temp./press. Monitor temp./tryk

(MTP) except PI 50, (MTP) uden PI 50, kun
only for BioFuel for BioFuel
08028-0D/H5250/94.08.12
08.03 - ES0
Plate
Page 1 (2) Terminal Box 50936-17H
V28/32S
585
597 382
154 154
274 274
166 166
573
345
561 154
274
536
130 166
548
345 142
250 632
262
ON/OFF switch
and fuses Led sensor power
Diagnose led 083

010
298 022
034
Connectors to be 046
mounted with
terminal block no. 058
071
ON/OFF switch
and fuses 619
Diagnose led 262
298 Led sensor power
083
083 010
08028-0D/H5250/94.08.12
010 022
ON/OFF switch
and fuses 022 034
Diagnose led 034 046

046 058
262
058 071
Led sensor power 071 357
620 357 369
619 619
07.44 - ES0
Plate
50936-17H Terminal Box Page 2 (2)
V28/32S
Item Item
010 12/E 3 pol connector 3 pol stik 620 1/E Bearing module Leje modul
022 3/E 5 pol connector 5 pol stik 632 1/E Conduit Ledningskanal
034 9/E 6 pol connector 6 pol stik
130 2/E Curcuit breaker Automatsikring

4 amp 4 amp
142 1/E Ground terminal Jordklemme
154 6/E End stop Endestop
166 91/E Terminal Klemme
250 1/E Conduit Ledningskanal
274 3/E End plate Endeplade
298 2/E Base module Base modul
345 2/E Output module Output modul
369 4/E Resistor 4.7 KR Modstand 4.7 KR
382 1/E Wall socket Stik
536 1/E Safety system, Sikkerhedssystem,

Base unit Baseunit

CPU CPU
561 1/E I/O module I/O modul
573 1/E End cap Endestykke
585 1/E Relay Relæ

08028-0D/H5250/94.08.12
597 1/E Socket Stik
619 3/E 5 pol double 5 pol dobbelt stik

connector
07.44 - ES0
08028-0D/H5250/94.08.12
07.51 - ES0
Plate
Page 1 (2)
166
274
154
and fuses
and fuses
and fuses
mounted with
Led sensor power

Diagnose led
Diagnose led
Diagnose led
ON/OFF switch
ON/OFF switch
ON/OFF switch
597
620
262
548
585
298
298
250
656
345
Connectors to be
terminal block no.
0 1 2 3 4 5 6 7 0 CO 1 C1 2 C2 2 3 C3 3 0 CO 1 C1 2 C2 2 3 C3 3
24VDC 400mA 0V 24V C 0 1 2 3 4 5 6 7
DC INPUT 0V 24V DC INPUT

SENSOR SUPPLY DC INPUT
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
POWER RUN ERR SUPPLY
SUPPLY SUPPLY
IN OUT OUT
IN
IN
OUT
8 9 10 11 12 13 14 15
0 1 2 3 4 5
MAX
07CR41 XI16E1 X0-08R2 X0-08R2

0
4P1 5P1 6P1 7P1
MAX
Advant Controller 31
EXTENSION EXTENSION
Basic Unit
EXTENSION
4 RELAY OUTPUT 2A 4 RELAY OUTPUT 2A
8 24VDC INPUTS
S 16 24VDC INPUTS
4 RELAY OUTPUT NO/NC 3A 4 RELAY OUTPUT NO/NC 3A
6 RELAY OUTPUTS
DC INPUT 0V 24V DC INPUT

POWER SUPPLY RELAY OUTPUT
4 C4 5 C5 6 C6 6 7 C7 7 4 C4 5 C5 6 C6 6 7 C7 7
8 9 10 11 12 13 14 15
L1 N 0 C 1 2 3 C 4 5
120/230VAC 20VA
Terminal Box
262
632
345
130
166
274
154
382
619
357
071
058
046
034
022
010
083
262
142
166
274
154
619
369
357
071
058
046
034
022
010
083
619
071
058
046
034
022
010
083
Led sensor power

Led sensor power
V28/32S
50936-21H
Plate
50936-21H Terminal Box Page 2 (2)
V28/32S
Item Item
130 2/E Curcuit breaker Automatsikring

4 amp 4 amp
142 1/E Ground terminal Jordklemme
154 6/E End stop Endestop
274 3/E End plate Endeplade
298 2/E Base module Base modul
345 2/E Output module Output modul
369 4/E Resistor 4.7 KR Modstand 4.7 KR
382 1/E Wall socket Stik

CPU CPU
585 1/E Relay Relæ
597 1/E Socket Stik
619 3/E 5 pol double 5 pol dobbelt stik

connector
620 1/E Bearing module Leje modul

08028-0D/H5250/94.08.12
656 1/E Input module Input modul
07.51 - ES0
Plate
Page 1 (2) Digital Load Sharing & Speed Control 50945-03
General
08028-0D/H5250/94.08.12
04.03 - EO0-ny
Plate
50945-03 Digital Load Sharing & Speed Control Page 2 (2)
General
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
021 1/E Digital load sharing & Digital speed

speed control control
08028-0D/H5250/94.08.12
Qty/Q = Qty/Plant Qty/Q = Qty/Anlæg
04.03 - EO0-ny
Plate
Page 1 (2) Alarm Panel 50946-01
General
015
High HT water temp. Low fuel oil press.

TAH 12 PAL 40
High lub. oil temp. Low start/stop air press.

TAH 21 PAL 70/71
High/low exh. gas temp. Overspeed

TDAH 60 SAH 81
High exh. gas temp. Jet system failure

TC outlet TAH 61 SX 32
High exh. gas temp. Power & system failure

TC inlet TAH 62 UX 95
High alternator winding Common shutdown

temp. TAH 98 SS86
Low LT water press. Start failure

PAL 01 SX 83
Low HT water press. Stop failure

PAL 10 SX 84
Low lub. oil press. Fuel leakage

PAL 22 LAH 42
High diff. press. lub. oil Low lub. oil level base
filter PDAH 21-22 frame LAL 28
Low lub. oil press. TC Low lub. oil level base

PAL 23 frame LAH 28
Low prelub. oil press. Turning bar engaged

PAL 25 ZS 75
027
08028-0D/H5250/94.08.12
00.39 - EO0-ny
Plate
50946-01 Alarm Panel Page 2 (2)
General
Item Item
015 1/E Alarm panel Alarm panel
08028-0D/H5250/94.08.12
00.39 - EO0-ny
Plate
Page 1 (2) Output Module 50947-03
General
083
201 225
213 237
262
274
095
105
OUTPUT MODULE 117
129
130
142
250
J11 J13 J6 J7 J2 J3 J1 J14
08028-0D/H5250/94.08.12
J12 J4 J5 J8 J9 J10
00.41 - EO0-ny
Plate
50947-03 Output Module Page 2 (2)
General
Item Item
083 1/E Panel Samlekasse
095 1/E Output module Udgangsmodul
105 1/E Resistor Modstand
201 1/E Cable union Kabel forskruning
213 1/E Nut Møtrik
237 2/E Nut Møtrik
262 2/E Cable union Kabelforskruning
274 2/E Nut Møtrik
08028-0D/H5250/94.08.12
00.41 - EO0-ny
Plate
Page 1 (2) Output Module 50947-04H
V28/32S
083
201 225
213 237
262
274
095
105
117
130
142
250
08028-0D/H5250/94.08.12
04.50 - EO0
Plate
50947-04H Output Module Page 2 (2)
V28/32S
Item Item
083 1/E Panel Samlekasse
095 1/E Output module Udgangsmodul
105 1/E Resistor Modstand
1/E 4 pol connector 4 pol stik
213 2/E Nut Møtrik
237 2/E Nut Møtrik
274 1/E Nut Møtrik
08028-0D/H5250/94.08.12
04.50 - EO0
Plate
Page 1 (2) APM Motor Control 50948-01
General
08028-0D/H5250/94.08.12
98.13 - EO0
Plate
50948-01 APM Motor Control Page 2 (2)
General
Item Item
016 1/E APM motor control APM motor control
08028-0D/H5250/94.08.12
98.13 - EO0
Plate
Page 1 (2) Valve Control Box 50949-01
General
Valve control Valve control

Engine 1 Engine 2
Ventilsteuerung Ventilsteuerung
011 Motor 1 Motor 2

023
035
047
059
060 084
072 096 106
118
08028-0D/H5250/94.08.12
131
143
98.16 - EO0-ny
Plate
50949-01 Valve Control Box Page 2 (2)
General
Item Item
011 2/E Pilot lamp, yellow Lampeglas, gul
023 2/E Pilot lamp, blue Lampeglas, blå
035 4/E Lamp holder Lampefatning
047 6/E Glow lamp Glødelampe
059 4/E Head, black Trykknap, sort
060 4/E Body Krop
072 4/E No contact block Sluttekontakt
084 10/E Auxillary relay Hjælperelæ
096 10/E Socket Sokkel
106 1/E Bridge rectifier Ensretterbro
118 1/E Transformer Transformer
131 12/E Fuse terminal Sikringsholder
143 12/E Fuse 2A Sikring 2A
08028-0D/H5250/94.08.12
98.16 - EO0-ny
Plate
Page 1 (2) Control Box 50949-02H
V28/32S
035
155
047
011
023
035
047 060
072
179
059
060
072
023
035
167
047
275
299 287
084 309 310 322 299
096
251
238
180
180
214
202
238
118 226
08028-0D/H5250/94.08.12
180
192
263
263 334
334
346
358 238
371
04.50 - EO0
Plate
50949-02H Control Box Page 2 (2)
V28/32S
Item Item
011 1/E Pilot lamp, yellow Lampeglas, gul 346 3/E Earth terminal Jordklemme
023 3/E Pilot lamp, green Lampeglas, grøn 358 3/E Terminal Klemme
035 4/E Lamp holder Lampefatning 371 1/E Earth terminal Jordklemme
059 2/E Head Trykknap
060 4/E Body Krop
072 6/E No contact block Sluttekontakt
155 1/E Panel Panel
167 1/E Selector switch Omskifter
179 2/E Head Trykknap
180 5/E Contactor Kontaktor
192 1/E Termal relay Terminalrelæ
202 2/E Termal relay Terminalrelæ
214 2/E Auxillary contact NC Hjælpekontakt
238 Channel track Kanalspor
251 Conduit Ledning
263 15/E End angle Endevinkel
275 3/E Circuit breaker Sikkerhedsafbryder
299 4/E Auxillary switch Hjælpekontakt

08028-0D/H5250/94.08.12
322 1/E Busbar Strømskinne
04.50 - EO0
Plate
Page 1 (2) Control Box 50949-03H
V28/32S
155 035
047
011
167
429 405 383

430 417 395
096 214 263 299

084 180 180 238 309 275
118 251
08028-0D/H5250/94.08.12
192
442
334 334 238 358

346 346 263 371
07.18 - EO0
Plate
50949-03H Control Box Page 2 (2)
V28/32S
Item Item
011 1/E Pilot lamp, yellow Lampeglas, gul
035 1/E Lamp holder Lampefatning
155 1/E Panel Panel
167 1/E Selector switch Omskifter
192 1/E Termal relay, 400 V Terminalrelæ, 400V
214 2/E Auxillary contact NC Hjælpekontakt
238 Channel track Kanalspor
251 Conduit Ledningskanal
263 14/E End angle Endevinkel
299 1/E Auxillary switch Hjælpekontakt
346 2/E Earth terminal Jordklemme
371 1/E Earth terminal Jordklemme
395 1/E Nut Møtrik
417 1/E Nut Møtrik

08028-0D/H5250/94.08.12
430 2/E Nut Møtrik
442 1/E Termal relay, 440 V Teminalrelæ, 440 V
07.18 - EO0
Plate
Page 1 (2) Converter 50956-01
General
(RS-232)
021
ADAM ADAM-4520
RS-232 TO RS-422/RS-485
CONVERTER
(B) GND 10
(RS 485)
(RS 422)
(R) +Vs
DATA +
DATA -
RX +
TX +
RX -
TX -
033
045
08028-0D/H5250/94.08.12
07.37 - ES0
Plate
50956-01 Converter Page 2 (2)
General
Item Item
021 1/E Coverter Converter
033 1/E Cable, length 1.8 m Kabel, længde 1.8 m
045 1/E Cable, length 10 m Kabel, længde 10 m
08028-0D/H5250/94.08.12
07.37 - ES0
Crankshaft
510/610
Your Notes :
Description 510.01
Page 1 (1) Crankshaft and Main Bearings Edition 04H
V28/32S
Crankshaft and Main Bearings Vibration Damper
The crankshaft, which is a one-piece forging, is A vibration damper is mounted on the crankshaft
suspended in underslung bearings. The main bear- to limit torsional vibrations. The damper consists
ings are of the trimetal type, which are coated with essentially of a heavy flywheel totally enclosed in a
a running layer. To attain a suitable bearing pressure light casing. A small clearance is allowed between
and vibration level the crankshaft is provided with the casing and the flywheel, and this space is filled
counterweights, which are attached to the crank- with a highly viscous fluid. The casing is rigidly
shaft by means of dovetail joints and secured with connected to the front end of the engine crankshaft
a centrally placed screw. and the only connection between the crankshaft
and the damper flywheel is through the fluid. Under
At the flywheel end the crankshaft is fitted with a conditions of no vibration, the casing and damper
gear wheel which through an intermediate wheel flywheel tend to rotate as one unit, since the force
drives the camshaft. required to shear the viscous film is considerable.
As the torsional vibration amplitudes increase, the
Also fitted here is a coupling flange for connection casing follows the movement of the crankshaft but
of a generator. At the opposite end (front end) there the flywheel tends to rotate uniformly by virtue of its
is a flexible gear wheel connection for lub. oil and inertia, and relative motion occurs between the fly-
water pumps. wheel and the casing. The viscous fluid film therefore
undergoes a shearing action, and vibration energy
Lubricating oil for the main bearings is supplied is absorbed and appears as heat.
through holes drilled in the engine frame. From
the main bearings the oil passes through bores in
the crankshaft to the crankpin bearings and hence
through channels in the connecting rods to lubricate
the piston pins and cooling of the pistons.
08028-0D/H5250/94.08.12
02.04 - ES0
Your Notes :
Page 1 (6) Checking of Main Bearings Alignment (Autolog) Edition 16H
V28/32S

Shut-off fuel oil
Description
Checking of main bearings alignment (autolog). Hand tools
Starting position
Turning gear in engagement. (If mounted).

Cover for crankshaft has been removed from
frame.
All indicator valves open.
Related procedure
Working time : 1 1/2 hours Plate No Item No Qty. /

Capacity : 2 men
Data

09.26 - ES0
Edition 16H Checking of Main Bearings Alignment (Autolog) Page 2 (6)
V28/32S
Alignment of Main Bearings
The lower main bearing shells should be positioned

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

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

shor tening during the turning of the throw increases Fig. 1. Placing of dial gauge.
in proportion to the difference in the height of the
bearing, it is measured as a check on the alignment
and condition of the bearing.
Checking The Deflection Measurement.
As the crankshafts of medium speed engines are very
stiff, any great deviations in the alignment will result The reading is entered in the table page 6, see
in clearance at the bottom shell of the bearings. example in fig. 2 - 6.
The cause of incorrect main bearing position may As "bottom" reading is used the mean value of the
be wear of the bearings or misalignmnet of the two "near bottom" readings X and Y, fig. 3.
engine.
The total deflection ("opening-closing") of the throw
during the turning from bottom to top position is
Effecting The Deflection Measurement entered in fig. 4.
The deflection measurement is effected by placing a These figures are due to vertical misalignment of
springloaded dial gauge in the centre punch marks the main bearings.
provided for this purpose, see fig. 1.
Similarly, horizontal misalignment procedures the
"Closing" of the throw in top dead centre is regarded figures in the table fig. 5.
as negative, (compression of the gauge).
Besides misalignment of the bearings, the readings
In the example, page 3, the deflection reading is can be influenced by ovality or eccentricity of the
therefore negative. journals.
As during the turning of the throw, the gauge and the

connecting rod will meet near the bottom position of Engines Equipped with Turning Gear
the throw, the measurement for the bottom position
is to be replaced by the average of the two near by When taking these deflection readings for the three
positions on either side. aftmost cylinders, the turning gear should at each
stoppage be turned a little backwards to ease off
The dial gauge is set to zero, when the crank throw the tangential pressure on the teeth of the turning
is in the near-bottom (x in fig. 8) and during the wheel as this pressure may otherwise falsify the
turning the throw is stopped in the position horizon- readings.
tal-top-horizontal-near bottom (P-T-S-Y in fig. 8) for
reading of the gauge.
09.26 - ES0
V28/32S
Deflection of crankshaft in 1/100 mm. (0.01 mm).
Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig 4
Left side P 2 0 2 0 -1 2
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Bottom stop Y 2 -1 0 1 0 2 Right side - left side

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

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

"Closing" of the crankthrow is considered Start in position X.
negative. Turn anti clockwise
Fig 7 Fig 8
09.26 - ES0
510-01.00 Checking of Main Bearings Alignment (Autolog) Working Card
V28/32S
Measurement of crank throw deflections by means of dial indicator (Autolog)
Crank throw deflection = Difference in dial indicator readings in two diametrically

opposite crank throw positions, i.e. two positions dis-
placed 180°.
Vertical deflection = Difference in top-bottom readings.
Horizontal deflection = Difference in side-side readings.
Horizontal deflections of crank throws
Unless otherwise stated the values refer to cold engine.
For new or realigned aggregate Aim for + or - 3/100 mm

Acceptable + or - 5/100 mm
For aggregate in service realignment

is recommended if deflections exceeds + or - 8/100 mm
Vertical deflections of crank throws with rigid coupling

between diesel engine and driven machine
Assembly condition
for engine Cold Warm Remarks
For new or
realigned aggregate 0 to +3/100 mm +5 to -15/100 mm Last throw (at flywheel end)
aim for + or -3/100 mm +5 to -7,5/100 mm Second last throw
(from flywheel)
+ or -3/100 mm +5 to -5/100 mm Other throws
Acceptable 0 to +5/100 mm +5 to -18/100 mm Last throw (at flywheel end)

+ or -5/100 mm +5 to -9/100 mm Second last throw
+ or -5/100 mm +5 to -6/100 mm Other throws
For aggregate in
service realignment 0 to +8/100 mm +5 to -20/100 mm Last throw (at flywheel end)
is recommended if + or -8/100 mm +5 to -10/100 mm Second last throw
deflections exceeds + or -8/100 mm +5 to -8/100 mm Other throws
09.26 - ES0
V28/32S
Process/Proces I.D. no.
Plant/Anlæg Page of/Side af
Engine Type/Motortype Engineer/Operatør Date/Dato
Instruction/Instruktion
Top
Right side Left side
Bottom end/ Bottom start/

1/100 mm Bund slut Bund start
Right side Right side
Cyl. no 1 2 3 Cyl. no 1 2 3
Left side Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
09.26 - ES0
510-01.00 Checking of Main Bearings Alignment (Autolog) Working Card
V28/32S
Component/Komponent Type I.D. no.
Process/Proces Page of/Side af
Test place/ Test bed/prøvehal Cold/Kold

Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal
Engine no.:
Motornr.:
Cyl. no. 1 2 3 4 5 6 7 8 9
Bottom X 0 0 0 0 0 0 0 0 0
Left side P
Top T
Right side S
Bottom Y
Bottom
(0.5xY)=B
Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V
Deflection from
horizontal mis-
alignment.
Left side - Right
side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
09.26 - ES0
Page 1 (3) Inspection of Main Bearing Shells Edition 05H
V28/32S

Shut-off cooling water 52010 10 2 pieces
Stopped lub. oil circul. 52010 15 2 pieces
Press Blocking - Reset 52010 30 Extra tools
52021 49 6 pieces
52021 51
Description 52021 20
Dismantling, inspection and/or replacement and

mounting of main bearing shells. Hand tools
Allen key, 12 mm.

Lead hammer.
Starting position Silastene.
Molycote.
Related procedure
Inspection of guide bearing shell, 510-01.10

Criteria for replacement of bearings, 506-01.16
08028-0D/H5250/94.08.12
Manpower
Working time : 2 hours
Capacity : 2 men Plate no Item no Qty/
Data

02.35- ES0
Edition 05H Inspection of Main Bearing Shells Page 2 (3)
V28/32S
Make Ready for Dismantling of the Main

Bearing
1) Dismount crankcase covers in front and oppo-

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

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

bearing stud nuts. For operation of the hydraulic
tools, see working card 520-01.05.
Fig 2. Mounting of Wire Straps
8) Lift the main bearing cap a little and unscrew

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

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

To pump cap and take out the bearing shell.
11) Fit the tool for upper main bearing, for dis-
mantling of upper main bearing shell, in the
Fig 1. Mounting of Hydraulic Tools lubricating hole in the crankshaft and turn out
the upper bearing shell by turning the crank-
shaft, see fig 3.
5) Dismount the hydraulic tools and slacken the
nuts somewhat.
Dismantling of the Main Bearing Cap
6) Fit the eye screws, diagonally, in the threaded

08028-0D/H5250/94.08.12
holes in the main bearing cap, see fig 2.
Pass the wire supplied through the eye screw

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

engine frame with a lead hammer or similar. Fig 3. Mounting of tool for upper main bearing
02.35 - ES0
Working Card 510.01-05
Page 3 (3) Inspection of Main Bearing Shells Edition 05H
V28/32S
Cleaning 17) Insert the lower bearing shell in the bearing

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

Mounting of the Main Bearing Cap
13) Inspect the main bearing shells according to
working card 506-01.16. 18) Raise the bearing cap into position, dismount
the guide tubes, coat the bearing studs with
Note: The bearing is marked according to size and molycote pasta or similar and fit the bearing
when replaced it must be by a new bearing of the stud nuts.
same size.
Make sure that the bearing cap and bearing
shell are in their correct position.
Mounting of the Main Bearing Shells
19) Dismantle the wire straps.
14) Push the upper bearing shell as far into position
as possible. 20) Mount the hydraulic tools, see working card
520-01.05, and tighten the nuts as prescribed
15) Fit the tool for upper main bearing in the lubrica- on page 500.40.
ting hole in the crankshaft and turn in the upper
bearing shell by turning the crankshaft. 21) Coat the back side of the bracing screws' (side
screws') hexagonal head with a thin coat of
Make sure that the shell enters its correct silastene or similar.
position then remove the tool for upper main
bearing. 22) Mount the screws and tighten with a torque
spanner as indicated on page 500.40.
16) Lubricate the end of the bearing shells with
molycote pasta or similar.
08028-0D/H5250/94.08.12
02.35 - ES0
Your Notes :
Page 1 (4) Inspection of Guide Bearing Shells Edition 02H
V28/32S

Shut-off cooling water 52006 28 140 - 760 Nm
Shut-off fuel oil 52010 10 2 pieces
52010 15 2 pieces
52010 30 Extra tools
Description 52021 49 2 pieces
52021 51
Dismantling, inspection and/or replacement 52021 20
and mounting of guide bearing shells and thrust
washer.
Hand tools
Starting position Allen key, 12 mm

Socket spanner, 36 mm
Lead hammer
Silastene
Molycote
Related procedure
Inspection of main bearing shells. 510-01.05

Criteria for replacement of bearing
shells. 506-01.16
08028-0D/H5250/94.08.12
Manpower
Working time : 2 hours

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

02.35 - ES0
Edition 02H Inspection of Guide Bearing Shells Page 2 (4)
V28/32S
Make Ready for Dismantling of the Guide

Bearing
1) Dismount the crankcase covers opposite the

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

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

loosen the guide bearing stud nuts. For ope-
ration of the hydraulic tools, see working card
520-01.05. Fig 2. Mounting of Wire Straps
8) Lift the guide bearing cap a little and unscrew

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

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

cap and take out the bearing shell.
To pump
Fig 1. Mounting of Hydraulic Tools

Thrust washer
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
Dismantling of the Guide Bearing Cap

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

holes in the guide bearing cap, see fig 2.
Pass the wire supplied through the eye screw Fig 3. Guide Bearing with Thrust Washer
and attach it as shown, so as to keep the
bearing cap in place when the guide bearing
stud nuts are removed. The thrust washer of the guide bearing is par-
tially countersunk into the engine frame and
7) Work the guide bearing cap loose from the attached by means of four screwed-on clamps
engine frame with a lead hammer or similar. which are visible after lowering the bearing cap,
see fig 3.
02.35 - ES0
Page 3 (4) Inspection of Guide Bearing Shells Edition 02H
V28/32S
In case the guide shell tool is locked between
guide bearing and bearing studs, use the bolt
on the back of the guide shell tool to dislodge
it.
Cleaning of Components
14) Clean all machined surfaces, on frame, bearing

cap, stud, nuts and bearing shells.
Guide for mounting of upper shell.
Fig 5. Mounting of Upper Shell in Guide Bearing
Fig 4. Dismounting of Upper Shell Inspection of Guide Bearing Shells
15) Inspect the guide bearing shells according to

11) Unscrew the clamns and push out the thrust
washers.
Mounting of the Guide Bearing Shells
12) Fit the tools for dismantling of upper guide
bearing shell, see fig 4, in the bearing cap and The bearing shells of the guide bearing, which are
raise the bearing cap into position, making sure identical to those of the main bearings, are narrower
that the guide shell is not being damaged. than the bore for the guide bearing and it is therefore
08028-0D/H5250/94.08.12
essential that the shells are positioned perfectly cor-

After that, dismount the guide tubes, fit and rect in the bore.
tighten the nuts slightly.
For this purpose a guide tool is supplied for positio-
13) With the guide shell tool, which is guided by ning on the engine frame when the upper bearing
the bearing cap, the upper bearing shell is shell is to be fitted, see fig 5.
carefully turned out into the bearing cap. Then
dismount the nuts and lower the bearing cap 16) Push the bearing shell as far as possible into
on the collar of the guide tubes. Take out the position through this guide tool.
bearing shell and the guide shell tool.
02.35 - ES0
Edition 02H Inspection of Guide Bearing Shells Page 4 (4)
V28/32S
17) Insert the guide shell tool in the bearing cap, 23) Insert the lower bearing shell in the bearing
which is resting on the collar of the guide tu- cap, and mount the locking piece.
bes.
18) Raise the bearing cap with the guide shell tool Mounting of Guide Bearing Cap
into its correct position, dismount the guide
tubes, fit and tighten the bearing stud nuts Lubricate the bearing shell and journal with clean
slightly. lubricating oil.
19) Now push the bearing shell into its correct 24) Raise the bearing cap into position, dismount
position with the guide shell tool.Make sure the guide tubes, coat the bearing stud with
that the shell enters its correct position. molycote pasta or similar and fit the bearing
stud nuts.
20) Then unscrew the bearing stud nuts, fit the guide
tubes and lower the bearing cap again. Make sure that the thrust washers, bearing shell
and bearing cap are in their correct position.
21) Fit the thrust washers and clamps.
25) Dismantle the wire straps.
Note: Clearance in guide bearing axially, see page
500.35. 26) Mount the hydraulic tools, see working card
520-01.05, and tighten the nuts as prescribed
22) Lubricate the end of the bearing shells with on page 500.40.
molycote pasta or similar.
27) Coat the back side of the bracing screws' (side
screws') hexagonal head with a thin coat of
silastene or similar.
28) Mount the screws and tighten with a torque

spanner as indicated on page 500.40.
08028-0D/H5250/94.08.12
02.35 - ES0
Page 1 (3) Vibration Damper Edition 05H
V28/32S

Shut-off fuel oil
Description
Taking a silicone oil sample Hand tools
Starting position
Related procedure
Man power
08028-0D/H5250/94.08.12

Working time : 2-4 hours
Capacity : 1 man Plate No Item No Qty. /
See plate 51004

Data

02.35 - ES0
Edition 05H Vibration Damper Page 2 (3)
V28/32S
The vibration damper is equipped with extraction 3) Rotate the engine in order to bring the extraction
plugs which provide the opportunity of testing the plugs (6) of the damper in optimal position, see
viscosity of the silicone oil inside the damper without fig. 2 A .
having to dismantle it.
Corresponding to the condition of the silicone oil an

approximate assessment of the damper efficiency
is possible. A
6
A silicone oil sample should be extracted as follows
by means of a special tube that can be required from
MAN B&W Holeby, see plate 51004.
1) After the engine is stopped let damper cool

down to nearly 40°C.
2) For access to the damper remove the blank

flange (A) on the front end cover (B) see fig. 6
1.
B
In some cases it is necessary to dismount the lub.
oil pump or the cooling water pump, for access to 5
the damper.
6
C
E
F
C
D
10 5 11
B
A
3
08028-0D/H5250/94.08.12
A. Blank flange or cooling water pump.

B. Front end cover.
C. Damper.
D. Gearwheel (if mounted) Fig 2. Vibration Damper
E. Main bearing (Frame)
F. Crankshaft.
4) Prepare the sample container (10) by removing

one of its caps (11), see fig. 2 C.
Fig 1. Mounting of Vibration Damper.
02.35 - ES0
Page 3 (3) Vibration Damper Edition 05H
V28/32S
5) Unscrew and remove one of the extraction plugs 8) Tighten both extraction plugs with thumb and
(6) and replace it with the sample container forefinger then turn them further 45° (about
(10). 20 Nm). Seal both plugs by caulking their
grooves.
If meeting the inertia ring (3) unscrew the
container one revolution. 9) Send the sample container to MAN B&W Ho-
leby, att.: Service Department, together with
6) Remove the second cap from the sample con- the label filled in with:
tainer and wait until silicone fluid (5) begins to
flow out from the free end. Depending on the -Name of ship.
silicone viscosity the process needs a certain - Engine type.
amount of time. If possible it, can be speeded - Engine no.
up by means of: -Running hours.
-Data for vibration damper.
A Turning the damper until the sample container
is underneath the crankshaft. B Temporarily 10) For hours between taking new samples, see
removing the second extraction plug too. page 500.25.
7) As soon as the silicone fluid begins to flow, The quantity of silicone oil removed its so small
shut the sample container by the cap. Remove that up to 10 such samples can be taken without
the container from the damper casing, wipe off risk.
the sealing jace round the extraction hole and
screw in the plugs together with new sealing
washers (7). Now close the second side of the
container.
08028-0D/H5250/94.08.12
02.35 - ES0
Your Notes :
Plate
Page 1 (2) Crankshaft 51001-07H
V28/32S
116
128
141
153
104
070
069
057
045
033+
021
177
189
082-165
094-165
06.33 - ES0
Plate
51001-07H Crankshaft Page 2 (2)
V28/32S
Item Item
021 1/E Crankshaft Krumtapaksel

033+ Counterweight Kontravægt

045 1/W Locking plate Sikringsplade
057 1/W Locking plate Sikringsplade
069 2/W Screw Skrue
070 1/W Screw for Skrue for

counterweight kontravægt
082 Plug screw Propskrue

141 1/E Oil throw ring Olieafslyngningsring

(crankshaft) (krumtap)


+ Item No. 033 + Item nr. 033

require an indivi- kræver en individuel
dual matching tilpasning før
before mounting montering, kontakt
contact MAN B&W, MAN B&W, Holeby
Holeby
Qty./W = Qty./Counterweight Antal/W = Antal/Kontravægt
Qty./I = Qty./Individual Antal/I = Antal/Individuelt
06.33 - ES0
Plate
Page 1 (2) Resilient Gear Wheel 51002-03H
V28/32S
015
Crankshaft,
see plate 51001
027
111
206
052
064
039
076
196
088
184 040
111 111
08028-0D/H5250/94.08.12
123
172
160
159
147
111
135
07.01 - ES0
Plate
51002-03H Resilient Gear Wheel Page 2 (2)
V28/32S
Item Item
015 1/E Resilient gear wheel, Fjedrende tandhjul,

complete incl. item komplet inkl. item 052,
052, 064, 076, 088, 064, 076, 088, 111, 123,
111, 123, 135, 147, 135, 147, 159, 184
159, 184
027 1/E Axel journal Akseltap
039 8/E Screw Skrue
052 1/E Hub Nav
064 6/E Slide shoe Glidesko
076 3/E Distance piece Afstandsstykke
135 6/E Spring guide Fjederstyr
147 6/E Spring Fjeder
159 3/E Distance piece Afstandsstykke
160 6/E Screw Skrue
172 3/E Locking plate Låseplade
184 1/E Side plate Sideplade
206 2/E Screw Kraterskrue
08028-0D/H5250/94.08.12
07.01 - ES0
Plate
Page 1 (2) Flywheel with Gear Rim 51003-07H
V28/32S
071
046
010
083
022
Crankshaft
(plate 51001)
058 034
02.40 - ES0
Plate
51003-07H Flywheel with Gear Rim Page 2 (2)
V28/32S
Item Item
010 1/E Flywheel Svinghjul
022 1/E Gear rim Tandkrans
058 16/E Nut Møtrik
071 2/E Screw Skrue
083 1/E Cyl. dowel Stift
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
02.40 - ES0
Plate
V28/32S
071
046
010
083
022
Crankshaft
(plate 51001)
058 034
02.40 - ES0
Plate
V28/32S
Item Item
071 2/E Screw Skrue
02.40 - ES0
Plate
V28/32S
071
046
010
083
022
Crankshaft
(plate 51001)
058 034
02.40 - ES0
Plate
V28/32S
Item Item
071 2/E Screw Skrue
02.40 - ES0
Plate
Page 1 (2) Torsional Vibration Damper 51004-06H
V28/32S
016
053
065
041+
028+
06.35 - ES0
Plate
51004-06H Torsional Vibration Damper Page 2 (2)
V28/32S
Item Item
016 1/E Torsional vibration Svingningsdæmper

damper, with 30 mm med 30 mm monterings
mounting flange flange
028+ 1/E Sampling kit for tor- Prøvesæt for sving-

sional vibration dam- ningsdæmper, Make 1
per, Make 1
041+ 1/E Sampling kit for tor- Prøvesæt for sving-

sional vibration dam- ningsdæmper, Make 2
per, Make 2


+ See also working + Se også arbejdskort

card 510-04.00 510-04.00
06.35 - ES0
Engine frame/Oil pan
511/611
Your Notes :
Description 511.01
Page 1 (1) Engine Frame and Base Frame Edition 05H
V28/32S
Engine Frame The front end of the frame is similarly shaped and
accommodates a vibration damper (and resilient
The engine frame is made of nodular cast iron and gear wheel drive for pumps etc.). The camshafts
is so designed that the hollow space between the which are carried in bearings are mounted on each
two banks of cylinders is utilized as a charge air side of the frame.
receiver.
Along the camshafts and the crankshaft the frame
The main bearings for the underslung crankshaft are has large openings on both sides for inspection of
carried in heavy supports in the frame plating and roller guides, cams, and main and crankpin bea-
are secured by bearing caps. To ensure strong and rings.
sturdy bedding of the caps, these are provided with
side guides and held in place by means of studs with The openings are closed by means of covers, and
hydraulically tightened nuts. those on the A-side of the engine are provided with
safety relief valves.
The two banks of cylinders forming a V are braced
at the top by a heavy top plate and at the bottom by
a flange and two longitudinal side walls assembled Base Frame
to form a box.
The engine and alternator are mounted on a com-
This box encases the cylinder liners whose top mon base frame.
flanges bear against the top plate and the bottom of
the cylinder liners are guided in the bottom flange. The rigid base frame construction is embedded to
the engine seating by means of resilient supports.
The gear wheel drive for the two camshafts is ar-
ranged in a hollow space at the flywheel end of the The inside of the base frame forms a reservoir for
frame, which is closed by a two-part end cover. the engine lubricating oil.
08028-0D/H5250/94.08.12
02.04 - ES0
Your Notes :
Page 1 (2) Functional Test of Crankcase Safety Relief Valves Edition 09H
V28/32S

Shut-off fuel oil
Description
Functional test of crankcase safety relief val-

ves. Hand tools
Starting position
Related procedure

Capacity : 1 man
51106 058 1/cyl.
Data 51106 071 12/relief valve
51106 740 1/relief valve
06.46 - ES0
Edition 09H Functional Test of Crankcase Safety Relief Valves Page 2 (2)
V28/32S
Functional Testing
Functional testing of the crankcase safety relief Cover

valves cannot be performed during operation of the
engine, but it must be checked during overhauls that
the valve flap is movable. Relief
valve
When Painting
When painting the engine, take care not to block up

the safety relief valves with paint.
Check of Opening Pressure
To check the proper opening pressure, proceed as

follows:
1) Remove the relief valve cover from the engi-

ne.
2) Place the cover on the floor with the pressure Fig 1 Cover with relief valve
area upwards.
3) Apply a weight at 18 kg on the pressure

area.
The relief valve must open under this pres-

sure.
4) Remount the relief valve cover of the engine.
If the safety relief valves are actuated, the

engine must be stopped immediately, and it
must not be restarted until the cause is detected
and the fault is detected, see also description
503.04, Ignition in Crankcase.
06.46 - ES0
Plate
Page 1 (3) Frame with Main Bearings 51101-11H
V28/32S
08028-0D/H5250/94.08.12
06.43 - ES0
Plate
51101-11H Frame with Main Bearings Page 2 (3)
V28/32S
Item Item
013 1/E Frame complete for Stativ komplet for 241 Bracing bolt Sideskrue
18V28/32S, incl. item 18V28/32S, inkl. item 14/E 12V28/32S 12V28/32S
049, 062, 108, 133, 145, 049, 062, 108, 133, 145, 18/E 16V28/32S 16V28/32S
169, 170, 216, 241, 290, 169, 170, 216, 241, 290, 20/E 18V28/32S 18V28/32S
300, 324, plate 50701 300, 324, plate 50701
item 048, 061, 073, item 048, 061, 073, 253 2/E Thrust washer Trykskive
276, plate 50705 item 276, plate 50705 item
350, 362 350, 362 265 4/E Safety sleeve Sikkerhedsbøsning
037 1/C Wear ring Slidring 290 4/E Screw Skrue
049 6/C Nut for cylinder Møtrik for cylinder- 300 1/E Guide bearing cap Styrelejedæksel
head stud dækseltap
050 3/C Protective cap Beskyttelseshætte
062 6/C Stud for cylinder Tap for
head cylinderdæksel 373 2/C Bracing stud Tap
074 2/E Plug Prop 397 1/E Frame complete for Stativ komplet for
16V28/32S, incl. item 16V28/32S, inkl. item
098 2/E Plug screw Propskrue 049, 062, 108, 133, 145, 049, 062, 108, 133, 145,
169, 170, 216, 241, 290, 169, 170, 216, 241, 290,
108 Main bearing cap Hovedlejedæksel 300, 324, plate 50701 300, 324, plate 50701
6/E 12V28/32S 12V28/32S item 048, 061, 073, item 048, 061, 073,
8/E 16V28/32S 16V28/32S 276, plate 50705 item 276, plate 50705 item
9/E 18V28/32S 18V28/32S 350, 362 350, 362
121 2/B Screw Skrue 407 1/E Packing ring Pakningsring
133 1/B Locking piece Låsestykke 419 Plug screw Propskrue

7/E 12V28/32S 12V28/32S
145 1/B Cylindrical pin Cylindrisk stift 10/E 16V28/32S 16V28/32S
12/E 18V28/32S 18V28/32S
157 Main bearing shell Hovedlejeskaller
7/E 2/2 2/2 420 Packing ring Pakningsring
9/E 12V28/32S 12V28/32S 7/E 12V28/32S 12V28/32S
10/E 16V28/32S 16V28/32S 10/E 16V28/32S 16V28/32S
18V28/32S 18V28/32S 12/E 18V28/32S 18V28/32S
169 Main bearing stud Hovedlejetap 432 3/C Protective cap Beskyttelseshætte
14/E 12V28/32S 12V28/32S
18/E 16V28/32S 16V28/32S 444 3/C O-ring O-ring
20/E 18V28/32S 18V28/32S
456 1/C Fixing piece Styrestykke
170 Nut for main Møtrik for
bearing stud hovedlejetap 468 Plug screw Propskrue
14/E 12V28/32S 12V28/32S 7/E 12V28/32S 12V28/32S
18/E 16V28/32S 16V28/32S 9/E 16V28/32S 16V28/32S
20/E 18V28/32S 18V28/32S 10/E 18V28/32S 18V28/32S
08028-0D/H5250/94.08.12
216 1/E Cylindrical pin Cylindrisk stift 481 Packing ring Pakningsring
7/E 12V28/32S 12V28/32S
9/E 16V28/32S 16V28/32S
10/E 18V28/32S 18V28/32S
Qty./B = Qty./Bearing Antal/B = Antal/Leje
06.43 - ES0
Plate
Page 3 (3) Frame with Main Bearings 51101-11H
V28/32S
Item Item
503 1/C Screw Skrue
515 6/C Sealing kit for Tætningssæt for

cap dæksel
527 Stud Tap

14/E 12V28/32S 12V28/32S
18/E 16V28/32S 16V28/32S
20/E 18V28/32S 18V28/32S
539 Nut Møtrik

14/E 12V28/32S 12V28/32S
18/E 16V28/32S 16V28/32S
20/E 18V28/32S 18V28/32S
552 1/E Frame complete for Stativ komplet for

12V28/32S, incl. item 12V28/32S, inkl. item
049, 062, 108, 133, 145, 049, 062, 108, 133, 145,
169, 170, 216, 241, 290, 169, 170, 216, 241, 290,
300, 324, plate 50701 300, 324, plate 50701
item 048, 061, 073, item 048, 061, 073,
276, plate 50705 item 276, plate 50705 item
350, 362 350, 362
+ Item No 108, 300 + Item nr. 108, 300

require an individual kræver en individuel til-
matching before pasning før montering,
mounting, contact kontakt MAN Diesel,
MAN Diesel, Holeby Holeby
08028-0D/H5250/94.08.12
Qty./B = Qty./Bearing Antal/B = Antal/Leje
06.43 - ES0
Your Notes :
Plate
Page 1 (2) Cover with Pumps 51102-09H
V28/32S
176
188
103 127
211
296
093 188
235
223
152
260
259 140
164
247
152 260
438
379
426
08028-0D/H5250/94.08.12
Freshwater pump, Lubricating oil pump,

see plate 51610 see plate 51501
06.35 - ES0
Plate
51102-09H Cover with Pumps Page 2 (2)
V28/32S
Item Item
093 1/E Front cover Fordæksel
164 2/E Cylindrical pin Cylinderstift
176 2/E Spray nozzle Sprøjterør
211 6/E Screw Skrue
247 2/E Nut Møtrik
296 1/E Spray nozzle Sprøjterør
379 6/E Screw Skrue
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Qty./Motor
06.35 - ES0
Plate
Page 1 (2) Covers on Frame 51106-18H
V28/32S
06.40 - ES0
Plate
51106-18H Covers on Frame Page 2 (2)
V28/32S
Item Item
010 6/D Screw Skrue 752 1/E Guard end after Skærm agter
(A-bank) (A-side)
071 12/D Washer Skive
083 6/D Self locking nut Selvlåsende møtrik
129 8/C Screw Skrue
191 2/C Stud Tap
823 6/E Screw Skrue
225 1/C Cover for camshaft Dæksel for kamaksel-
housing hus 835 1/D Safety valve, Sikkerhedsventil,
complete komplet
847 1/D Flange Flange
859 1/E Guard end fore Skærm for
250 24/E Washer Skive (A-bank) (A-side)
262 1/E Guard end aft Skærm, agter

(B-bank) (B-side)
+ item 703, 715 are + item 703, 715 er kun
286 2/C Spring pin Fjederstift only mounted if the monteret hvis motoren
engine is delivered er leveret uden fuelolie-
298 2/C Handle Håndtag without fuel oil feed forpumpe.
pump.
321 1/C Guard, Skærm,
intermediate mellem
382 1/E Guard end fore Skærm, for

(B-bank) (B-side)
416 Cover for Dæksel for

crankcase krumtaphus
490 Cover with safety Dæksel med sikker-

valve, complete incl. hedsventil, komplet inkl.
item 010, 071, 083 item 010, 071, 083
500 1/C Guard intermediate Mellemskærm, komplet

complete, incl. item inkl. item 191, 286,
191, 286, 298, 321 298, 321
703+ 1/E Cover Dæksel
715+ 6/E Screw Skrue
740 1/D O-ring O-ring
Qty./D = Qty./Safety cover Antal/D = Antal/sikkerhedsdæksel
06.40 - ES0
Plate
Page 1 (2) Cover on Frame 51106-26H
V28/32S
08028-0D/H5250/94.08.12
06.35 - ES0
Plate
51106-26H Cover on Frame Page 2 (2)
V28/32S
Item Item
835 2/E Screw Skrue
859 4/E Guide pin Styrestift
860 4/E Nut Møtrik
872 8/E Screw Skrue
884 1/E Cover complete, Dæksel komplet,

incl item 872 inkl. item 872
906 6/E Screw Skrue
08028-0D/H5250/94.08.12
06.35 - ES0
Plate
Page 1 (2) Base Frame 51111-04H
V28/32S
08028-0D/H5250/94.08.12
03.03 - ES0
Plate
51111-04H Base Frame Page 2 (2)
V28/32S
Item Item
031 1/E Base frame, Bundramme,



126 Screw Skrue

187 2/E Stud Tap
209 2/E Nut Møtrik
210 Screw Skrue

222 6/E Screw Skrue
234 4/E Alignment screw Stilleskrue
246 4/E Screw Skrue
258 8/E Screw Skrue
271 8/E Alignment screw Stilleskrue
08028-0D/H5250/94.08.12
03.03 - ES0
Turbocharger
512/612
Your Notes :
Description
Turbocharger System 512.01
V28/32S
Fig. 1 Diagram for Turbocharger System
Turbocharger System The charging air coolers are of the compact tube-
type with a large cooling surface. The cooling water
The turbocharger system of the engine, which is a is passed twice through the coolers, the end covers
constant pressure system, consists of an exhaust being designed with partitions which cause the
gas receiver, two turbochargers, two charging air cooling water to turn.
coolers and a charging air receiver, the latter being
integrated in the engine frame. The cooling water tubes are fixed to the tube plates
by expansion.
The turbine wheels of the turbochargers are driven
by the engine exhaust gas, and the turbine wheel From the exhaust valves, the exhaust is led through
dri-ves the turbocharger compressors, which are water cooled intermediate pieces to the exhaust gas
moun-ted on the same shaft. receiver where the pulsatory pressure from the indi-
vidual exhaust valves is equalized and passed to the
Turbochargers, see separate manual. turbochargers as a constant pressure, and further to
the exhaust outlet and silencer arrangement.
The turbochargers pump the air through the charging
air coolers to the charging air receiver. From the The exhaust gas receiver is made of pipe sections,
charging air receiver, the air flows to each cylinder one for each cylinder.The pipe sections are connected
through the inlet valves. to each other with compensators.This prevents exces-
sive stress in the pipes due to heat expansion.
02.45 - ES2
512.01 Turbocharger System Description
Page 2 (2)
Edition 08H
V28/32S
In the cooled intermediate piece a sensor for remote The turbochargers are equipped with a jet system
reading of the exhaust gas temperature is fitted. for supply of extra driving torque to the compressors.
The purpose is to increase the compressor perfor-
To avoid excessive thermal loss and to ensure a mance. With this system the engine can take up a
reasonably low surface temperature, the exhaust large momentary load increase.
gas receiver is insulated.
The system is activated automatically and only when
the engine is exposed to a large momentary load
increase, see section 509.
02.45 - ES2
Description Cleaning the Turbocharger In Service 512.05
Page 1 (1)
Water Washing of Compressor Edition 01
General
Compressor Chemical cleaning will not improve the cleaning

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

water before the compressor wheel will reduce the
fouling rate considerably, and consequently prolong
the intervals between dismantling necessary for
mechanical cleaning.
94.26 - ES0U-G
Your Notes :
Description Cleaning the Turbocharger in Service 512.10
Page 1 (3)
Dry Cleaning - Turbine Edition 02H
L21/31, L27/38
L23/30H, V28/32S
Description Cleaning System
The tendency to fouling on the gas side of turbo- The cleaning system consists of a cleaning agent
chargers depends on the combustion conditions, container (2) with a capacity of approx. 0.5 liters and
which are a result of the load and the maintenance a removable cover. Furthermore the system consists
condition of the engine as well as the quality of the of an air valve (3), a closing valve (1) and two snap
fuel oil used. on connectors.
Fouling of the gas ways will cause higher exhaust The position numbers (2) and (3) indicate the system's
gas temperatures and higher wall temperatures of "blow-gun". Only one "blow-gun" is used for each
the combustion chamber components and will also engine plant. The blow-gun is working according to
lead to a higher fuel consumption rate. the ejector principle with pressure air (working air)
at 5-7 bar as driven medium. Injection time approx.
Tests and practical experience have shown that radi- 2 min. Air consumption approx. 5 Nm3/2 min.
al-flow turbines can be successfully cleaned by the
dry cleaning method.
This cleaning method employs cleaning agents con-

sisting of dry solid bodies in the form of granules. A
certain amount of these granules, depending on the
turbocharger size, is, by means of compressed air,
blown into the exhaust gas line before the gas inlet
casing of the turbocharger.
The injection of granules is done by means of wor-

king air with a pressure of 5-7 bar.
On account of their hardness, particularly suited

blasting agents such as nut-shells, broken or artifi-
cially shaped activated charcoal with a grain size of
1.0 mm to max. 1.5 mm should be used as cleaning
agents.
1 Closing valve 2 Container
The solid bodies have a mechanical cleaning effect 3 Air valve 4 working air inlet
which removes any deposits on nozzle vanes and 5 Exhaust pipe 6 Snap coupling
turbine blades.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine
Dry cleaning can be executed at full engine load and
does not require any subsequent operating period of
the engine in order to dry out the exhaust system.
Experience has shown that regular cleaning intervals

are essential to successful cleaning, as excessive
fouling is thus avoided. Cleaning every second day
during operation is recommended.
The cleaning intervals can be shorter or longer based

on operational experience.
97.08 - ES2
512.10 Cleaning the Turbocharger in Service Description
Page 2 (3)
Edition 02H Dry Cleaning - Turbine
L21/31, L27/38
L23/30H, V28/32S
Dry cleaning of turbochargers
Suppliers of cleaning agents:
1. "Solf Blast Grit, Grade 14/25"
TURCO Products B.V.

Verl. Blokkenweg 12, 617 AD EDE - Holland
Tel.:08380 - 31380, Fax.: 08380 - 37069
2. Designation unknown
Neptunes Vinke B.V.

Schuttevaerweg 24, 3044 BB Rotterdam
Potbus 11032, 3004 E.A. Rotterdam, Holland
Tel.: 010 - 4373166 Fax.: 4623466
3. "Grade 16/10"
FA. Poul Auer GmbH

Strahltechnik
D-6800 Mainheim 31, Germany
4. "Granulated Nut Shells"
Eisenwerke Würth GmbH + Co.

4107 Bad Friederichshall, Germany
Tel.: 0 71 36-60 01
5. "Soft Blasting Grade 12/3a"
H.S. Hansen Eftf. Kattegatvej 2

2100 Copenhagen Ø, Denmark
Tel.:(31) 29 97 00 Telex: 19038
6. "Crushed Nutshells"
Brigantine, Hong Kong
7. "Turbine Wash"
Ishikawajima-Harima Heavy Industries Co.

Ishiko Bldg., 2-9-7 Yassu, Chuo-Ku
Tokyo 104, Japan
Tel.: 03-2 77-42 91
97.08 - ES2
Page 3 (3)
Dry Cleaning - Turbine Edition 02H
L21/31, L27/38
L23/30H, V28/32S
8. "A-C Cleaner" (Activated Coal)
Mitsui Kozan Co. Ltd. (Fuel Dept.)

Yamaguchi Bldg., 2-1-1 Nihonbashi
Muromachi, Chuo-Ku
Tokyo 103, Japan
9. "OMT-701"
Marix KK
Kimura Bldg., 6-2-1 Shinbashi
Minato-Ku, Tokyo 105, Japan
Tel.: 03-4 36-63 71, Telex: 242-7232 MAIX J
10. "OMT-701"
OMT Incorporated
4F, Kiji Bldg., 2-8 Hatchobori,
4-chome, Chuo-Ku, Tokyo 104, Japan
Tel.: 03-5 53-50 77, Telex: 252-2747 OMTINC J
11. "Marine Grid No. 14" (Walnut)
Hikawa Marine
Kaigan-Dori 1-1-1, Kobe 650, Japan
Tel.: 0 78-3 21-66 56
12. "Marine Grid No. 14"
Mashin Shokai
Irie-Dori, 3-1-13, Hyogo-Ku
Kobe 652, Japan
Tel.: 0 78-6 51-15 81
13. Granulate
MAN Diesel
Teglholmsgade 41 2450 København SV, Danmark
Tel.: +45 33 851100 Fax.: +45 33 851030
The list is for guidance only and must not be considered complete. We
undertake no responsibility that might be caused by these or other pro-
ducts.
97.08 - ES2
Your Notes :
Page 1 (1)
Water Washing - Turbine Side Edition 01
General
Description
The tendency to fouling on the gas side of turbo Heavily contaminated turbines, which where not
chargers depends on the combustion conditions, cleaned periodically from the very beginning or after
which are a result of the load on and the maintenance an overhaul, cannot be cleaned by this method.
condition of the engine as well as the quality of the
fuel oil used. If vibration in the turbocharger occur after water-wa
shing has been carried out, the washing should be
Fouling of the gas ways will cause higher exhaust repeated. If unbalance still exists, this is presumably
gas temperatures and higher surface temperatures due to heavy fouling, and the engine must be stop
of the combustion chamber components and will ped and the turbocharger dismantled and manually
also lead to a lower performance. cleaned.
Tests and practical experience have shown that The washing water should be taken from the fresh
radial-flow turbines can be successfully cleaned water system and not from the fresh cooling water
by injection water into the inlet pipe of the turbine. system or salt water system. No cleaning agents and
The cleaning effect is based on the water solubility solvents need to be added to the water.
of the deposits and on the mechanical action of the
impinging water droplets and the water flow rate. To avoid corrosion during standstill, the engine must,
upon completing of water washing run for at least 1
The necessary water flow is dependent on the gas hour before stop so that all parts are dry.
flow and the gas temperature. Enough water must be
injected per time unit so that, not the entire flow will
evaporate, but about 0.25 l/min. will flow off through Water Washing System
the drainage opening in the gas outlet.Thus ensuring
that sufficient water has been injected. The water washing system consists of a pipe system
equipped with a regulating valve, a manoeuvring
Service experience has shown that the above men valve, a 3-way cock and a drain pipe with a drain
tioned water flow gives the optimal cleaning effect. If valve from the gas outlet, see illustration on working
the water flow is reduced the cleaning effect will be card 512-15.00.
reduced or disappear. If the recommended water flow
is exceed, there is a certain risk of a accumulation The water for washing the turbine, is supplied from
of water in the turbine casing, which can result in the external fresh water system through a flexible
damage on the turbocharger. hose with couplings. The flexible hose must be
disconnected after water washing.
The best cleaning effect is obtained by cleaning at
low engine load approx. 20% MCR. Cleaning at low By activating the manoeuvring valve and the regu
load will also reduce temperature shocks. lating valve, water is led through the 3-way cock to
the exhaust pipe intermediate flange, equipped with
Experience has shown, that washing at regular inter a channel to lead the water to the gas inlet of the
vals is essential to successful cleaning, as excessive turbocharger.
fouling is thus avoided. Washing at intervals of 100
hours is therefore recommended. Depending on the The water which is not evaporated, is led out through
fuel quality these intervals can be shorter or longer. the drain pipe in the gas outlet.
However, the turbine must be washed at the latest
when the exhaust gas temperature upstream of the
turbine has risen about 20° C above the normal
temperature.
96.39 - ES0
Your Notes :
Working Card
Page 1 (3) Overhaul of Charging Air Cooler 512-01.00
Edition 07H
V28/32S

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

Hand tools

Starting position Allen key, 10 mm.
Wire rope.
Tackle.
Related procedure

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

Capacity : 2 men
51201 257 1/cooler
Data 51201 390 1/cooler
51201 400 1/cooler
Data for pressure and tolerance (Page 500.35) 51201 639 1/cooler
08.35 - ES0
512-01.00 Overhaul of Charging Air Cooler
Working Card
Page 2 (3)
Edition 07H
V28/32S
The charging air cooler is normally cleaned and
overhauled at the intervals indicated in the "Planned 2
2
Maintenance Program", or if observations prove that
the cooler does not work satisfactory, see section 1
602.
3
6
Overhaul of Charging Air Cooler
1) Close the cooling water inlet and outlet valves 5

and disconnect the pipes.
2
2) Remove screws (fig. 1).
5
3) Remove the screws (1), fig. 2, which secure the
end cover of the cooler element to the cooler
housing, and pull the cooler element half-way
2
out.
4
Place a wire rope round the cooler element and at-
tach a tackle hook, after which the elements are lifted
and pulled out of the cooler housing and landed on
a couple of wooden planks on the floor. 2
Fig 2
d
en de
el
w he ulsen 5) Clean the cooler element of the water and air
Fly ingh j
Charge air cooler
Sv sides.
Screw
After using cleaning agents the manufacting recom-

mendting must be followed.
The greatest care must be exercised when dismant-

ling cleaning and mounting the cooler element, as
the thin fins of the tubes cannot stand impacts and
Screw
pressure.
Screw
If nevertheless, the metal is damaged, it should be
carefully straightened, as bent fins will increase the
pressure drop across the cooler considerably.
08028-0D/H5250/94.08.12
Fig 1
Should one ore more cooler tubes become leaky
it/they must immediately be made tight, either by
4) Remove screws (2) and end cover (3) reversal expending the tube ends into the tube plates or by
chamber (4), side plates (5) and water mist blanking of the tube(s) concerned with plugs.
catcher (7).
08.35 - ES0
Working Card
Page 3 (3) Overhaul of Charging Air Cooler 512-01.00
Edition 07H
V28/32S
It is important that the charging air cooler is not leaky

as any sea water that leaks in will be carried along
with the air to the cylinders where the salt contained
in the water will damage valves, piston rings, and
cylinder liners.
6) Also clean end cover and coat it on the inside

with an anti-corrosion blocks agent. Inspect the anti-
corrosion (6) and renew if necessary.
Note: That paint or similar must not be applied to

these blocks.
7) Fouling and deposite in the pipes can be removed

by using a hand or machine operated circular
steel brush. The pipe inner diameter is 13 mm.
8) When mounting the air cooler, renew all gas-

kets.
Very important:
Tighten the screws in fig. 1 with exactly 25 Nm.
Out of Service Periods
At longer periods out of service the air cooler is drained

if the coolant is sea water followed by flushing with fresh
water and left with drain and venting cocks open.
At fresh water coolant systems recommendations for

the entire system is followed.
08028-0D/H5250/94.08.12
08.35 - ES0
Your Notes :
Page 1 (2) Exhaust Pipe Compensator Edition 02
L21/31,
L27/38, V28/32S

Shut-off fuel oil
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : 1/4 hour Plate no Item no Qty./

Capacity : 1 man
Data

03.05 - ES0
Edition 02 Exhaust Pipe Compensator Page 2 (2)
L21/31,
L27/38, V28/32S
Description
To minimize toxic gases in the engine room and to

keep the exhaust gas insulation in good condition,
it is necessary to keep the exhaust pipe compen-
sators tight.
1) Start the engine.
2) Feel and look for any leak in the exhaust gas

pipe compensators.
Note: If any leak is discovered, the compensator

in question must be renewed.
08028-0D/H5250/94.08.12
03.05 - ES0
Page 1 (3) Water Washing of Compressor Side Edition 01
General

Shut-off fuel oil
Water washing of compressor side.

Turbocharger cleaning with engine in service.
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : 1/4 hour Plate no Item no Qty /

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

02.20 - ES0S-G
Edition 01 Water Washing of Compressor Side Page 2 (3)
General
Before Cleaning
The cleaning process is only to be carried out when 3) Fill the container with 2 litres fresh water (see
the engine is at operating temperature (see Opera- the scale on the container).
ting Data 500.30) and when it is loaded as close as
possible to full load (see Main Data 500.00).
Warning: Do not use sea water or cooling water.
See also "Cleaning the Turbocharger in Service,
Water Washing of Compressor", 512.05.
4) Mount the top cover on the container.
Cleaning Procedure 5) Blow air into the container by means of a blow

gun, until an operation pressure of 3 bar is reached
1) Run the engine with as high a load as pos- (see fig 2).
sible.
2) Discharge the excesspressure in the container The safety valve will open at a pressure of 4 bar.
by drawing out the spindle in the safety valve (see
fig. 1) before loosening the top cover. Excesspressure will discharge through the safety
valve.
The spindle returns automatically by means of a
built-in spring.
08028-0D/H5250/94.08.12
Fig 1 Fig 2
02.20 - ES0S-G
Working Card
Water Washing of Compressor Side 512-05.00
General
6) Connect the plug-in coupling of the lance to
the snap coupling on the pipe (see fig 3).
7) Depress the handle on the hand valve until

the water is completely injected into the compressor
(approx. 30 seconds).
The water will enter the compressor in atomized

condition, impinge the vanes of the compressor
wheel with high velocity and thus wash off the dirt
deposited.
8) Release the plug-in coupling and vent the

container by drawing the spindle out of the safety
valve.
After Cleaning
9) Run the engine for minimum 10 minutes at

1 Injection tube 5 Hand valve with handle unaltered high load.
2 Pipe 6 Container
3 Snap coupling 7 Charge air line
4 Plug-in coupling 10) Compare the measurements of the operating
data (see fig 4) before and after the cleaning proce-
dure (see Operating Data 500.30).
Fig 3
IF THEN
the comparison indicates success of the the water washing of the compressor side
washing procedure is finished
the comparison indicates lack of the wa- carry out the washing procedure from step
shing procedure 1 with 10 minutes interval from the initial
washing
08028-0D/H5250/94.08.12
severe dirt is being deposited in the com- dismantling of the compressor components
pressor for manual cleaning is necessary (see spe-
cial turbocharger manual in section 512).
Fig 4
02.20 - ES0S-G
Your Notes :
Page 1 (2) Cleaning the Turbine, dry cleaning Edition 05
L21/31,
L27/38, V28/32S

Shut-off fuel oil
Cleaning the turbine.
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : 1/4 hour Plate no Item no Qty./

Capacity : 1 man
Data

03.05 - ES0
Edition 05 Cleaning the Turbine, dry cleaning Page 2 (2)
L21/31,
L27/38, V28/32S
5-7 bar
1 Stop valve
2 Container
3 Valve
4 Working air
1 2 3 4
Fig 1 Dry cleaning
Dry cleaning 2) Fill the container (2) with granulate.The amount

depending on the type of turbocharger;
The device is connected immediately before the TC
gas inlet. NR12, NR14, NR15,
NR17, NR20 0.3 litre
Appropriate cleaning materials are granulates from
nut shells or activated charcoal of a grain size of 1 NR24, NR26 0.4 litre
mm (max. 1.5 mm)
NR29, NR34 0.5 litre
Cleaning sequence 3) Connect to the working air system (4).
Please also consult the instruction plate on the 4) Connect the dry cleaning device to valve (1) and
engine. open valve (3). Then open valve (1) slowly until
a hissing sound indicates that the granulate is
The cleaning is to be carried out at high engine load, being injected. Injection period: Approx. 2 min
min. 75 % MCR. or until the container is emty.
08028-0D/H5250/94.08.12
1) Before connecting the cleaning device, see Note: If vibrations occure after cleaning the tur-
fig 1, open the stop valve (1) and check that bine it is necessary to repeat the cleaning process
the passage is not blocked. Close the valve until no vibrations are observed.
again.
03.05 - ES0
Plate
Page 1 (2) Charging Air Cooler 51201-18
V28/32S
3 27 23 28
15 22
2 23
1 6
24 20
5 8
18
16
17
25
19
12
12
10
13
11
14
21 7
4 8
26 29 30
10.09 - ES0
Plate
51201-18 Charging Air Cooler Page 2 (2)
V28/32S

Item Item
001 1/K End cover Endedæksel 027 2//K Screw Skrue
002 8/K Gasket Pakning 028 1/K Hex. end cap Slutmuffe
003 8/K Plug screw Propskrue 029 1/K Gasket Pakning
004 1/K Gasket RC Pakning VK 030 1/K Adhesive Klæbemiddel
005 1/K Gasket EC Pakning ED 031 2/E Charging air cooler, Ladeluftkøler, komplet
complete
006 1/K Cooler block incl. Kølerblok inkl. WMC
WMC
007 6/K Screw Skrue
008 16/K Screw Skrue
009 1/K Water mist catcher Vandudskiller
010 2/K Spacer pipe Afstandsrør
011 2/K Tie bar Stag
012 4/K Nut Møtrik
013 12/K Washer Skive
015 2/K Drain pipe WMC Drænrør WMC
016 1/K Side plate, right Sideplade, højre
017 8/K Spring pin Spændstift
018 4/K U-profile U-profil
019 8/K Spring Fjeder
020 1/K Side plate, left Sideplade, venstre
021 1/K Reversing chamber Vendekammer
022 5/K Screw Skrue
023 4/K Screw Skrue
024 2/K Brass ring Bøsning
025 2/K O-ring O-ring
Qty./K = Qty./Cooler Antal/K = Antal/Køler
10.09 - ES0
Plate
Page 1 (2) Cooler Box 51201-14H
V28/32S
d e
en
e el send
wh jul
Charge air cooler Fly ingh
see plate 51201 Sv
880
892
855
879
867
880
892
880
892
843
06.40 - ES0
Plate
51201-14H Cooler Box Page 2 (2)
V28/32S
Item Item
843 1/E Cooler box, front end Kølerbox, forende
855 1/E Cooler box, flywheel Kølerbox, svinghjulsen-

end de
867 4/E Screw Skrue
879 4/E Nut Møtrik
880 4/E Screw Skrue
892 4/E Nut Møtrik
06.40 - ES0
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-06H
18V28/32S
08028-0D/H5250/94.08.12
05.06 - ES0
Plate
51202-06H Exhaust Pipe Arrangement Page 2 (2)
18V28/32S
Item Item
323 2/C Disc Skive
335 1/C Packing Pakning
347 1/E Exhaust pipe Udstødsrør
384 8/E Compensator Kompensator
396 2/E Axial compensator Axial kompensator
418 24/E Hexagon screw Skrue
480 1/C Connecting piece Mellemstykke
502 4/C Hexagon head screw Skrue
514 4/C Packing ring Pakningsring
538 2/C Screw Skrue
551 1/C Hexagon socket plug Propskrue
599 1/C Cooling water nipple Kølevandsnippel

08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50 Ved bestilling af reservedele, se også side 500.50
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
05.06 - ES0
Plate
12V28/32S
08028-0D/H5250/94.08.12
05.06 - ES0
Plate
12V28/32S
Item Item
264 1/C O-ring O-ring 609 2/E Plug screw Propskrue
311 1/C O-ring O-ring 610 4/E Packing ring Pakningsring
323 2/C Disc Skive 622 4/E Plug screw Propskrue
443 24/E Hexagon head screw Skrue
538 2/C Screw Skrue

08028-0D/H5250/94.08.12
05.06 - ES0
Plate
16V28/32S
08028-0D/H5250/94.08.12
05.06 - ES0
Plate
16V28/32S
Item Item
323 2/C Disc Skive
396 2/E Axial compensator Axial kompensator
538 2/C Screw Skrue

08028-0D/H5250/94.08.12
05.06 - ES0
Plate
Page 1 (2) Turbocharger Arrangement 51203-13H
12V28/32S
08028-0D/H5250/94.08.12
05.36 - ES0
Plate
51203-13H Turbocharger Arrangement Page 2 (2)
12V28/32S
Item Item
354 16/E Sleeve Bøsning
366 1/E Cooler box Køleboks
391 52/E Hexagon socket Skrue

head cap screw
437 4/E Nut Møtrik
449 1/E Inlet box Indstrømningsboks

head cap screw
474 2/E Packing, Silicone

silicone paste

head cap screw

head cap screw

head cap screw
569 1/E Bracket Konsol
582 12/E Hexagon head Skrue

08028-0D/H5250/94.08.12
screws
594 12/E Spring lock Fjederlås
05.36 - ES0
Plate
Page 1 (2) Turbocharger Arrangement 51203-23H
16, 18
V28/32S
08028-0D/H5250/94.08.12
05.36 - ES0
Plate
51203-23H Turbocharger Arrangement Page 2 (2)
16, 18
V28/32S
Item Item
354 24/E Sleeve Bøsning

head cap screw
437 4/E Nut Møtrik

head cap screw
474 1/E Packing, Silicone

silicone paste

head cap screw

head cap screw
08028-0D/H5250/94.08.12
05.36 - ES0
Plate
Page 1 (2) Water Washing of Compressor Side 51205-01
General
296*
260
284*
272*
306 019*
020*
032*
081
044*
093
056*
103
068*
115
259
247 127
235 139
223 140*
103
115
211
176
152*
188
164*
94.01 - ES0S-G
Plate
51205-01 Water Washing of Compressor Side Page 2 (2)
General

Item Item
019* 1/E Top cover with non- Topdæksel med kon- 284* 1/E Straight male stud Ligeforskruning
return valve traventil coupling
020* 1/E O-ring for top cover O-ring for topdæksel 296* 1/E Plug in coupling Kobling
032* 1/E O-ring for non-return O-ring for kontraventil 306 1/E Lance complete, incl. Lanse komplet, inkl.
valve item 272-284 and 296 item 272-284 and 296
044* 1/E Valve seat Ventilsæde 318 1/E Container complete, Beholder komplet, som
as shown on plate vist på plate
056* 1/E Spring for non-return Fjeder for kontraventil
valve
068* 1/E Cap screw for non- Omløber til kontraven-

return valve til
081 1/E Top cover with non- Topdæksel med kontra-

return valve complete, ventil komplet, inkl. item
incl. item 019-020-032- 019-020-032-044-056
044-056 and 068 and 068
093 1/E Safety valve Sikkerhedsventil
103 2/E O-ring O-ring
115 2/E Finger nut Fingermøtrik
127 1/E Cap Top
139 1/E Gasket for the cap Pakning for top
140* 1/E Cable binder Kabelbinder
152* 1/E Strap Gjord
164* 1/E Eye for strap Øje for gjord
176 1/E Strap complete, incl. Gjord komplet, inkl.

item 140-152 and 164 item 140-152 and 164
188 1/E Container Beholder
211 1/E Flexible pipe Fleksibel slange
223 1/E Handle with flexible Håndtag med fleksibel

pipe and cap screw slange og omløber
235 1/E Filter insert Filterinsats
247 1/E Gasket for handle Pakning til håndtag
259 1/E Hand valve Håndventil
260 1/E Gasket for hand val- Pakning til håndventil

ve
272* 1/E Lance Lanse
94.01 - ES0S-G
Plate
Page 1 (2) Steam Trap 51208-01H
L23/30H
V28/32S
015
052
027
064
039
040
076
08028-0D/H5250/94.08.12
97.07 - ES0S
Plate
51208-01H Steam Trap Page 2 (2)
L23/30H
V28/32S
Item Item
015 1/E Steam trap, Vandudlader,

complete komplet
039 1/E Clip Klemme
040 1/E House, bottom Hus, bund
052 1/E House, top Hus, top
064 1/E Swimmer Svømmer
076 1/E Valve Ventil
08028-0D/H5250/94.08.12
97.07 - ES0S
Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 51210-01
L23/30H, L21/31,
L27/38, V28/32S
053
016 112 028 041 028 065 077
089 148
100
136
08028-0D/H5250/94.08.12
01.12 - ES0
Plate
51210-01 Blowgun for Dry Cleaning of Turbocharger Page 2 (2)
L23/30H, L21/31,
L27/38, V28/32S
Item Item
016 1/E Snap coupling Snapkobling
028 2/E Nipple Nippel
041 1/E Tee T-stykke
053 1/E Ball valve Kugleventil
100 1/E Container, complete beholder, komplet
112 1/E Socket Muffe
136 1/E Blowgun, complete Rensepistol, complete
148 /I Granulate Granulat
08028-0D/H5250/94.08.12
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
01.12 - ES0
Compressed air system
513/613
Your Notes :
Description
Compressed Air System 513.01
V28/32S
Fig. 1 Diagram for Turbocharger System
General Starting System
The compressed air system on the engine contains The engine is started by means of one built-on air
a starting system, starting control system and safety starter, which is of the turbine motor type, equipped
system. Further, the system supplies air to the jet with gear box, safety clutch and drive shaft with
system. pinion. In the inlet line to the starter there are placed
a main starting valve.
The compressed air is supplied from the starting
air receivers (30 bar) through a reduction station,
where from compressed air at 8.5-10 bar is supplied Control System
to the engine.
The air starter is activated electrically with a pneu-
To avoid dirt particles in the internal system, a dirt se- matic 3/2 way solenoid valve. The valve can be
parator is mounted in the inlet line to the engine. activated manually from the starting box on the
engine, and it can be arranged for remote control,
manual or automatic.
03.35 - ES2
513.01 Compressed Air System Description
Page 2 (2)
Edition 13H
V28/32S
For activation, the starting spool is connected so Pneumatic Start Sequence

that every starting signal to the starting spool goes
through the safe start function, which is connected When the starting valve is opened, air will be
to the converter for engine RPM. supplied to the drive shaft housing of the air
starter.
Safety System The air supply will bring the drive pinions into
engagement with the gear rim on the engine
As standard the engine is equipped with a pneu- fly wheel.
matical/electrical overspeed device, which starts
to operate if the maximum permissible RPM is When the pinion of the starter is fully engaged,
exceeded. the pilot air will flow to, and open the main starting
When the maximum permissible RPM is exceeded, valves, whereby air will be led to the air starter,
the overspeed device will activate a pneumatically which will start to turn the engine.
controlled stop cylinder, which will bring the fuel
index to zero and stop the engine. When the RPM exceeds approx. 140, at which
firing has taken place, the starting valve is closed
whereby the air starters is disengaged.
03.35 - ES2
Page 1 (2) Air Filter Edition 02
General

Shut-off fuel oil
Cleaning and/or maintenance of air filter.
Starting position
Related procedure
08028-0D/H5250/94.08.12
Working time : hours Plate no Item no Qty/

Capacity : man
Data

08.21 - ES0
Edition 02 Air Filter Page 2 (2)
General
Cleaning Air Filter To replace filter element
1) Depressurize unit. 7) Depressurize unit.
2) Remove bowl and bowl guard assembly by 8) Remove bowl and bowl assembly by turning
turning counter-clockwise. counter-clockwise.
3) Inspect bowl for damage seals and replace, if 9) Unscrew baffle by turning counter-clockwise.
nessesary.
10) Remove filter element and discard.
4) If bowl becomes dirty clean it by wiping the
bowl with a soft dry cloth or mild detergent. 11) Install new filter element and reassemble in
reverse order.
5) Before returning to service, insure that all seals
have been reinstalled or replaced. 12) Before returning to service, insure that all seals
have been reinstalled or replaced.
6) Reinstall bowl and bowl guard assembly and
rotate bowl guard clockwise to securely lock in 13) Reinstall bowl and bowl guard assembly and
place. Align arrow on bowl guard with arrow on filter rotate bowl guard clockwise to securely lock in
body. place. Align arrow on bowl guard with arrow on filter
body.
08028-0D/H5250/94.08.12
Fig 1 Air Filter
08.21 - ES0
Page 1 (10) Overhaul, Test and Inspection of Air Starter Edition 04H
L27/38
V28/32S

Shut-off fuel oil
Check of air starter

Disassembly, overhaul and assembly of the air
starter.
Starting position
All connections to the air starter have been remo-

ved, and air starter is removed.
Related procedure
Working time : hours Plate No Item No Qty/

Capacity : man
51309 161 1 (spare part kit)
Data

06.08 - ES0
Edition 04H Overhaul, Test and Inspection of Air Starter Page 2 (10)
L27/38
V28/32S
As with all TDI air starter products, there are no rub- It is important to properly install and operate the
bing parts so there is no lubrication required. This starters to receive the full benefits of the turbine
eliminates failures due to lubricator problems, the drive advantages.
expense of installing and maintaining the system, and
the messy and hazardous oil film around the starter General
exhaust. The starter is factory grease packed for the
life of the starter so it requires no maintenance. Turbine housing assembly
The Turbine housing assembly, please see Fig 1,

Operation consists of a stage one (13) and a stage two (5)
turbine wheel mounted on sungear shaft (30). The
The starters are powered by a pair of axial flow tur- front bearing (8) is secured by a retainer plate (29).
bines coupled to a simple planetary gear reduction The aft bearing (8) is preloaded by a wavy spring
set. The starters incorporate an inertia bendix drive (10). The ring gear (27) is installed between the
coupled to the starter gearbox drive train to provide turbine assembly (23) and the gearbox housing and
a means of disengaging the pinion from the engine’s secured by four screws (25).
ring gear.
Fig 1 Turbine housing assembly
06.08 - ES0
L27/38
V28/32S
Gearbox housing assembly The carrier shaft is mounted on two ball bearings
(38) in the gearbox housing (48). The aft bearing is
The gearbox housing assembly, please see Fig 2, preloaded by use of spring washers (39).The forward
consist of a planet gear carrier shaft (32), three planet bearing is installed into the bearing housing (43),
gears (34), needle bearings (35), spacers (33), and which is secured by four screws (44) to the gearbox
bearing pins (36). housing. The spur gear (45) is installed on the carrier
shaft and secured by the bearing locknut (47).
Fig 2 Gearbox housing assembly
Drive assembly The roller bearing (69) is installed into spur gear
(65) and secured by retaining ring (70). The forward
The drive assembly, please see Fig 3, consists of bearing (66) is pressed into the drive housing. The
a piston (53), helical shaft spline (56), dental clutch lip seal (75) is pressed into the forward side of drive
(58) and drive pinion shaft (61). The clutch assembly housing (72).
(56 thru 64) is installed into the spur gear (65). The The pinion collar (76) is installed on pinion shaft (61)
spur gear (65) is supported by the aft bearing (66), behind pinion (77), which is secured by washer (78)
which is secured by the retaining ring (67). and screw (79).
06.08 - ES0
L27/38
V28/32S
Fig 3 Drive assembly
General
Tool description No
Always mark adjacent parts on the starter hou- Spanner wrench 52-20134
sing; Spanner wrench 52-21345
Nozzle 2/ Containment Ring (11), Turbine Housing Shaft Removal Tool 2-26945
Stage 2 Rotor Puller Tool 52-20076
(23), Gearbox Housing (48), and Drive Housing (72) Carrier Shaft Holding Tool 52-20202
so these parts can be located in the same relative Tool, Bearing Pressing 52-20143
position when the starter is reassembled. Tool, Bearing/Seal 2-26943
Do not disassemble the starter any further than ne- Table 1 Service tools
cessary to replace a worn or damaged part.
Always have a complete set of seals and o-rings Drive housing

on hand before starting any overall of a the starter.
Never use old seals or o-rings. Removal of drive housing
The tools listed in Table 1 are suggested for use by Mark position of drive assembly (72) relative to gear-
technicians servicing the starters. box housing (48) for reference during reassembly.
The best results can be expected when these tools
are used, however the use of other tools are ac- Remove the eight screws (73), please see Fig 3, and
ceptable. pull drive assembly from gearbox housing. If drive
housing is too tight, tap it with a mallet to loosen.
06.08 - ES0
L27/38
V28/32S
Remove o-ring (71) from aft end of drive hou- Gearbox housing
sing(72).
Removal of gearbox housing
Note: Before removing the eight screws (73), install
a spacer between pinion (77) and drive housing (72) Remove the screws (25) securing the gearbox (48)
to allow for easy installation during reassembly. to the turbine assembly (23).
Pre-engaged Drive Disassembly Remove ring gear (27) from turbine (23) or gearbox as-
sembly (48). The ring gear could remain on either
Secure pinion (77) in a soft tooth vise while sup- assembly when separation occurs.
porting aft end of the air starter. Rotate pinion screw
(79) counterclockwise to remove using a 3/4" socket Gearbox disassembly
and wrench.
Place gearbox assembly (48), please see Fig 2 on
Note: Use only a soft tooth vise to secure the pinion flat surface with aft end facing up.
to avoid damaging pinion.
Remove four screws (44) and lift carrier shaft as-
This screw is torqued to 60 lb ft during assembly sembly (32) from gearbox housing.
therefore a large wrench may be required when
removing screw. Place carrier shaft assembly on carrier shaft holding
tool (52-20202) and use a screwdriver to remove tang
Remove washer (78), pinion (77) and spacer (76) of lock washer (46) from slot of retainer nut (47).
from pinion shaft (61). If pinion is too tight, place a Place tool No 52-20134 (Spanner Wrench) over shaft
screwdriver underneath pinion and lift up on pinion and into slots of retainer nut (47). Hold carrier shaft
to remove from shaft. assembly down and turn spanner wrench counter
clockwise to remove retainer nut, lock washer (46),
Remove helical spline shaft assembly (54-64) from spur gear (45), and woodruff key (37) from carrier
spur gear shaft (65). Remove spring (64) from shaft (32).
shaft.
Use an arbor press to remove carrier shaft (32) from
Use press tool and arbor press to remove spur gear bearing housing (43). The bearing housing must be
shaft (65) from drive housing (72). elevated and supported to remove carrier shaft.
Use a screwdriver to remove lip seal (75) from forward Note: Do not support the bearing housing on the
end of drive housing (72). four lips as they could break while pressing on car-
rier shaft.
Remove retainer ring (70) and bearing (69) from
forward end of spur gear shaft (65). Remove spring washer (39), spring retaining plates
(40), and bearing spacer (42) from carrier shaft.
Remove retainer ring (67) and press bearing (66) Remove aft bearing (38) from shaft by pressing shaft
from spur gear shaft (65). while supporting bearing.
Remove retainer ring (54) and bearing (55) from Planet gear disassembly
helical spline shaft (56).
Remove retainer ring (31) from planet shaft (36) and
push planet shaft through assembly.
Slide the planet gear (34) from carrier shaft and

remove two spacers (33).
Use press tool to remove needle bearing (35) from

planet gear (34).
06.08 - ES0
L27/38
V28/32S
Turbine Housing Remove stage 1 rotor (13) and o-ring (12) from
nozzle 2.
Stage 2 rotor removal
Remove the four screws (16) and nozzle 1 (17) from
Place the turbine assembly (23), please see Fig 1, the turbine assembly. It may be necessary to tap the
with ring gear (27) on a flat surface with (exhaust) screws with a hammer and chisel to loosen.
end up and remove the six screws (1), and the
screen (2). Remove o-ring (19) from aft end of turbine hou-
sing.
Secure the stage 2 rotor (5) and remove the turbine
screw (3) and washer (4). Remove the seal spacer (15) from the forward side
of nozzle 2 (11). Place the stage 2 nozzle on the
Install the rotor puller tool No 52-20076 and remove exhaust end. Press through the forward lip seal onto
the stage 2 rotor. the bearing until it, including the aft lip seal and seal
spacer disengages from the nozzle. Turn the nozzle
Remove the woodruff key (6) from the turbine shaft over and press on the forward lip seal to remove.
(30).
Turbine Shaft Removal Cleaning
Place the turbine housing on a flat surface with the Degrease all metal parts, except bearings, using a
sun gear end facing up. commercially approved solvent.
Remove four screws (16) and bearing retainer plate Clean aluminum parts. Remove parts, rinse in hot
(29) from turbine housing. water, and dry thoroughly.
Using the shaft removal tool No 2-26945, press on Clean corroded steel parts with a commercially ap-
the aft end of the turbine shaft (30) while supporting proved stripper.
the turbine housing (23).
Clean corroded aluminum parts and rinse in hot
Press the turbine shaft (30) through the aft bearing water and dry thoroughly.
(8) until the shaft is completely out of the housing
(23).
Inspection
Remove the woodruff key (14), seal spacer (7),
bearing spacer (28), and bearing (8) from turbine Use Table 2 as a guide to check for acceptable
shaft (30). condition of the parts listed.
The bearing can be removed from the shaft by pres-
sing the shaft through the bearing while supporting Check all threaded parts for galled, crossed stripped,
bearing. or broken threads.
Separate the stage 2 nozzle assembly (11) from the Check all parts for cracks, corrosion, distortion,
turbine assembly (23) by firmly holding the turbine scoring, or general damage.
assembly, while tapping nozzle 2 with a mallet. If
nozzle 2 is too tight, it can be removed by installing Check all bearing bores for wear and scoring. Bearing
two threaded screws into nozzle 2 and using them bores shall be free of scoring lines, not to exceed
as jacks to separate nozzle 2 from the turbine as- 0.005" width and 0.005" depth.
sembly.
Check gear teeth and turbine housing ring gear for
Note: Rotate the stage 1 rotor if necessary to allow wear. In general, visually check for spalling, fretting,
the jacks to travel through the large holes in the rotor. surface flaking, chipping, splitting, and corrosion.
The jacks will damage the stage 1 rotor if pressure
is applied to the rotor while removing nozzle 2.
06.08 - ES0
L27/38
V28/32S
If wear is apparent, check the gear teeth dimensions
in accordance with Table 3. Nicks and dents that
cannot be felt with a .020 inch radius scribe are
acceptable.
Part Description Check For Requirements
(Defective Parts Must Be Replaced)
Pinion Chipped Teeth, Cracks Defective unit to be replaced. Use Fig. 3 as a guideline for
acceptable pinion wear.
Drive Housing Cracks and breakage Cracks are not acceptable
Planet Gear Cracked, chipped, or galled teeth. Wear must not exceed limits per Table 3.
Wear must not exceed limits per
Table 4. There shall be no evidence of excessive wear.
Carrier Shaft Cracks, scoring or raised metal in Deformation or metal smearing in planet pin holes and
planet shaft holes and keyways. keyways are not acceptable. Scoring on bearing diameter not
Integrity of knurl connection. to exceed .005" depth.
Wear must not exceed limits per Table 3.
Planet Pins Wear grooves or flat spots Wear grooves in flat spots not permitted.
Wear must not exceed limits per Table 3.
Washers Wear created grooves Wear must not exceed limits per Table 3.
Gearbox Housing Cracks and Breakage Cracks and breakage not acceptable.
Sungear / Turbine Cracks, scoring, wear created Wear must not exceed limits per Table 3.
Shaft grooves, chipped or broken
gear- teeth, galling or scoring on
bearing surface of shaft.
Raised metal on the keyway.
Spacers Parallelism of end surfaces Ends must be parallel within 0.0005".
Turbine Housing Cracks and breakage Cracks and breakage are not acceptable.
Minor surface damage is permitted if function is not impaired.
Ring Gear Cracks, wear, chipped, or Wear must not exceed limits per Table 3.
broken gear teeth.
Seal Assembly Wear grooves or scratched Wear is not permitted.

surfaces on carbon ring.
Seal Spacer Wear Grooves No wear permitted.
Needle Bearings Freedom of needle rollers Replace bearings
Ball bearings Freedom of rotation without Replace bearings

excessive play between races
Containment Corrosion, erosion, cracks Cracks and breakage are not acceptable.
Ring/ Nozzle and broken nozzle edges. Minor surface damage is permitted if function is not impaired.
Turbine Rotors Corrosion, erosion, cracks Minor tip rub is permitted if function is not impaired.
and broken edges.
Tip wear; bore and key way wear Wear is not permitted.
Table 2. Parts Inspection Check Requirements
06.08 - ES0
L27/38
V28/32S
Part description Limit, Inches Turbine housing
Ring gear / Turbine Housing Turbine shaft installation
Internal measurement
between two .084" diameter pins. 5.0890 max.
Press the bearing (8), please see Fig 1, onto the
Sun Gear / Turbine Shaft shaft (30) until seated.
Bearing diameter 0.6690 min Support the shaft and press on the inner race only
External measurement over
two .096 diameter pins. with press tool No 2-26943 as shown in Table 1.
7.5:1 0.952 min
9:1 0.808 min Press the bearing/shaft assembly (8, 30), keyway
11.4:1 0.670 min end first, into bearing housing of the turbine housing
Planet Gear (23). Use press tool No 2-26943 if required. Do not
External measurement over press on the end of the shaft because the load could
two .0864" diameter pins. damage the balls of the bearing.
7.5:1 2.3067 min
9:1 2.3699 min
11.4:1 2.4359 min Install bearing retainer plate (29) and secure with
four screws (16). Torque screws to 40 in-lbs.
Carrier Shaft
Bearing Diameter 1.1800 min Place turbine housing with sun gear end down on a flat
Planet Pin Bore 0.8750 max
surface, while using ring gear to support turbine
Planet Pins housing. Install long bearing space (28) and seal
Bearing Diameter 0.873 min spacer (7) over shaft.
Thrust Washer
Thickness .055 min Install the O-ring (19) into the aft face of the turbine
housing (23).
Table 3. Parts Wear Limits
Nozzle 1 installation
General Press the aft seal (15) into nozzle 1 (19) using
press tool No 2-26943 per Table 1, with the lips
The tools listed in Table 1 are suggested for use by facing up.
technicians servicing the starters. The best results
can be expected when the proper tools are used, Install nozzle 1 onto the turbine housing (23). Orient
however, use of other tools is acceptable. the nozzles facing the air inlet (21) and install four
screws (16) to secure the nozzle. Do not tighten the
Caution: Replace all screws , O-rings, lip seals, and screws at this time.
bearings when the starter is reassembled.
Note: The rotation of the turbine assembly is opposite
Note: Always press the inner race of a ball bearing from the pinion rotation, therefore this nozzle must
when installing a bearing on a shaft. Always press be configured for LH (CCW) if the pinion rotation
the outer race of a ball bearing when installing into is RH (CCW), or configured for RH (CW) if pinion
a housing. rotation is LH (CCW).
The list of kits and components, which are available Rotor 1 installation
to aid in rebuilding the starters. Lubricate all O-rings
with petroleum jelly or Parker-O-Ring Lube before Install the large woodruff key (14) for stage 1 rotor
assembly. into the turbine shaft (30).
Caution: The screws that secure the Containment Install the stage 1 rotor (13), while supporting sun
Ring/ Stage 2. Nozzle must have a drop of Loctite gear end of shaft, onto the turbine shaft by aligning
RC290 applied to the threads before being used. the slot in the rotor with the woodruff key and hand
press the rotor until firmly seated. Use press tool No
2-26943 if required.
06.08 - ES0
L27/38
V28/32S
Visually inspect that the key was not pushed out Install the exhaust screen (2) and secure with six
during assembly. Note that the direction of rotation screws (1). Tighten the screws to 80 in-lb.
was oriented properly. This turbine rotor can be
installed backwards. Air inlet installation
Install spacer (7) onto sun gear (30). Place the O-ring (22) into the groove on the air inlet
(21).
To center nozzle 1, temporarily install Nozzle 2 (11)
on the turbine housing and tighten the four screws Install the 2" NPT air inlet flange (21) and secure with
that secure nozzle 1 (17) to 30 in-lb. The four screws six screws (20). Tighten the six screws to 170 in-lb.
can be accessed via the holes in nozzle 2 and the
first stage turbine rotor. Remove Nozzle 2 when the
four screws are tight. Gearbox Housing
Nozzle 2 installation Planetary gear carrier reassembly
Install the O-ring (9) into the bearing bore of nozzle Press needle bearing (35) into planet gears (34).
2 (11). Do not lubricate this O-ring. The planet gears are not identified by part number,
therefore, dimensionally check if correct gears are
Install O-ring (12) onto the outer diameter of nozzle being used. Use Table 3 for over the wire mea–su-
2 and install nozzle 2 (11) onto the turbine housing rements.
(23).
With a thrust washer (33), please see Fig 2, on each
Note: The rotation of the turbine assembly is opposite side of gear, slide gear into carrier shaft slots (32),
from the pinion rotation, therefore this nozzle must and align with pin holes.
be configured for LH (CCW) rotation if the pinion
rotation is RH (CW), or configured for RH (CW) if Lightly slide plant shafts into aligned holes, making
pinion rotation is LH (CCW). sure retainer ring groove on end of pins goes in
first.
Install the seal spacer (7) onto the shaft and the
wavy spring washer (10) into the bearing bore of Note: Make sure that anti-rotation pins on shafts
the stage 2 nozzle. are properly located in retaining slots of carrier
shaft (32).
While supporting the sun gear end of the shaft, press
the aft bearing (8) onto the shaft by pressing onto Install retainer ring (31) onto planet shaft (36) using
the inner and outer race simultaneously. Use press a retainer ring tool.
tool No 2-26943 per Table 1. Press until bearing is
seated. Gearbox reassembly
Install the stage 2 woodruff key (6) into the shaft
(30). Install bearing (38) into the bearing housing (43) and
secure with retaining ring (41).
Stage 2 rotor installation
Press aft bearing (38) onto carrier shaft (32) using Tool
Install the stage 2 rotor (5) onto the shaft. Use press No 52-20143 per Table 1. Pressing force should
tool No 2-26943 if required. Visually inspect that the be on the inner race of bearing.
key was not pushed out during assembly. Note that
the direction of rotation was oriented properly. This Install spring washer (39), spring retaining plate
turbine can be installed backwards. (40) and bearing spacer (42) onto shaft and locate
against bearing.
Install the rotor washer (4) and secure with screws
(3). Tighten screw to 100 in-lb. Position bearing housing assembly (38,41,43) over
carrier shaft (32) and press until firmly seated.
06.08 - ES0
L27/38
V28/32S
Install woodruff key (37) into slot on carrier shaft (32) Lubricate inner diameter of spur gear assembly (65)
and install spur gear (45) on carrier shaft aligning using grease No 9-94121-002.
slot on gear with woodruff key.
Install spacer (62), spring (64), and pinion spacer
Place bearing housing assembly on carrier shaft hol- (76) onto pinion drive shaft assembly (56-61) then
ding tool No 2-20202 per Table 1. Install lockwasher install into aft end of spur gear (65). The gears on
(46) and retainer nut (47). Torque to 90- helical shaft (56) must be aligned into the aft end of
100 ft.lb. After the slotted round nut (47) has been the spur gear shaft (65).
tightened, the tab of the washer (46) is driven into
one of the slots. Press the helical shaft assembly into the spur gear
shaft (65) until end of shaft protrudes from forward
Place O-ring (12) onto outer diameter of gearbox end of drive housing.
housing (48).
Maintain pressing force and install pinion onto drive
Install carrier shaft assembly into aft side of gearbox shaft (61). Secure with screw (79). Torque to 60 ft.
housing (48) and secure with four screws (44).Torque lb.
to 113 in-lbs.
Install spacer between pinion (79) and drive housing
(72) before releasing pressure from helical shaft.
Drive Housing
Final assembly
Drive reassembly
Place turbine assembly (23) with aft end on a flat sur-
Install bearing (69), please see Fig 3, into forward face and install ring gear. Ensure notches on ring
end of spur gear shaft (65) and secure with retaining gear are aligned with screw positions on turbine
ring (70). housing.
Press bearing (66) onto spur gear shaft (65) and Thoroughly grease planet gears (34), ring gear (27),
secure with retaining ring (67). sun gear (30), spur gears (45, 65) using grease No
9-94121-002.
Press bearing (68) into drive housing (72) until seated
firmly into housing. Rotate carrier shaft (35) slightly, and at the same time,
align gearbox into the front of turbine housing (26).
Press lip seal (75) into forward end of drive housing
(72) and install O-ring into O-ring groove on drive Install six gearbox to turbine assembly screws (25)
housing. and torque 113 in-lbs.
Install spur gear assembly (65-67) into gearbox drive Install drive assembly (72) onto gearbox assembly
housing (72) until firmly seated. (48) and secure with eight screws (73). Torque to
113 in.lbs.
Install bearing (55) onto aft end of drive shaft as-
sembly (56-61) and secure with retaining ring (54).
Lubricate drive shaft assembly using grease No
9-94121-002.
06.08 - ES0
Page 1 (2) Check of Compressed Air Piping System Edition 03
General

Shut-off fuel oil
Check of compressed air piping system. Screwdriver.
Starting position
Compressed air connected to the engine.
Related procedure

Manpower
08028-0D/H5250/94.08.12
Capacity : 1 man
Data

02.20 - ES0
Edition 03 Check of Compressed Air Piping System Page 2 (2)
General
With Air Connected With Air Disconnected and Stopped En-
gine
1) Examine the piping system for leaks.
6) Move all valves and cocks in the piping sys-
2) Retighten all bolts and nuts in the piping sy- tem. Lubricate valve spindles with graphite or
stem. similar.
3) Drain the system for condensed water. This 7) Connect the air supply and make a function
should be based on observations. test of the emergency valve. See Description
513.01.
4) Check flexible connections for leaks and da-
mages.
It is important that the flexible connections are free

from paint and grease and in healthy condition.
5) Check manometers.
08028-0D/H5250/94.08.12
02.20 - ES0
Page 1 (2) Electric Turning Gear Edition 01H
L2/31, L27/38
V28/32S

Shut-off cooling water Please see related electric diagram
Shut-off fuel oil
Press (Blocking - Reset)
Electric turning of engine.
Starting position
Indicator valve in cylinder head

are open 50501-05H
Related procedure
Working time : 1/4 hour Plate no Item no Qty. /

Capacity : 1 man

Data

10.47 - E0O
Edition 01H Electric Turning Gear Page 2 (2)
L21/31, L27/38
V28/32S
Warning: The diesel engine can be started locally Disengagement of turning gear
on the emergency start arrangement eventhough
the turning gear is engaged. Disconnect the turning gear.
Adjustment of position switch for the turn- Close the indicator valve in the cylinder head.
ing gear
Start and stop the engine in local before leaving the
1) Pull the gearwheel out of engagement with the engine in remote position.
gear rim until the secured position is reached.
2) Adjust the position switch in such a way that Maintenance

the signal from the switch changes as soon as
secured position is left. Lubrication of gear shaft to avoid rust on the shaft.
3) Tighten the position switch in this position and

check once more. Trouble tracing
Motor is not running:

Engagement of turning gear
- Check the electrical system.
Connect the remote push button panel to the turning
Turning gear shaft can not be moved easily:
gear motor starter panel.
- Dismantle the shaft and clean for rust.
Check the rotation of the gear before connection of
New lubrication to avoid rust.
the gear to the engine. Forward, clockwise rotation
- gear turning handle.
Turning gear in position, turning motor is running,
but flywheel is not moving:
Open the indicator valve in the cylinder head.
- Driving gear wheel is loose.
Pull out the lock pin and press the turning handle
towards the flywheel, so the lock pin can lock in
Engine is not starting:
turning position.
- Check the microswitch ZS 75 mounted
It can be necessary to turn the gear in steps for con-
on the turning gear.
nection to and from flywheel.
Note: During repair work, see note on plate 51325.
Note: Inform all staff working on the engine.
Press the warning push button before turning the

engine .
10.47 - E0O
Plate
Page 1 (2) Air Starter 51309-09H
V28/32S
L27/38
23
25
26
28
29
32
30
31
08028-0D/H5250/94.08.12
09.19 - ES0
Plate
51309-09H Air Starter Page 2 (2)
V28/32S
L27/38
Item Item
1* 6/S Screw Skrue 62b 1/S Shaft (RH) Aksel (RH)
3* 1/S Screw Skrue 63* 2/S Thrust washer Trykskive
7* 1/S Bearing spacer Lejering 64* 1/S Retaining ring Sikringsring
8* 2/S Bearing Leje 67* 1/S Ball bearing Kugleleje
9* 1/S O-ring O-ring 69* 1/S Ball bearing Kugleleje
10* 1/S Spring washer Fjederskive 70* 1/S Bearing, needle roller Leje
13* 2/S O-ring O-ring 72* 1/S O-ring O-ring
14* 2/S Seal spacer Pakningsdåse 74* 1/S Screw Skrue
15* 2/S Lip seal Tætningsring 76* 1/S Lip seal Tætningsring
18* 8/S Screw Skrue 78 1/S Pinion Tandhjul
21* 1/S O-ring O-ring 79* 1/S Washer, pinion Skive, tandhjul
22* 6/S Screw Skrue 80* 1/S Screw Skrue
23* 1/S Inlet flange Indgangsflange 160 1/E Air starter, complete Startemotor, komplet
Output gear ratio
24* 1/S O-ring O-ring 11.7:1
25* 1/S Turbine housing Turbinehus 161 1/S Spare parts kit, com- Reservedelssæt, be-
prising of item 1, 3, 7, stående af item 1, 3, 7,
26* 1/S Pipe plug Rørprop 8, 9, 10, 13, 14, 15, 18, 8, 9, 10, 13, 14, 15, 18,
21, 22, 24, 27, 36, 39, 21, 22, 24, 27, 36, 39,
27* 1/S O-ring O-ring 45, 50, 56, 61, 63, 64, 45, 50, 56, 61, 63, 64,
67, 69, 70, 72, 74, 76 67, 69, 70, 72, 74, 76
28* 1/S Ring gear Kronhjul
162 1/S Spare parts kit, com- Reservedelssæt be-
29* 1/S Bearing spacer Lejering prising of item 23, 24, stående af item 23, 24,
25, 26, 27, 28, 29, 30, 25, 26, 27, 28, 29, 30,
30* 1/S Clamping plate Spændplade 31 and 32 31 and 32
31* 1/S Turbine shaft Turbineaksel
32* 3/S Retainer ring Sikringsring
36* 3/S Needle bearing Leje
39* 2/S Bearing Leje
45* 4/S Screw Skrue
50* 6/S Screw Skrue

08028-0D/H5250/94.08.12
56* 1/S Bearing Leje
61* 1/S Bearing, needle roller Leje
62a 1/S Shaft (LH) Aksel (LH)
Qty/E = Qty./Engine Qty./E = Qty/Motor
Qty./S = Qty./Starter Qty./S = Qty./Starter
09.19 - ES0
Plate
Page 1 (2) Main Starting Valve 51310-04
L21/31, L27/38,
V28/32S
153
165
141
128 177
189
116
190*
200*
212
224*
236
319
320 307
332
248*
08028-0D/H5250/94.08.12
261*
273
285*
297
04.04 - ES0
Plate
51310-04 Main Starting Valve Page 2 (2)
L21/31, L27/38,
V28/32S
Item Item
116 1/V Housing Hus
128 1/V Delay timer Timer
141 Connectors Konnektor
153 1/V Screw Skrue
165 1/V Washer Skive
177 1/V Retainer Sikringsring
189 1/V Screen Skærm
190* 1/V O-ring O-ring
212 1/V Piston Stempel
224* 1/V Dampener, shock Dæmper
236 1/V O-ring, cap O-ring
248* 1/V Spring Fjeder
273 1/V End cap Endedæksel
297 1/V Retainer Sikringsring
307 1/V O-ring O-ring
319 1/V Part of item 320 Del af item 320
320 1/V Solenoid valve Magnetventil
332 2/V Screw Skrue
344 1/S Main starting valve, Hovedstartventil,

complete komplet
356 1/V Spare parts kit, com- Reserevedelssæt,

prising item bestående af item
190, 200, 224, 248, 190, 200, 224, 248,
261, 285 261, 285
08028-0D/H5250/94.08.12
Qty/E = Qty./Engine Qty./E = Qty/Motor
Qty./S = Qty./Starter Qty./S = Qty./Starter
Qty./V = Qty./Valve Qty./V = Qty./Ventil
04.04 - ES0
Plate
Page 1 (2) Main Stop Valve 51315-04H
V28/32S
005
017
029
030 042
10.01 - EO0
Plate
51315-04H Main Stop Valve Page 2 (2)
V28/32S

Item Item
005 1/V Gland flange Pakflange
017 1/V Spindel Spindel
029 1/V Gasket Pakning
030 1/E Stop valve, complete Stopventil, komplet

(straight way) (ligeløb)
042 1/E Stop valve, complete Stopventil, komplet

(angel way) (vinkelløb)
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./V = Qty./Valve. Antal/V = Antal/Ventil.
10.01 - EO0
Plate
Page 1 (2) Solenoid Valve, 3/2 51318-01H
Generel
08028-0D/H5250/94.08.12
05.33 - EO0
Plate
51318-01H Solenoid Valve, 3/2 Page 2 (2)
L27/38
Item Item
001 1/E Solenoid valve, Magnetventil,

complete komplet
08028-0D/H5250/94.08.12
05.33 - ES0
Plate
Page 1 (2) Safety Valve 51319-03H
V28/32S
007
019
032
020
10.01 - ES0
Plate
51319-03H Safety Valve Page 2 (2)
V28/32S

Item Item
007 1/E Safety valve, Sikkerhedsventil,

(10 bar) (10 bar)
019 1/E Safety valve, Sikkerhedsventil,

(16 bar) (16 bar)
020 1/E Protective device Beskyttelseshætte
032 3/E Screw Skrue
10.01 - ES0
Plate
Page 1 (2) ON-OFF Valve for Jet System 51320-03
V28/32S
014
038
051
063
075
087
08028-0D/H5250/94.08.12
06.37 - ES0
Plate
51320-03 ON-OFF Valve for Jet System Page 2 (2)
V28/32S
Item Item
014 1/V Coil Spole
038 1/E Valve, complete ¾" Ventil, komplet ¾"

connecting branch tilslutningsstuds
051 1/E Valve, complete 1" Ventil, komplet 1"

Connecting branch Tilslutningsstuds
063 1/E Valve, complete 1 ¼" Ventil, komplet 1 ¼"

075 1/E Valve, complete 1 ½" Ventil, komplet 1 ½"

087 1/E Valve, complete 2" Ventil, komplet 2"

08028-0D/H5250/94.08.12
Qty./V = Qty./Valve. Antal/V = Antal/Ventil.
06.37 - ES0
Plate
Page 1 (2) Air Filter 51321-03
General
190
08.21 - ES0
Plate
51321-03 Air Filter Page 2 (2)
General
Item Item
190 1/E Filter complete Filter komplet
200 1/F Repair kit Reparationssæt

(filter and O-ring) (filter og O-ring)
08.21 - ES0
Plate
Page 1 (2) Pressure Reduction Valve 51322-04H
General
08028-0D/H5250/94.08.12
03.22 - ES0
Plate
51322-04H Pressure Reduction Valve Page 2 (2)
General
Item Item
015 1/V Cover Dæksel
027 10/V Screw Skrue
039* 2/V Filter Filter
040 1/V Tube incl. o-ring Rør, inkl. o-ring
064* 1/V Diaphragh Membran
111 1/V Valve, complete Ventil, komplet
135* 1/V Valve spring Ventilfjeder
160 1/V Bottom plug, incl. Bundprop, inkl.

o-ring o-ring
172 2/V Pipe plug Rørprop
196 1/V Repair kit, incl. item Reparationssæt, inkl.

039, 052, 064, 076, 088, item 039, 052, 064, 076,
123, 135, 147, 159, 088, 123, 135, 147, 159,
and 184 and 184
206 1/E Reduction valve, Reduktionsventil,

complete komplet
218 1/E Pilot valve, complete Styreventil, komplet
231 1/V Repair kit for Reparationssæt for

item 218 item 218
243 2/V Screw Skrue
255 1/V Manometer Manometer

0-25 bar - PI 70 0-25 bar - PI 70
08028-0D/H5250/94.08.12
267 1/E Pressure reduction Trykreduktionsventil,

valve, complete as komplet som plate
plate 61322 61322
279 1/V Repair kit for Reparationssæt for

item 206 item 206
Qty/E = Qty/Engine Antal/E = Antal/Motor
Qty/V = Qty/Valve Antal/V = Antal/Ventil
03.22 - ES0
Plate
Page 1 (2) Pressure Reduction Valve 51322-07H
General
08028-0D/H5250/94.08.12
06.09 - ES0
Plate
51322-07H Pressure Reduction Valve Page 2 (2)
General
Item Item
280 1/V Filter Filter
292 1/V Pressure reduction Reduktionsventil

valve
302 1/V Pressure indicator Trykindikator
314 1/V Safety valve Sikkerhedsventil
326 2/V Bushing Bøsning
338 1/V Tee-piece T-stykke
351 1/V Thread adapter Gevindstykke
363 1/V Wall fittings Vægbeslag
375 1/E Pressure reduction Reduktionsventil,

valve, complete komplet
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine Antal/E = Antal/Motor
Qty/V = Qty/Valve Antal/V = Antal/Ventil
06.09 - ES0
Plate
Page 1 (2) Electric Turning Gear 51325-05H
V28/32S
L27/38
08028-0D/H5250/94.08.12
02.32 - EO0
Plate
51325-05H Electric Turning Gear Page 2 (2)
V28/32S
L27/38
Item Item
513 1/E El motor El-motor 800 1/E Plate Plade
537 1/E Counter nuts for Møtrik, sekskantet 812 1/E Hex. socket head cap Cylinderskrue
pull rods screw
562 1/E Shaft Aksel
586 4/E Hex. socket head Cylinderskrue

cap screw
598 1/E Retaining rings Seeger-sikring

for shaft
621 1/E Key Not
633 1/E Worm gear Snekkegear
645 4/E Hex. head screw Sætskrue

cap screw
670 1/E Shaft Aksel
682 1/E Lock pin Låsepind
694 1/E Pipe Rør
704 1/E Shaft Aksel
716 1/E Spring pin Fjederstift
728 1/E Turning handle Tørne håndtag
741 1/E Studs Studs
753 1/E Self-locking hex. nut Selvlåsende møtrik
765 1/E Position switch Position switch
777
08028-0D/H5250/94.08.12
2/E Hex. socket head Cylinderskrue

cap screw
789 1/E Plate Plade

cap screw
02.32 - ES0
Plate
Page 1 (2) Cover for Turning Gear 51325-12
L21/31, L27/38,
V28/32S
226
214
238
180
251
263
192
202
For turning gear, see plate 51325

08028-0D/H5250/94.08.12
08.17 - ES0
Plate
51325-12 Cover for Turning Gear Page 2 (2)
L21/31, L27/38,
V28/32S
Item Item
192 3/E Stud Tap
202 3/E Nut Møtrik
214 1/E Plate Plade
226 1/E Limit switch Afbryder
238 2/E Screw Skrue
251 2/E Screw Skrue
08028-0D/H5250/94.08.12
08.17 - ES0
Plate
Page 1 (2) Manual Turning Gear 51325-20
L21/31, L27/38,
V28/32S
645
789
981
777
765 885
777 574
873
550
728 669 633 657
944
956
968
586
549 S4
S5
537 716
562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12
S5-S5 S4-S4
897
694 621
682
09.34 - ES0
Plate
51325-20 Manual Turning Gear Page 2 (2)
L21/31, L27/38,
V28/32S
Item Item
537 1/E Counter nuts for Møtrik, sekskantet 907 /I Glue Lim
pull rods
944 1/E Shaft Aksel
956 1/E Spindle Spindel
968 1/E Key Not
562 1/E Shaft Aksel
981 1/E Turning gear, Tørnegear, komplet
574 1/E Flange Flange complete
586 4/E Cyl. screw Cylinderskrue
598 1/E Retaining ring Seeger-sikring

for shaft
621 1/E Key Not
670 1/E Shaft Aksel
682 1/E Handle knob with pin Håndtag med stift
694 1/E Pipe Rør
728 1/E Handle Håndtag
765 1/E Limit switch Limit switch
789 1/E Plate Plade
836 1/E Disc Skive
848 1/E Compression spring Trykfjeder
861 1/E Disc Skive

08028-0D/H5250/94.08.12
873 1/E Cover plate Dækplade
897 1/E Circlip Låsering
09.34 - ES0
Plate
Page 1 (2) Pneumatic Turning Gear 51325-21
L21/31, L27/38,
V28/32S
993
645
932
789
777
765 885
777 574
873 550
728 669 633 657
586
549 S4
S5
537 716
562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12
S5-S5 S4-S4
897
694 621
682
09.34 - EO0
Plate
51325-21 Pneumatic Turning Gear Page 2 (2)
L21/31, L27/38,
V28/32S
Item Item
pull rods
549 1/E Washer Skive complete
562 1/E Shaft Aksel

for shaft
621 1/E Key Not
670 1/E Shaft Aksel
694 1/E Pipe Rør
789 1/E Plate Plade
836 1/E Disc Skive
861 1/E Disc Skive

08028-0D/H5250/94.08.12
09.34 - EO0
Plate
Page 1 (2) Electric Turning Gear (3 x 400V) 51325-22
L21/31, L27/38,
V28/32S
970
645
513
789
777
765 885
777 574
873 550
728 669 633 657
586
549 S4
S5
537 716
562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12
S5-S5 S4-S4
897
694 621
682
09.34 - EO0
Plate
51325-22 Electric Turning Gear (3 x 400V) Page 2 (2)
L21/31, L27/38,
V28/32S
Item Item
513 1/E El motor El-motor 897 1/E Circlip Låsering
pull rods
549 1/E Washer Skive complete
562 1/E Shaft Aksel

for shaft
621 1/E Key Not
670 1/E Shaft Aksel
694 1/E Pipe Rør
789 1/E Plate Plade
836 1/E Disc Skive
848
08028-0D/H5250/94.08.12
1/E Compression spring Trykfjeder
861 1/E Disc Skive
09.34 - EO0
Plate
L21/31, L27/38,
V28/32S
275
645
287
789
777
765 885
777 574
873 550
728 669 633 657
586
549 S4
S5
537 716
562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12
S5-S5 S4-S4
897
694 621
682
09.34 - EO0
Plate
L21/31, L27/38,
V28/32S
Item Item

complete 885 2/E Washer Skive
287 1/E El motor El-motor 897 1/E Circlip Låsering
pull rods
562 1/E Shaft Aksel

for shaft
621 1/E Key Not
670 1/E Shaft Aksel
694 1/E Pipe Rør
789 1/E Plate Plade

08028-0D/H5250/94.08.12
836 1/E Disc Skive
861 1/E Disc Skive
09.34 - EO0
Plate
L21/31, L27/38,
V28/32S
299
645
309
789
777
765 885
777 574
873 550
728 669 633 657
586
549 S4
S5
537 716
562
753
598 907
670 836 848 861
608 S4
S5
08028-0D/H5250/94.08.12
S5-S5 S4-S4
897
694 621
682
09.34 - EO0
Plate
L21/31, L27/38,
V28/32S
Item Item
299 1/E Turning gear, Tørnegear, komplet 885 2/E Washer Skive
complete
309 1/E El motor El-motor
907 /I Glue Lim
537 1/E Counter nuts for Møtrik, sekskantet
pull rods
562 1/E Shaft Aksel

for shaft
621 1/E Key Not
670 1/E Shaft Aksel
694 1/E Pipe Rør
789 1/E Plate Plade

08028-0D/H5250/94.08.12
836 1/E Disc Skive
861 1/E Disc Skive
09.34 - EO0
Fuel oil system
514/614
Your Notes :
Description
Internal Fuel Oil System 514.01
V28/32S
TE
51
A8
El. driven nozz.
cool. oil pump
PT
A7 50
PT PI
40 40
Drain box incl. Leak from
fuel leakage alarm fuel valve
Cyl. 1A
Cyl. 1B
TE ZT
40 45 Drain from
TI cyl. head
40
Fuel oil return
High pressure Fuel oil pump
LAH pipe
a) 42 Fuel oil inlet
Leak from
fuel oil pump
Leak from
a) Running-in filter fuel oil pump
A1 A3 A2
Fig 1 Diagram for fuel oil system.
General Running-in Filter
The internal built-on fuel oil system as shown in fig The running-in filter has a fineness of 50 µ and is
1 consists of the following parts: placed in the fuel inlet pipe. Its function is to remove
impurities in the fuel pipe between safety filter and
– the running-in filter the engine in the running-in period.
– the high-pressure injection equipment
– a nozzle cooling system Note: The filter must be removed before ship delivery
– a waste oil system or before handling over to the customer.
It is adviced to install the filter every time the external

Fuel Oil System fuel pipe system has been dismantled, but it is impor-
tant to remove the filter again when the extern fuel oil
The fuel oil is delivered to the injection pumps by system is considered to be clean for any impurities.
means of an external feed pump through an external
safety filter.
Fuel Injection Equipment
The safety filter is a duplex filter of the split type with
a filter fineness of 25 my abs. The filter is equipped Each cylinder unit has its own set of injection equip-
with a common three-way cock for manual change ment, comprising injection pump, high-pressure pipe
of both the inlet and outlet side. and injection valve.
10.23 - ES0
514.01 Description
Edition 11 Internal Fuel Oil System Page 2 (2)
V28/32S
The injection equipment and the distribution supply A bore in the cylinder head vents the space below
pipes are housed in a fully enclosed compartment the bottom rubber sealing ring on the injection valve,
thus minimizing heat losses from the preheated fuel. thus preventing any pressure build-up due to gas
This arrangment reduces external surface tempe leakage, but also unveiling any malfunction of the
ratures and the risk of fire caused by fuel leakage. bottom rubber sealing ring for leak oil.
The injection pumps are installed on the roller guide

housings directly above the camshaft, and they are Internal Nozzle Cooling System
activated by the cams on the camshaft through roller
guides fitted in the roller guide housings. The nozzles of the injection valves on HFO-engines
are temperature controlled by means of a separate
The amount of fuel injected into each cylinder unit circuit containing diesel oil or thermal oil as media.
is adjusted by means of the governor, which main
tains the engine speed at the preset value by a The system maintains a nozzle surface temperature
continuous positioning of the fuel pump racks, via a low enough to prevent formation of carbon trumpets
common regulating shaft and spring-loaded linkages on the nozzle tips during high load operation and
for each pump. high enough to avoid cold corrosion during idling or
low-load operation.
The injection valve is for "deep" building-in to the
centre of the cylinder head.
Waste Oil System
The injection oil is supplied from the injection pump
to the injection valve via a double-walled pressure Waste and leak oil from the compartments and fuel
pipe installed in a bore, in the cylinder head. valves is led to one common fuel leakage alarm unit.
This bore has an external connection to conduct the The alarm unit consists of a box with a float switch
leak oil from the injection valve and high-pressure for level monitoring. In case of a leakage larger than
pipe to the waste oil system. normal, the float switch will initiate alarm. The fuel oil
outlet from the engine is lead through the unit in order
to keep it heated up, thereby ensuring free drainage
passage even for high-viscous waste/leak oil.
10.23 - ES0
Description 514.25
Page 1 (2) HFO/MDO Changing Valves (V1 and V2) Edition 02H
L21/31
L27/38
V28/32S
Description To maintain recirculation in the HFO flow line when
the GenSet is operated on MDO a by-pass valve
The fuel changing system consist for GenSet of two must be installed between the inlet changing valve
three-way valves (V1 and V2) with a electric/pneu- (V1) and the outlet valve (V2) at each GenSet as
matically operated actuator of the simplex type with shown in fig. 1.
spring return and a common valve control box for
the total GenSet plant.
Valve Control Box
The system facilitates a flexible selection of MDO and
HFO-operating at any load condition. This system Electrical power supply to the valve control box is
gives the advantage of individually choosing MDO 380 Volt - 50 Hz, or 440 Volt - 60 Hz, depending on
or HFO mode of operation of the GenSets. the plant specification, and is established in form of
a single cable connection from the switchboard.
Filter PI
Air pressure: 6 bar
Water trap Reduction Air consumption

valve per stroke : 1.1 litre
ø6 ø6
Valve con-
trol box
*
MDO MDO
* *
Valve V1 Valve V2
HFO HFO
A1 A2
08028-0D/H5250/94.08.12
Inlet engine Outlet engine
* MAN B&W Supply

Fig. 1 Pneumatic diagram for 3-way changing valves V1 & V2.
The three-way valves should be placed as near as Due to a built-in transformer, the power supply voltage
possible to the engines.The control box can be placed will be converted to a 24 Volt DC pilot voltage for ser-
in the engine room or in the engine control room. ving the relays, contactors, and indication lamps.
05.35 - EO0
514.25 Description
Edition 02H HFO/MDO Changing Valves (V1 and V2) Page 2 (2)
L21/31
L27/38
V28/32S
Furthermore the 24 V DC pilot voltage is used for In case of black-out and other situations resulting in
operating the fuel changing valves with a pneumati- dead voltage potential, the fuel changing valves will
cally and electrically operated actuator of the simplex be de-energized and automatically take MDO-posi-
type with return springs. tion due to the built-in return spring.
The mode of valve operation is:
HFO-position: Energized
MDO-position: De-energized
Fig 1 Ball valve with actuator.

08028-0D/H5250/94.08.12
05.35 - EO0
Description 514.25
Page 1 (1) Ball Valve with Actuator Edition 01
General
Installation description
The valve has to be open in MDO in/outlet to engine When solenoid valve is energized and with air supply
in/outlet position, when solenoid valve is de-energi- to actuator, the valve has to be open in HFO in/outlet
zed, and with no air supply to actuator. to engine in/outlet position.
Fig 1 Ball valve with actuator.

08028-0D/H5250/94.08.12
99.19 - EO0
Your Notes :
Page 1 (4) Fuel Injection Pump and Fuel Injection Pipe Edition 10H
V28/32S
Stopped engine Plate No. Item No. Note

Press Blocking - Reset 52006 26 20-120 Nm
52006 28 140-760 Nm
Dismounting, inspection/overhaul and mounting Ring and open end spanner 13 mm

of fuel injection pump. Inspection of fuel injection Ring and open end spanner 14 mm
pipe. Ring and open end spanner 17 mm
Allen key 8 mm, 10 mm
Plier for lock ring.
Tools for cleaning.
Starting position Clean kerosene or gas oil.
Clean lubricating oil.
Cover in front of fuel injection pump has been Anti seize product (Copaslip, Molykote GN Plus
removed. or similar).
Related procedure
Inspection of roller guide for fuel injection pump

508-01.05.
Man power Spare and wearing parts
Working time : 4 Hours Plate No. Item No. Qty./

Capacity : 1 Man
51401 189 1/pump
51401 190 1/pump
51401 266 1/pump
Data 51401 248 1/pump
51401 254 1/pump
Data for pressure and tolerance (Page 500.35) 51401 236 1/pump
02.47 - ES0
Edition 10H Fuel Injection Pump and Fuel Injection Pipe Page 2 (4)
V28/32S
Dismounting of fuel injection pump 7) Press the thrust cap (N) fig. 2 downwards and
remove the securing ring (P). Remove the thrust cap
1) Dismount the fuel injection pipe pos. 1 fig. 1 (N) with lower spring plate (O) and plunger (M). Be
and the fuel inlet pipe pos. 2. sure not to damage the plunger.
2) Separate the spring loaded lever from the

regulating rod on the fuel injection pump.
D
A
C
1 2
B
F
E
1
2
G
G
4
5
J 6
R
K
Fig. 1 View from Control Side I
3) Remove the pipe for lub.oil and drain. H

M
4) Remove the screws in the bottom flange (4
pieces) and take the fuel injection pump away. L
Separation of fuel injection pump O
5) If necessary, clean the exterior of the injection P

pump.
1. Back-up ring (spirally coiled)
6) Mount the injection pump in the clamping 2. O-ring inside dia. 45.7 mm x 2.6
bracket PYO-W020 (see plate 52014 item 03), on 3. O-ring inside dia. 51 mm x 3
the test pump. 4. Back-up ring
5. O-ring inside dia. 43 mm x 3.5
6. O-ring inside dia. 37 mm x 3
Fig. 2 Cross Section of Fuel Injection Pump
02.47 - ES0
Page 3 (4) Fuel Injection Pump and Fuel Injection Pipe Edition 10H
V28/32S
8) Take out the plunger spring (L), upper spring 14) The axial clearance between lower spring plate
plate (K) and pinion (J). If necessary remove the lock and plunger foot must not exceed 0.25 mm. The
ring (R) and guide pin (I) and dismount the regulating clearance between lower spring plate and plunger
rod (H) as well as the cap screw in the opposite end foot is 0.05 to 0.1 mm when new. See fig. 3.
of the regulating rod (H).
15) Check the cavitation plugs (G) for wear and
9) Unscrew the four screws (A) and remove the renew if necessary.
connecting piece (B). Take out the valve spring (D)
and the non-return valve (F). 16) Barrel (E), plunger (M) and non-return valve
(F) are manufactured to very close tolerances.
10) Loosen and remove the four screws (C) and Any attempt to refinish these parts causes altera-
take out the barrel (E). tions of the tolerances and must therefore NOT be
carried out.
11) Remove all the O-rings and back-up rings from If during the visual inspection of the parts, heavy
the injection pump. abrasion symptoms or damage can be observed,
the part in question must be replaced.
12) All parts must be cleaned, using kerosene or
gas oil and a hand brush (not a steel brush).
Blow through the holes for sealing oil in the pump Assembling of fuel injection pump
houses and the barrel (E).
17) When assembling the injection pump, proceed
in the reverse order to disassembling. Pay attention
Inspection of fuel injection pump to the following:
13) Insert plunger (M) and non-return valve (F)

into the barrel (E) after wetting with clean gas oil.
Plunger and non-return valve must slide into the
barrel by their own weight.
Plunger (M)
Marking on
regulating rod
Tooth with chamfer
Max. 0.25 mm
Marking on pinion
Spring (L)
Lower spring
Plate (O)
Fig. 4 Mounting of Regulating Rod Mechanism
Fig. 3 Clearance between Lower Spring Plate and Plunger

A. At initial tightening up of new parts the following
(C) for barrel (E).
Tighten screws to 90 Nm, loosen and tighten again
to 90 Nm and then tighten to 90 Nm + 10 Nm.
Employ the same procedure when tightening the
other pump components for the first time.
02.47 - ES0
Edition 10H Fuel Injection Pump and Fuel Injection Pipe Page 4 (4)
V28/32S
B. Renew all sealing and back-up rings. For placing Mounting of fuel injection pump
of the rings, see fig. 1.
19) Before mounting the fuel injection pump, clean
C. Coat all the threads with an anti seize pro- the roller guide spring and washer for spring in the
duct. roller guide housing.
D. Wipe dry with paper plane sealing surface on 20) Reconnect the regulating rod (H) to the spring
barrel (E) and connecting piece (B). loaded lever and all the pipes to the fuel pump.
E. Before inserting the pinion (J), the easy mo-

tion of the plunger (M) in the barrel (E) must be Fuel injection pipe
checked.
By normal working conditions the fuel injection pipe
F. When assembling the pinion (J), ascertain that require very little maintenance except replacement
the tooth (recognizable by the chamfer) will enter the of O-rings and gasket in connection with the normal
space of the regulating rod (H) marked by two sings, overhaul of fuel injection equipment. (See also de-
see fig. 4. scription of fuel injection pipe page 514.10).
G. The marking on the guide cam of the plunger

(M), must be in line with the marking in the slots of
the pinion (J). (Not shown on fig. 4).
18. After assembling, the easy motion of the re-

gulating rod (H), must be checked and the plunger
(M) must be moved from the no-load stop to full-load
stop.
02.47 - ES0
Page 1 (4) Fuel Injection Valve Edition 11H
V28/32S
Safety precautions: Special tools:

Shut-off cooling water 52006 26 20-120 Nm
Press Blocking - Reset 52014 30 Extra tools
52014 35
52014 40
Description:
Dismounting, overhaul, pressure testing and

mounting of fuel injection valve.
Starting position: Hand tools:
Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump have been dismounted. Ring and open end spanner 24 mm
For dismounting of fuel injection pipe, see working Socket spanner 24 mm
card 614-01.05. Socket spanner 30 mm
Tools for cleaning.
Clean kerosene or gas oil.
Antiseize product.
Related procedure: (Copaslip, Molykote GN Plus or similar).
Working time : 2 hours Plate no Item no Qty. /

Capacity : 1 man
51402 116 2/V
51402 332 1/V
51402 344 1/V
Data:

02.47 - ES3
Edition 11H Fuel Injection Valve Page 2 (4)
V28/32S
The fuel injection valve is the one component that 3. Clean the lower part of the nozzle (J) of car-
has the greatest influence on the diesel engine bonized oil deposits before dismantling the nozzle
condition. nut (H).
Various operation forms the fuel oil and quality af- Attention!
fect the overhaul intervals. In some cases it may Do not damage the lapped surfaces, when removing
be necessary to shorten the prescribed overhaul the nozzle nut (H) and the nozzle (J).
inter-vals.
Dismounting and cleaning:

D
1. Dismount the fuel injection valve from the cy-
linder head by means of the special tool as shown B
in fig 1.
B. Lock nut
C. Sealing ring
D. Adjusting screw F
E. Sealing ring
F. Nozzle spring
G. Spring spindle G
H. Nozzle nut
J. Nozzle H
J
Fig 2 Fuel injection valve.
4. The nozzle spring (F) and the spring spindle

(G) are to be taken out by unscrewing the adjusting
screw (D) completely.
Fig 1 Dismounting of fuel injection valve from cylinder head. 5. Clean all parts with kerosene or gas oil and
with a hard brush (not a steel brush).
2. Mount the fuel injection valve into the clamping 6. Clean the nozzle holes of charred coke by
bracket VTO-W022 (see plate 52014, item 117) on means of the supplied special drill with holder.
the pressure testing pump, and loosen the lock nut
(B) fig 2. 7. Clean the cooling chamber and the cooling
ducts in the nozzle guide and injector body.
Unstress the nozzle spring by turning the adjusting
screw (D). Place them in a cleaning liquid and then blow through
the parts with working air.
02.47 - ES3
Page 3 (4) Fuel Injection Valve Edition 11H
V28/32S
Inspection of the parts: 12. Lubricate the shoulder of the nozzle which
is in contact with the nozzle nut with an antiseize
The nozzle body and needle are matched by lapping product.
and are therefore only interchangeable as units.
13. Wipe the plane sealing surface of body and
8. Insert the nozzle needle with gas oil in the ne- nozzle dry with paper.
edle guide. It must be controlled whether the nozzle
needle slides down by its dead weight on its seat. 14. Renew the sealing rings (C) and (E).
9. Check if the holes in the nozzle are worn Tightening torque for nozzle nut, see page 500.40.
oval.
This is done by means of a magnifying glass. Pressure testing of fuel injection valve:
The most effective checking of the fuel valves is

WHEN the nozzle holes.. THEN obtained through pressure testing, preferably carried
out after each overhaul and also in case of irregu-
are worn oval Scrap the nozzles larities in operation.
are not worn oval Re-use the nozzles
The pressure testing is carried out in the following
way by means of the pressure testing apparatus
The best way, however, to check if the holes are worn supplied.
out is to control the flow rate of the nozzle which, in
general, only can be made by MAN B&W Holeby. 15. Mount the fuel injection valve in the bracket VTO-
W022. The bracket must be in such a position that
10. Replace parts with heavy abrasion symptoms, the nozzle of the injector is pointing downwards.
respectively damages, which were observed at the
visual inspection of the parts.
IF THEN
Every effort to refinish will result in alterations of
these values and malfunction of the nozzle. the engine is mount the test pipe
mounted with VWM-W007
If heavy abrasion symptoms, respectively damages cooling oil system (see plate 52014, item 332)
are observed at the visual inspection of the parts, on to the bracket for test
the parts in question must be replaced. of the cooling oil system.
Increase the pressure

Reassembling: by using the lever on
the test pump.
When all parts have been carefully cleaned, inspected
and overhauled and found in good order, then as- Apply pressure to the
semble the fuel injection valve. cooling oil system,
(see data page 500.35)
When assembling the injection valve, proceed in the after venting.
opposite order compared to the disassembly.
Check the sealing
Pay attention to the following: tightness of the O-rings.
11. Lubricate the threads on the adjusting screw

(D) with lub. oil, and the threads of the nozzle holder 16. Mount the test pipe VTO-W023 (see plate
for the nozzle nut. 52014, item 116) for test of the injection pressure
and atomizing.
02.47 - ES3
Edition 11H Fuel Injection Valve Page 4 (4)
V28/32S
17. Adjust the opening pressure to 320 bar by Mounting of the fuel injection valve in the
means of the adjusting screw (D), see fig 2, then cylinder head:
tighten the lock nut (B).
20. Clean and inspect the valve bore in the cylinder
18. Check opening pressure again. head before mounting the fuel valve.
Do not expect chattering, but make sure that the 21. Grind the seating face, if necessary, with the
nozzle spray from all holes is in the same angle. The grinding tool (see fig 3).
nozzle might chatter if the lever is worked very fast,
actually by hitting it. 22. Coat the O-rings and the lower part of the valve
with an anti seize product and place the valve in the
Do not expect a nozzle tip with more than 1000 cylinder head, and press it down to the seat.
running hours to perform like a new nozzle in the
test pump. 23. Mount the high pressure pipe before tightening
the nuts. Then it is easier to fit the threads.
19. Increase the pressure to 300 bar and keep the
pressure by working the lever slowly downwards. 24. Put on the distance pieces, fit the nuts and
tighten up with a torque spanner (for torque moment,
When the pressure is kept at 300 bar, there should see page 500.40).
be no more than one drip from the nozzle tip for
approx. 3-5 sec.
WARNING:
Keep out of the fuel jets as they will penetrate
the skin. Fuel which has penetrated the skin
can cause painful inflammations (blood poiso-
ning).
Fig 4 Grinding tools for fuel injection valve (extra tools).
Fig 3 Grinding tools for seat for fuel and liner i njection valve.
02.47 - ES3
Page 1 (2) Check of Fuel Oil Piping System Edition 01H
L23/30H
V28/32S

Shut-off fuel oil
Description
Check of fuel oil piping system.

Hand tools
Starting position
Engine is running.
Related procedure

08028-0D/H5250/94.08.12
Working time: ½ hour Plate no Item no Qty /

Capacity : 1 man
Data

92.04 - ES0S-G
Edition 01H Check of Fuel Oil Piping System Page 2 (2)
L23/30H
V28/32S
Fuel Oil System 4) Move all valves and cocks in the piping sy-
stem.
1) Dismount the covers to the injection pumps. Lubricate valve spindles with graphite or si-
Blow-through drain pipes. milar.
2) Examine the piping system for leaks. 5) Check flexible connections 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 injecting valves by means of the venting
pipe.
For fuel oil condition, see section 504.
Venting pipe
Fig 1. Cross section of cylinder head

08028-0D/H5250/94.08.12
92.04 - ES0S-G
Page 1 (3) Adjustment of The Maximum Combustion Pressure Edition 02H
V28/32S

Adjustment of the maximum combustion pressure Ring and open end spanner, 19 mm.
for the cylinders one by one and for all cylinders Socket spanner, 19 mm.
in total. Depth gauge.
Plastic hammer.
Starting position
Camshaft mounted and adjusted in

relation to the crankshaft (lead), 507-01.20
Intermediate wheel mounted.
Related procedure
08028-0D/H5250/94.08.12
Working time : 2-5 Hours Plate no. Item no. Qty. /

Capacity : 1 man
50801 124 1 set/cyl.
Data

02.47 - ES0
Edition 02H Adjustment of The Maximum Combustion Pressure Page 2 (3)
V28/32S
If fuel oil valve, piston, inlet and exhaust valves as well Thinner and/or fewer shims (increase of the distance
as turbocharger and charge air cooler are working “X”) results in a delayed injection timing and a lower
correct and the compression pressure Pcomp is normal Pmax.
the maximum combustion pressure will indicate the
injection timing for the fuel oil pump. Thicker and/or more shims (reduction of the distance
“X”) results in an advanced injection timing and a
If Pmax is too low it indicates that the injection timing higher Pmax.
is delayed.
If the distance “X” is to be changed the trigger (1) is
If Pmax is too high it indicates that the injection timing used for dismantling of the thrust piece (2), where-
is advanced. after the thickness and/or the number of shims (3)
can be changed.
The injection timing can be altered by inserting or
removing shims under the thrust piece on the roller By changing “X” with 0.10 mm the maximum combu-
guide, thus changing the measure “X”, see fig. 1. stion pressure is changed with - see page 500.35.
After replacement of shims the thrust piece is re-

mounted in the roller guide (4) with a soft hammer
(5).
Measure "x"
1 5
1
2 2
3 2
3 3
Total height 4
4 4
1 Extractor 2 Thrust piece

3 Shims 4 Roller guide
5 Soft hammer
Fig. 1.
Fig. 3.
08028-0D/H5250/94.08.12
Action Results
Total height Distance Injection Max. combustion

on roller guide "x" timing pressure
increased ↑ Reduced ↓ Advanced ↑ increased ↑

Reduced ↓ increased ↑ Delayed ↓ Reduced ↓
Fig. 2.
02.47 - ES0
Page 3 (3) Adjustment of The Maximum Combustion Pressure Edition 02H
V28/32S
When changing “X” it must be ensured that the di-
stance between the upper edge of the roller guide
housing and the thrust piece on the roller guide is not
exceeded, when the roller is resting on the circular
part of the fuel cam, see page 500.35.
In all cases “X” must be checked and adjusted, if

necessary, when fuel oil pump, roller guide, roller
guide housing and/or camshaft section have been
replaced/dismantled.
Note: If several fuel oil pumps, roller guides, rol-

ler guide housings and/or camshaft sections are
dismantled at the same time it is advisable to num-
ber the parts in order to facilitate remounting and
adjustment.
If the maximum combustion pressure differs from the

test bed records after adjustment of each individual
pump the camshafts placement can be changed,
as the camshafts gear wheels are provided with
oblonged holes so that they can be turned in relation
Fig. 4.
to the hub.
The gear wheel is provided with an engraved scale,

see fig. 4, and the hub of the cam shaft is provided If the crankshaft is turned in the engines normal
with a mark. direction of rotation the maximum combustion pres-
sure P-max. is reduced.
When the screws, which fasten the gear wheel, are
loosened the gear wheel is turned (by turning the If the crankshaft is turned against the engines normal
crankshaft) in relation to the camshaft. By reading direction of rotation the maximum combustion pres-
the angle in which the gear wheel is displaced in sure P-max. is increased.
relation to the camshaft the altered Pmax can be
calculated. A line on the scale corresponds to: see After the adjustment the screws are fastened with a
page 500.35. torque wrench, see page 500.40, and secured.
08028-0D/H5250/94.08.12
02.47 - ES0
Your Notes :
Plate
Page 1 (2) Fuel Injection Pump 51401-08H
V28/32S
285
224
319
307
141
094
153
069/
959/960
069/959/960
212 165
254*
248* 177
189*
200
266*
325
236*
313*
190* 301 337
021
033 864
045*
070*
278
116
291* 045*
08028-0D/H5250/94.08.12
033
082*
368
261 104*
128
273
344
972/984/996
356*
10.23 - ES0, L'Orange

51401-08H Fuel Injection Pump
Plate
Page 2 (2)
V28/32S

Item Item
021 1/P Pump housing Pumpehus

301 1/P Throttle screw Drosselskrue
033 2/P Shock screw Stødskrue
307 1/P Ring Ring
045* 2/P Joint washer Pakning
313* 1/P Gasket Pakning
069 1/P Plunger and barrel, Stempel og cylinder
incl. non-return valve inkl. kontraventil (HFO) 319 1/P Pinion Tanddrev
(HFO)
325 4/P Screw Skrue
337 1/P Flange Flange
082* 3/P Disc Skive
344 1/P Plug screw Propskrue
094 4/P Screw Skrue
349 1/P Kit comprising item Sæt bestående af item
104* 1/P Lock washer Låseskive 045, 070, 082, 104, 189, 045, 070, 082, 104, 189,
190, 236, 248, 254, 266, 190, 236, 248, 254, 266,
116 1/P Regulating rod Reguleringstandstang 291, 313, 356 291, 313, 356
128 1/P Locating bolt Styrebolt 356* 1/P Gasket Pakning
141 1/P Upper spring plate Øverste fjederplade 368 4/P Screw f. mounting Skrue f. montering
153 1/P Spring Fjeder 864 1/P Cap screw Hætteskrue
165 1/P Lower spring plate Nederste fjederplade 959 1/P Plunger and barrel, Stempel og cylinder
incl. non-return valve inkl. kontraventil (MDO)
177 1/P Thrust cap Trykhætte (MDO)
189* 1/P O-ring O-ring 960 1/P Plunger and barrel, Stempel og cylinder
incl. non-return valve inkl. kontraventil (Svovl-
190* 1/P O-ring O-ring (Low sulphur fuel, fattig brændstof, WC/C)
WC/C)
200 1/P Circlip Låsering
972 1/C Fuel injection pump, Fuel indsprøjtnings-
212 1/P Non-return valve Kontraventilfjeder complete (HFO) pumpe, komplet (HFO)
spring
984 1/C Fuel injection pump, Fuel indsprøjtnings-
224 1/P Connecting piece Forbindelsesstykke complete (MDO) pumpe, komplet (MDO)
236* 1/P O-ring O-ring 996 1/C Fuel injection pump, Fuel indsprøjtnings-
complete (Low sul- pumpe, komplet (Svovl-
248* 1/P O-ring O-ring phur fuel, WC/C) fattig brændstof, WC/C)
254* 1/P Back-up ring Støttering
261 1/P Pointer Viser
266* 1/P Back-up ring Støttering

08028-0D/H5250/94.08.12
273 1/P Nut Møtrik
278 1/P Screw Skrue
285 4/P Screw Skrue
Qty./P = Qty./Pump Qty./P = Qty./Pump
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
10.23 - ES0, L'Orange

Plate
Page 1 (2) Fuel Injection Valve 51402-09H
V28/32S
08028-0D/H5250/94.08.12
01.35 - ES0
Plate
51402-09H Fuel Injection Valve Page 2 (2)
V28/32S
Item Item
021 1/V Injector housing Ventilhus
033 1/V Nozzle, complete Forstøver, komplet
045 2/V Dowel pin Styrestift
057 1/V Screw cap Omløber
069 1/V Thrust spindle Trykspindel
082 1/V Spring Fjeder
094 1/V Adjusting screw Justeringsskrue
104 1/V Lock nut Låsemøtrik
177 1/C Fuel injection valve, Brændselsventii,

complete komplet
08028-0D/H5250/94.08.12
Qty./V = Qty./Valve Qty./V = Qty./Ventil
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
01.35 - ES0
Plate
Page 1 (2) Fuel Injection Pipe 51404-09H
V28/32S
08028-0D/H5250/94.08.12
02.43 - ES0
Plate
51404-09H Fuel Injection Pipe Page 2 (2)
V28/32S
Item Item
010 1/C Fuel injection pipe, Højtryksrør,

complete komplet
095 1/C Sleeve Styrebøsning
142 1/C Flange Flange
154 2/C Screw Skrue
201 2/C Sleeve in 2/2 Bøsning 2-delt
213 2/C Wire lock ring Wire låsering
237 1/C Screwed socket Gevindmuffe
08028-0D/H5250/94.08.12
Qty./C = Qty./Cylinder. Qty./C = Qty./Cylinder.
02.43 - ES0
Plate
Page 1 (2) Safety Filter 51415-05
L21/31
V28/32S
70
72
73
12 11 18 21
20
19
23 19
36
37
38
22
16
3
4
10
13
6
08028-0D/H5250/94.08.12
08.04 - EO0
Plate
51415-05 Safety Filter Page 2 (2)
L21/31
V28/32S
Item Item
1 1/E Fuel oil filter duplex, Brændselsoliespalte-

complete filter, komplet
2 2/F Screw plug Propskrue
3 2/F Gasket Pakning
10 6/F Bolt Bolt
11 2/F Cover Dæksel
12 2/F O-ring O-ring
13 8/F Nut Møtrik
16 1/F Ball valve Kugleventil
18 1/F Cock Hane
20 1/F Circlip ring Sikringsring
21 1/F Plug key Prop
22 2/F Filter element Filterelement
37 8/F Bolt Bolt
38 8/F Nut Møtrik
70 2/F Screw Skrue
72 2/F Nut Møtrik
73 2/F Spring washer Fjederskive

08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Qty./Engine
Qty./F = Qty./Filter Qty./F = Qty./Filter
08.04 - EO0
Plate
Page 1 (2) Fuel Oil Filter Duplex 51415-06
General
117 105
083
129
095
08028-0D/H5250/94.08.12
130
10.35 - EO0
Plate
51415-06 Fuel Oil Filter Duplex Page 2 (2)
General

Item Item
083 1/E Fuel oil filter duplex, Brændselsoliespalte-

complete, excl. clea- filter, komplet eksl. ren-
ning tool seværktøj
095 2/F Candle filter element Stav filterelement
105 1/F Locking ring Låsering
129 1/F Differential pressure Differential trykindikator

indicator
130 1/F Cleaning tool Renseværktøj
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Qty./Engine
Qty./F = Qty./Filter Qty./F = Qty./Filter
10.35 - EO0
Plate
Page 1 (2) Ball Valve with Actuator 51425-01
General
015
027 039
Seen from A
08028-0D/H5250/94.08.12
040
07.17 - ES0
Plate
51425-01 Ball Valve with Actuator Page 2 (2)
General
Item Item
015 1/Q Solenoid valve Magnetventil
027 1/Q Actuator Actuator
039 1/Q Limit switch Grænseafbryder
040 2/Q Ball valve Kugleventil
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
07.17 - ES0
Plate
Page 1 (2) Butterfly Valve with Actuator 51425-02H
General
08028-0D/H5250/94.08.12
00.34 - ES0
Plate
51425-02H Butterfly Valve with Actuator Page 2 (2)
General
Item Item
064 1/Q Butterfly valve Kugleventil
076 1/Q Spare parts kit Reservedelssæt
08028-0D/H5250/94.08.12
00.34 - ES0
Plate
General
088
052
064
08028-0D/H5250/94.08.12
07.17 - ES0
Plate
General
Item Item
088 1/Q Butterfly valve with Kugleventil med actua-

actuator complete tor komplet
08028-0D/H5250/94.08.12
07.17 - ES0
Plate
General
015
027 039
Seen from A
08028-0D/H5250/94.08.12
040
07.17 - ES0
Plate
General
Item Item
08028-0D/H5250/94.08.12
07.17 - ES0
Plate
General
015
027 039
Seen from A
08028-0D/H5250/94.08.12
040
07.17 - ES0
Plate
General
Item Item
08028-0D/H5250/94.08.12
07.17 - ES0
Plate
General
088
052
064
08028-0D/H5250/94.08.12
07.18
Plate
General
Item Item
088 1/Q Butterfly valve with Kugleventil med actua-

actuator complete tor komplet
08028-0D/H5250/94.08.12
07.18
Plate
Page 1 (3) Fuel Oil Arrangement 51430-11H
V28/32S
825 813
Fuel oil leakage alarm,

see plate 50925
372 837
384, 396 012

024
406
036
168, 193, 455 048
168, 193
061
264
431 107, 119
418 239 276 288

264 705 801 695
264
239 729 252 156 193

778 658 323 372
144 168
239 384, 396 599, 609
311 791 144, 156, 168,

193, 479, 480,
683 492
717 730
240 239 634, 646
239, 671 347, 766
203, 215, 227 144, 156, 467
335 742 Noozle cooling pump,

see plate 51440
443, 203
610 203
347, 359, 360 754 526 239
08028-0D/H5250/94.08.12
085
144, 156, 502
073 144
156
144, 156
622, 264
120
587 514 239 538 Filter, see
097 plate 51445
599, 609
132
551, 563, 575
168, 181
07.02 - ES0
Plate
51430-11H Fuel Oil Arrangement Page 2 (3)
V28/32S
Item Item
012 1/E Screw Skrue 323 1/E Pipe Rør
024 1/E Screw Skrue 335 1/E Pipe Rør
036 2/E Washer Skive 347 2/E Straight male stud Ligeforskruning
coupling
359 1/E Non-return valve Kontraventil
061 1/E Plate Plade
360 1/E Nipple Nippel
073 1/E Pipe, Rør,
fuel oil inlet tilgang brændolie 372 2/E Pipe Rør
085 1/E Pipe, Rør, 384 2/E Adjustable elbow Justerbar vinkel-
fuel oil outlet afgang brændolie coupling forskruning
097 1/E Pipe, drain Rør, dræn 396 2/E Adjustable Justerbar
L-coupling L-forskruning
406 1/E Pipe Rør
418 1/E Pipe Rør
431 1/E Pipe Rør
443 1/E Pipe Rør
144 13/E Pipe clamp Rørholder
455 1/E Flat steel bar Fladstål
467 1/E Flat steel bar Fladstål
492 4/E Self-locking nut Selvlåsende møtrik
203 3/E Adjustable elbow Justebar
coupling vinkelforskruning 502 2/E Bracket Konsol
215 1/E Packing ring Pakningsring 514 1/E Pipe, cooling oil Rør, køleolie
227 1/E Pipe Rør 526 1/E Pipe Rør
239 8/E Straight tee T-forskruning 538 1/E Pipe, cooling oil Rør, køleolie
coupling
551 8/E Screw Skrue
240 1/E Pipe Rør
563 8/E Nut Møtrik
252 1/E Pipe Rør
264 7/E Equal elbow coupling Vinkelforskruning
08028-0D/H5250/94.08.12
587 1/E Pipe, cooling oil inlet Rør, køleolie tilgang

276 1/E Pipe Rør engine motor
288 1/E Pipe Rør 599 2/E Bleeding screw Skrue
311 1/E Pipe Rør 609 2/E Packing ring Pakningsring
07.02 - ES0
Plate
V28/32S
Item Item
610 4/E Screw Skrue
622 1/E Pipe Rør
634 1/E Reducing fitting for Reduceringssvejse-

welding forskruning
646 1/E Pipe Rør
658 1/E Pipe Rør
671 2/E Reducing standpipe Reduceringsstandrør
683 1/E Pipe Rør
695 1/E Pipe Rør
705 1/E Pipe Rør
717 1/E Pipe Rør
729 1/E Pipe Rør
730 1/E Pipe Rør
742 1/E Holder for Termometerholder

termometer
754 1/E Pipe, cooling oil Rør, køleolie
766 1/E Pipe Rør
778 1/E Pipe Rør
791 1/E Pipe Rør
801 1/E Pipe Rør

08028-0D/H5250/94.08.12
07.02 - ES0
Your Notes :
Plate
V28/32S
825 813
Fuel oil leakage alarm,

see plate 50925
372 837
384, 396 012

024
406
036
168, 193, 455 048
193
061
264
849 107, 119
418 431
264 276 288 695
849
156 193
Lub. oil inlet 778 239 323 252
Fuel oil outlet 144 168
Fuel oil inlet 886 372
311 791 384, 396
144, 156, 168,

193, 479, 480,
492
240 239
874, 766
203, 215, 227
335
384, 396, 443, 862
347, 359, 360

08028-0D/H5250/94.08.12
085
073
144, 156
120
097
132
168, 181
07.09 - ES0
Plate
51430-12H Fuel Oil Arrangement Page 2 (3)
V28/32S
Item Item
012 1/E Screw Skrue 288 1/E Pipe, Rør,

fuel oil outlet afgang brændolie
024 1/E Screw Skrue
311 1/E Pipe, Rør,
036 2/E Washer Skive fuel oil outlet afgang brændolie
048 2/E Spring lock Fjederlås 323 1/E Pipe Rør
061 1/E Plate Plade 335 1/E Pipe, Rør,

fuel oil outlet afgang brændolie
073 1/E Pipe, Rør,
fuel oil inlet tilgang brændolie 347 1/E Straight male stud Ligeforskruning
coupling
085 1/E Pipe, Rør,
fuel oil outlet afgang brændolie 359 1/E Non-return valve Kontraventil
097 1/E Pipe, drain Rør, dræn 360 1/E Nipple Nippel
107 3/E Packing Pakning 372 2/E Pipe, drain Rør, dræn
119 12/E Screw Skrue 384 3/E Adjustable elbow Justerbar vinkel-
coupling forskruning
396 3/E Adjustable Justerbar
132 1/E Bracket Konsol L-coupling L-forskruning
144 7/E Pipe clamp Rørholder 406 1/E Pipe, drain Rør, dræn
156 14/E Screw Skrue 418 1/E Pipe, drain Rør, dræn
168 1/E Pipe clamp Rørholder 431 1/E Pipe, drain Rør, dræn
181 24/E Screw Skrue 443 1/E Pipe, drain Rør, dræn
193 8/E Pipe clamp Rørholder 455 1/E Flat steel bar Fladstål
203 1/E Adjustable elbow Justebar 479 1/E Bracket Konsol

coupling vinkelforskruning
492 4/E Self-locking nut Selvlåsende møtrik
227 1/E Pipe, Rør,
239 2/E Straight tee T-forskruning 766 1/E Pipe Rør

coupling
778 1/E Pipe Rør
240 1/E Pipe, Rør,
252 1/E Pipe Rør 813 1/E Bracket Konsol

08028-0D/H5250/94.08.12
264 1/E Equal elbow coupling Vinkelforskruning 825 1/E Bracket Konsol
276 1/E Pipe, Rør, 837 2/E Plug screw Propskrue

fuel oil inlet tilgang brændolie
849 3/E Equal elbow coupling Vinkelforskruning
07.09 - ES0
Plate
V28/32S
Item Item
850 1/E Straight coupling Ligeforskruning
862 1/E Adjustable elbow Justérbar

coupling vinkelforskruning
874 1/E Straight male stud Ligeforskruning

coupling
886 1/E Equal T-coupling T-forskruning

08028-0D/H5250/94.08.12
07.09 - ES0
Your Notes :
Plate
Page 1 (2) Main Pipes on Cylinder Section 51431-01H
12V28/32S
A-Bank
329 305 305 283 080 067 043 317 378
305 342 079 055 031 295
A
Lubricating oil
Cooling oil inlet
Cooling oil outlet
Drain and leakoil
Fuel oil outlet
Sealing oil
A
354 295 330
Seen from A-A Seen from B-B

151, 163 151, 163
199, 187 199, 187
175, 187 175, 187
092 092
102, 114 102, 114
138 126 126 138
B-Bank
283
271 295
B
Lubricating oil
Cooling oil inlet
08028-0D/H5250/94.08.12
Cooling oil outlet

Drain and leakoil
Fuel oil outlet
Sealing oil
295 354 080 246 222 305 342

317 330 258 234 210 329 305 305 283
07.04 - ES0
Plate
51431-01H Main Pipes on Cylinder Section Page 2 (2)
12V28/32S
Item Item
031 1/E Pipe (A-bank), Rør (A-side), 295 4/E Straight male stud Ligeforskruning
lubricating oil smøreolie coupling
cooling oil inlet køleolie tilgang coupling
055 1/E Pipe (A-bank), Rør (A-side) 317 2/E Equal elbow coupling Vinkelforskruning
cooling oil outlet køleolie afgang
067 1/E Pipe (A-bank), Rør (A-side), coupling
drain and leakoil dræn og lækageolie
330 2/E Adjustable elbow Justerbar vinkel-
079 1/E Pipe (A-bank), Rør (A-side), coupling forskruning
fuel oil outlet brændolie afgang
080 2/E Pipe, Rør, coupling
sealing oil spærreolie
092 10/E Support Støtte
210 1/E Pipe (B-bank), Rør (B-side),

lubricating oil smøreolie

cooling oil inlet køleolie tilgang

cooling oil outlet løkeolie afgang


08028-0D/H5250/94.08.12
271 1/E Equal T-coupling Lige T-forskruning

T-coupling T-forskruning
07.04 - ES0
Plate
16V28/32S
A-Bank
329 305 305 283 080 067 043 317 378
305 342 079 055 031 295
A
Lubricating oil
Cooling oil inlet
Cooling oil outlet
Drain and leakoil
Fuel oil outlet
Sealing oil
A
354 295 330

151, 163 151, 163
199, 187 199, 187
175, 187 175, 187
092 092
102, 114 102, 114
138 126 126 138
B-Bank
283
271 295
B
Lubricating oil
Cooling oil inlet
08028-0D/H5250/94.08.12
Cooling oil outlet

Drain and leakoil
Fuel oil outlet
Sealing oil
295 354 080 246 222 305 342

317 330 258 234 210 329 305 305 283
07.04 - ES0
Plate
16V28/32S
Item Item





08028-0D/H5250/94.08.12

07.04 - ES0
Plate
18V28/32S
A-Bank
329 305 305 283 080 067 043 317 378
305 342 079 055 031 295
A
Lubricating oil
Cooling oil inlet
Cooling oil outlet
Drain and leakoil
Fuel oil outlet
Sealing oil
A
354 295 330

151, 163 151, 163
199, 187 199, 187
175, 187 175, 187
092 092
102, 114 102, 114
138 126 126 138
B-Bank
283
271 295
B
Lubricating oil
Cooling oil inlet
08028-0D/H5250/94.08.12
Cooling oil outlet

Drain and leakoil
Fuel oil outlet
Sealing oil
295 354 080 246 222 305 342

317 330 258 234 210 329 305 305 283
07.04 - ES0
Plate
18V28/32S
Item Item





08028-0D/H5250/94.08.12

07.04 - ES0
Plate
16V28/32S
A-Bank
329 305 305 283 080 067 043 317 378
305 342 079 055 031 295
A
Lubricating oil
Cooling oil inlet
Cooling oil outlet
Drain and leakoil
Fuel oil outlet
Sealing oil
A
354 295 330

151, 163 151, 163
199, 187 199, 187
175, 187 175, 187
092 092
102, 114 102, 114
138 126 126 138
B-Bank
283
271 295
B
Lubricating oil
Cooling oil inlet
08028-0D/H5250/94.08.12
Cooling oil outlet

Drain and leakoil
Fuel oil outlet
Sealing oil
295 354 080 246 222 305 342

317 330 258 234 210 329 305 305 283
07.04 - ES0 - BioFuel

Plate
16V28/32S
Item Item





08028-0D/H5250/94.08.12


Plate
18V28/32S
A-Bank
329 305 305 283 080 067 043 317 378
305 342 079 055 031 295
A
Lubricating oil
Cooling oil inlet
Cooling oil outlet
Drain and leakoil
Fuel oil outlet
Sealing oil
A
354 295 330

151, 163 151, 163
199, 187 199, 187
175, 187 175, 187
092 092
102, 114 102, 114
138 126 126 138
B-Bank
283
271 295
B
Lubricating oil
Cooling oil inlet
08028-0D/H5250/94.08.12
Cooling oil outlet

Drain and leakoil
Fuel oil outlet
Sealing oil
295 354 080 246 222 305 342

317 330 258 234 210 329 305 305 283

Plate
18V28/32S
Item Item





08028-0D/H5250/94.08.12


Plate
Page 1 (2) Fuel Oil Inlet Cylinder Section 51432-01H
V28/32S
A-bank See plate 51404 074, 086, 098
025 013 049 145

037 169 050
170
Seen from A Seen from B
062
062
108, 121, 133

108, 121, 133
025, 037
025, 037
B-bank See plate 51404 074, 086, 098
B
08028-0D/H5250/94.08.12
145 025 157 049

037 182 050
194
07.04 - ES0
Plate
51432-01H Fuel Oil Inlet Cylinder Section Page 2 (2)
V28/32S
Item Item
013 1/E Distributor pipe Fordelingsrør 194 1/E Distributor pipe Fordelingsrør
(A-bank) (A-side) (B-bank) (B-side)
12 cyl. engine 12 cyl. motor 18 cyl. engine 18 cyl. motor
025 Support Støtte

037 Screw Skrue

049 Pipe clamp Rørholder

050 Screw Screw

062 1/C Pipe, Rør, tilgang

inlet fuel oil pump brændselspumpe
074 1/C Packing, sqare Pakning, firkantet
086 4/C Screw Skrue
098 4/C Spring lock Fjederlås
108 1/C Packing, oval Pakning, oval
121 2/C Screw Skrue

157 1/E Distributor pipe Fordelingsrør

(B-bank) (B-side)

(A-bank) (A-side)

08028-0D/H5250/94.08.12
(A-bank) (A-side)

(B-bank) (B-side)
07.04 - ES0
Plate
Page 1 (2) Fuel Oil Inlet Cylinder Section 51432-02H
16+18V28/32S
A-bank See plate 51404 074, 086, 098
025 169 049 145

037 170 050
062
062
108, 121, 133

108, 121, 133
025, 037
025, 037
B-bank See plate 51404 074, 086, 098
B
08028-0D/H5250/94.08.12
145 025 182 049

037 194 050

Plate
51432-02H Fuel Oil Inlet Cylinder Section Page 2 (2)
16+18V28/32S
Item Item
025 Support Støtte

037 Screw Skrue

049 Pipe clamp Rørholder

050 Screw Screw

062 1/C Pipe, Rør, tilgang

inlet fuel oil pump brændselspumpe
074 1/C Packing, sqare Pakning, firkantet
086 4/C Screw Skrue
108 1/C Packing, oval Pakning, oval
121 2/C Screw Skrue


(A-bank) (A-side)

(A-bank) (A-side)

(B-bank) (B-side)

(B-bank) (B-side)
08028-0D/H5250/94.08.12

Plate
Page 1 (2) Branch Pipe on Cylinder Section 51433-01H
V28/32S
A-bank The banjo couplings are
pre-installed in the cylinder head.
140 139 115 127 056 093 044 019 164
152 140 081 068 032 020 081 081
056
103
093
Flywheel end Front end
247 260 176 140

235 259 318

223 223
211 211
188 188
B-bank The banjo couplings are

pre-installed in the cylinder head.
296 140 139 081 068 032 020 081 081
306 152 140 115 127 056 093 044 019 164 272
093
08028-0D/H5250/94.08.12
282
093
Front end Flywheel end
176 140
07.04 - ES0
Plate
51433-01H Branch Pipe on Cylinder Section Page 2 (2)
V28/32S
Item Item
019 1/C Branch pipe, Stikrør, 223 1/C Nut Møtrik

fuel oil exh. Brændselsolie uds.
235 Straight male stud Ligeforskruning
020 1/C Banjo coupling Banjoforskruning coupling (A-bank) (A-side)
032 1/C Branch pipe, Stikrør, 16/E 16 cyl. engine 16 cyl. motor
lubricating oil smøreolie 18/E 18 cyl. engine 18 cyl. motor
044 1/C Banjo coupling Banjoforskruning 247 Pipe, lub. oil Rør, smøreolie
(A-bank) (A-side)
056 Branch pipe, Stikrør, smøreolie for 12/E 12 cyl. engine 12 cyl. motor
lub. oil for rocker arm vippearm 16/E 16 cyl. engine 16 cyl. motor
11/E 12 cyl. engine 12 cyl. motor 18/E 18 cyl. engine 18 cyl. motor
17/E 18 cyl. engine 18 cyl. motor 259 Pipe (A-bank) Rør (A-side)
068 Pipe, lub. oil Rør, smøreolie 32/E 16 cyl. engine 16 cyl. motor
16/E 18 cyl. engine 18 cyl. motor 260 Adjustable T-coupling Justerbar T-forskruning
(A-bank) (A-side)
081 2/C Straight male stud Ligeforskruning 24/E 12 cyl. engine 12 cyl. motor
coupling 32/E 16 cyl. engine 16 cyl. motor
coupling 272 1/E Pipe, lub. oil for Rør, smøreolie for
13/E 12 cyl. engine 12 cyl. motor rocker arm (B-bank) vippearm (B-side)
19/E 18 cyl. engine 18 cyl. motor 284 1/E Pipe, lub. oil Rør, smøreolie
(B-bank) (B-side)
103 1/E Pipe, lub. oil Rør, smøreolie
(A-bank) (A-side) 296 1/E Reducing stand pipe Reduceret standrør
(B-bank) (B-side)
115 1/C Branch pipe, Stikrør,
cooling oil køleolie 306 1/E Pipe, lub. oil Rør, smøreolie
(B-bank) (B-side)
cooling oil køleolie 318 Adjustable elbow Justerbar vinkel-
coupling (A-bank) forskruning (A-side)
139 1/C Branch pipe, Stikrør, 12/E 12 cyl. engine 12 cyl. motor
cylinder head cylinderdæksel 16/E 16 cyl. engine 16 cyl. motor
140 3/C Banjo coupling Banjoforskruning
152 1/C Pipe from fuel pump Drænrør for

drain brændselspumpe
164 1/C Drain pipe from Drænrør fra

cylinder head cylinderdæksel
176 1/C Pipe from fuel pump Drænrør fra

08028-0D/H5250/94.08.12
188 1/C Pipe clamp Rørholder
211 1/C Screw Skrue
07.04 - ES0
Plate
Page 1 (2) Branch Pipe on Cylinder Section 51433-02H
16+18V28/32S
A-bank
140 139 326 056 093 044 019 164
152 140 081 068 032 020 081 081
056
103
093
Flywheel end Front end
247 260 176 140

235 259 318

223 223
211 211
188 188
B-bank
296 140 139 326 081 068 032 020 081 081
306 152 140 056 093 044 019 164 272
093
08028-0D/H5250/94.08.12
282
093
Front end Flywheel end
176 140

Plate
51433-02H Branch Pipe on Cylinder Section Page 2 (2)
16+18V28/32S
Item Item
019 1/C Branch pipe, Stikrør, 247 Pipe, lub. oil Rør, smøreolie
fuel oil exh. Brændselsolie uds. (A-bank) (A-side)
020 1/C Banjo coupling Banjoforskruning 18/E 18 cyl. engine 18 cyl. motor
032 1/C Branch pipe, Stikrør, 259 Pipe (A-bank) Rør (A-side)
lubricating oil smøreolie 32/E 16 cyl. engine 16 cyl. motor
260 Adjustable T-coupling Justerbar T-forskruning
056 Branch pipe, Stikrør, smøreolie for (A-bank) (A-side)
lub. oil for rocker arm vippearm 32/E 16 cyl. engine 16 cyl. motor
272 1/E Pipe, lub. oil for Rør, smøreolie for
068 Pipe, lub. oil Rør, smøreolie rocker arm (B-bank) vippearm (B-side)
16/E 18 cyl. engine 18 cyl. motor 284 1/E Pipe, lub. oil Rør, smøreolie
(B-bank) (B-side)
081 2/C Straight male stud Ligeforskruning
coupling 296 1/E Reducing stand pipe Reduceret standrør
(B-bank) (B-side)
coupling 306 1/E Pipe, lub. oil Rør, smøreolie
17/E 16 cyl. engine 16 cyl. motor (B-bank) (B-side)
318 Adjustable elbow Justerbar vinkel-
103 1/E Pipe, lub. oil Rør, smøreolie coupling (A-bank) forskruning (A-side)
(A-bank) (A-side) 16/E 16 cyl. engine 16 cyl. motor
cylinder head cylinderdæksel 326 32/E Plug Prop
152 1/C Pipe from fuel pump Drænrør for

164 1/C Drain pipe from Drænrør fra

cylinder head cylinderdæksel
176 1/C Pipe from fuel pump Drænrør fra

188 1/C Pipe clamp Rørholder
211 1/C Screw Skrue
223 1/C Nut Møtrik

08028-0D/H5250/94.08.12
coupling (A-bank) (A-side)


Plate
Page 1 (2) Nozzle Cooling Pump 51440-04H
V28/32S
05.32 - ES0
Plate
51440-04H Nozzle Cooling Pump Page 2 (2)
V28/32S
Item Item
01 1/P Power rotor Driv rotor 28 1/P Rear cover Endedæksel
02 1/P Key Nøgle 29 1/P Gasket Pakning
03 1/P Ball bearing Kugleleje 30 1/P Plug Tap
04 1/P Secondary seal Sekondær tætning 31 1/P Washer Skive
05 2/P Idler rotor Drevet rotor 32 1/P O-ring O-ring
06 1/P Balancing bush Afbalancerings- 33 1/P Valve spindle Ventilspindel

bøsning
34 1/P Tension pin Trækstift
07 1/P Pump body Pumpehus
35 1/P Set screw Sætskrue
08 1/P Suction Flange Sugeflange
36 1/P Pin Stift
09 8/P Screw Skrue
37 1/P Valve piston Ventilstempel
10 1/P Gasket to suction Pakning for suge-
flange flange 38 1/P Valve spring Ventilfjeder
11 1/P Gasket to discharge Pakning for udløbs- 39 1/P Complete seal Komplet tætnings-
flange flange guard, only for unit, kun ved drift
operation on HFO med HFO
12 1/P Discharge flange Udløbsflange
40 1/E Nozzle cooling Dysekølepumpe.
13 1/P Return valve Sikkerhedsventil pump, compl. komplet
14 1/P Seal chamber plug Tætningshus prop
15 1/P Tension pin Trækstift
16 1/P O-ring O-ring
17 4/P Screw Skrue
18 4/P Screw Skrue
19 1/P Plug Tap
20 1/P Sealing washer Tætningsskive
21 1/P Plug Tap
22 1/P Sealing washer Tætningsskive
23 1/P Front cover Fordæksel
24 1/P Gasket Pakning
25 1/P Shaft seal Akseltætning
26 2/P Deaeration plug Afluftningsskrue
27 2/P Washer Skive
05.32 - ES0
Plate
Page 1 (2) Filter 51445-01H
V28/32S
014 026
07.10 - ES0
Plate
51445-01H Filter Page 2 (2)
V28/32S
Item Item
014 1/E Filter, complete Filter, komplet
026 1/E Filter cartridge Filter element
07.10 - ES0
Your Notes :
Lubricating oil system
515/615
Your Notes :
Description 515.01
Page 1 (3) Internal Lubricating Oil System Edition 08H
V28/32S
Fig 1 Diagram for internal lubricating oil system.
General Consumption at MCR

Engine type
kg/hours
As standard the lubricating oil system is based on
wet sump lubrication. 12 1.98
16 2.64
All moving parts of the engine are lubricated with
oil circulating under pressure in a closed built-on 18 2.97
system.
Table 2 Lubricating oil consumption for V28/32S, tolerance
The lubricating oil is furthermore used for the pur-
pose of cooling the pistons.
The standard engine is equipped with built-on: Quality of Oil
– Engine driven lubricating oil pump Only HD lubricating oil (Delegent Lubricating Oil)
08028-0D/H5250/94.08.12
– Duplex lubricating oil filter should be used, characteristic stated in "Lub. oil
– Prelubricating oil pump spec. 504.01".
Lubricating Oil Consumption System Flow
The lubricating oil consumption of MCR is: The lubricating oil pump draws oil from the oil sump
and presses the oil through the cooler and filter to
It should, however, be observed that during the run- the main lubricating oil pipe, from where the oil is
ning in period the lubricating oil consumption may distributed to the individual lubricating points. From
exceed the values stated. the lubricating points the oil returns by gravity to
the oil sump.
01.48 - ES0
515.01 Internal Lubricating Oil System Description
V28/32S
The main groups of components to be lubricated ad 6) Through a bore in the frame lub. oil is led
are: to the first camshaft bearing and through bores in
the camshaft from where it is distributed to the other
camshaft bearings.
1 – Turbochargers
2 – Main bearings, big-end bearings
Lubricating Oil Pump
etc.
3 – Camshaft drive The lubricating oil pump, which is of the gear wheel
type, is mounted on the front end of the engine and
4 – Governor drive
is driven by means of the crankshaft through a cou-
5 – Rocker arms pling. The oil pressure is controlled by an adjustable
spring- loaded relief valve.
6 – Camshafts
ad 1) For priming and during operation, the tur-

Lubricating Oil Cooler
bochargers is connected to the lub. oil circuit of the
engine, the oil serves for bearing lubrication.
As standard the lubricating oil cooler is of the plate
type. The cooler is delivered separately with the
The inlet line to each of the turbochargers is equipped
engine.
with a fixed throttle in order to adjust the oil flow.
ad 2) Lubricating oil for the main bearings is sup-

Thermostatic Valve
plied through holes drilled in the engine frame. From
the main bearings it passes through bores in the
The thermostatic valve is a fully automatic three-way
crankshaft to the connecting rod big-end bearings.
valve with thermostatic elements set of fixed tempe-
rature.The thermostatic valve is delivered separately
The connecting rods have bored channels for supply
with the engine.
of oil from the big-end bearings to the small-end bear-
ings, which has an inner circumferential groove, and
a pocket for distribution of oil in the bush itself and for
Lubricating Oil Filter
supply of oil to the pin bosses and the piston cooling
through holes and channels in the piston pin.
The lubricating oil filter is of the duplex paper cart-
ridge type, with a fineness of 10-15 microns, and a
From the front main bearings channels are bored in
safety filter, with a fineness of 60 microns.
the crankshaft for lubricating of the pump drive.
ad 3) The lubricating oil pipes, for the camshaft

Pre-lubricating
drive gear wheels, are equipped with nozzles which
are adjusted to apply the oil at the points where the
As standard the engine is equipped with an electric-
gear wheels are in mesh.
08028-0D/H5250/94.08.12
driven prelub. pump mounted parallel to the main

pump. The pump must be arranged for automatic
ad 4) The lubricating oil pipe, and the gear wheels
operation, ensuring stand-still of the prelubricating
for the governor drive are adjusted to apply the oil
pump when the engine is running, and running dur-
at the points where the gear wheels are in mesh.
ing engine stand-still in stand-by position.
ad 5) The lubricating oil to the rocker arms is led
Running period of the prelubricating pump is prefer-
through pipes to each cylinder head. It continues
ably to be continuous. If intermittent running is requi-
through bores in the cylinder head and rocker arm
red for energy saving purpose, the timing equipment
to the movable parts to be lubricated at rocker arms
and valve bridge. Further, lub. oil is led to the movable
parts in need of lubrication.
01.48 - ES0
Description 515.01
Page 3 (3) Internal Lubricating Oil System Edition 08H
V28/32S
should be set for shortest possible intervals, say 2 The ventilation pipe should be designed to eliminate
minutes of running, 10 minures of stand-still, etc. Fur- the risk of water condensation in the pipe flowing back
ther, it is recommended that the prelub. pump is led into the engine and should end in the open air:
from the emergency switch board thus securing that
the engine is not started without prelubrication. – The connection between engine (C13) and the
ventilation pipe must be flexible.
– The ventilation pipe should be continuously
Draining of the Oil Sump inclined (min. 5 degrees).
– A continuous drain has to be installed near the
It is recommended to use the separator suction pipe engine. The drain must not be lead back to the
for draining of the lubricating oil sump. engine.
– Dimension of the flexible connection DN100.
– Dimension of the ventilation pipe after the flex-
Crankcase Ventilation ible connection min. DN125.
The crankcase ventilation is not to be directly con-

nected with any other piping system. It is preferable Optionals
that the crankcase ventilation pipe from each engine
is led independently to the weather. The outlet is Besides the standard components, the following
to be fitted with corrosion resistant flame screen standard optionals can be built-on:
separately for each engine.
– Magnetic filter
However, if a manifold arrangements is used, its – Level switch for low level in oil sump
arrangements are to be as follows: (LAL 28)
– Centrifugal by-pass filter
1) The vent pipe from each engine is to run
indepently to the manifold, and be fitted with Branches for:
corrosion resistant flame screen within the
manifold. – External fine filter
– External full/flow filter
2) The manifold is to be located as high as practi- – Pressure lubricating to alternator bearings
cable so as to allow substantial length of piping
separating the crankcase. Branches for separator is standard.
3) The manifold is to be vented to the weather,

such that the vent outlet is fitted with corrosion
resistant flame screen, and the clear open area
of the vent outlet is not less than the aggregate
area of the individual crankcase vent pipes
entering the manifold.
08028-0D/H5250/94.08.12
4) The manifold is to be provided with drainage

arrangement.
01.48 - ES0
Your Notes :
Description
Lubricating Oil Thermostatic Valve - External 515.03
V28/32S
Thermostatic Valve
The thermostatic valve is designed as a T-piece with A

the inlet in the cover (A) under which the thermostatic
elements are located.
The outlet to the engine (by-passing cooler) is mar-

ked (B) and outlet to the cooler is marked (C). In the
warming up period, the oil is by-passing the cooler.
When the oil from the engine reaches the normal
temperature (see section 500) a controlled amount C B
af oil passes through the cooler.
The thermostatic elements must be replaced if the

temperature during normal operation deviates es-
sentially from the one stated in the test report.
Fig 1 Thermostatic Valve
The valve cannot be set or adjusted, and it requires
no maintenance.
08028-0D/H5250/94.08.12
02.36 - ES0
Your Notes :
Description
Lubricating Oil Cooler - External 515.06
Page 1 (1)
Edition 02H
V28/32S
Principle of the Plate Heat Exchanger Plates
The lubricating oil cooler is a plate heat exchan- After clamping of the plate pack, the plates - which
ger. are fitted gaskets - ensure an effective seal between
fluids and atmosphere. In addition, intermixing of the
The plate heat exchanger consist of a number of cold fluids is eliminated by a double gasket seal around
pressed plates which are compressed between a the inlet ports.
frame plate (head) and the pressure plate (follower)
by means of tie bolts. Every second plate is turned through 180°. This
means that the double gasket seal occurs around
The plates are made with special corrugations, every second inlet to the channels between the
which ensures turbolent flow and high heat transfer plates.
cofficients.
The plate pack now forms a series of parallel flow
channels in which the fluids flow in a counter cur-
rent regime.
08028-0E/H5250/94.08.12
02.36 - ES0
Your Notes :
Description
Centrifugal By-Pass Filter 515.15
Page 1 (1)
Edition 01H
L23/30H
V28/32S
Description
The centrifugal filter is a by-pass filter mounted directly For proper filtration, it is important that the rotor is
at the engine base frame. The centrifugal filter is a always correctly balanced.
supplement to the main filter.
An out-of-balance condition can occur as a result
During service, a part of the lubricating oil supplied of an uneven built-up of sludge or as a result of ex-
from the engine driven lubricating oil pump enters cessive bearing or spindle wear.
the centrifugal filter and returns to the oil sump in
the base frame.
The centrifugal filter relies on the centrifugal force

and can therefore remove high density, sub-micron
particles.
Principle of Operation
D
Oil enters the base of the filter and depresses the
B
cut-off valve (A) which has a pre-set pressure valve.
The cut-off valve is fitted to ensure that at low pres- E
sure and flow conditions the entire oil pump output
C
is supplied to the engine working parts. Having
depressed the cut-off valve the oil travels up the
centre of the spindle. Through holes at the top (B)
and enters the rotor (C) at the maximum height above
F
the stand tube. The oil completely fills the cleaning
chamber (D) and travels through the strainer (E)
into the drive chamber (F), leaving under pressure A
via diametrically opposed tangential nozzles in the
bottom of the rotor.
The reaction of the oil leaving the nozzles provides

A Cut-off valve D Cleaning chamber
the driving force causing the rotor to spin about the
B Top E Strainer
spindle at high speed. The oil leaving the nozzles is C Rotor F Drive chamber
then allowed to drain back to the sump, by gravity
at atmospheric pressure.
Fig 1. Diagram showing Principle of Operation.
The centrifugal force field within the spinning rotor
forces the contaminants to travel to the inner wall of
the rotor, where they form a dense rubber-like sludge
which is easily removed.
96.03 - ES0S-G
Your Notes :
Page 1 (3) Prelubricating Pump Edition 08
General
Stopped engine Plate No Item No Note.

Shut-off fuel oil
Hand tools
Description
Bench vice.
Dismounting, replacement of the rotary shaft seal Spanner.
and assembly of prelubricating pump. Torque spanner.
Plier for lock ring.
Soft hammer.
Starting position
Related procedure:
08028-0D/H5250/94.08.12
Working time : 2-3 Hours Plate No Item No Qty./

Capacity : 1 man
See plate 51504.
Data:

02.39 - ES0
Edition 08 Prelubricating Pump Page 2 (3)
General
Overhauls We advise not to change the bearing bushes. In
connectin with damages on the bearings it is normal
Overhauls for the purpose of avoiding functional that also the shafts and the parts in the gear box will
trouble are not normally necessary for the prelubri- be damaged.
cating pumps, when properly used, there is very little
wear on the pump gear shaft. When ordering spare parts, do not forget to state
the factory no. of the pump.
Spare Parts
Replacement of mechanical seal
Before any overhaul is done, please note the fol-
lowing: 1) Disconnect the cable and pipe connection to
the pump.
If a pump gets unusable by wear, it must be repla-
ced. Installation of spare parts cannot bring it back 2) Remove the pump from the engine base
to normal condition. frame.
It pays to keep extra pumps in stock or to have repairs 3) Separate the pump and the el-motor.
(overhauls) carried out at our repair shop.
4) Remove the coupling part and key (109), see
The shaft seal needs only to be replaced in case fig. 1, from the driving gear shaft (051).
of leakage or after dismounting of drive shaft. The
marks from the seal do not necessarily mean that 5) Tighten the pump to the flange. Pressure control
the sealing is defective, but there is a risk of leakage valve (038) upwards.
after replacement of sealing.
6) Loosen screws (075) and take off the pressure
control valve (038).
109 099 122 014 051 026 038 075

08028-0D/H5250/94.08.12
Fig 1. Prelubricating Pump
02.39 - ES0
Page 3 (3) Prelubricating Pump Edition 08
General
7) Take off the gear box (026), if necessary use Mounting
a soft hammer for separation.
13) The mounting process follows in 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 of screw pos. (075):
the rotary shaft seal (122).
R25 10 Nm
10) Press out the driving gear shaft bearing bush, R35 50 Nm
pull out the running bearing bush with the inner
wheel puller. In connection with the bearing bush, attention must
be paid to the placement of the 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 new shaft seal cannot be pressed into the pro-
tection cover before exact mounting of the pump.
12) Pressure control valve (038). The pressure
control valve can be dismounted also without O-ring must be changed.
dismounting the pump.
08028-0D/H5250/94.08.12
02.39 - ES0
Your Notes :
Page 1 (3) Lubricating Oil Filter Edition 05H
V28/32S

Shut-off fuel oil
Description
Replacement of paper filter element(s). Hand tools

Cleaning of safety filter and filter housing.
Adjustable spanner.
Starting position
Related procedure
08028-0D/H5250/94.08.12

Capacity : 1 man
51502 013 See plate 51502
Data 51502 194 See plate 51502

02.37 - ES0
Edition 05H Lubricating Oil Filter Page 2 (3)
V28/32S
The lubricating oil filter is dimensioned so that each of 4) Filter housing cap is dismantled.
the two filter parts has sufficent capacity to treat the
amount of lubricating oil delivered by the pump. 5) Remove the inner safety element. Clean the ele-
ment with detergent. Check that it is intact.
The three-way valve positioned is determining
whether the left hand or the right hand filter chamber 6) Remove the outer element(s). Filter element
is in operation, and also gives the possibility of having is of disposable type. It change always to new
both filter chambers in operation simultaneously. original filter.
The three-way valve is marked with flow directions 7) Clean the filter housing and the cap. Be careful
and the figure indicates the operation modes accor- of not to let the oil from the dirty side to go into
ding to valve positions. the clean oil channel in the middle of bottom.
Three-way valve positions 5 6 5
Left hand filter cam- Right hand filter

ber in operation. camber in operation.
8 1 2 8
7
4
3
Both filter camber in
operation.
1 Left hand filter camber 2 Right hand filter chamber

Fig 1. Three-way valve positions 3 Inlet 4 Outlet
5 Vent screw 6 Three-way valve/
switch valve
7 Fill-up valve 8 Drain plug
Service Procedure
08028-0D/H5250/94.08.12
1) Turn the three-way valve, see fig. 2, into the

position setting the stand-by filter chamber Fig 2 Lubricating oil filter
in operation and the filter chamber requiring
service out of operation.
2) Open the vent screw (5) on the top of the filter 8) Check the seal on the bottom of the filter hou-
to get the pressure out of the filter half. sing and in the cap. Change if needed.
9) Assemble the filter in opposite order.
3) Open the drain plug (8) under the filter housing
and drain off oil.
02.37 - ES0
Page 3 (3) Lubricating Oil Filter Edition 05H
V28/32S
10) Let the air valve be open and fill the filter housing
with oil by means of the slow fill-up valve (7)
Fill-up valve positions in position FILL, see fig. 3. This valve is inside
the three-way valve and by using it, the filling
Operation Changing over can be made so slowly that the pressure on
the other part of the filter does not drop too
much.
11) Close the vent screw (5) after the housing is

filled up with oil.
Switch in normal Switch in fill 12) Open the three-way valve (6) and close the fill-
operation position position up valve (7) by turning it to position CLOSED,
see fig. 3.
13) The filter just serviced is now ready to be set

Fig 3. Fill-up valve position in operation.
Inspect for oil leakages in order to ascertain all

sealings to be tight.
Check that pressure drop across filter is correct.
Clean the other side of the filter correspondingly.

08028-0D/H5250/94.08.12
02.37 - ES0
Your Notes :
Page 1 (2) Lubricating Oil, Thermostatic Valve - external Edition 06H
V28/32S
Stopped engine Plate No. Item No. Note.

Shut-off fuel oil
Description
Inspection of thermostatic valve and replacement Hand tools

of elements.
Copaslip
Tools and cleaning preparation for cleaning.
Starting position
Lubricating oil drained from engine (if neces-

sary).
Related procedure
08028-0D/H5250/94.08.12
Man power
Working time : 2 Hour Replacement and wearing parts

Capacity : 1 Man
Plate No. Item No. Qty./
Data
51503 020 4/engine
Data for pressure and tolerance (Page 500.35) 51503 044 4/engine
Data for torque moment (Page 500.40) 51503 093 3/engine
02.36 - ES0
Edition 06H Lubricating Oil, Thermostatic Valve - external Page 2 (2)
V28/32S
The thermostatic valve cannot be adjusted and un- Replacement of elements
der normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements in the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part of the hou-

sing.
1
2 3) Remove the assembled elements (3) and the
3 elements O-ring sealing.
5
4) Remove the gaskets between the upper and
lower part of the housing.
4
5) The upper and lower part of the housing are
thoroughly cleaned inside and on the gasket
surfaces.
6) The sealing rings (4) for the elements in the

housing are replaced and lubricated with a thin
layer of copaslip.
7) Remount the assembled elements in the hou-

sing by wriggling these somewhat over side.
8) Upper and lower part of the housing are as-

sembled with a new gasket (5), the nuts (1)
1. Nut
are mounted and tightened "cross-wise".
2. Washer
3. Element
Note:
4. O-rings sealing
5. Gasket
After inspection or replacement of the elements the
lub. oil temperature is checked to ensure that the
elements are working correctly.
Fig 1 Thermostatic valve
08028-0D/H5250/94.08.12
02.36 - ES0
Page 1 (2) Check of Lubricating Oil Piping System Edition 04H
V28/32S

Shut-off fuel oil
Description
Check and examination of the lubricating oil Hand tools

piping system.
Starting position
Engine running.
Related procedure
08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty. /

Capacity : 1 man
Data

02.37 - ES0
Edition 04H Check of Lubricating Oil Piping System Page 2 (2)
V28/32S
Checks to be carried out
1) Examine the piping system for leaks.
2) Retighten all bolts and nuts in the piping sy-

stem.
3) Move all valves and cocks in the piping sy-
stem. Lubricate valve spindles with graphite
or similar.
4) Blow-through drain pipes.
5) Check flexible connections for leaks and da-

mages.
Note: It is important that the flexible connections

are free from paint and grease and in healthy
condition.
For lubricating oil condition, see section 504.
08028-0D/H5250/94.08.12
02.37 - ES0
Page 1 (3) Centrifugal Bypass Filter Edition 05H
V28/32S
Stopped engine Plate No Item No Note.

Shut-off fuel oil
Description
Cleaning procedure, cleaning intervals. Mainte- Hand tools

nance intervals and procedures.
Big adjustable spanner.
Tools for cleaning.
Starting position
Isolate the filter for lub. oil inlet
Related procedure
Man power
Working time : 1 Hour Replacement and wearing parts

Capacity : 1 man
Plate No Item No Qty. /
Data
51515 39 1/Filter
Data for pressure and tolerance (Page 500.35) 51515 40 1/Filter
Data for torque moment (Page 500.40) 51515 41 1/Filter
Declaration of weight (Page 500.45) 51515 42 1/Filter
02.36 - ES0
Edition 05H Centrifugal Bypass Filter Page 2 (3 )
V28/32S
6) Reassemble rotor body on to rotor base. Ensure
Cleaning procedure that locating pins (8) and (9) in joint face of body
align with holes in cover and that standtube fits
1) Isolate the filter by closing the valve for lubri- correctly in the rotor base.
cating oil inlet to the filter.
7) Examine spindle in areas corresponding to
2) Slacken cover clamp ring (26), see fig. 1. Uns- top and bottom bushes. If damaged or worn
crew cover nut (27) and lift off cover (31). replace with body assembly complete (25).
8) Replace rotor on to spindle ensuring rotor re-

volves freely. Then replace body cover. Tighten
21 cover nut by hand only and refit safety cover
27
02 24 clamp ring. The clamp ring must be securely
31 01 fitted at all times when the filter is running. Do
not run filter with clamp ring loose.
08
04
9) Open for lubricating oil.
09
10) With filter running, check all joints for leakage.
10
Check for excessive vibration.
18
07
26 Cleaning intervals
25
It is recommended to clean the centrifugal filter

every 100 hours maximum or when the dirt deposit
is 25 mm thick, whichever comes first. For cleaning
intervals, see also page 500.25.
Fig 1 Centrifugal Bypass Filter Maintenance intervals and procedures
Recommended maintenance intervals for the filter

3) Lift off rotor assembly (01) having allowed the are as follows:
oil to drain from the nozzles. Ensure that the
rotor assembly is removed from and replaced At 3000 hours change O-rings (23, 06 and 29). Chan-
on to the spindle (24) with extreme care so as ge these sooner if damaged. See Plate 51515.
not to damage the bushes (18) and (21).
At 12000 hours change tube assembly (17). The pro-
4) Unscrew rotor cover jacking nut (2) and separate cedure for removing the tube assembly is to secure
rotor cover (4) from rotor body (10). the rotor base in a tool, loosen circlip (19) and with
pressure applied via a fly press or hide mallet extract
5) Remove sludge from inside the rotor by means tube assembly from rotor base. See Plate 51515.
of a spatula and wipe clean. Then remove
standtube (07). Ensure that all rotor compo- For inserting new tube assembly invert the rotor base
nents are thoroughly cleaned and free from and follow reverse of above procedure ensuring that
deposits of dirt before reassembling the rotor. pin (20) is correctly aligned with recess in rotor base.
Failure to do so could cause an out-of-balance See Plate 51515.
condition which will accelerate bearing and
spindle wear. At 24000 hours replace the filter complete.
02.36 - ES0
Page 3 (3 ) Centrifugal Bypass Filter Edition 05H
V28/32S
Important note The spindle/body assembly (25) and the rotor bearing tube
assembly (17) are factory assembled items and should only
The maximum bush clearances when new are 0.10 be replaced with complete assemblies.
mm in the top bush (21) and 0.13 mm in the bottom
bush (18). See fig. 1. All rotors are precision balanced before leaving the
Dependent on the conditions, wear will eventually factory.
take place both on the spindle and on the bushes
and if clearance is found to be in excess of 0.35 mm Trouble shooting guide for centrifugal bypass filter,
in top bush or 0.33 mm in bottom bush, then replace see page 503.05
with new bearing tube assembly.
02.36 - ES0
Your Notes :
Plate
Page 1 (2) Lubricating Oil Pump 51501-09H
V28/32S
043
175
114
092
163
138
126
031
080
067
102 079
018 055 151
08028-0D/H5250/94.08.12
02.39 - ES0
Plate
51501-09H Lubricating Oil Pump Page 2 (2)
V28/32S
Item Item
031 1/P End cover Endedæksel
043 1/P Gear wheel Tandhjul
079 5/P Bush Bøsning
080 1/P Self locking nut Selvlåsende møtrik
092 2/P Cylindrical pin Cylindrisk stift
102 1/P Key Feder
114 10/P Screw Skrue
138 2/P Packing ring Pakningsring
151 1/E Silicone paste Silicone
163 1/E Screw Skrue
175 1/E Lub. oil pump Smøreoliepumpe,

complete komplet
08028-0D/H5250/94.08.12
02.39 - ES0
Plate
Page 1 (2) Lubricating Oil Filter (Suppl. for Plate 51502-06H/07H) 51502-02H
L23/30H
V28/32S
08028-0D/H5250/94.08.12
02.16 - ES0-G
Plate
51502-02H Lubricating Oil Filter (Suppl. for Plate 51502-06H/07H) Page 2 (2)
L23/30H
V28/32S
Item Item
312 1/F Cap Dæksel
324 2/F By-pass valve seat By-passventilsæde
336 2/F By-pass valve spool By-passvnetilspindel
348 2/F Flange Flange
361 2/F Flange Flange
373 2/F Screw Skrue
385 2/F By-pass valve spring By-passventilfjeder
397 8/F Seal Tætningsring
407 2/F Spring Fjeder
419 2/F Spring Fjeder
420 6/F Pin Stift
08028-0D/H5250/94.08.12
Qty./F = Qty./Filter Antal/F = Antal/Filter
02.16 - ES0-G
Plate
Page 1 (2) Lubricating Oil Filter (Type B) 51502-06H
V28/32S
169
182
157
121
204
013 133 062 +
050+ 013 290 049 312
037 +
133 025
145 074 086 +

194 216 098
170 253
265
108
277
241
228
08028-0D/H5250/94.08.12
289
+ For detaljer se / for details see Plate 51502-02H
06.38 - ES0
Plate
51502-06H Lubricating Oil Filter (Type B) Page 2 (2)
V28/32S
Item Item
013 4/F Paper element Papirelement 277 2/F Opening guard, incl. Åbningsbeskyttelses-
vent screw skærm, inkl. luftskrue
025 2/F Safety element Sikkerhedselement
289 2/F Drain plug Drænskrue
037 + 1/F Valve housing, incl. Ventilhus, inkl.
item 074, 216 and item 074, 216 og 300 290 2/F Spacer ring, Afstandsring, komplet
300 complete incl. seal inkl. tætning
049 2/F Housing, incl. O-ring Hus, inkl. O-ring 300 1/F Seal kit, not shown Pakningssæt, ikke vist
on the front side of på forsiden af platen
050 + 2/F Cap, complete, incl. Dæksel , komplet, inkl. the plate
item 348, 361, 373, 397 item 348, 361, 373, 397
and 407 og 407 312 1/E Lub. oil filter, Smøreoliefilter,
complete komplet
062 + 1/F Spindle, incl. item Spindel, inkl. item 312,
312, 121 and 444 from 121 og 444 fra
suppl. Plate suppl. Plate
074 2/F Thrust ring Trykring
086 + 2/F By-pass code, incl. By-passventil, inkl. item

item 324, 336, 385, 432 324, 336, 385, 432
and 493 og 493
098 2/F Plug to indicator hole, Propskrue til indikator

incl. O-rings hul, inkl. O-ringe
108 2/F Vent screw, incl. item Luftskrue, inkl. item 228
228 and 241 og 241
121 1/F Fill-up valve Opfyldningsventil
133 8/F Sealing ring Tætningsring
145 12/F Stud Støttetap
157 12/F Screw Skrue
169 4/F Screw Skrue
170 12/F Nut Møtrik
182 4/F Washer Skive
216 5/F Pin Tap
228 6/F Pin Tap

08028-0D/H5250/94.08.12
06.38 - ES0
Plate
Page 1 (2) Lubricating Oil Thermostatic Valve 51503-02H
V28/32S
08028-0D/H5250/94.08.12
02.35 - ES0
Plate
51503-02H Lubricating Oil Thermostatic Valve Page 2 (2)
V28/32S
Item Item
019 4/T Screw Skrue
020 4/T O-ring O-ring
032 4/T Thermostatic Følerelement

element
056 4/T Sleeve Bøsning
068 4/T Washer Skive
081 28/T Nut Møtrik
093 3/T Gasket Pakning
103 24/T Screw Skrue
115 1/E Thermostatic Termostatventil,

08028-0D/H5250/94.08.12
Qty./T = Qty./Thermostatic valve Antal/T = Antal/Termostatsventil
02.35 - ES0
Plate
Page 1 (2) Prelubricating Pump with El-Motor 51504-05
General
349 337 362 254 325 301 291 266 374 350 278 313
421
470
445
470
408
494, 541 482
553, 565 433
386
504
398
08028-0D/H5250/94.08.12
457
469
528
516
09.37 - ES0
Plate
51504-05 Prelubricating Pump with El-Motor Page 2 (2)
General

Item Item
254 1/P Driving cover Medbringerdæksel 516 1/E Ball bearing, rear Kugleleje, bagside
266 1/P Gear casing Gearhus 528 1/E Ball bearing, front Kugleleje, forside
278 1/P End cover, complete, Endedæksel, komplet 541 1/E El-motor, 3x480 volt, El-motor, 3x480 volt, komplet
incl. item 386, 398, 408, inkl. item 386, 398, 408, complete
421, 433, 445, 457, 469 421, 433, 445, 457, 469
and 470 og 470 553 1/E El-motor, 220-240/380- El-motor, 220-240/380-420 volt,
420 volt, complete komplet
291 1/P Driving gear shaft Drivende gearaksel
565 1/E El-motor, 400/690 volt, El-motor, 400/690 volt, komplet
301 1/P Gear shaft Gearaksel complete
313 4/P Screw Skrue
325 2/P Parallel pin Styrestift
337 1/P Retaining ring Sikringsring
349 1/P Parallel key Not
362 1/P Rotary shaft seal Roterende akseltæt

ning
374 1/E Pump, complete Pumpe, komplet uden

without el-motor el-motor
386 1/P End cover Endedæksel
398 1/P Piston Stempel
408 1/P Spindle Spindel
421 1/P Dome nut Lukkemøtrik
433 1/P Spring Fjeder
445 1/P Pipe nut Rørmøtrik
457 2/P Screwed plug Propskrue
469 2/P Sealing ring Tætningsring
470 2/P Sealing ring Tætningsring
482 1/P Coupling, complete Kobling, komplet
494 1/E El-motor, 3x400/3x440 El-motor, 3x400/3x440

volt, complete volt, komplet
504 1/E Pre.lub oil pump, Forsmørepumpe,

08028-0D/H5250/94.08.12
complete with el- komplet med el-motor

motor
09.37 - ES0
Plate
Page 1 (2) Prelubricating Pump with El-Motor 51504-08H
General
109 099 122 014 087 063 051 026 134 110 038 075
266
183
230
205
230
171
242
195
146
254 158
08028-0D/H5250/94.08.12
217
229
02.39 - ES0
Plate
51504-08H Prelubricating Pump with El-Motor Page 2 (2)
General
Item Item
014 1/P Driving cover Medbringerdæksel
026 1/P Gear casing Gearhus
038 1/P End cover, complete, Endedæksel, komplet

incl. item 21 to 29 inkl. item 21 til 29
051 1/P Driving gear shaft Drivende gearaksel
063 1/P Gear shaft Gearaksel
075 4/P Screw Skrue
087 2/P Parallel pin Styrestift
099 1/P Retaining ring Sikringsring
109 1/P Parallel key Not
122 1/P Rotary shaft seal Roterende akseltæt-

ning
134 1/E Pump, complete
without El-motor Pumpe, komplet uden
el-motor
146 1/P End cover
Endedæksel
158 1/P Piston
Stempel
171 1/P Spindle
Spindel
183 1/P Dome nut
Lukkemøtrik
195 1/P Spring
Fjeder
205 1/P Pipe nut
Rørmøtrik
217 2/P Screwed plug
Propskrue
229 2/P Sealing ring
Tætningsring
230 2/P Sealing ring
Tætningsring
242 1/P Coupling, complete
Kobling, komplet
254 1/E El-motor, complete
El-motor, komplet
266 1/E Pre.lub. oil pump,
complete with el- Forsmørepumpe,
motor komplet med el-motor
08028-0D/H5250/94.08.12
02.39 - ES0
Plate
Page 1 (2) Pressure Regulating Valve 51507-01H
V28/32S
03.51 - ES0
Plate
51507-01H Pressure Regulating Valve Page 2 (2)
V28/32S
Item Item
010 Pressure regulating Trykreguleringsventel,

022 1/V Spare parts kit Reservedelssæt

consisting of: bestående af:
6 O-rings 6 O-ringe
1 pressure spring 1 trykfjeder
1 pilot valve 1 pilotventil
Qty./V = Qty./Valve Antal/V = Antal/Ventil
03.51 - ES0
Plate
Page 1 (2) Centrifugal By-Pass Filter 51515-05H
V28/32S
349* 361 134*
110 443*
171
301
455*
158*
242* 337
146*
409
195 122
373
183
385
242*
109*
230
397
08028-0E/H5250/94.08.12
205
217
014
026*
431* 099*
087* 313
063*
07.37 - ES0
Plate
51515-05H Centrifugal By-Pass Filter Page 2 (2)
V28/32S
Item Item
014 1/F Body, assembly Sokkel, komplet 397 1/F Rotor base Rotor bund
026* 1/F Valve body Ventilsokkel 409 1/F Rotor tube Rotor rør
063* 1/F Valve adaptor Ventiladapter 431* 1/F Spring Fjeder
087* 1/F Valve seal Ventiltætning 443* 1/F Circlip Låsering
099* 1/F Flange gasket Flangepakning 455* 1/F Circlip Låsering
109* 1/F Filter body O-ring Filtersokkel O-ring
110 1/F Cover, complete Dæksel, komplet
122 1/F Cover Dæksel
134* 1/F Cover nut pin Stift for dækselmøtrik
146* 1/F Cover fixing nut Dækselmøtrik
158* 1/F Cover nut O-ring Dækselmøtrik O-ring
171 1/F Jacking nut kit, incl Møtrik kit, inkl 349 og
item 349 and 455 455
183 1/F Band clamp Spændering
195 1/F Rotor, complete Rotor, komplet inkl
205 1/F Nozzle Dyse
217 1/F Bearing tube Lejerør
230 1/F Circlip Låsering
242* 2/F Rotor O-ring Rotor O-ring
301 1/F Cover nut fixing kit, Dækselmøtrikskit, inkl

incl item 146, 158, 443 item 146, 158, 443
and 134 og 134
313 1/F Valve kit, incl item 026, Ventilkit, inkl item 026,
063, 087, 431 063, 087, 431
325 1/F Seals kit, incl item 099, Tætningskit, 099, 109,
109, 242 242
337 1/E Centrifugal by-pass Centrifugal by-pass fil-

filter, complete ter, komplet
349* 1/F Nut Møtrik

08028-0E/H5250/94.08.12
361 1/F Rotor top Rotortop
373 1/F Paper insert Papir indsats
385 1/F Separation cone Afstandsbøsning
07.37 - ES0
Plate
Page 1 (2) Hand Wing Pump 51525-02H
V28/32S
01
08028-0E/H5250/94.08.12
02.37 - ES0
Plate
51525-02H Hand Wing Pump Page 2 (2)
V28/32S
Item Item
019 1/E Hand wing pump, Håndvingepumpe,

complete komplet
08028-0E/H5250/94.08.12
02.37 - ES0
Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-04H
V28/32S
013 013
025 025
08028-0D/H5250/94.08.12
02.43 - ES0
Plate
51535-04H Prelubricating Oil Arrangement Page 2 (2)
V28/32S
Item Item
08028-0D/H5250/94.08.12
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
02.43 - ES0
Cooling water system
516/616
Your Notes :
Description 516.01
Page 1 (1) Cooling Water System Edition 01H
L23/30H
V28/32S
Description High Temperature Circuit
The cooling water system consists of two separate The high temperature circuit is used for cooling of
systems. The low temperature (LT) and the high the cylinder units.
temperature (HT) circuits.
Cooling water is led through a distributing pipe to
the bottom of the cooling water space between the
Low Temperature Circuit liner and the frame of each cylinder unit. The water
is led out through bores in the top of the frame via
The low temperature circuit is used for cooling of the the cooling water guide jacket to the bore.
charge air and the lubricating oil, and the alternator
if the latter is water cooled.
96.03 - ES0U-G
Your Notes :
Description
Cooling Water Thermostatic Valve 516.04
Page 1 (1)
Edition 01H
L23/30H
V28/32S
Thermostatic Valve The thermostatic valve cannot be set or adjusted,
and requires no maintenance.
The thermostatic valve in the high temperature cir-
cuit is mainly located imediately after the outlet of In some plants a corresponding thermostatic valve
the engine, but alternatively in the external cooling is installed in the low temperature circuit. The ther-
system near the fresh water cooler. mostatic elements of this valve have an other tem-
perature range.
The cooling water enters through the cover (A) under
which the thermostatic elements are located.
The number of elements depends on the size of

A
the valve.
The outlet to the suction side of the pump is marked

(B) and outlet to the cooler is marked (C).
In the warming-up period the cooling water is by-

passing the cooler. When the outlet water from the
cylinder heads reaches the normal temperature
(75-85° C) a controlled amount of water passes C B
through the cooler.
The thermostatic elements must be replaced if the

cooling water temperature during normal operation
deviates essentially from the one stated in the test
report. Fig. 1 Thermostatic Valve
94.26 - ES0S-G
Your Notes :
Page 1 (2) Check of Cooling Water System Edition 01H
V28/32S

Shut-off fuel oil
Check of cooling water system.
Starting position
Engine is running
Related procedure
08028-0D/H5250/94.08.12
Working time : ½ hour Plate no Item no Qty/

Capacity : 1 man
Data

92.04 - ES0U-G
Edition 01H Check of Cooling Water System Page 2 (2)
V28/32S
5) Check manometers and thermometers for pos-
Checks to be carried out sible damages.
1) Examine the piping system for leaks. 6) Check the condition of the uppermost of the two
O-rings (which makes up the tightening between
2) Retighten all bolts and nuts in the piping system. the jacket cooling water space in the frame and the
crankcase) by means of the inspection holes in the
3) Move all valves and cocks in the piping system. engine frame - see also Working Card 506-01.40.
Lubricate valve spindles with graphite or similar.
For check of the fresh water condition, see section
4) Check flexible connections for leaks. 504.
08028-0D/H5250/94.08.12
92.04 - ES0U-G
Page 1 (2) Cooling Water, Thermostatic Valve Edition 05H
V28/32S

Shut-off fuel oil
Inspection of thermostatic valve and replacement Ring and open end spanner 24 mm
of elements. Copaslip
Tools and cleaning preparation for cleaning.
Starting position
Cooling water drained from engine (if neces-

sary).
Related procedure
08028-0D/H5250/94.08.12
Working time : 2 hours Plate No Item No Qty/

Capacity : 1 Man
51604 126 1/th. valve
Data 51604 055 6 or 9/th. valve
51604 092 3/th. valve
02.46 - ES0
Edition 05H Cooling Water, Thermostatic Valve Page 2 (2)
V28/32S
The thermostatic valve cannot be adjusted and un- Replacement of elements
der normal working conditions maintenance is not
required. However, in some cases it is necessary to 1) Remove nuts (1) and washers (2), 4 or 6 pcs.
replace the elements in the thermostatic valve. See fig. 1.
2) Disconnect upper and lower part of the hou-

sing.
1
2 3) Remove the assembled elements (3) and the
3 elements O-ring sealing.
5
4) Remove the gaskets between the upper and
lower part of the housing.
4
5) The upper and lower part of the housing are
thoroughly cleaned inside and on the gasket sur-
faces.
6) The sealing rings (4) for the elements in the

housing are replaced and lubricated with a thin layer
of copaslip.
7) Remount the assembled elements in the hou-

sing by wriggling these somewhat over side.
8) Upper and lower part of the housing are as-

sembled with a new gasket (5), the nuts (1) are
1. Nut
mounted and tightened "cross-wise".
2. Washer
3. Element
Note:
4. O-rings sealing
5. Gasket
After inspection or replacement of the elements the
cooling water temperature is checked to ensure that
the elements are working correctly.
Fig. 1 Thermostatic valve
08028-0D/H5250/94.08.12
02.46 - ES0
Plate
Page 1 (2) HT Freshwater Thermostatic Valve 51604-02H
V28/32S
02.36 - ES0
Plate
51604-02H HT Freshwater Thermostatic Valve Page 2 (2)
V28/32S

Item Item
018 6/T Screw Skrue

element

138 2/T Threaded pin Gevindtap
02.36 - ES0
Plate
Page 1 (2) LT Freshwater Thermostatic Valve 51604-03H
V28/32S
02.36 - ES0
Plate
51604-03H LT Freshwater Thermostatic Valve Page 2 (2)
V28/32S

Item Item
018 8/T Screw Skrue

element

02.36 - ES0
Plate
Page 1 (2) Fresh Water Pump 51610-06H
V28/32S
08028-0D/H5250/94.08.12
02.46 - ES0
Plate
51610-06H Fresh Water Pump Page 2 (2)
V28/32S
Item Item
237 1/P Ball valve Kugleventil
250 1/P Impeller Skovlhjul
262 1/P Key Not
274 1/P Lock nut Låsemøtrik
321 1/P Key Not
345 1/P Retaining ring for Låsering for leje

bearing
357 2/P Ball bearing Kugleleje
369 1/P Shaft Aksel
370 1/P Oil sealing ring Olietætningsring
382 1/P Rotating packing Roterende pakning
394 8/P Screw Skrue
404 1/P Bearing housing Lejehus
416 1/E Pump, complete Pumpe, komplet

08028-0D/H5250/94.08.12
02.46 - ES0
Plate
Page 1 (2) Fresh Water Pump 51610-08H
12V28/32S
022 034 046 058 083 071 083 095 105

010
130
117
142
154 129
166
191
08028-0D/H5250/94.08.12
178
03.16 - ES0
Plate
51610-08H Fresh Water Pump Page 2 (2)
12V28/32S
Item Item
010 1/P Ball cock Ballofix
022 1/P Bearing housing Lejehus
034 8/P Screw Skrue
046 1/P Rotating packing Roterende pakning
058 1/P Oil sealing ring Olietætningsring
071 1/P Shaft Aksel
083 2/P Bearing Leje
095 1/P Retaining ring Låsering
105 1/P Key Not
130 1/E Pump, complete Pumpe, komplet
142 1/P Impeller Impeller
154 1/P Key Not
178 3/P Plug Propskrue
191 3/P Packing Pakning
08028-0D/H5250/94.08.12
03.16 - ES0
Plate
Page 1 (2) Pipes on Cylinder Head 51625-02H
V28/32S
132
048, 156, 181

085, 144, 168 107
119
012
024
061
036
073
132
097
08028-0D/H5250/94.08.12
Cylinder Head
Plate 50501, 50502,
50508, and 50510
06.42 - ES0
Plate
51625-02H Pipes on Cylinder Head Page 2 (2)
V28/32S
Item Item
012 1/C Cooling water Forbindelsessrør

connecting pipe for kølevand
024 2/C Screw Skrue
036 2/C Screw Skrue
048 1/E H.T. collecting H.T. samlerør

pipe (B-bank) for (B-side) for
12V28/32S 12V28/32S
061 2/C Nut Møtrik
073 3/C Screw Skrue

pipe (A-bank) for (A-side) for
12V28/32S 12V28/32S

16V28/32S 16V28/32S

16V28/32S 16V28/32S

18V28/32S 18V28/32S

18V28/32S 18V28/32S 08028-0D/H5250/94.08.12
06.42 - ES0
Plate
Page 1 (2) Preheater - Fresh Water 51635-04H
L23/30H
V28/32S
08028-0D/H5250/94.08.12
07.46 - ES0
Plate
51635-04H Preheater - Fresh Water Page 2 (2)
L23/30H
V28/32S
Item Item
353 1/E Pipe for preheater Rør for forvarmer
365* 1/E Preheater Forvarmer

5 L23/30H, 5 L23/30H,
stationary stationær

6, 7 L23/30H, 6, 7 L23/30H,

8 L23/30H, 8 L23/30H,

5 L23/30H, 5 L23/30H,
marine marine
400* 1/E Preheater Forvarme

6, 7 L23/30H, 6, 7 L23/30H,
marine marine

8 L23/30H, 8 L23/30H,
marine marine

12 V28/32S 12 V28/32S

16, 18 V28/32S 16, 18 V28/32S
* At ordering please * Ved ordre oplyses

inform of voltage (V) spænding (V) og ef-
and output (W) fekt (W)
08028-0D/H5250/94.08.12
07.46 - ES0
Special equipment
517/617
Your Notes :
Kit
Page 1 (2) Kit for Cylinder Unit 51704-05
V28/32S
08028-0D/H5250/94.08.12
05.34 - ES0
Kit
51704-05 Kit for Cylinder Unit Page 2 (2)
V28/32S
Item
no Qty Designation Where to find in the engine instruction book
021 1/C Kit for cylinder unit, complete Plate 50500 Item 021
consisting of:
1/C Snap ring Plate 50501 Item 040
1/C O-ring Plate 50501 Item 064
1/C Gasket Plate 50508 Item 025
4/C Sealing ring Plate 50801 Item 185
Please Note that this is a kit supply, and that any exceeding number of o-rings and gaskets
are not accepted as return goods.
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
05.34 - ES0
Plate
Page 1 (2) Kit for renewal of Piston Rings 51706-09
V28/32S
See Working Card 506-01.10
093*
103*
235*
127*
* Please order item 085
11.03 - EO0
Plate
51706-09 Kit for renewal of Piston Rings Page 2 (2)
V28/32S
Item
No Qty Designation Where to find in the engine instruction book
085 Kit per renewal of piston rings for one piston, complete consisting of:
1 Piston ring Plate 50601 Item 093
1 Oil scraper ring Plate 50601 Item 127
11.03 - EO0
Kit
Page 1 (2) Kit for Fuel Injection Pump 51730-08
V28/32S
001
Please see working card 514-01.05
254
248
189
266
236
313
190
045
070
291 045
08028-0D/H5250/94.08.12
082
104
356
09.40
Kit
51730-08 Kit for Fuel Injection Pump Page 2 (2)
V28/32S
Item
no Qty Designation Where to find in the engine instruction book
001 1/P Kit for fuel injection pump complete consisting of:
2/P Joint washer Plate 51401 Item 045
3/P Disc Plate 51401 Item 082
1/P Lock washer Plate 51401 Item 104
1/P O-ring Plate 51401 Item 189
1/P Back-up ring Plate 51401 Item 254
1/P Back-up ring Plate 51401 Item 266
1/P Gasket Plate 51401 Item 313
1/P Gasket Plate 51401 Item 356
08028-0D/H5250/94.08.12
Please Note that this is a kit supply and that

any exceeding number of o-rings and gaskets
are not accepted as return goods.
Qty/P = Qty/Pump
Qty/C = Qty/Cylinder
09.40
Specific plant
information
519/619
Your Notes :
Description 519.03
Page 1 (1) Resilient Mounting of Generating Sets Edition 09
L16/24, L21/31, L27/38,

L23/30H, V28/32S
Resilient Mounting of Generating Sets Check of Crankshaft Deflection
On resilient mounted generating sets, the diesel The resilient mounted generating set is normally
engine and the alternator are placed on a common delivered from the factory with engine and alternator
rigid base frame mounted on e.g. concrete founda- mounted on the common base frame.
tion by means of resilient supports, type Sandwich. Eventhough engine and alternator have been ad-
justed by the engine builder, with the alternator rotor
All connections from the generating set to the ex- placed correctly in the stator and the crankshaft de-
ternal systems should be equipped with flexible flection of the engine (autolog) within the prescribed
connec-tions, and pipes etc. must not be welded to tolerances, it is recommended to check the crankshaft
the external part of the installation. deflection ( autolog) before starting up the GenSet.
Resilient Support Maintenance
A resilient mounting of the generating set is made Generally the mountings will not require maintenance
with a number of sandwich mountings. The number or reconditioning in service unless misused or ac-
and the distance between them depend on the size cidently damaged.
and weight of the plant. The mountings are bolted
onto the base frame. Oil contamination is the most likely cause of damage
and therefore the rubber elements are treated with
The standard height of the sandwich mountings is an oil resistant coating.
125 mm in unloaded condition - when loaded the
setting is normally 6-8 mm. Certainly elements showing signs of severe swelling
or evidence of rubber to metal separation should be
The exact setting can be found in the calculation of replaced.
the sandwich mountings for the plant in question.
Engine
Alternator
Base Frame
Sandwich mountings
Foundation
Fig 1 Resilient Mounting of Generating Sets
10.33 - ES0
Your Notes :
Working card Fitting Instructions for Resilient Mounting of 519-03.00
Page 1 (2)
Landbased GenSets Edition 23
L16/24, L21/31, L27/38

L23/30H, V28/32S

Shut-off fuel oil
Stopped lub. oil circulation
Description
Mounting and adjustment instruction for new

GenSets, and adjustment instruction for existing
plants. Hand tools
Ring and open end spanner, 24 mm

Measurement tool
Hydraulic jack (if necessary)
Starting position
The foundation should be prepared according

to tolerances.
Related procedure
Check of crankshaft bend (autolog)
Man power Spare and wearing parts
Working hours : x Hours Plate No. Item No. Qty./

Capacity : 2 Men

Data

11.05 - ES0
519-03.00 Fitting Instructions for Resilient Mounting of Working card
Edition 23
Landbased GenSets Page 2 (2)
L16/24, L21/31, L27/38

L23/30H, V28/32S
Check of Crankshaft Deflection Example :

H1 + H2 + H3 —— Hn
The resilient mounted generating set is normally Average = mm.
delivered from the factory with engine and alternator N
mounted on the common base frame.
Eventhough engine and alternator have been ad- N = Number of sandwich mounting.
justed by the engine builder, with the alternator rotor
placed correctly in the stator and the crankshaft de- 6) The mounting(s) with the largest deviation (from
flection of the engine (autolog) within the prescribed the average) should be adjusted first with steel
tolerances, it is recommended to check the crankshaft shims.
deflection ( autolog) before starting up the GenSet. Hereby it should be noted that with the steel
shims the mounting deflection can only be
increased. Therefore it can be necessary to fit,
Mounting and Adjustment Instructions for not only one, but all mountings with steel shims
New Generating Sets to release one mounting.
1) In case the sandwich mountings have not

been mounted in the factory, they have to be Method of Fixing the Generating Set to the
mounted at the location on the base frame. Base Plates
2) Fit the filling pieces to the sandwich mountings 7) After the final adjustment, fix the Generating
by means of four M16 bolt each, see page 4. Set to the base plates by welding the filling
The filling pieces have to be machined accord- pieces to the base plates according to the
ing to the drawing from MAN Diesel & Turbo. drawing from MAN Diesel & Turbo.
3) Align the generating set above the base plates This method of fixing the Generating Sets to the base
according to the drawing from MAN Diesel & plates is suitable for earthquake conditions up to 7
Turbo. on the Richter scale.
4) Lower the generating set until it rests completely

on the base plates. Instructions for Maintenance
5) After 48 hours, level and load distribution is Generally speaking the mountings will not require
checked by measuring the height of the ele- maintenance or reconditioning in service unless
ments. The difference between the mountings mis-used or accidently damaged.
should be as small as possible and should not
exceed ± 2 mm from average. Oil contamination is the most likely cause of damage
and therefore the rubber elements are treated with
an oil resistant coating.
Certainly elements showing signs of severe swelling
or evidence of rubber to metal seperation should be
replaced.
11.05 - ES0
Plate
Page 1 (2) Flexible External Connections 51902-11H
V28/32S
Item
Fig. Designation Connection
no
Fuel oil, inlet A1 018
Fuel oil, outlet A2
Waste oil, outlet A3 043
Venting to expansion tank F3
Inlet from expansion tank F15
Nozzle cooling oil, inlet A7 342
Nozzle cooling oil, outlet A8
Lubricating oil from separator, C3/C16 079

inlet/Lub. oil supply, inlet
Lubricating oil to separator, C4

outlet
08028-0D/H5250/94.08.12
HT freshwater, inlet F1 209
HT freshwater, outlet F2
LT freshwater/rawwater, inlet G1
LT freshwater/rawwater, outlet G2
02.33 - ES0
Plate
51902-11H Flexible External Connections Page 2 (2)
V28/32S
Item
Fig. Designation Connection
no
Lubricating oil, inlet C1 354
Lubricating oil, outlet C2
Oil vapour discharge, outlet C13 126
Compressed air, inlet K1 271
Charge air, inlet M1 366
08028-0D/H5250/94.08.12
Exhaust gas, outlet P2 317
02.33 - ES0
Plate
Page 1 (2) Sandwich Mounting 51904-01
L16/24, L21/31, L27/38

L23/30H, V28/32S
08.36 - ES0
Plate
51904-01 Sandwich Mounting Page 2 (2)
L16/24, L21/31, L27/38

L23/30H, V28/32S
Item Item
013 1/M Sandwich mounting, "Sandwich" element,

complete komplet
074 4/M Screw Skrue
Qty/M = Qty/Sandwich mounting Qty/M = Qty/Sandwich element
08.36 - ES0
Tools
520/620
Your Notes :
Description 520.01
Page 1 (1) Introduction to Spare Part Plates for Tools Edition 01H
L23/30H
V28/32S
The contents of these spare part plates with tools However, some tools such as torque spanners, hy-
are a summary of STANDARD TOOLS for normal draulic tools etc. may also have other applications.
maintenance and EXTRA TOOLS for reconditioning, Information about the exact use of the tools appears
which can be supplied by MAN B&W Diesel A/S, from the relevant sections in the instruction book.
Holeby. Thus, the list comprises the total extent of
tools available for this engine type. Note: The table on the spare part plates is marked
with an S or an E. An S means that the tools are
For each specific plant the amount of tools delivered supplied when ordering Standard tools and an E
depends of the contractual specifications. means that the tools are supplied when ordering
Extra tools, i.e. Tools for Reconditioning (extra tools
The tools listed are assembled in sections corres- are not standard delivery)
ponding to the chapters of the instruction book.
08028-0D/H5250/94.08.12
96.03 - ES0
Your Notes :
Page 1 (7) Function of the Hydraulic Tools Edition 02
General

Shut-off fuel oil
Safety hints and function of hydraulic tools.
Starting position
Application of hydraulic tools 520-01.06
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
Edition 02 Function of the Hydraulic Tools Page 2 (7)
General
Function of the Bolt Tensioning Device 8. The operation and handling of the device are
to be carried out by expert staff only.
In order to achieve an optimal result with one or
several devices, some rules have to be considered. 9. The given max. operation pressure is not to
We expressly point out that a conscientious handling be exceeded in any case and is to be watched
of the device as well as the accessories is of high- at the manometer of the pressure generator
est importance. To ignore these rules or separate during the complete tensioning or loosening
hints means danger to life or danger of injuries! See procedure. When having achieved the given
Safety Hints. pressure, stop the pressurization immedi-
ately.
Safety Hints 10. During the pressurization when tensioning or

loosening the bolt connection, always watch
Beside regarding the general accident-prevention the admissible stroke of the device. Exceed-
rules, the safe handling of the device and the hydraulic ing this stroke is connected with insufficient
accessories demand especially the consideration of generating of tensioning force because the
the following hints. When disregarding even single device is tensioned in itselve or the hydraulic
items, you can cause danger to life and/or danger pressure is bleeded automaticly.
of injuries!
11. On principle, when connecting high-pressure
1. When leakages occur during the pressuriza- hoses it has to be taken care that the connec-
tion, bleed pressure immediately and seal the tions are correct (see also separate hints).
leakage or replace defect parts.
12. The hydraulic hoses have to be installed in a
2. In case of repair, use exclusively original spare way that they are not run over by vehicles or
parts. Inexpert substitution of damaged parts unnecessarily walked over by people. Never lay
by non-original spare parts is prohibited. hoses across sharp objects (danger of cuts)
and never bend or jam them in.
3. All assembly parts are to be handled in corre-
spondence to the working cards only. A change 13. Never hold or transport the device by using the
in the procedure or another operation of the high-pressure hoses.
device is not allowed.
14. An incorrect working manometer that doesn´t
4. Make sure that the components to be tensioned show the right pressure leads to overstressing
do not exceed the admissible strain. of the parts and to an incorrect bolt connec-
tion. Apart from damaged parts an incorrect
5. In order to use the device, the thread has to bolt connection can also cause conditions that
be sufficiently exceeding in order to avoid that are danger to life. Therefore take care that
the turn of a thread cracks, see item 4. the manometer shows the right value or the
tensioning force is checked in an other way
08028-0D/H5250/94.08.12
6. During the pressurization the people involved (for example by using a master manometer).
have to remain in an appropriate distance. Tensioning forces can be checked for example
Staying in direction towards the bolt axis is by measuring the linear deformation. Damaged
forbidden. manometers have to be exchanged immedi-
ately.
7. Tensioning pressures or tensioning forces are
to be given or changed by authorized personnel
only while considering the admissible compo-
nent loads, see item 4.
99.43 - ES0
General
Working Hints
In order to achieve a bolt connection of high precision,

it is vital to consider the following working hints:
- Prior to setting the device, clean all threads and

remove possible damages in order to avoide
a “freeze on”.
- The base plate for the device must be plain

and free of dirt. Further check the squareness
towards the bolt axis in order to avoid that the
bolt has a bending stress during the pressuri-
zation (tensioning).
- The stroke of the device may not at any point

be exceeded.
- For transporting the device it is necessary to

uncouple all high-pressure hoses. Fig. 1. Turnable connection unit.
- After each pressurization, bring the device

back to zero, see also Piston Return Stroke. Exchange of the Seals
Should leakages show up at the connection unit, it

Turnable Connection Unit might be necessary to exchange the seals.
For doing so, loosen the securing ring and take the
In order to simplify the connection of the hydraulic disc off the bolt nipple. Having removed the seals,
hose, a turnable connection unit is mounted on clean the components with fluff-free cleaning material.
some devices. You can also apply compressed air. Having checked
The turnable connection unit consists of the follow- the components for damages and oiled them slightly,
ing components: apply new seals by help of the entry guide and reas-
semble the turnable connection unit.
- bolt nipple
- disc Hint: - For the cleaning, never use aggressive
- seal cleaning liquids.
- securing ring - For oiling the parts, use exclusively hydraulic
oil.
Furthermore, an entry guide is available or contained - For replacements, use exclusively new
08028-0D/H5250/94.08.12
in the scope of supply, see fig.1. seals.
Coupling of the High-Pressure Hoses
- Only couple when the hydraulic system is in a

pressureless condition.
- To produce a high-pressure connection, put

one coupling and one nipple into each other
while the coupling socket is pulled back. When
letting the coupling socket go, there is a form
fit barring the connection.
99.43 - ES0
Edition 02 Function of the Hydraulic Tools Page 4 (7)
General
- By drawing the hose with a manual force of that the max. admissible stroke of the device is not
about 100 N make sure that the connection is exceeded. Beside that, it has to be ensured that the
correctly barred. cylinder and the support sleeve remain centrically
towards each other (consider centering shoulder).
- For decoupling the high-pressure hose in
a pressureless condition, first pull back the Having made all hydraulic connections correctly,
coupling socket and then take off the hose. see fig. 2, start the pressurization for the tensioning
procedure. If the necessary pressure is achieved
stop pressurization. The inducted force causes the
bolt to extend or an edging of the components to
be tensioned so that the main nut is lifted from the
flange. Screw it back to the flange, see fig. 3. Check
by help of a feeler gauge leaf whether the main nut
really fits tight to the flange. After that, bleed hydraulic
pressure. Now the connection is tensioned.
Fig. 2. Coupling of the high-pressure hoses. Having brought the piston to its zero position, see fig.
4, the hydraulic hoses can be decoupled. In order to
prevent impurities, it is advisable to close coupling
Hoses with fast-lock coupling sockets avoid, also sockets and coupling nipples at once by protecting
when uncoupled, that oil runs out. When the hoses caps. The device can be unscrewed from the bolt.
get heated, there can be an inside pressure in the
uncoupled condition making a coupling impossible. ● Always consider the safety and working
By loosening one screw connection (see fig. 2) the hints!
pressure can be bleeded
- To avoid a contamination use protecting caps Loosening Procedure

for the sockets.
In order to loosen an existing bolt connection, screw
the device onto the bolt. First put the support sleeve
Tensioning Procedure on the bolt and align it centrically to the bolt axis.
When screwing on the device take care that the
Prior to the tensioning procedure make sure that support sleeve at the cylinder is correctly centered
the components to be tensioned are correctly posi- (consider centering shoulder).
tioned towards each other. Then screw the device
onto the bolt. The piston of the device must be at its zero position.
Having screwed the device down until the support
First put the support sleeve on the bolt and align it sleeve or the support cylinder fits tight to the flange,
centrically to the bolt axis. When screwing on the de- turn back the device by at least the value (slit meas-
vice take care that the support sleeve at the cylinder
08028-0D/H5250/94.08.12
ure) which the bolt and the components spring back

is correctly centered (consider centering shoulder). elastically during the loosening procedure.
Screw the device until the support sleeve or the sup- Hint: The adjusted slit measure may never exceed
port cylinder fits exactly to the flange. The piston of the admissible stroke of the device! Furthermore,
the device must be at its zero position. Furthermore, take care that the window for the adjusting rod are
take care that the hydraulic connector and the window well accessible.
for the adjusting rod is well accessible. Having made all hydraulic connections correctly, see
If necessary, turn back the device, but make sure fig. 2, start the pressurization.
99.43 - ES0
General
During the pressurization, a slight turn-back momen- Hint:
tum is applied to the main nut with the adjusting rod.
At the moment, when the main nut can be loosened, a) Should it be impossible to unscrew the device
interrupt the pressurization. Should it not be possible after the depressurization, it has been turned
to loosen the main nut when achieving the original back by a too low measure prior to the pres-
tensioning pressure, interrupt the pressurization im- surization. Pressurize again until the original
mediately. Find the cause with expert staff. tensioning pressure is reached, turn the main
nut and bleed the pressure again (tensioning
Having achieved the loosening pressure, turn back procedure). Now you can turn back the device
the main nut by the value that the bolt and the com- further. (Attention: consider the admissible
ponents spring back during the loosening procedure. stroke of the device!) Now repeat the loosening
The slit measure, however, must be lower than the procedure explained above.
slit measure adjusted at the device before, see also
hint b. b) Should it be impossible to loosen the main nut
after the depressurization, it has been turned
The main nut may never be turned back until it fits back by a too low measure prior to the pres-
to the piston or the cylinder since then the device surization. Pressurize again and turn the main
can be tensioned in itself. nut further back. Bleed the pressure again.
Having turned back the main nut, the pressure can Hint: Never screw the main nut back until it fits to
be bled. The bolt connection is loosened. Before the piston since the device can be tensioned
unscrewing the device, bring the piston back to its in itself.
zero position, see fig. 4. After that, the hydraulic hoses
can be decoupled. In order to prevent impurities, it
is advisable to close coupling sockets and coupling Adjustment and Turn Back of the Main Nut
nipples at once by protecting caps. The device can
be unscrewed from the bolt. During the pressurization of the device, the bolt
is being extended by the tensioning force and the
● Make sure that no operational forces (e.g. components are being edged. The result is that the
inner pressure) affect the components to be main nut does no longer fit to the flange.
loosened since only part of the bolts take over
these forces and thus the bolts, which are not Having achieved the necessary pressure, adjust the
yet loosened, might be overburdened. main nut - when tensioning - until it fits to the flange
again before bleeding the pressure, see Tensioning
● The pressure when the main nut can be loos- Procedure. When loosening the bolts, turn back the
ened may never exceed the tensioning pressure main nut after the pressurization according to the
by help of which the connection was tensioned! bolt and component deformations, (see Loosening
Should it not be possible to loosen the main nut Procedure.
when reaching the original tensioning pressure
08028-0D/H5250/94.08.12
interrupt the pressurization immediately. Find Hint: During the loosening procedure, never turn
the cause with expert staff. back the main nut until it fits to the piston or the
cylinder since the main nut sticks after the depres-
● Always consider the safety and working surization.
hints!
The main nut is equipped with several radial bores
where the adjusting rod can be put in. The main nut
is accessible through the window in the support
sleeve.
99.43 - ES0
520-01.05 Function of the Hydraulic Tools Working Card
General
During the piston return stroke, considerable back-
pressures can occur in the piston area of the device
since quite large quantities of oil have to flow back
through the small cross sections of the high-pres-
sure connections.
In order not to unnecessarily increase the force for

the piston return stroke turn the piston slowly. On
principle the piston of the device has to be pushed
back until it fits to the cylinder again.
Exchange of the Seals

Fig. 3 Adjustment and turn back of the main nut.
Should leakages occur at the piston of the device,
an exchange of the seals might be necessary.
Piston Return Stroke Drive out the piston by carefully beating with a hammer
while using a plastic spacer in order to protect the
After each pressurization it must be ensured that device from unnecessary damages. After removing
the piston of the device is brought back to its zero the hydraulic connector, you can also carefully lead
position. On principle, it has to be considered that compressed air into the piston area.
hydraulic oil is being displaced from the piston area.
In order to enable the oil to flow back to the tank of Attention: Sudden input of compressed air can lead
the pressure generator, the corresponding hydraulic to the piston’s uncontrolled outlet.
connections must be done. After removal of the piston, the seals and the backup
rings can be removed from the piston and the cyl-
The piston return stroke is done by a screw-down at inder.
the bolt itself before the device is taken off.
Carefully clean the components with fluff-free mate-
Hint: When using fast lock coupling elements, the rial and check them for damages. If necessary, use
oil’s running out and thus a piston return stroke in compressed air for the cleaning, but never aggres-
an uncoupled condition is impossible! sive cleaning liquids. After that, slightly oil these
components with hydraulic oil and assemble new
backup rings as well as new seals to the piston and
the cylinder according to the drawing.
08028-0D/H5250/94.08.12
Fig. 4. Piston return stroke.
Fig. 5. Exchange of the seals.
99.43 - ES0
General
As shown in the picture, first assemble the backup
ring, then put the seal onto the backup ring. Piston
and cylinder can now be assembled again by putting
the components together. By slightly hammering on
the piston (with plastic spacer), it can be driven in
until it fits tightly to the cylinder (piston in its zero
position). It is essential that the piston does not tilt
during being driven in since this might damage the
seals as well as the components. When assembling
the piston it has to be taken care that the air can
come out of the piston area.
Maintenance and Storage
Regular maintenance of the device is not necessary,

but you should consider the following points:
a) Storage
After each operation, repair possible damages and

clean the device in order for it to be ready for the
next operation immediately. In order to avoid a cor-
rosion it is advisable to oil the device and especially
its thread. All coupling nipples, coupling sockets and
also loosened screw connections are to be closed
by protecting caps.
In addition, check the components of the device and

its accessories for completion.
Keep the device in the tool box also offering protec-
tion from mechanical damages.
The temperature must be between -20 C and +70 C
in order to exclude a damage of the seals.
b) Start-up of the device
Prior to the device’s operation, repair possible dam-

ages and clean the device.
08028-0D/H5250/94.08.12
Check the components of the device and its acces-

sories for completion.
The operating manual has to be read by all users.
99.43 - ES0
Your Notes :
Page 1 (2) Application of Hydraulic Tools Edition 07H
V28/32S

Shut-off cooling water See page 2
Shut-off fuel oil
Application of hydraulic tools.
Starting position
Function of hydraulic tools 520-01.05
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

02.34 - ES0
Edition 07H Application of Hydraulic Tools Page 2 (2)
V28/32S
This working card gives the information for applica-

tion of hydraulic tools, to be used in connection with
Please note:
The numbers refer to the
plate items in section 520.
Fig 1 Hydraulic tools.

08028-0D/H5250/94.08.12
02.34 - ES0
Page 1 (4) Hand Lever Pump Edition 01
General

Shut-off fuel oil
Application of hydraulic tools.
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

08.35 - ES0
Edition 01 Hand Lever Pump Page 2 (4)
General
Warning: The hand lever pump is not equipped with Initial Start-up and Venting
a pressure relief valve.
Never use the pump without a mounted manometer. In general and venting
Always pay attention to the given pressure of the
connected pressure consumers. Do never exceed Please make sure that all parts of the pump, espe-
this pressure or the max. pressure of the hand lever cially the manometer and the pressure port, are in a
pump. perfect condition. Defect parts are to be exchanged
against new ones immediately.
Important: Except for hydraulic oil, never use different
liquids such as petrol, water, diesel oil, alcohol or brake Turn the carrying handle with counter-clockwise
liquid, since these can lead to damages or even to rotation out of his fixing. Then turn it into the hand
destruction of the pump and/or the parts connected lever of the pump against the stopping face.
with it. Choose a place of assembling and operation
where the pump can always stand safe and firm on Attention: If the carrying handle is not srewed-in
a horizontal plain. There should always be sufficient into the hand lever, it can cause injuries while using
space for operating the pump. the pump.
Never handle the pump lever with oiled hands and
never use hand lever extensions. Never expose the Open the oil filler cap and check the oil level. If nec-
pump to great heat, fire or extreme coldness, since cessary, fill up the tank with hydraulic oil according
this leads to damages or even destruction. Protect to IS0 VG 32. Never overfill the tank. Close the oil
the pump from falling objects and avoid hard blows filler cap.
or pushes. Open the tank breather with the square wrench
(included in the scope of supply) by about one turn.
Attention - Danger to life Now loosen the breather screw at the pump on the
Check the manometer of the pump for the needed left side on the pump housing with an allen key SW
hydraulic pressure, given by an authorized person, 2,5 by about one turn. Close the depressurization
not to be exceeded. Make sure that the pressure valve tightly. Seal the nipple on the pump with a hose
you want to generate is also admissible for all con- and pump at the hand lever until oil flows out of the
nection parts. breather screw bladder-free. Only then are you al-
lowed to close the breather screw. The pump is now
All pressure connections and connecting elements vented and ready for operation.
have to be clean and undamaged. High-pressure
connections from the pump to the tools have to be After each operation and for the transport, close
established correctly prior to any pressurization. the tank breather in order to avoid the hydraulic oil’s
Disregard leads to danger to life. Please see working running out.
card 520-01.06.
Attention - Danger on injuries Pressurization

Loads being lifted by the pump may never be held
by the pump valves alone. Use additional non-return - Open the tank breather with the square wrench
08028-0D/H5250/94.08.12
valves or safety relief valves and secure the load by approx. one turn.
sufficient support against falling.
Remark: The pump is only to be operated with open
tank breather.
- Close the depressurization valve at the pump

when turning clockwise by handoperation.
08.35 - ES0
Page 3 (4) Hand Lever Pump Edition 01
General
Remark: The depressurization valve is designed Below of the pressure relief valve is an adjusting screw
for manual operation. The use of any tools at the with inner hexagon (wrench size 10 mm). Turning out
depressurization valve could cause damages of the counter-clockwisely the adjusting screw minimizes
valve or the valve seat. the change-over pressure, turning in clockwise ma-
ximizes the change-over pressure.
- Pump at the hand lever until the wanted pres-
sure is achieved. Check the pressurization Attention: Inside of the adjusting screw is another
at the manometer and take care of possible grub screw with inner hexagon (wrench size 4 mm) to
leakages. limit the stroke of the change-over piston inside of
the pump block. It is absolutely necessary, to screw
Remark: The pump works with two stages. The out the grub screw approx. 2 times before turning
change from the first stage to the second stage the adjusting screw!
happens automatical at a system pressure of about
30 bar. The regulation of the adjusting screw follows gra-
dually in approx. 10° - steps. After everv adjusting
Attention: The pump is not equipped with an internal step the grub screw is to screw in until it fits closely
pressure relief valve.The use of a manometer and the and approx. a l/4 turn to loosen.
control of the system pressure during pressurization
is indispensable. Check by carefully pumping if the change-over pres-
sure wanted has been reached. If necessary, repeat
Attention: Do not stand directly over the moving the procedure as described above.
line of the pump lever. Under arising circumstances
the lever can “hit back”. To avoid accidents stand
sideways the pump.
Attention - High-pressure hydraulic

On principle, tihen leakages occur during the pressu-
rization, immediately release the hydraulic pressure
and seal the leakage or renew defect parts.
Depressurization
- Open the depressurization valve slowly by a

turn to the left.
- Make sure that the hydraulic pressure at the

manometer has been completely released.
Consider the returning time of the hydraulic
oil.
08028-0D/H5250/94.08.12
Adjustment of change-over pressure from

stage 1 to stage 2
In exeptional case, it can be useful to adjust the

change-over pressure from stage 1 to stage 2 (factory
adjusted at approx. 30 bar).
08.35 - ES0
Edition 01 Hand Lever Pump Page 4 (4)
General
Analysis and Correction of Malfunction Pressure Port
Correction of malfunctions The pressure port of the pump is produced accor-

ding to our customers’ wishes. In addition, there is a
In case of malfunctions at the pump, the following variety of possibilities to connect the pump with one
points are to help you with the analysis of the problem or more pressure consumers.
and correcting it yourself.
For this, uncouple or unscrew all consumer and Attention - Danger to life
high-pressure hoses from the pump. Prior to the pump’ s start-up please make sure that,
no matter which pressure port you chose, all con-
nection elements are in a perfect condition. Convince
yourself of the fact that these are correctly connected
Malfunction Correction
and suitable for the necessary pressure.
No pressurization 1. Check the oil level and, if
necessary, fill it up as Attention - High-pressure hydraulic
described in chapter On principle, when leakages occur during the pressu-
maintenance and storage.
2. Close depressurization valve. rization, immediately release the hydraulic pressure
3. Visual inspection whether and seal the leakane or renew defect parts.
there are leakages. If so,
seal them.
4. Vent the pump as described
in chapter initial start-up and Maintenance and Storage
venting.
The pump should be lubricated frequently at the
Insufficient pressurization 1. Check the oil level and, if
necessary, fill it up, as
movable parts. Protect it from contamination because
described in chapter dirt in the oil or in the pressure port can lead to the
(prior to any corrections, mainteance and storage. pump’ s failure. A dry storage avoids the steel parts’
open de-pressurization 2. Close depressurization valve. getting rusty.
valve and release hydraulic 3. Visual inspection whether ther
pressure completely) are leakages. If so, seal them.
The storage and transport of the pump should always
4. Vent the pump as described be done in a horizontal position. Thus, you avoid a
in chapter initial start-up and possibly necessary venting of the pump during its
venting. start-up.
Pressure drop 1. Visual inspection whether
there are leakages. If so, For checking the oil level, please open the depres-
(prior to any corrections, seal them. surization valve and let the oil completely flow back
open de-pressurization 2. Close depressurization valve. into the tank. Open the oil filler cap and fill up hydraulic
valve and release hydraulic
pressure completely).
oil according to IS0 VG 32, if neccessary. Do not
overcharge the tank. Close the oil filler
If the problem cannot be solved, please contact cap.
MAN Diesel.
08028-0D/H5250/94.08.12
The use of the pump in a dirty area requires a regular

oil change. Fill the pump with clean hydraulic oil and
lubricate all moving parts (hinges) regulary.
08.35 - ES0
Page 1 (2) Max Pressure Indicator Edition 01H
L23/30H
V28/32S

Shut-off cooling water 52005 109 Max. press.
Shut-off fuel oil indicator
Description
Operation.
Overhaul intervals.
Dismantling, overhaul and assembly. Hand tools
Allen key, 3 and 6 mm.

Copaslip or similar.
Starting position
Related procedure
Manpower

Capacity : 1 man
08028-0D/H5250/94.08.12
Data Plate no Item no Qty/
Data for pressure and tolerance See Plate 52005

Data for torque moment
Declaration of weight
96.03 - ES0
Edition 01H Max. Pressure Indicator Page 2 (2)
L23/30H
V28/32S
Operation
1) Open the indicator valve and blow through 1

shortly.
2) Connect the max pressure indicator to the

indicator valve and open the valve.
3) After 3-5 seconds read the max. pressure on 2

the gauge. 5
Attention: The indicator valve has to be open while

reading the max. pressure on the gauge. The meas- 4
uring period should not exceed 30 seconds.
3
4) Close the indicator valve and open the valve
screw (5), fig 1.
1 Housing 2 Allen screw
5) Disconnect the max. pressure indicator and 3 Sealing 4 Screw
close the valve screw (5), fig 1. 5 Valve screw
6) Measure the remaining cylinders by following Fig 1 Pressure Indicator.

step 1 to 5.
4) After separation of the upper and lower part,

Overhaul Intervals take off the non-return valve assembly.
1) Dismount and clean the non-return valve after 5) Lap the valve and the valve seat.
200 measuring periods. If the pressure drop is
more than 5 bar within 60 seconds (test pres- 6) Renew the sealing ring (3) and screws (2), if
sure 100 bar) it is recommended to relap the necessary.
non-return valve.
7) When mounting the upper and lower part, use
2) Check the pressure gauge after 1,000 measur- only original screws.
ing periods or after 12 months use.
8) Coat the screws (2) with copaslip or similar
Attention: Use only exhaust gas or nitrogen gas and tighten to 10 Nm.
and never oil for testing the pressure drop and the
pressure gauge. By using oil carbon will deposit 9) After assembly the instrument can be used
08028-0D/H5250/94.08.12
inside the measuring instrument. without any new calibration.
Dismantling and Assembly Check of the Pressure Gauge
1) Dismount the valve screw (5), fig 1. 10) Testing of the instrument should only be made
by skilled specialists, and it is recommended
2) Turn the screw (4) into the instrument to enable to send the instrument to MAN Diesel for cali-
dismounting of the housing (1). bration.
3) Loosen the screws (2) (4 pieces) for separating

upper and lower part.
96.03 - ES0
Plate
Page 1 (5) Tools for Cylinder Head 52005-05H
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Lifting tool for cylinder head

(complete) 380 400 230 S 01
B
Mounting tool for valves (com-

06 B plete) 155 290 190 S 05
07 C
Nut 06
Thrust bearing 07
Max. pressure indicator S 10
Spare Parts:
Valve screw 11
08028-0D/H5250/94.08.12
Non return valve, complete incl.

seals and housing screws 12
Connecting nut incl. wedge for

mounting 13
Pressure gauge 0-180 bar 14
06.06 - ES0
Plate
52005-05H Tools for Cylinder Head Page 2 (5)
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Grinding ring for cylinder head

A and cylinder liner 376 30 S 20
B Grinding table for cylinder head,

with bracket for wall mounting
(complete) 650 825 400 E 25
C
Grinding table for cylinder head,

with frame for floor mounting
(complete) 715 805 1050 E 30
C
08028-0D/H5250/94.08.12
A
B
06.06 - ES0
Plate
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Grinding machine for valve seat

ring (complete) E 35
Spare parts:
Stone 36
Guide 37
40 Grinding machine for valve

spindle (complete) E 40
Spare parts:
Stone 41
41
B Mounting tool for valve seat

rings (complete) 472 101 E 45
08028-0D/H5250/94.08.12
06.06 - ES0
Plate
52005-05H Tools for Cylinder Head Page 4 (5)
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
B
Extractor for valve seat ring
(complete) 300 140 E 50
A
Tools for grinding of valves 110 95 ø90 S 55
Mandrel for dismounting of 400 ø17.5 ø25 E 60

valve guide
08028-0D/H5250/94.08.12
C B
A
06.06 - ES0
Plate
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Handwheel for indicator valve ø80 110 17 S 65
Grinding machine for valve E E 70

seat ring incl. wooden box,
complete
E E 71
Mandrel
E E 72
Cutting tool
08028-0D/H5250/94.08.12
06.06 - ES0
Your Notes :
Plate Tools for Piston, Connecting Rod
Page 1 (5) and Cylinder Liner 52006-09H
V28/32S
Dimensions Item
V28/32S
Fig. Designation
A B C No.
Lifting tool for piston 270 75 100 S 05
Eye bolt for piston lift at check M16 65 611 S 07

of connecting rod big-end
bearing
B Back stop for cylinder liner 325 48 65 S 09

(2 pieces)
08028-0D/H5250/94.08.12
06.33 - ES0
Tools for Piston, Connecting Rod Plate
52006-09H and Cylinder Liner Page 2 (5)
V28/32S
Dimensions Item
V28/32S
Fig. Designation
A B C No.
Guide ring for mounting of pi- 358 150 S 11

ston. (Cylinder liner with flame
ring)
Piston ring opener S 13
Testing mandrel for piston ring

and scraper ring grooves
Grooves for piston ring 6.43 S 14

08028-0D/H5250/94.08.12
A
Grooves for piston ring 5.43 S 15
Grooves for scraper ring 8.43 S 16
06.33 - ES0
V28/32S
Dimensions Item
V28/32S
Fig. Designation
A B C No.
Plier for piston pin lock ring 550 25 ø3.5 S 20
B
C
Guide fork for connecting rod 90 740 ø25 S 24
Torque spanner 20-120 Nm 463 1/2" S 26

Torque spanner 50-300 Nm 618 1/2" S 27
08028-0D/H5250/94.08.12
06.33 - ES0
Tools for Piston, Connecting Rod Plate
52006-09H and Cylinder Liner Page 4 (5)
V28/32S
Dimensions Item
V28/32S
Fig. Designation
A B C No.
Pneumatic impact spanner 1" E 41
Lifting tool for cylinder liner 1116 465 304 S 45
B
A
Honing brush ø280 900 S 50

08028-0D/H5250/94.08.12
06.33 - ES0
V28/32S
Dimensions Item
V28/32S
Fig. Designation
A B C No.
A Funnel for honing of cylinder ø323 1610 S 51

liner
Magnifier (30 x) 140 50 S 55
Inside micrometer:
08028-0D/H5250/94.08.12
Measuring range
275-300 mm (cylinder liner) E 60
20
275 80
15
10
Measuring range
225-250 mm (connecting rod) E 61
06.33 - ES0
Your Notes :
Plate Tools for Operating Gear for Inlet Valves
Page 1 (1) Exhaust Valves and Fuel Injection Pumps 52008-06H
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Feeler gauge for inlet valves 0.5 0.4 13 S 01
Feeler gauge for exhaust 1.0 0.9 13 S 02

valves
(2 sets of each)
Extractor for thrust piece, on

roller guide for fuel pump 49 ø M24 S 06
29.5 x 1.5
01.11 - ES0
Your Notes :
Plate
Page 1 (3) Tools for Crankshaft and Main Bearing 52010-07H
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Crankshaft alignment gauge

(autolog) 210 150 S 05
Guide pipe for main bearing

cap, 2 pieces ø65 220 M48 S 10
08028-0D/H5250/94.08.12
07.19 - ES0
Plate
52010-07H Tools for Crankshaft and Main Bearings Page 2 (3)
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Lifting straps for main and guide

bearing cap, 2 pieces 1000 M16 20 S 15
Dismantling tool for guide bea-

ring shells 250 32 S 19
Tool for upper main bearing ø50 52.5 S 22
O-ring ø9.9 ø2.6 S 23

08028-0D/H5250/94.08.12
07.19 - ES0
Plate
Page 3 (3) Tools for Crankshaft and Main Bearings 52010-07H
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Guide tools for mounting of up-

per guide bearing shell 148 120 S 25
Lifting handle for main bearing

cap 315 500 210 E 30
Angle for mounting on crank-

web without counterweight 84 60 25 S 40
(for checking of main bear-
ings
alignment - autolog)
08028-0D/H5250/94.08.12
07.19 - ES0
Your Notes :
Plate
Page 1 (3) Tools for Fuel Oil System and Injection Equipment 52014-05H
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Pressure testing pump, compl.

01
03 GOU-G001 S 01
02
Clamping bracket for fuel

injector, VTO-W022 02
04 Clamping bracket for fuel

05
injection pump, PYO-W020 03
Fuel pipe, VTO-W023 04
Fuel pipe, VWM-W007 05
Cleaning tool for fuel injector,

consist of: S 10
1 pcs tool holder
5 pcs needles
C
Spanner for high pressure pipe 30 270 19 S 15
08028-0D/H5250/94.08.12
05.06 - ES0
Plate
52014-05H Tools for Fuel Oil System and Injection Equipment Page 2 (3)
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Spanner for fuel injection

pump (left side) 270 88 24 S 20
A B
C
Spanner for fuel injection
B
pump (right side) 270 88 24 S 25
Spanner for fuel injection pump

(right side) 270 88 24 S 27
08028-0D/H5250/94.08.12
05.06 - ES0
Plate
Page 3 (3) Tools for Fuel Oil System and Injection Equipment 52014-05H
V28/32S
V28/32S
Dimensions Item
Fig. Designation
A B C No.
Grinding tool for fuel injection

valve 25 ø20 ø55 E 30
Fuel Nozzle
Grinding tool for seat for fuel

injection valve ø20 530 ø70 S 35
Extractor for fuel injector valve 150 215 58 S 40

08028-0D/H5250/94.08.12
A
C
05.06 - ES0
Your Notes :
Plate
Page 1 (6) Hydraulic Tools 52021-08H
V28/32S
Dimensions
V28/32S
Item
Fig. Designation
A B C No.
Pressure pump, complete, with

wooden box S 01
Manometer 02
Gasket for Item 07 06
Quick coupling 07
Distributor 08
Distributing piece for cylinder

head, complete S 15
Gasket 16
Quick coupling 17
Distributing piece for main bea-

ring, complete S 20
08028-0D/H5250/94.08.12
Gasket 16
Quick coupling 17
10.19 - ES0
Plate
52021-08H Hydraulic Tools Page 2 (6)
V28/32S
Dimensions
V28/32S
Item
Fig. Designation
A B C No.
Quick coupling 17
Allen key, 7 mm 26
Venting screw 27
Tommy bar 33
Ball 37
Adapter 38
Stroke indicator band 39
Hydraulic tools for connecting

rod with wooden box, complete
S 70
Piston for hydraulic jack
71
O-ring with back-up ring
72
O-ring with back-up ring
74
Cylinder for hydraulic jack
73
Spacer piece
75
Angle piece complete, incl. item
77, 78, 79, 81
76
O-ring
77
Adapter
78
08028-0D/H5250/94.08.12
Coupling socket
79
Hydraulic jack as item nos. 17,
27, 38, 39, 47, 71, 72, 73, 74, 75
Quick coupling 80
81
10.19 - ES0
Plate
V28/32S
Dimensions
V28/32S
Item
Fig. Designation
A B C No.
Quick coupling 17
Hydraulic tools for cylinder head

with wooden box, complete S 25
Allen key, 7 mm 26
Venting screw 27
Piston for hydraulic jack 28
O-ring with back-up ring 29
Cylinder for hydraulic jack 31
Spacer piece 32
Tommy bar 33
Tension screw 34
Hydraulic jack as Item Nos. 17, 35

27, 28, 29, 30, 31, 37, 38, 47
Tools for cylinder head with

wooden box, complete S 36
Ball 37
08028-0D/H5250/94.08.12
Adapter 38
10.19 - ES0
Plate
V28/32S
Dimensions
V28/32S
Item
Fig. Designation
A B C No.
Quick coupling 17
Allen key, 7 mm 26
Venting screw 27
Tommy bar 33
Ball 37
Adapter 38
Hydraulic tools for main

bearings with wooden box,
complete S 40
Spacer piece 41
Cylinder for hydraulic jack 42
Piston for hydraulic jack 45
Hydraulic jack as Item 17, 27,

37, 38, 42, 43, 44, 45, 82 46

08028-0D/H5250/94.08.12
10.19 - ES0
Plate
V28/32S
Dimensions
V28/32S
Item
Fig. Designation
A B C No.
Hose for hydraulic tools, 6 pie-

ces complete 600 ø27 S 49
Hose for hydraulic tools, 1 pie-

ces complete 3000 ø27 S 51
Hose 3000 53
Quick coupling with protecting

cap 54
Hose 600 56
Adapter 57
Air driven High pressure 367 256 326 E 60

pump for hydraulic tools.
C
08028-0D/H5250/94.08.12
10.19 - ES0
Plate
V28/32S
Dimensions
V28/32S
Item
Fig. Designation
A B C No.
Spacer ring ø115 S 65

(only to be used if the
vibration damper is to big
for the hydraulic tools)
08028-0D/H5250/94.08.12
10.19 - ES0
Operating manual
Test rig GXO-G010a / GXO-G011a

Technical Operating manual
documentation for test rig
GXO-D001 GXO-G010a / GXO-G011a
Die Betriebsanleitung ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher
vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Außerhalb dieses
Verwendungszwecks darf die Betriebsanleitung ohne unsere vorherige Zustimmung nicht benutzt, vervielfältigt
oder Dritten sonstwie zugänglich gemacht werden.
Änderungen bleiben vorbehalten
The owner should make this operating manual available to maintenance and operating staff who should follow
the instructions it contains to prevent malfunctions or damage during operation. Other than for this purpose, the
operating manual may not be reproduced, used or disclosed to third parties by any other means without our
prior consent.
Subject to alterations and amendments
Änderungsdienst/Amendments service!
Falls Sie in den Änderungsdienst von L'Orange aufgenommen werden möchten, können Sie
uns das mit einer Postkarte an untenstehende Adresse mit folgenden Angaben mitteilen:
If you would like to be included in the L'Orange amendments service, send a postcard to the
address below including the following details:
Name / Name Betriebsanleitung für GXO-G010a / -G011a

Firma / Company
Straße / Street GXO-D001
Postfach / PO Box Operating manual for GXO-G010a / -G011a
PLZ / Postcode / Zip code
Ort / City GXO-D001/E
Land / Country
Betriebsanleitungs-Nr. / Operating manual No.
© 2007
L'Orange GmbH
Abteilung KVAM
Postfach 40 05 40
70405 Stuttgart
Germany
Contents
Section Page
1 Structure of the test rig (exterior) .....................................................................................................1
2 Structure of test rig (interior) ............................................................................................................2
3 Handling the test rig.........................................................................................................................5
4 Maintenance ....................................................................................................................................6
5 General safety instructions ..............................................................................................................7
5.1 Use in accordance with purpose.............................................................................................7
5.2 Handling the system ...............................................................................................................7
5.2.1 Hazards in handling the test rig ..........................................................................................7
5.2.2 Safety measures in normal operation .................................................................................7
5.2.3 Hazards from electrical energy ...........................................................................................7
5.2.4 Hazards from hydraulic energy...........................................................................................8
5.2.5 Servicing – Maintenance – Troubleshooting.......................................................................8
5.2.6 Organizational measures....................................................................................................8
5.3 Staff ........................................................................................................................................9
5.3.1 Notes relating to staff..........................................................................................................9
5.3.2 Outside normal operation ...................................................................................................9
5.4 General operating instructions................................................................................................9
5.4.1 How to behave....................................................................................................................9
5.4.2 Rules for operation .............................................................................................................9
6 Commissioning ..............................................................................................................................10
6.1 Transport ..............................................................................................................................10
6.2 Setting up .............................................................................................................................12
6.2.1 General information ..........................................................................................................12
6.2.2 Bench-top mounting (GXO-G011a) ..................................................................................12
6.2.3 Floor mounting (GXO-G010a) ..........................................................................................14
6.3 Commissioning the hydraulic system ...................................................................................16
6.4 Commissioning the electrical system....................................................................................17
6.5 Preparations for commissioning the test rig..........................................................................18
7 Technical data ...............................................................................................................................22
7.1 GXO-G010a (floor-mounted system)....................................................................................22
7.2 GXO-G011a (bench-top system) ..........................................................................................22
8 Parts list and exploded drawing.....................................................................................................23
1 Structure of the test rig (exterior)
Item Part Item Part Item Part

1.4 Selector switch for mode 5 Relief valve 17.3 Plexiglass tube
(sight glass)
3 Pressure gauge 15.1 Cover 17.6 Extraction
(pressure display bar/psi) (tray) (spray container)
4 Hand lever 15.2 Knurled screw 17.9 Oil collector
(hand pump) (to fix cover in position)
a Rotary receiver d Release lever f Oil sight glass

(pump/valve) (rotating mechanism)
b Height adjustment e Storage compartments g Switch
(extraction)
c Socket
(test line)
Editor Ruf (TEDO) Status as at: 00 Page 1

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2 Structure of test rig (interior)

1 Booster 4 Hand pump 15.4 Mesh filter
a Rotary receiver (pump/valve) b Test oil reservoir c Oil sight glass

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6 Tube 9 Tube 13b Hose
Pump – booster Booster – pressure gauge Oil container – pump
7 Tube 13a Hose 13c Hose
Booster – test line connection Relief valve – test oil reservoir Booster – test oil reservoir
8 Tube
Booster – relief valve

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The test rig was developed for checking leaks, pressure-testing injection, measuring the
pressure drop of injection valves and for assembling/dismantling all L'O devices for medium-
speed large diesel engines.
There are two versions: GXO-G010a has a base for mounting directly to the floor, whilst
GXO-G011a is intended to be fitted to a bench. Both devices have identical functions and
operation.
GXO-G010a GXO-G011a
The test rig has a safety valve (integrated in the booster) which opens at 900 bar!

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3 Handling the test rig
This operating manual applies primarily to the professional assembly/dismantling of L'O

devices, in particular injection pumps and injection valves. The instructions below must be
followed.
• In the event of malfunctions, the test rig must be professionally examined and repaired
with the utmost care by specialist staff. We therefore recommend that you make use of
the fitter service set up by L'Orange or take the test rig to a L'Orange customer service
center.
• L'Orange is unable to accept any liability for any damage caused by independent
assembly or repair work performed on the test rig.
• In the event of special circumstances requiring immediate work on the test rig, proceed in
accordance with the instructions in Assembly Instruction GXO-D002.
• The components of hand pump GCO-G005d are precision-engineered to match and can
consequently only be replaced as an entire unit (paired).
• Repair work may only be performed using the tools intended for the purpose.
• The test rig serves solely for testing, assembling and dismantling components up to a
maximum weight of 120 kg. All components are to be professionally attached to the
receiver and secured against rotation using the locator angle and screws.
• All locator angles for the preceding type (GUO, GXO) will fit the new test rigs without
modification.
• The function test (pressure drop time, opening pressure, leak test) of injection valves is
meaningful only up to a needle diameter of Ø 12 mm (e.g. VVO, VWM). The function test
on larger injection valves should be performed on test rig GXO-G004.

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4 Maintenance
The test rig is largely maintenance-free. Moving parts are subject to natural wear which
experience shows is very limited. However, the wear characteristics of the components
depend largely on the test rig being handled and cared for properly. To ensure smooth
operation of the test rig in the long term, please note and comply with the following care and
maintenance instructions.
• Clean the outside of the test rig after every use.
• Subject all components to a visual inspection once a month – damaged or worn

components should be replaced by specialist staff if required.
• All electrical components should be inspected for damage once a month. Likewise check
monthly that plug connections are tight – damaged components should be replaced by
specialist staff if required.
• Check all hydraulic lines and components once a month for pressure loss and damage.
The lines must be located firmly in their screwed connections to prevent them coming
loose – damaged components should be replaced by specialist staff if required.
• Check six-monthly that mechanical components have not come loose and are tight – if
required, components should be adjusted and tightened up.
• Check once a month that safety devices are working properly.
• All moving parts on the device should be greased. The locking bolt and sliding bar on the
spray container should also be oiled occasionally.
• Check the oil collector daily. Empty the collector if necessary. Used oil must be disposed
of properly and may not, under any circumstances, be reused.

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5 General safety instructions
5.1 Use in accordance with purpose
The test rig is solely for assembling/dismantling injection pumps which do not exceed a total
maximum weight of 120 kg (injection pump incl. valve) and for testing injection valves up to
size "VVO".
The owner of the system is responsible for those setting up, operating or maintaining the
device and for third parties following the safety precautions outlined in this operating manual.
L'Orange hereby refuses to accept any liability for damage to those operating or setting up
the device, to maintenance staff, to the company and/or to other third parties if the system is
used in any way not covered by "use in accordance with purpose", unless L'Orange causes
such damage deliberately or as a result of gross negligence.
5.2 Handling the system
5.2.1 Hazards in handling the test rig
The test rig is built in accordance with the state of the art and satisfies recognized safety
regulations. Nevertheless, its use can still present a hazard to the life and limb of the user or
of third parties, as well as damage to the system or to other material resources. The system
should therefore only be used in accordance with purpose and when it is in a perfectly safe
condition. Faults which may impair safety should be eliminated immediately and avoided
during operation.
5.2.2 Safety measures in normal operation
Operate the test rig only if all the safety devices are fully functional. Check the system for
externally visible damage and always check that the safety devices are working before
starting operation.
Before assembling, dismantling or modifying any circuit:

switch off the power supply and depressurize the test rig.
Follow the general safety instructions of DIN 58126 and VDE 0100.
5.2.3 Hazards from electrical energy
Once maintenance work is complete, check that the safety devices are working properly.
Only a professional trained electrician or electronics engineer may perform any work on the
electrical supply.

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5.2.4 Hazards from hydraulic energy
Keep away from the spray jet during the function test (pressure build-up) – risk of blood
poisoning!
Observed the permitted opening pressure for the injection valve in question (see catalogue
sheet).
5.2.5 Servicing – Maintenance – Troubleshooting
During the warranty period, servicing and maintenance work will be performed within the
scope of the maintenance contract. Make sure that the specified setting and servicing work is
performed at the prescribed intervals. Secure the hydraulic and electrical systems from being
switched on unintentionally.
The test rig must be disconnected from the power supply and depressurized for all
maintenance, servicing and repair work. Check that all screwed connections undone in the
course of maintenance, servicing and repair work are firm.
5.2.6 Organizational measures
All safety devices provided are to be checked regularly.

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5.3 Staff
5.3.1 Notes relating to staff
• The test rig may only be operated by persons who have received instruction. This applies
to both operation and the safety devices of the test rig.
• Wear safety footwear when working on the test rig.
• Wear oil-resistant clothing.
• Wear safety glasses.
• Wear oil-resistant gloves and clothing.
• Avoid several people working on maintenance and set-up tasks at the same time.
• Naked flames and smoking are forbidden within a radius of 5 m of the test rig!
5.3.2 Outside normal operation
Activities involved in maintaining, servicing or repairing the system may be performed only by
people with adequate specialist qualifications.
5.4 General operating instructions
The test rig demands some rules of operation which must be complied with. If these rules are
ignored, it is possible for faults to arise in the testing process and hazards to physical health
cannot be ruled out. You are strongly advised to follow the rules below.
5.4.1 How to behave
• Naked flames and smoking are absolutely prohibited at the test rig and within a radius of
5 m.
• It is prohibited to reach into the spray container (plexiglass tube) during the testing
process.
• Stations should be made safe by mechanical means in the event of relatively large groups
of spectators.
• It is prohibited to pull out any live cable connection.
• Water of any kind is to be kept away from the system.
• Test lines should be carefully examined for cracks or leaks before each use.
5.4.2 Rules for operation
• The test rig may only be operated by people who have received instruction.
• Operation should be in accordance with the operating manual.
• Prevent unsupervised operation of any equipment.

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6 Commissioning
6.1 Transport
When the test rig is delivered, ensure that it is only transported using suitable transportation
equipment. The GXO-G010a weighs approx. 150 kg and the GXO-G011a approx. 75 kg.
The routes to be taken should be cleared for transport and be accessible for the
transportation equipment. If appropriate, put up warning signs or barrier tape.
Take care when opening the transport box, preventing extra components like the test oil
supplied from falling out. Once the transport box is open and any additional components
have been removed, the test rig can be removed and taken to its final location.
Please check that all screwed connections are tight. Vibration during transport may have
caused them to come loose. The test rig may not be gripped by its feet and certainly not
under the feet – increased risk of crushing or trapping.

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State in which GXO-G010a delivered
Canister [b] containing the test oil is in the

base of the test rig.
The lever for the pump is enclosed with the

delivery and needs to be fitted for com-
missioning [a].
State in which GXO-G011a delivered
The lever for the pump is enclosed with the

delivery and needs to be fitted for com-
missioning [a].

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6.2 Setting up
6.2.1 General information
The test rig should be screwed to the floor (GXO-G010a) or bench (GXO-G011a) at its
intended location. In addition, the workbench should likewise be affixed to the floor to prevent
tipping over. A loadbearing/solid floor is a prerequisite for smooth assembly and operation.
An appropriate gap should be planned between the test rig and the wall.
Keep dust and dirt away from the test rig (cover).
6.2.2 Bench-top mounting (GXO-G011a)
• Remove screw [15.2].
• Remove cover [15.1].
• Fit dismantling aid [a] and hold the body

[15] steady using a crane.
• Undo and remove screws [b].
• Carefully lift body [15] using the crane

and place it aside.

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• The baseplate [a] is now in front of you

ready for assembly.
• Transfer the bores in the baseplate as

shown in the sketch to the workbench
and drill into the worktop using a
Ø 12 mm bit.
Line A represents the edge of the bench!
• Screw the baseplate firmly to the bench

using M10 screws (length depending on
the thickness of the workbench). The
screws must be pushed in from above
and tightened up from underneath with
washers and a nut.
• Put body [15] on the baseplate and

attach with screws [b].

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6.2.3 Floor mounting (GXO-G010a)
• Remove screw [15.2].
• Remove cover [15.1].
• Align the test rig and transfer the bore

positions for baseplate [1] to the floor.

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• Fit dismantling aid [a].
• Carefully lift subframe [20] using a crane

and place it aside.
• Drill holes in the floor.
• Use the crane to return subframe [20] to

its assembly position.
• Remove the dismantling aid [a].
• Depending on the substrate, attach the

baseplate of the test rig with four screws
[a].

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6.3 Commissioning the hydraulic system
The owner commissions the rig independently. The procedure required to do so is described
below. A prerequisite is that the test rig is already firmly screwed as described in the previous
section.
• Remove transport sealing plug [a].
• Fit filter [15.4].
• Pour Fuchs Renotest test oil into the test

oil reservoir to at least oil sight glass [a]
(capacity approx. 3.5 liters).

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• Fit cover [15.1] and fix in position with

screw [15.2].
• Pump lever [4] until test oil escapes from

connection [a] without bubbles.
6.4 Commissioning the electrical system
• Connect the cable for non-heating

appliances supplied to socket [a] and
supply with electrical power.
Extraction operates at a voltage of 230 V

and cannot be switched to 110 V!
The fitted plug can be changed if

required, but this should be done only by
a qualified specialist. The connection for
this must be fused at a rating to suit the
consumers. To prevent problems in oper-
ation, we strongly recommend separate
fuse protection for the test rig.

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6.5 Preparations for commissioning the test rig
If rotary receiver [1] needs to be swivelled, follow the instructions below.
• 360° rotation
The swivel restriction can be released

using release lever [b]. If the lever is
moved to the right and held there, rotary
receiver [a] can be turned through 360°.
Warning, risk of injury!

The valve can rotate in an uncontrolled
manner once the swivel restriction is
released.
• 12.5° rotation
If lever [b] is moved only briefly to the

right and then returned to the left-hand
position, rotary receiver [a] can be turned
through 12.5°.

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Make the following preparations every time you use the test rig.
• Follow the safety instructions!
• Only staff who have received instruction

may operate the test rig.
• The test rig must be depressurized com-

pletely using relief valve [5].

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• Use height adjuster [c] to move the spray

container right to the bottom and secure
the lever in the lowest latching position
[b].
• Fit valve receiver on rotary receiver [a].
• Fit valve in receiver.

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• Connect the injection valve to connector

[a] of the test rig using the corresponding
test line. Tighten screwed connections
firmly!
• Use height adjuster [b] to move the spray

container upwards until the injection
nozzle of the valve is inside the plexi-
glass tube. Secure the lever in one of the
latching positions!
• Switch on extraction.
• You can now select operating mode.

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7 Technical data
7.1 GXO-G010a (floor-mounted system)
Purpose: medium-speed diesel engines

Weight: GXO-G010a = 146 kg
Dimensions: height: 1130 mm
width: 440 mm excl. spray container
width: 670 mm incl. spray container
depth: 510 mm excl. spray container
depth: 560 mm incl. spray container
Piston diameter: 8 mm
Safety valve: opening pressure = 900 bar
Pressure gauge: display up to 1000 bar / 14400 psi
Test oil: Fuchs Renotest LO
Test oil viscosity: 4.5 cSt/40°C
Test oil reservoir: approx. 3.5 liters
Test oil line: connecting thread 24 x 1.5
Maximum load: 120 kg (receiver)
7.2 GXO-G011a (bench-top system)
Purpose: medium-speed diesel engines

Weight: GXO-G011a = 71 kg
Dimensions: height: 330 mm excl. spray container
height: 1120 mm incl. spray container
width: 440 mm excl. spray container
width: 670 mm incl. spray container
depth: 510 mm excl. spray container
depth: 560 mm incl. spray container
Piston diameter: 8 mm
Safety valve: opening pressure = 900 bar
Pressure gauge: display up to 1000 bar / 14400 psi
Test oil: Fuchs Renotest LO
Test oil viscosity: 4.5 cSt/40°C
Test oil reservoir: approx. 3.5 liters
Test oil line: connecting thread 24 x 1.5
Maximum load: 120 kg (receiver)

www.lorange.de
8 Parts list and exploded drawing
GXO-G011a GXO-G010a
Weight Weight
Item Pcs. Part L'O-No. g
Item Pcs. Part L'O-No. g
Test rig GXO-G011a (replacement for all GUO-G...) 71000 15,2 Screw D464-M8x16 10
1 Booster, compl. GXO-U058 13500 15,3 Perforated plate GXO-T133 700
1,1 Booster GXO-U056 12000 15,4 Filter screw GCO-T065 60
1,2 4 Connection piece GXO-T173 30 15,5 Mesh filter FSH-1 5
1,3 2 Screw D912-M10x40-12.9 35 17 Spray container GXO-U065 7150
1,4 Valve actuator GXO-U057 1350 17,1 Cover GXO-U067 1100
3 Gauge FMA-160.1000AH 1100 17,2 Perforated plate GXO-T159 700

4 Hand pump Ø8 GCO-G005d 2700 17,3 Plexiglass tube GXO-T155 1350
5 Relief valve GXO-U059 350 17,5 3 Screw D7380-M8x25 15
6 Tube GXO-T126 110 17,6 Spray container GXO-U066 3900

7 Tube GXO-T127 130 17,8 Screw D7380-M8x20 12
8 Tube GXO-T128 130 17,9 Collector GUO-T041 75
9 Tube GXO-T129 125

10 9 Screw D7380-M6x20 7 Test rig GXO-G010a (replacement for all GXO-G003...) 146000
11 2 Screw D7380-M5x12 5 20 Lower section GXO-U055 57500
12 2 Screw D912-M8x60-12.9 30 20,1 4 Screw D912-M10x20-10.9 25

13 3 Hose GXO-T130 L = 1200 mm 50 20,2 Screw D7380-M8x25 15
15 Body GXO-U062 44150
15,1 Oil tray GXO-U063 2150 not specified items like GXO-G011a 06/07

www.lorange.de

V28-32S PowerPlantDDD

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Instruction book for :

MAN Diesel Identification No. for Instruction Book.

Identification No for Description: 000.00

Identification No for Working Card: 000 - 00.00

Identification No for Plates: 00000 - 00 H

For ordering of spare parts, see page 500.50.

Text Index Drawing No.

Engine data 500/600

Questionnaire Description A501

Operation of engine 501/601

Operation Description 501.01 (08)

Performance and condition 502/602

Engine performance and condition Description 502.01 (01H)

Trouble shooting 503/603

Starting failures Description 503.01 (02)

Media specification 504/604

Text Index Drawing No.

Cylinder head 505/605

Cylinder head Description 505.01 (04H)

Piston/connecting rod 506/606

Piston, connecting rod and cylinder liner Description 506.01 (04H)

Text Index Drawing No.

Camshaft and camshaft drive Description 507.01 (04H)

Operating gear 508/608

Safety, control and monitoring system Description 509.01 (17)

Crankshaft and main bearings Description 510.01 (04H)

Text Index Drawing No.

Checking of main bearings alignment (autolog) Working card 510-01.00 (16H)

Engine frame/Oil pan 511/611

Engine frame and base frame Description 511.01 (05H)

Turbocharger system Description 512.01 (08H)

Compressed air system 513/613

Compressed air system Description 513.01 (13H)

Text Index Drawing No.

Pressure reduction valve Plate 51322-07H

Fuel oil system 514/614

Internal fuel oil system Description 514.01 (11)

Lubricating oil system 515/615

Internal lubricating oil system Description 515.01 (08H)

Text Index Drawing No.

Lubricating oil filter (Type B) Plate 51502-06H

Cooling water system 516/616

Cooling water system Description 516.01 (01H)

Special equipment 517/617

Kit for cylinder unit Kit 51704-05

Specific plant information 519/619

Resilient mounting of generating sets Description 519.03 (09)

Introduction to spare part plates for tools Description 520.01 (01H)

Conf guration : V-built

Cyl. Nos. available : 12-16-18

Power range : 2700 - 4230 kW

Speed : 720/750 rpm

Stroke/bore ratio : 1.14:1

Piston area per cyl. : 616 cm2

Swept volume per cyl. : 19.7 ltr.

Compression ratio : 13.9:1

Max. combustion pressure : 145 bar

Turbocharging principle : Constant pressure system and intercooling

Fuel quality acceptance : HFO up to 700 cSt/50° C (BSMA 100-M9)

Power lay-out MCR version

Speed rpm 720 750

Mean piston speed m/sec. 7.7 8.0

Mean effective pressure bar 19.0 19.1

Max. combustion pressure bar 145 145

Power per cylinder kW/cyl. 225 235

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