L2738 Marine

MAN Diesel
GenSet Index
L27/38
Text Index Drawing No.
Engine data 500/600
Warning Description A500

Main data for engine Description 500.00 (12H)
Introduction Description 500.01 (02)
Safety Description 500.02 (02)
Cross section Description 500.05 (04H)-f
Cross section Description 500.05 (04H)-s
Key for engine designation Description 500.10 (02)
Designation of cylinders Description 500.11 (03)
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, major overhaul/inspection Description 500.25 (11H)
Planned maintenance programme, duties during operation Description 500.26 (13H)
Operation data and set points Description 500.30 (54H)
Green Passport Description 500.33 (01)
Data for pressure and tolerance Description 500.35 (28H)
Data for tightening torque Description 500.40 (12H)
Declaration of weight Description 500.45 (03H)
Ordering of spare parts Description 500.50 (02)
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 (11H)

Operation Description 501.01 (08)
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 (01)
sulphur fuel oil
Performance and condition 502/602
Engine performance and condition Description 502.01 (03H)

Evaluation of readings regarding combustion condition Description 502.02 (02)
Condensate amount Description 502.05 (03)
Engine performance data Working card 502-01.00 (04H)
Check of leakage from inspection holes Working card 502-05.00 (02H)
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 (03)
Trouble shooting guide for air starter Description 503.06 (04)
Trouble shooting guide for air starter Description 503.06 (05H)
Trouble shooting guide for air starter Description 503.06 (06H)
Trouble shooting for cooling water system Description 503.09 (03)
Trouble shooting for lubricating cooler Description 503.10 (01)
Trouble shooting / electrical failures Description 503.20 (09H)
MAN Diesel
Index GenSet
L27/38
Media specification 504/604
Quality of lube oil (SAE40) for heavy fuel oil operation (HFO) Description 504.01-10
Quality of lube oil (SAE40) for operation on gas oil and diesel oil Description 504.01-11
(MGO/MDO) and biofuel
Lubricating points Description 504.05 (03)
Lubricating oil in base frame Description 504.06 (03H)
Specific lubricating oil consumption - SLOC Description 504.07 (03)
Quality of heavy fuel oil (HFO) Description 504.20-08
Quality of marine diesel fuel (MDO) Description 504.20-09
Quality of gas oil / diesel fuel (MGO) Description 504.20-10
Analysis data Description 504.27 (02)
Fuel oil cleaning Description 504.30 (01)
Fresh water system treatment Description 504.40 (02)
Cylinder head 505/605
Cylinder head and water jacket Description 505.01 (03H)

Dismantling of cylinder unit from engine Working card 505-01.00 (04H)
Disassembly of cylinder unit Working card 505-01.01 (03H)
Inspection of inlet valve, exhaust valve and valve guide Working card 505-01.05 (04H)
Reconditioning of valve spindle seat and valve seat ring Working card 505-01.10 (04)
Valve rotator Working card 505-01.15 (05)
Replacement of valve guide Working card 505-01.20 (10)
Check / adjustment of safety valve opening pressure Working card 505-01.25 (01H)
Indicator valve Working card 505-01.26 (05)
Replacement of valve seat ring Working card 505-01.35 (04)
Inspection of cylinder head cooling water space Working card 505-01.45 (03)
Assembly of cylinder unit Working card 505-01.50 (04H)
Mounting of cylinder unit in engine Working card 505-01.55 (03H)
Cylinder head Plate 50501-05H
Valve spindles and valve gear Plate 50502-04H
Cylinder head, top cover Plate 50510-03H
Cylinder unit Plate 50515-08H
Cylinder unit Plate 50515-09H
Piston/connecting rod 506/606
Piston, connecting rod and cylinder liner Description 506.01 (03H)

Separation/assembly of piston and piston rod and fitting of piston rings Working card 506-01.05 (06H)
Piston Working card 506-01.10 (04H)
Connecting rod Working card 506-01.15 (07)
Criteria for replacement of connecting rod big-end and main bearing Working card 506-01.16 (03H)
shells
Removal/mounting of marine head from engine Working card 506-01.24 (01)
Hydraulic tightening of piston and marine head screws Working card 506-01.25 (06H)
In-situ inspection of connecting rod big-end bearing Working card 506-01.30 (03H)
Inspection and honing of cylinder liner Working card 506-01.35 (03H)
Grinding of seal face on cylinder liner and cylinder head Working card 506-01.45 (03H)
Dismantling of piston and cylinder liner at low overhaul height Working card 506-01.50 (06H)
Piston and connecting rod Plate 50601-20H
Cylinder liner Plate 50610-11H
Camshaft 507/607
MAN Diesel
GenSet Index
L27/38
Camshaft and camshaft drive Description 507.01 (03H

Check of camshaft and camshaft drive Working card 507-01.00 (05H)
Inspection and replacement of camshaft bearing Working card 507-01.05 (04H)
Adjustment of camshaft for valve and injection timing Working card 507-01.20 (07H)
Intermediate wheel Plate 50701-03H
Camshaft (injection camshaft) Plate 50705-21H
Camshaft (valve camshaft) Plate 50705-22H
Operating gear 508/608
Operating gear for inlet valves, exhaust valves and fuel injection Description 508.01 (03H)
pumps
Inspection of valve roller guide Working card 508-01.00 (04H)
Control and adjusting of valve clearance Working card 508-01.10 (12H)
Roller guide and push rods Plate 50801-05H
Control/safety 509/609
Safety, control and monitoring system Description 509.01 (13)

Lambda controller Description 509.10 (06)
Communication from the GenSet Description 509.55 (09)
Functional test and adjustment of safety, alarm and monitoring Working card 509-01.00 (03H)
equipment
Function test of shutdown Working card 509-01.05 (07)
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 Working card 509-10.00 (10H)
Governor and governor drive Plate 50901-07H
Regulatiing device Plate 50902-05H
Instruments Plate 50907-20
Level switch in oil sump (LAL/LAH 28) Plate 50920-03H
Fuel oil leakage alarm (LAH 42) Plate 50925-07
Monitoring box Plate 50935-20H
Terminal box Plate 50936-18H
Digital load sharing & speed control Plate 50945-03
Alarm panel Plate 50946-01
Output module Plate 50947-05
APM motor control Plate 50948-01
Valve control box Plate 50949-01
Converter Plate 50956-01
Oil mist detector Plate 50960-02
Oil mist detector Plate 50960-01H
Crankshaft 510/610
Crankshaft and main bearings Description 510.01 (05H)

Checking of main bearings alignment (autolog) Working card 510-01.00 (14H)
Inspection of main and guide bearing shells Working card 510-01.05 (10H)
Vibration damper Working card 510-04.00 (04H)
Vibration damper Working card 510-04.00 (06H)
Crankshaft Plate 51001-10H
Crankshaft Plate 51001-11H
MAN Diesel
Index GenSet
L27/38
Flywheel with gear rim Plate 51003-14H

Vibration damper with attachment Plate 51004-19
Engine frame/Oil pan 511/611
Engine frame and base frame Description 511.01 (04)

Functional test of crankcase safety relief valves Working card 511-01.00 (08H)
Frame with main bearings Plate 51101-19H
Front-end box (seen from front) Plate 51103-18H
Front-end box (seen from right) Plate 51103-19H
Front-end box (seen from left) Plate 51103-08H
Covers on frame Plate 51106-24H
Covers on frame Plate 51106-28H
Cover on frame Plate 51106-23H
Base frame Plate 51111-07H
Base frame Plate 51111-08H
Covering Plate 51120-01H
Turbocharger 512/612
Turbocharger system Description 512.01 (06H)

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)
Control air for charge air blow off Description 512.38 (01H)
Overhaul of charging air cooler Working card 512-01.00 (03H)
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)
Charge air cooler Plate 51201-15H
Exhaust pipe arrangement Plate 51202-05H
Mounting of turbocharger Plate 51203-08H
Water washing of compressor side Plate 51205-01
Drain trap Plate 51208-02H
Blowgun for dry cleaning of turbocharger Plate 51210-01
Charge air pipes Plate 51230-02H
Lubricating oil pipes TC Plate 51231-05H
Mounting of charge air cooler Plate 51235-02H
Mounting of charge air cooler Plate 51235-03H
Control air for preheating valve Plate 51236-01H
Control air for charge air blow off Plate 51238-01H
Compressed air system 513/613
Compressed air system Description 513.01 (09H)

Compressed air system Description 513.01 (14H)
Air filter Working card 513-01.21 (02)
Overhaul, test and inspection of air starter Working card 513-01.30 (04H)
Overhaul, test and inspection of air starter Working card 513-01.30 (05H)
Emergency starting valve Working card 513-01.40 (03H)
Check of compressed air piping system Working card 513-01.90 (03)
Electric turning gear Working card 513-25.00 (01H)
MAN Diesel
GenSet Index
L27/38
Manual turning gear Working card 513-25.00 (02H)

Air starter Plate 51309-09H
Air starter Plate 51309-11H
Air starter (supplement for plate 51309-11H) Plate 51309-12H
Air starter (supplement for plate 51309-11H) Plate 51309-13H
Main starting valve Plate 51310-04
Main stop valve Plate 51315-03
Solenoid valve, 3/2 Plate 51318-01H
Air filter Plate 51321-03
Pressure reduction valve Plate 51322-06H
Pressure reduction valve Plate 51322-04H
Turning gear with attachment Plate 51325-03
Electric turning gear Plate 51325-05H
Overspeed stop valve Plate 51327-01H
Arrangement of jet system Plate 51330-05H
Arrangement of jet system Plate 51330-06H
Starting air receiver Plate 51335-01
Fuel oil system 514/614
Internal fuel oil system Description 514.01 (05H)

HFO/MDO changing valves (V1 and V2) Description 514.25 (02)
Dismounting/mounting of fuel injection pump Working card 514-01.05 (08H)
Disassembly/assembly and repair of fuel injection pump Working card 514-01.06 (07H)
Fuel injection valve Working card 514-01.10 (16H)
Check of fuel oil piping system Working card 514-01.90 (05)
Fuel injection pump Plate 51401-05H
Fuel injection valve Plate 51402-15H
Fuel injection pipe Plate 51404-14H
Safety filter Plate 51415-03
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 51430-07H
Pipes on cylinder section Plate 51434-01H
Fuel injection pump connections Plate 51435-07H
Installation & operation of safety filter Description 2.04.5
Lubricating oil system 515/615
Internal lubricating oil system Description 515.01 (06H)

Lubricating oil pump Working card 515-01.00 (04H)
Prelubricating pump Working card 515-01.05 (08)
Lubricating oil filter Working card 515-01.10 (03H)
Lubricating oil, thermostatic valve Working card 515-01.20 (04H)
Check of lubricating oil piping system Working card 515-01.90 (03)
Lubricating oil cooler Working card 515-06.00 (05H)
Centrifugal bypass filter Working card 515-15.00 (04)
Lubricating oil pump Plate 51501-07H
Lubricating oil filter Plate 51502-15H
Prelubricating pump with el-motor Plate 51504-05
Prelubricating oil pump with el-motor Plate 51504-08H
Lubricating oil cooler Plate 51506-09H
Centrifugal bypass filter Plate 51515-03
MAN Diesel
Index GenSet
L27/38
Crankcase venting Plate 51531-03H

Prelubricating pump arrangement Plate 51535-08H
Cooling water system 516/616
Internal cooling water system Description 516.01 (03H)

Internal cooling water system Description 516.01 (09H)
Check of cooling water system Working card 516-01.90 (03)
Cooling water, thermostatic valve Working card 516-04.00 (03H)
HT and LT water pumps Working card 516-10.00 (02H)
High and low temperature fresh water pumps Plate 51610-10H
Cooling water connections Plate 51630-07H
Preheater unit Plate 51635-02H
Special equipment 517/617
Kit for Inspection of fuel valve Kit 51701-01

Kit for overhaul of fuel valve Kit 51702-01
Kit for complete cylinder unit exchange Kit 51703-01
Kit for cylinder unit Kit 51704-01
Kit for overhaul of rotocap Kit 51705-01
Kit for renewal of piston rings Kit 51706-01
Kit for high- and low temperature freshwater pumps Kit 51710-01
Kit for cover, centrifugal by-pass filter Kit 51715-01
Kit for rotor, centrifugal by-pass filter Kit 51716-01
Kit for cover nut, centrifugal by-pass filter Kit 51717-01
Kit for valve, centrifugal by-pass filter Kit 51718-01
Kit for seals, centrifugal by-pass filter Kit 51719-01
Kit for lubricating oil filter Kit 51725-01
Specific plant information 519/619
Resilient mounting of generating sets Description 519.03 (08H)

Fitting instruction for resilient mounting of GenSets Working card 519-03.00 (27H)
Replacement of conicals Working card 519-03.05 (03H)
Maintenance of conicals Working card 519-03.10 (03H)
Flexible external connections Plate 51902-13H
Conical element Plate 51903-03H
Conical element Plate 51903-07H
Tools 520/620
Function of the hydraulic tools Working card 520-01.05 (02)

Application of hydraulic tools Working card 520-01.06 (05H)
Hand lever pump Working card 520-01.07 (01)
Standard tools for normal maintenance Plate 52000-02H
Tools for reconditioning Plate 52001-01H
Extra tools Plate 52002-01H
Special tools for low dismantling height Plate 52003-02H
Engine data
500/600
MAN Diesel
Description
Page 1 (1) Warning A500
General
Warning !
(Marine engines only)
It is important that all MAN Diesel engines are oper-

ated within the given specifications and performance
tolerances specified in the engines' Technical Files
and are maintained according to the MAN Diesel
maintenance instructions in order to comply with
given emissions regulations.
In accordance with Chapter I of the Code of Federal

Regulations, Part 94, Subpart C, 94.211 NOTICE
is hereby given that Chapter I of the Code of Fed-
eral Regulations, Part 94, Subpart K, 94.1004
requires that the emissions related maintenance of
the diesel engine shall be performed as specified in
MAN Diesel instructions including, but not limited
to, the instructions to that effect included in the
Technical File.
08028-0D/H5250/94.08.12
08.16 - ES0
MAN Diesel
Description
Main Particulars 500.00
Page 1 (1) Edition 12H
L27/38
Cycle : 4-stroke
Configuration : In-line
Cyl. nos available : 5-6-7-8-9
Power range : 1500-2970 kW
Speed : 720/750 rpm
Bore : 270 mm
Stroke : 380 mm
Stroke/bore ratio : 1.4:1
Piston area per cyl. : 572.6 cm2
Swept volume per cyl. : 21.8 ltr.
Compression ratio : 15.9:1
Turbocharging principle : Constant pressure system and intercooling
Fuel quality acceptance : HFO up to 700 cSt/50 C

(ISO 8217 RMH55 and RMK55)
Firing order : 5 cyl. 1-2-4-5-3

(clockwise rotation, seen from aft end) 6 cyl. 1-2-4-6-5-3
7 cyl. 1-2-4-6-7-5-3
8 cyl. 1-2-4-6-8-7-5-3
9 cyl. 1-2-4-6-8-9-7-5-3
Power lay-out MCR version
Speed rpm 720 750
Mean piston speed m/sec. 9.1 9.5

08028-0D/H5250/94.08.12
Mean effective pressure:
5 cylinder engine bar 23.0 23.5

6, 7, 8, 9 cylinder engine bar 25.3 24.3
Max. combustion pressure
5 cylinder engine bar 190 190

6, 7, 8, 9 cylinder engine bar 200 200
Power per cylinder:
5 cylinder engine kW/cyl. 300 320

6, 7, 8, 9 cylinder engine kW/cyl. 330 330
05.33 - ES1
MAN Diesel
Description
Introduction 500.01
Page 1 (1)
Edition 02
General
Description
This instruction book serves the purpose to provide Reliable and economical operation of the plant is
general information for operation and maintenance, conditional upon its correct operation and mainte-
and to describe the design. It can also be used as nance in accordance with MAN B&W Diesel A/S'
a reference when ordering spare parts. instructions. Emissions related maintenance of the
diesel engine shall be performed as specified in MAN
B&W Diesel A/S' instructions and any additional
instructions to that effect included in the Technical
File. Consequently, it is essential that the engine
room personnel are fully acquainted with the con-
tents of this book and, in respect of instructions on
emissions related maintenance of the diesel engine,
also the additional instructions to that effect set out
Section 505-519
Spare parts plates in the Technical File.
The book is a basic instruction manual for the particu-

Working card lar engine supplied, with plant-adapted information
such as basic media-system drawings, electrical
wiring diagrams and test bed reports.
Description
The first five sections (500-504) of the book serve

as a guide to engine operation, and the next fifteen
sections (505-519) contain technical descriptions,
spare parts illustrations with appurtenant parts lists,
as well as working cards.
The last section (520) comprises tools.
The engine is divided into a number of main com-

Fig. 1 Structure of instruction book.
ponents/assemblies, each of which is described in
a section of this book (section 505-519).
Each of these sections starts with technical de-

scriptions of the systems/components, followed by
working cards and the spare parts illustration plates
and parts lists.
08028-0D/H5250/94.08.12
03.36 - ES0
MAN Diesel
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
MAN Diesel
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
MAN Diesel
Description
Cross Section 500.05
L27/38
08028-0D/H5250/94.08.12
99.40 - ES1
MAN Diesel
Description
Cross Section 500.05
L27/38
08028-0D/H5250/94.08.12
99.40 - ES1
MAN Diesel
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
MAN Diesel
Description 500.11
Page 1 (1) Designation of Cylinders Edition 03
General
08028-0D/H5250/94.08.12
98.19 - ES1
MAN Diesel
Description 500.12
Page 1 (1) Engine Rotation Clockwise Edition 02
General
Direction Clockwise of diesel engine seen from flywheel end
Engine
08028-0D/H5250/94.08.12
Alternator
98.18 - ES1
MAN Diesel
Description
Code Identification for Instruments 500.20
Page 1 (2) Edition 03
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
MAN Diesel
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
MAN Diesel
Description
Introduction to Planned Maintenance Programme 500.24
Page 1 (2)
Edition 03
General
General The front page indicates the following:
The overhaul intervals are based on operation on 1) Safety regulations, which MUST be carried out
a specified fuel oil quality at normal service output, before the maintenance work can start.
which means 70-100% of MCR.
2) A brief description of the work.
In the long run it is not possible to achieve safe and
optimum economical running without an effective 3) Reference to any work which must be carried
maintenance system. out before the maintenance work can start.
The structure and amount of information in the main- 4) Related procedures - indicates other works,
tenance programme mean that it can be integrated in depending on the present work - or works
the entire ship's/power station's maintenance system which it would be expedient to carry out.
or it can be used separately.
5) Indicates x number of men in x number of hours
The core of the maintenance system is the key dia- to accomplish the work.
gram, see pages 500.25 and 500.26, indicating the
inspection intervals for the components/systems, The stated consumption of hours is only intended
so that the crew can make the necessary overhauls as a guide.
based on the engines' condition and/or the time
criteria.
The maintenance system is divided into 2 main

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

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

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

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

front page and one or several pages describing and
illustrating the maintenance work.
98.19 - ES0
MAN Diesel
500.24 Description
Edition 03
Introduction to Planned Maintenance Programme Page 2 (2)
General
Experience with the specific station/personnel may 8) Various requisite hand tools.
lead to updating.
9) Indicates the components/parts which it is
6) Refers to data required to carry out the work. advisible to replace during the maintenance
work. Please note that this is a condition for
7) Special tools which must be used. Please note the intervals stated.
that not all tools are standard equipment.
08028-0D/H5250/94.08.12
98.19 - ES0
MAN Diesel
Description 500.25
Page 1 (3) Planned Maintenance Programme Edition 11H
L27/38
Major overhaul/inspection
Time Between Overhauls
overhauled parts
Working
Observations
3rd month
Description
after - hours
= Overhaul to be carried out Card
Check new/
Monthly
Weekly
200
16000
32000
50
2000
8000
Daily
= Check the condition No
Cylinder Unit:
Dismantling of cylinder unit ............................................. 505-01.55

Dismantling of cylinder head, water jacket and cyl. liner.
Cylinder Head and Water Jacket
Inspection of inlet, exhaust valves and valve guide ......... 505-01.05

Valve rotator .................................................................... 505-01.15
Safety valve - overhaul and adjustment of
opening pressure ............................................................. 505-01.25
Indicator valve ................................................................. 505-01.26
Cylinder head cooling water space - Inspection .............. 505-01.45
Cylinder head nut - Retightening ..................................... 200 505-01.55
Piston, Connecting Rod and Cylinder Liner
Inspection of piston ......................................................... 506-01.10

Piston ring and scraper 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 bearing shells ................................ 506-01.16
Connecting rod - Retightening ......................................... 200 506-01.25
Cylinder liner - Cleaning, honing and measuring ............ 506-01.35

08028-0D/H5250/94.08.12
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
02.49 - ES0
MAN Diesel
500.25 Description
Edition 11H Planned Maintenance Programme Page 2 (3)
L27/38
overhauled parts
Working
Observations
= Overhaul to be carried out
3rd month
Description
after - hours
Card
Check new/
Monthly
Weekly

200
8000
16000
32000
50
2000
Daily
= Check the condition
No
Operating Gear for Inlet Valves and

Exhaust Valves
Roller guide for valve gear ............................................... 508-01.00

Valve gear - Valve bridge, spring, push rod, etc .............. 508-01.10
Lubricating of operating gear - Check ............................. 508-01.00
Crankshaft and Main Bearing
Inspection of main bearing .............................................. 510-01.05

Inspection of guide bearing ............................................. 510-01.05
Vibration damper, see working card ................................ 510-04.00
Counterweight - Retightening, see page 500.40 ............. 200
Main and guide bearing cap - Retightening..................... 200 510-01.05
Engine Frame and Base Frame
Bolts between engine frame and base frame -

Retightening, see page 500.40 ....................................... 200
Turbocharger System
Charging air cooler - Cleaning and inspection ................ 512-01.00

Retightening of all bolts and connections, see special instruc-
08028-0D/H5250/94.08.12
tion book ..........................................................................

For turbocharger, see special instruction book ................
Air starter motor - Dismantling and inspection ................ 513-01.30
02.49 - ES0
MAN Diesel
Description 500.25
L27/38
overhauled parts
Working
Observations
3rd month
Description
after - hours
Card
Check new/
Monthly
Weekly

200
8000
16000
32000
50
2000
Daily
= Check the condition
No
Fuel Oil System and Injection Equipment
Fuel oil injection pump - Check of condition .................... 514-01.06
Fuel injection valve - Adjustment of opening pressure .... 200* 514-01.10
* After major overhaul
Lubricating oil pump - Engine driven ............................... 515-01.00

Lubricating oil cooler ....................................................... 515-06.00
Prelubricating pump - El. driven ...................................... 515-01.05

Thermostatic valve .......................................................... 515-01.20
Cooling Water System
Cooling water pump - Engine driven (HT / LT water).......

Thermostatic valve .......................................................... 516-04.00
Alternator - see special instruction book in section 518
Planned maintenance programme during operation,

08028-0D/H5250/94.08.12
see 500.26.
02.49 - ES0
MAN Diesel
Description 500.26
L27/38
Duties during Operation
overhauled parts
Working
Observations
3rd month
after - hours
Description
Check new/
Monthly
200
8000
16000
32000
Weekly
50
2000
= Overhaul to be carried out Card
Daily
Operating of Engine
Readings of data for Engine and Generator, with refer-

ence to "Engine Performance Data", section 502-1 ........ 502-01.00
Check for leakages .......................................................... 502-05.00
Specification - Cooling water
Cooling water system - Water samples, see section 504 516-01.90
Cylinder Head
Inlet and exhaust valve - check and adjustment of valve

clearance ......................................................................... 508-01.10
Lubricating of operating gear - Check .............................
Check of valve rotators' rotation during engine rotation . 505-01.15
Control and Safety System, Automatics and

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

Lambda controller - Adjustment ...................................... 509-10.00
Governor - Check oil level, see governor instruction
book, section 509 ........................................................... section 509
Turbocharger System
08028-0D/H5250/94.08.12
Dry cleaning of turbine side ............................................ 512-10.00

Water washing of compressor side ................................ 512-05.00
Exhaust pipe compensator .............................................. 512-01.10
Retightening of all bolts and connections, se special
Instruction book ...............................................................
Cleaning of air filter - Compressor side, see special
instruction book ...............................................................
07.29
MAN Diesel
500.26 Description
Edition 13H Planned Maintenance Programme Page 2 (2)
L27/38
Duties during Operation
Time Between Overhaul
Overhauled parts
Working
Observations
3th month
Description
Check new/
after -hours
50
2000
8000
200
32000
Weekly
16000
Card
Montly
Daily
Function test - Main and emergency starting valve ......... 513-01.40

Air filter, draining of bowl (filter element to be replaced
when pressure drop exceeds 0,7 bar) ............................. 513-01.21
Compressed air system - Check of the system ............... 513-01.90
Fuel Oil System and Injection Equipment
Fuel oil system - Check the system ................................. 514-01.90

Fuel oil - Oil samples after every bunkering, see sec.504 section 504
Fuel injection valve .......................................................... 514-01.10
Lubricating oil filter - Cleaning and replacement ............ 515-01.10

Centrifugal filter - Cleaning and replacement paper filter 515-15.00
Lubricating oil - Oil samples ...........................................

Lubricating oil system - Check the system ...................... 515-01.90
Cooling water system - Water samples ..........................

Cooling water system - Check the system ...................... 516-01.90
Engine Frame and Bedplate

08028-0D/H5250/94.08.12
Flexible mounting - Check anti-vibration mountings ........ 519-03.00

Safety cover - Function test .............................................
Alternator - see special instruction book
Major overhaul/inspection, see 500.25
07.29
MAN Diesel
Description
Operation Data & Set Points 500.30
L27/38
Acceptable Alarm Set point

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

(inlet filter) SAE 40 TI 21 68-73 C <73 C TAH 21 80 C 3
Pressure after filter(inlet engine) PI 22 4.2-5.0 bar >4.5 bar PAL 22 3.5 bar 3 PSL 22 3.0 bar
(PSL 22) (2.5 bar) (D)
Pressure drop across filter PDAH 0.1-1 bar <0.5 bar PDAH 1.5 bar 3
21-22 21-22
Prelubricating pressure (PI 22) 0.14-1.4 bar <1.0 bar PAL 25 0.12 bar (H) 60
Pressure inlet turbocharger PI 23 1.3 - 2.2 bar >1.3 bar PAL 23 0.9 bar 3
(C)
Lub. oil level in base frame LAL 28 Low level 30
LAH 28 High level 30
Pressure before filter PI 21 4.5-5.5 bar
Crankcase protection LAH 92 High level (K) 3 LSH 92 High level (K)
TAH 92 75 C (K) 3 TSH 92 78 C (K)
TDAH 92 2 C (K) 3 TDSH 92 3 C (K)
Temp. main bearing TI 29 80-95 C TAH 29 100 C (K) 3 TSH 29 105 C (K)
Fuel Oil System
Pressure after filter MDO PI 40 3-6 bar PAL 40 2 bar 5

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

HFO TI 40 110-140C
Press. LT system, inlet engine PI 01 2.5-4.5 bar >1.8 bar PAL 01 0.4 + (B) bar 3
Press. HT system, inlet engine PI 10 2.0-4.0 bar >1.8-<6 bar PAL 10 0.4 + (B) bar 3
Temp. HT system, outlet engine TI 12 75-85C <85 C TAH 12 90 C 3 TSH 12 95 C (D)
TAH 12-2 93 C 3 (TSH 12) (100 C)
Temp. LT system, inlet engine TI 01 30-40C
Exhaust Gas and Charge Air
Exh. gas temp. before TC TI 62 480-530 C TAH 62 570 C 10

TAH 62-2 620 C 3
Exh. gas temp. outlet cyl. TI 60 350-450 C TAH 60 465 C 3
08028-0D/H5250/94.08.12
Diff. between individual cyl. average average TAD 60 average (L) 60

30 C 25 C 50 C
Exh. gas temp. after TC
330 kW/cyl TI 61 275-400 C TAH 61 450 C 3
300-320 kW/cyl TI 61 275-375 C TAH 61 450 C 3
Ch. air press. after cooler PI 31 2.8-3.1 bar
Ch. air temp. after cooler TI 31 40-55 C <55 C
Press. inlet engine PI 70 8- 10 bar >7.5-<10 bar PAL 70 7.5 bar 15
08.23 - ES1
MAN Diesel
500.30 Operating Data and Set Points Description

Edition 54H Page 2 (4)
L27/38
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 90 750 rpm SAH 81 862 rpm 0 SSH 81 850 rpm
(SSH 81) (862 rpm) (D)
SI 90 720 rpm SAH 81 828 rpm 0 SSH 81 815 rpm
(SSH 81) (828 rpm) (D)
Turbocharger speed SI 89 (M) SAH 89 (J) 3
Alternator
Winding temperature TI 98 100 C TAH 98 130 C 3

Bearing temperature TI 27 40-60 C TAH 27 85 C 3
Miscellaneous
Jet system failure SX 32 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 ZS 75 Engaged (F) 0
Local indication ZS 96 switch 0
Remote indication ZS 97 switch 0
Common shutdown SS 86 switch (F) 0
Monitoring sensor cable failure SX 86-1 switch 120
Safety sensor cable failure SX 86-2 switch 120
Start failure SX 83 switch (G) 10
Stop signal SS 84 switch (F) 0
Stop failure SX 84 switch 30
Engine run SI 90 720/750 rpm SS 90 710 rpm (I) 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
MAN Diesel
Description
Operation Data & Set Points 500.30
L27/38
Remarks to Individual Parameters F. Start Interlock
The following signals are used for start interlock/

A. Fuel Oil Pressure, HFO-operation blocking:
When operating on HFO, the system pressure must 1) Turning must not be engaged
be sufficient to depress any tendency to gasification 2) Engine must not be running
of the hot fuel. 3) "Remote" must be activated
4) No shutdowns must be activated.
The system pressure has to be adjusted according 5) The prelub. oil pressure must be OK, 20 min.
to the fuel oil preheating temperature. after stop.
6) "Stop" signal must not be activated
B. Cooling Water Pressure, Alarm Set Points
G. Start Failure
As the system pressure in case of pump failure will
depend on the height of the expansion tank above the If remote start is activated and the engine is in block-
engine, the alarm set point has to be adjusted to 0.4 ing or local mode or turning is engaged the alarm
bar plus the static pressure. The static pressure set time delay is 2 sec.
point can be adjusted on the base module SW3. Start failure will be activated if revulutions are below
50 rpm within 5 sec. from start or revulutions are
C. Lub. Oil Pressure, Offset Adjustment below 210 rpm 10 sec. from start.
Start failure alarm will automatically be released after
The read outs of lub. oil pressure has an offset 30 sec. of activation.
adjustment because of the transmitter placement.
This has to be taken into account in case of test and H. Alarm Hysterese
calibration of the transmitter.
On all alarm points (except prelub. oil pressure) a
D. Software Created Signal hysterese of 0.5% of full scale are present. On prelub.
oil pressure alarm the hysterese is 0.2%.
Software created signal from PI 22, TI 12, SI 90.
I. Engine Run Signal
E. Set Points depending on Fuel Temperature
The engine run signal is activated when engine rpm
>710 or lube oil pressure >3.0 bar or TC rpm >5000
rpm.
If engine rpm is above 210 rpm but below 710 rpm
within 30 sec. the engine run signal will be acti-
vated.
J. Limits for Turbocharger Overspeed Alarm

(SAH 89)
08028-0D/H5250/94.08.12
Engine type 720 rpm 750 rpm

5L27/38 / NR 20/S 44,700 44,700
6L27/38 / NR 24/S 44,700 37,300
7L27/38 / NR 24/S 37,300 37,300
8L27/38 / NR 24/S 37,300 37,300
9L27/38 / NR 29/S 31,300 31,300
Fig 1 Set point curve.
08.23 - ES1
MAN Diesel
500.30 Operating Data and Set Points Description

L27/38
K. Crankcase Protection M. Turbocharger Speed
For engines above 2250 kW crankcase protection Normal value at full load of the turbocharger is de-
is standard for marine application. This will be done pendent on engine type (cyl. no) and engine rpm.
by an oil mist detector (LAH/LSH 92) as standard or The value given is just a guide line. Actual values
with a splash oil/crankcase protection system (TAH/ can be found in the acceptance test protocol.
TSH/TDAH/TDSH 92 + TAH/TSH 29) as option.
L. Exhaust Gas Temperatures
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
MAN Diesel
Description
"Green Passport" 500.33
General
List of potentially hazardous materials of MAN four-
stroke diesel engines that are relevant to be delivered
to recycling facilities according to IMO resolution
A.962(23) Adopted on 5 december 2003.
Asbestos
Type of asbestos Materials Location Approximate quantity/volume
- - None
Plastic Materials
Type Location Approximate quantity/volume
Copolymer, based on acrylnitrile and O-rings (Inside engine) *)
butadiene: NBR
Copolymer, based on vinylidene-fluoride O-rings (Inside engine) *)
and hexafluoro-propene: FPM
FPI 155, Flame retardant according to Cable jacket < 100 m
IEC 332-3 cat. 3
Materials containing PCBs, PCTs, PBBs at levels of 50 mg/kg or more

None
Gases sealed in the machinery

Argon Exhaust thermometers *)
Chemicals in engine
Anti-seize Compounds Used on high temperature screws *)
Engine Additives None
Water Treatment: Nitrite-borate inhibitor Fresh water system See instruction manual
Other Substances in engine

Fuel oil Engine F.O. pipe system < 0,020 m3
Lubricating oil Engine frame See instruction manual
Filter cartridge Lub. oil filter on engine 2 pcs. 1)
Filter cartridge Lub. oil filter on engine/filter candles 2 pcs./48 pcs. 2)
Mercury None
Lithium battery (if installed) Electronic cabinet 1 pcs.
08028-0D/H5250/94.08.12
Lead Pb - for soldering circuit board Electronic cabinet < 10 g/engine 2)
*) The component is most likely bound in an alloy or present at a very low concentration
1
) only valid for GenSets
2
) only valid for Propulsion engines
07.36 - ES0
MAN Diesel
Description
Data for Pressure and Tolerance 500.35
L27/38
Section Description mm / bar
505 Safety valve to be adjusted to 230 bar

(7 bar at 20C)
Maximum inner diameter, valve guide 20.2 mm
For grinding of valve spindle and valve seat ring
(see also working card 505-01.10)
Minimum height of valve head, inlet valve and exhaust valve, "H"1 9.0 mm
506 Piston and piston ring grooves (see working card 506-01.10)
Maximum clearance between connecting rod bush and piston pin 0.29 mm
Maximum ovalness in big-end bore (without bearing) 0.02 mm
Maximum inside diameter cylinder liner, maximum ovalness 0.1 mm 270.2 mm
Sealing minimum height above the cylinder liner 0.2 mm
507 Maximum tolerance at the valve cam bearing 0.3 mm

Maximum tolerance at the fuel cam bearing 0.35 mm
508 Valve clearance, Inlet valve (cold engine 15 - 50C) 0.7 mm

Valve clearance, Exhaust valve (cold engine 15 - 50C) 0.7 mm
Maximum clearance between rocker arm bush and rocker arm shaft 0.3 mm
Maximum total tolerance between shaft bushing and roller 0.35 mm
509 Free spand between pick-up and band steel (Lambda controller) 1 mm
510 Deflection of crankshaft (autolog) (see working card 510-01.00)

Minimum axial guide bearing clearance 0.400 mm
Maximum axial guide bearing clearance 0.663 mm
Minimum radial main bearing clearance 0.225 mm
Maximum radial main bearing clearance 0.336 mm
514 Combustion pressure range at full load 185 - 200 bar

08028-0D/H5250/94.08.12
Individual cylinders; admissible deviation from average 5 bar

Fuel valve, adjusment of opening pressure 400 - 410 bar
(when new spring) (420 bar)
Clearance (A) of plunger between thrust plate 0.07-0.11 mm

and plunger base plate / fuel injection pump
Total axial clearance of follower / fuel injection pump 0.4 - 0.7 mm
08.03 - ES0
MAN Diesel
Description 500.40
Page 1 (5) Data for Tightening Torque Edition 12H
L27/38
Lubricant
Pressure limitation of the hydraulic high pressure

M Lubricating paste up to 200C Coefficient of
friction 0.08 - 0.12 pump to be set to 50 bar above hydraulic oil pres-
sure for tightening.
MH High temperature lubricating Coefficient of Hydraulic oil pressure for untightening max. 5% above
paste above 200C friction 0.08 - 0.12
hydraulic oil pressure for tightening.
O Oil
XX Screw in with Loctite 243 until it

sits squerely Note: For tightening bolts to a specified torqe,
only use the specified lubricants. For component
Angle when slackening temperatures p to 200C, e.g. Molykote Pasta d or
L Number of holes by which the Optimoly Paste White-T. For component tempera-
nut must be turned back tures above 200C, e.g. Molykote Paste HSC or Copa
Slip.
Pv Pre-tightening pressure
l Elongation of screw
Tab. 1.
Oil Screw-in Tightening Please see Please see

Screw Connection pressure moment torques (Nm) Working Plate, Item
(bar) torsions angle Card
012 Cylinder Crankcase
012-1
Cap main bearing / 1.step 100 HAND/hand-M O 510-01.05 51101 182, 086, 194
Cylinder crankcase 2.step 1200 Loctite 243
l = 3.2-3.9, Pv = 400
012-2
Cap main bearing / 1.step 400 HAND/hand-M MH 510-01.05 51101 216, 228
Cylinder crankcase 2.step 1200 HAND/hand-M MH
012-3
Crankcase / 1200 HAND/hand-M MH 505-01-55 51101 062, 086
Cylinder head 900 / 20L
012-4
Crankcase/ 22-M 190-HM 514-01.05 51101 277, 289
Fuel injection pump
08028-0D/H5250/94.08.12
020 Crankshaft
020-1
Crankshaft / Counter 1200 130-M M 51001 082, 094
weight l = 0.55-0.70, Pv = 100 360 / 8L
020-2
Crankshaft/ 200-M 51001 141
Spur wheel
020-3
Lock of crankshaft lub. oil bores 1. step 50-M
2. step 250-M
04.04 - ES0
MAN Diesel
500.40 Description
Edition 12H Data for Tightening Torque Page 2 (5)
L27/38

020-4
1st gear wheel part / 270-M 51001 189
2nd gear wheel part
026 Turning Gear
026-1
Spur gear/Shaft 260-M 51325 179
027 Vibration Damper
027-1
Gear wheel / Damper 1200 HAND/hand-M M 51004 053,161
360 / 8L
030 Connecting Rod
030-1
Connecting rod cover / Con- 1200 HAND/hand-M M 506-01.25 50601 152, 164
necting rod cover l = 0.35-0.55, Pv = 600 450 / 10L
030-2
Connection shaft / connecting 1200 HAND/hand-M M 506-01.25 50601 188, 211
rod bearing body l = 0.3-0.4, Pv = 100 270 / 6L
034 Piston
034-1
Piston 506-01.10 50601 176
034-2
Piston 506-01.10 50601 176
056 Mounting of Fuel Injection Valve
056-1
Clamp / Cylinder head 115-MH 514-01.10 51402 153, 177
08028-0D/H5250/94.08.12
072 Covering on free end
072-1
Oil filter cover/front end box 15 M 51502 755
165-M
100 Control Drive
100-1
Cylinder crankcase / 1200 HAND/hand-M M 507-01.20 50701 073, 119
Stepped spur gear l = 0.65-0.80, Pv = 100
04.04 - ES0
MAN Diesel
Description 500.40
L27/38

101 Camshaft (Valve camshaft)
101-1
Camshaft part piece / 200-M 507-01.00 50705 266
Bearing disk
101 Camshaft (Injection camshaft)
101-4
Camshaft part piece / 210-M 507-01.00 50705 266
Bearing disk 507-01.05
111 Valve Bridge
111-1
Valve bridge / Settting screws 200-M 508-01.00 50502 071, 154
111 Rocker arm
111-1
Rocker arm / Setting screws 200-M 508-01.00 50502 071, 142
200 Fuel Injection Pump with drive
200-1
Valve support/Pump element 1. step 25-M 514-01.05/06 51401 421
2. step 50-M
3. step 75-M
200-1
Thrust ring/Pump casing 90-M 514-01.05/06 51401 600
200-2
Screw plug, disc 250-M 514-01.05/06 51401 242
221 Fuel Injection Valve
221-1
Support body/Nozzle body 270-MH 514-01.10 51402 045
08028-0D/H5250/94.08.12
221-2
Lock nut for setting screw 150-200 MH 514-01.10 51402 082
289 Exhaust Pipe
289-1
Pipe piece / Compensator 80-MH 512-01.10 51202 036, 048
289-2
Clamping strap/Cover 80-MH 505-01.55 51202 xxx
04.04 - ES0
MAN Diesel
500.40 Description
Edition 12H Data for Tightening Torque Page 4 (5)
L27/38

289 Exhaust Pipe before Turbocharger
289-3
Pipe piece/Compensator 80-MH 512-01.10
289-4
Pipe piece / Turbocharger 34-MH 512-01.10
289-4
Pipe piece/Turbocharger 34-MH 512-01.10
300 Lub Oil Pump with Attachment
300-1
Pinion spindle/Spur gear 550-M 515-01.00 51501 199
350 Fresh Water Pump
350-2
Water pump shaft/Spur gear 110-O 516-10.00 51610 237
Water pump shaft/Impeller 50-O 516-10.00 51610 191
434 Fuel Injection Pipe
434-1
High pressure lance/
Fuel injection valve 75-M 51404 010
434-2
Fuel Injection pipe/
Threaded piece 50-M 51404
Fuel injection pipe/
Fuel injection pump
701 Flywheel with Gear Ring
701-1
Crankshaft / Flywheel 1200 HAND/hand-M M 51003 095, 105
08028-0D/H5250/94.08.12
Lub. Oil Cooler
Lub. oil cooler 515-06.00
Note: See also working

card 515-06.00
04.04 - ES0
MAN Diesel
Description 500.40
L27/38
Tightening of Screwed Connections by the
Strength class 5.6 6.8 10.9 12.9
Torque
Conversion factor x 0.47 0.75 1.40 1.7
If screwed connections other than those listed are
to be tightened using a torque wrench, see tab. 3,
Tab. 2. Conversion factors for tightening torques as a function of
should be looked up for approximate tightening the bolt strength class.
torques. The following should be observed:
- The load acting on a screwed connection

depends on the tightening torque applied, on
the lubricant used, the finished condition of
the surfaces and threads, and on the materials
paired. It is, therefore, of great importance that
all these conditions are met.
- Tab. 3 lists the tightening torques for various

threads as a function of the coefficient of friction
, i.e. of the lubricant used. The torques are
based on bolt material of the strength class 8.8
with the bolts stressed up to approximately 7%
of the elastic limit. For other strength classes,
the tightening torques listed in the table have to
be multiplied by the corresponding conversion
factors. the strength class is stamped on the
bolt head.
Thread Tightening torque in Nm

nominal size 8.8 10.9
M/MH O M/MH O
M 6 7 10 10 14
M 8 17 25 25 35
M 10 35 50 50 70
M 12 60 85 85 120
M 14 90 130 130 190
M 16 140 200 200 280
M 18 200 280 280 390
08028-0D/H5250/94.08.12
M 20 270 400 380 560
Tab. 3. Tightening torques for schoulder screws.

Valve from AN 268 (if no data given in tabel).
04.04 - ES0
MAN Diesel
Description 500.45
Page 1 (1) Declaration of Weight Edition 03H
L27/38
Section Component Plate No Item No Weight in Kg
505 Cylinder head, incl. rocker arms 50501 027 400

50502 010/022
Cylinder unit 50500 021 680
506 Piston, complete 50601 081 66

Connecting rod, complete 50601 068 115
Cylinder liner, complete 50610 018 140
511 Cover for crankcase 51106 010 31.5
512 Turbocharger, NR20/R, complete 512 320

Turbocharger, NR24/S, complete 512 505
Turbocharger, NR26/R, complete 512 790
Air cooler 51201 162 380
514 Fuel injection pump 51401 565 75
515 Lubricating oil pump 51501 031/043 40
516 HT- and LT-cooling water pump 51610 105 30

08028-0D/H5250/94.08.12
00.32 - ES0
MAN Diesel
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 with
Name of customer/ship the individual components of a specific engine.
IMO number
Engine Type Note: For ordering of spare parts for governor, turbo-
Engine no charger and alternator, please see the special chapter
Built by in the instruction book for these components.
Plate number
Item no
Description
Qty.
Information found on page 500.15 or 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 Conn
ecting
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
07.04
MAN Diesel
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
07.04
MAN Diesel
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
MAN Diesel
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 1 ft. lbf 1.356 J
106 mega M 10-9 nano n 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
103 kilo k 10-12 pico p 1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
102 hecto h 10-15 femto f
10 deca da 10-18 atto a * Exact value: 4.1868 J
I.T. = International Steam Table
Area (m2)
1 sq. in (square inch) 0.6452 x 10-3 m2

1 sq. ft (square foot) 92.90 x 10-3 m2
04.37 - ES0
MAN Diesel
500.60 Conversion Table Description

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 25C 298 K

Blower inlet pressure 1000 mbar
1 C (Celsius) 1K Charge air coolant temperature 25C 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
tF (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 1C = 1 k**
* For mechanical stresses N/mm2 is widely used. 1 N/mm2 = 106 N/m2

** t (C) = T(K) - T0(K), where T0 = 273.15 K
04.37 - ES0
MAN Diesel
Description
Conversion Table 500.60
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 K = temperature difference
r = density in kg/m3 Cp = heat capacity in J/(kg DK)
t 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 40C
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 100C 1.013 bar 2.256 x 106 J/kg
Fuel oil. Lower calorific value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)
04.37 - ES0
MAN Diesel
Description
Page 1 (3) Basic Symbols for Piping 500.65
Edition 01
General
No Symbol Symbol designation No Symbol Symbol designation

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

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

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

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

08028-0D/H5250/94.08.12
2.8 Joint, sleeve 3.11 Quick-opening valve
2.9 Joint, quick-releasing 3.12 Quick-closing valve
2.10 Expansion joint with gland 3.13 Regulating valve
2.11 Expansion pipe 3.14 Ball valve (cock)
2.12 Cap nut 3.15 Butterfly valve
2.13 Blank flange 3.16 Gate valve
05.02 - ES0
MAN Diesel
500.65 Basic Symbols for Piping

Description
Page 2 (3)
Edition 01
General
No Symbol Symbol designation No Symbol Symbol designation

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

5. APPLIANCES
08028-0D/H5250/94.08.12
3.34 Non-return valve (air) 5.1 Mudbox
3.35 3/2 spring return valve, normally closed 5.2 Filter or strainer
3.36 2/2 spring return valve, normally closed 5.3 Magnetic filter
3.37 3/2 spring return valve contr. by solenoid 5.4 Separator
3.38 Reducing valve (adjustable) 5.5 Steam trap
3.39 5.6 Centrifugal pump

On/off valve controlled by solenoid and pilot
directional valve and with spring return
05.02 - ES0
MAN Diesel
Description
Basic Symbols for Piping 500.65
General
No. Symbol Symbol designation No. Symbol Symbol designation

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

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

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

08028-0D/H5250/94.08.12
05.02 - ES0
Operation of engine
501/601
MAN Diesel
Description
Operation 501.01
L27/38
Preparations for Starting 4) Check pre. lub. oil pressure at inlet to filter, inlet
of the engine and inlet turbocharger on the
The following describes what to do before starting monitoring box display according to the data
when the engine has been out of service for a period and setpoints sheet.
of time.

5) Open the cooling water supply.
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.
a) to preheat the engine. Cooling water at least
Note: The engine must be prelubricated for at least 60C should be circulated through the frame
30 minutes prior to start-up (at the first starting-up, or and cylinder head for at least 2 hours before
if the engine is cold, the engine must be prelubricated start:
for at least 60 minutes)
or - by means of cooling water from engines which
check that there is oil coming out at bearings, pistons are running or by means of a preheater (if
and rocker arms. installed).
08028-0D/H5250/94.08.12
Fig 1 Monitoring of temperature/pressure (MTP). Fig 2 Governor.
02.38 - ES0
MAN Diesel
501.01 Description
Edition 11H Operation Page 2 (3)
L27/38
b) When starting without preheated cooling

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

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

pumps until correct working temperatures have been
achieved. This normally takes 30-60 minutes.
8) Regulating gear - please check:
- that all fuel injection pumps are set at index

"0" when the regulating shaft is in STOP 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
Fig 3 Operation box (OB).
is removed.
Starting Air System Check the following on the monitoring box according
to the data and setpoints sheet.
9) Check the pressure in the starting air
receiver(s). 14) Check the lubricating oil pressure.
10) Drain the starting air system. 15) Check the cooling water pressure.
11) Open the starting air supply. 16) Check the fuel oil feed pressure.
08028-0D/H5250/94.08.12
12) Check the air pressure on the operating box 17) Check that the turbocharger is running.
according to the data and setpoints sheet.
18) Check that the prelubricating oil pump stops
automatically.
Starting
19) Check that all cylinders are firing, see exhaust
13) Start the engine by activating the start button gas temperatures.
on the operation box; push the button until the
engine ignites, see Fig 3. Note: Check the stop cylinder (Lambda controller) for
regulating the shaft works properly, both when stop-
ping normally and at overspeed and shut down.
Testing during Running
Check that all shutdowns are connected and func-
See Description 509.05 before operating the control tion satisfactory.
panel.
02.38 - ES0
MAN Diesel
Description
Operation 501.01
L27/38
20) Test the overspeed, see Working Card 29) To ensure full operational reliability, the con-
509-01.05. dition of the engine should be continuously
observed so that order for preventive mainte-
21) Check that all alarms are connected. nance work can be carried out before serious
breakdowns occur, see also section 502.
Operation
Stopping
The engine should not be run up to more than 50%
load to begin with, and the increase to 100% should 30) Before stopping, it is recommended to run the
take place gradually over 5 to 10 minutes. engine at reduced load, max. 2 min.
Note: When the engine is running the planned 31) The engine is stopped by activating the stop
maintenance programme and the following should button on the operating box. Only one push is
be checked: needed.
22) The lubricating oil pressure must be within the

stated limits and may not fall below the stated Starting and Stopping on HFO
minimum pressure. The paper filter cartridges
must be replaced before the pressure drop Starting and stopping of the engine should take
across the filter reaches the stated maximum place on HFO in order to prevent any incompatibility
value, or the pressure after the filter has fallen problems on changeover to MDO.
below the stated minimum value. Dirty filter
cartridges cannot be cleaned for re-use. MDO should only be used in connection with mainte-
nance work on the engine or before a longer period
23) The lubricating oil temperature must be kept of engine standstill.
within the stated limits indicated on the data
and setpoints sheet. Before starting on HFO the engine must be properly
preheated as described in "Preparations for Starting"
24) The fuel oil pressure must be kept at the stated and as described below.
value.
Stopping the engine on HFO is no problem, but it
25) The cylinder cooling water temperature must should be ensured that the temperature of fuel pipes
be kept within the limits indicated on the data is not reduced to a level below the pour point of the
and setpoints sheet. fuel. Otherwise reestablishing the circulation might
cause problems.
26) The exhaust gases should be free of visible
smoke at all loads. For normal exhaust tem-
Starting on MDO
08028-0D/H5250/94.08.12
peratures, see the test report from shop and

sea trials.
For starting on MDO there are no restrictions except
27) Keep the charging air pressure and tempera- that lubricating oil viscosity may not be higher than
ture under control. For normal values, see the 1500 cSt (10C SAE 40).
test report from shop and sea trials.
Initial ignition may be difficult if the engine and ambient
28) Recharge the starting air receivers to the de- temperatures are lower than 5C and 15C cooling
scribed value. A starting air pressure above 10 water temperature.
bar is sufficient for the L16/24 engine.
02.38 - ES0
MAN Diesel
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
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
02.49 - ES0
MAN Diesel
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.
6) Check the cooling water pressure.
Note: To avoid shock effects owing to large tem-

perature fluctuations just after start, it is recom-
mended:

60C 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).


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

achieved. This normally takes 30-60 minutes. 12) Check the air pressure on the operating box
according to the data and setpoints sheet.
- 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
MAN Diesel
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-
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.
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
MAN Diesel
501.01 Description
Edition 08
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.
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 (10C 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 5C and 15C 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
MAN Diesel
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
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
MAN Diesel
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:

60C 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).


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
of-service-periods and after overhauls, which
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
MAN Diesel
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
17) Check the lubricating oil pressure.
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-
22) Check that all cylinders are firing, see exhaust sea trials.
gas temperatures.
30) Keep the charging air pressure and tempera-
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
MAN Diesel
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 (10C 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 5C and 15C cooling
of engine standstill. water temperature.
08028-0D/H5250/94.08.12
06.19 - ES0
MAN Diesel
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
MAN Diesel
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
MAN Diesel
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
MAN Diesel
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
Admissible low-load operation Necessary operating period
(load percent/period) on HFO. with min. 70% load after low-
load operation on HFO.
15 Running-up period to 70%

load: approx. 15 min.
a b 70% load
10 HFO or MDO
08028-0D\H5250\94.08.12
5
a b
Operating period (h) Operating period (h)

Example: a) with 10% load 19 hours maximum operation on HFO admissible, then change-over to MDO
or b) operate engine for approx. 1.2 hours with 70% rating minimum, in order to burn off residues.
Afterwards low load operation on HFO can be continued.
Fig 1 Low-load operation.
08.20 - ES1
MAN Diesel
Description Guidelines Regarding MAN DIesel GenSets Operating 501.16

Page 1 (1) on Low Sulphur Fuel Oil Edition 01
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
plications. This guideline covers the engine related cause problems, but please notice the following
aspects of the use of such fuels. restrictions:
Low sulphur HFO In order to avoid seizure of the fuel oil injection
pump components the viscosity at engine fuel oil
From an engine manufacturers point of view there inlet must be > 1.5 cSt (except for L32/40 - required
is no lower limit for the sulphur content of HFO. We viscosity at engine fuel oil inlet > 2.0 cSt). In order
have not experienced any trouble with the currently achieve this it may be necessary to install a fuel oil
available low sulphur HFO, that are related to the cooler, when the engine is running on MGO. This is
sulphur content or specific to low sulphur HFO. This both to ensure correct viscosity and avoid heating
may change in the future if new methods are applied up the service tank, which is important as the fuel
for the production of low sulphur HFO (desulphuriza- oil injection pumps are cooled by the fuel.
tion, uncommon blending components). MAN Diesel
will monitor developments and inform our customers When operating on MDO/MGO a larger leak oil
if necessary. amount from fuel oil injection pumps and fuel oil
injection valves can be expected compared to op-
If the engine is not operated permanently on low eration on HFO.
sulphur HFO, then the lubricating oil should be se-
lected according to the highest sulphur content of In order to carry out a quick change between HFO
the fuels in operation. and MDO/MGO the change over should be carried
out by means of the valve V1-V2 installed in front
of the engine.
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.
08028-0D/H5250/94.08.12
07.12 - ES1
Performance and
condition
502/602
MAN Diesel
Description
Engine Performance and Condition 502.01
L27/38
Performance Data and Engine Condition An increase in charge air temperature involves a cor-
responding increase in the exhaust gas temperature
During operation small changes in the engine condi- level by a ratio of about 1:1.5, i.e. 1C higher charge
tion take place continuously as a result of combustion, air temperature causes about 1.5C higher exhaust
including fouling of airways and gasways, formation of gas temperature.
deposits, wear, corrosion, etc. If continuously record-
ed, these changes in the condition can give valuable Reduction of the charge air pressure results in a
information about the operational and maintenance corresponding reduction of the compression pres-
condition of the engine. Continuous observation can sure and max. combustion pressure. When checking
contribute to forming a precise and valuable basis for the max. pressure adjustment of the engine, it is
evaluation of the optimum operation and maintenance therefore to be ensured that the existing charge air
programmes for the individual plant. pressure is correct.
Engine Performance Data Fuel Injection Pump
If abnormal or incomprehensible deviations in opera- The amount of fuel injected is equivalent to the
tion are recorded, expert assistance in the evaluation supplied energy and is thus an expression of the
thereof should be obtained. load and mean effective pressure of the engine. The
fuel pump index can therefore be assumed to be
We recommend taking weekly records of the most proportional to the mean pressure. Consequently,
important performance data of the engine plant. Dur- it can be assumed that the connected values of the
ing recording (working card 502-01.00 can be used) pump index are proportional to the load.
the observations are to be compared continuously in
order to ascertain alterations at an early stage and The specific fuel consumption, SFOC (measured by
before these exert any appreciable influence on the weight) will, on the whole, remain unchanged whether
operation of the plant. the engine is operating on HFO or on MDO, when
considering the difference in calorimetric heat value.
As a reference condition for the performance data, However, when operating on HFO, the combination
the testbed measurements of the engine or possibly of density and calorific value may result in a change
the measurements taken during the sea trial on the of up to 6% in the volumetric consumption at a given
delivery of the ship can be used. If considerable de- load. This will result in a corresponding change in
viations from the normal conditions are observed, it the fuel pump index, and attention should be paid to
will be possible, in a majority of cases, to diagnose this when adjusting the overload preventive device
the cause of such deviations by means of a total of the engine.
evaluation and a set of measurements, after which
possible adjustment/overhauls can be decided on Abrasive particles in the fuel oil result in wear of fuel
and planned. injection pumps and fuel valve nozzles. Effective
treatment of the fuel oil in the purifier can keep the
content of abrasive particles to a minimum. Worn
Evaluation of Performance Data
08028-0D/H5250/94.08.12
fuel injection pumps will result in an increase of the

index on account of an increased loss in the pumps
Air Cooler due to leakage.
Fouling of the air side of the air cooler will manifest When evaluating operational results, a distinction is
itself as an increasing pressure drop, lower charge to be made between changes which affect the whole
air pressure and an increased exhaust/charge air engine (all cylinder units) and changes which occur
temperature level (with consequential influence on in only one or a few cylinders.
the overhaul intervals for the exhaust valves).
98.27 - ES0
MAN Diesel
502.01 Engine Performance and Condition Description
L27/38
Deviations occuring for a few cylinders are, as a rule, If, for any reason, the surface temperature of the fuel
caused by malfunctioning of individual components, valve nozzle is lower than the condensation tempera-
for example a fuel valve with a too low opening pres- ture of sulphuric acid, sulphuric acid condensate
sure, blocked nozzle holes, wear or other defects, an can form and corrosion take place (cold corrosion).
inlet or exhaust valve with wrongly adjusted clearance, The formation of sulphuric acid also depends on the
burned valve seat, etc. sulphur content in the fuel oil.
Normally, the fuel nozzle temperature will be higher

Turbochargers than the approx. 180C at which cold corrosion
starts to occur.
Fouling of the turbine side of the turbocharger will,
in its first phase, manifest itself in increasing turbo- Abrasive particles in the fuel oil involve heavier wear
charger revolutions on account of increased gas of the fuel valve needle, seat, and fuel nozzle holes.
velocity through the narrowed nozzle ring area. In Therefore, abrasive particles are to the greatest pos-
the long run, the charging air quantity will decrease sible extent to be removed at the purification.
on account of the greater flow resistance through the
nozzle ring, resulting in higher wall temperatures in
the combustion chambers. Exhaust Valves
Service experience has shown that the turbine side The overhaul intervals for exhaust valves is one of
is exposed to increased fouling when operating on the key parameters when the reliability of the entire
HFO. engine is to be judged. The performance of the ex-
haust valves is therefore extremely informative.
The rate of fouling and thereby the influence on
the operation of the engine is greatest for small Especially under unfavourable conditions, fuel quali-
turbochargers where the flow openings between the ties with a high vanadium and sodium content will
guide vanes of the nozzle ring are relatively small. promote burning of the valve seats. Combinations of
Deposits occur especially on the guide vanes of the vanadium and sodium oxides with a corrosive effect
nozzle ring and on the rotor blades. In the long run, will be formed during combustion. This adhesive ash
fouling will reduce the efficiency of the turbocharger may, especially in the event of increased valve tem-
and thereby also the quantity of air supplied for the peratures, form deposits on the seats. An increasing
combustion of the engine. A reduced quantity of air sodium content will reduce the melting point and
will result in higher wall temperatures in the combus- thereby the adhesive temperature of the ash, which
tion spaces of the engine. will involve a greater risk of deposits. This condition
will be especially unfavourable when the va na weight
Detailed information and instructions regarding ratio increases beyond 1:3.
water washing of the turbocharger are given in sec-
tion 512. The exhaust valve temperature depends on the actual
maintenance condition and the load of the engine.
With correct maintenance, the valve temperature is
Fuel Valves kept at a satisfactory low level at all loads. The air
08028-0D/H5250/94.08.12
supply to the engine (turbocharger/air cooler) and the

Assuming that the fuel oil is purified effectively and maximum pressure adjustment are key parameters
that the engine is well-maintained, the operational in this connection.
conditions for the fuel valves and the overhaul in-
tervals will not normally be altered essentially when It is important for the functioning of the valves that
operating on HFO. the valve seats are overhauled correctly in accord-
ance with our instructions.
The use of rotocaps ensures a uniform distribution

of temperature on the valves.
98.27 - ES0
MAN Diesel
Description
Engine Performance and Condition 502.01
L27/38
Air Inlet Valves Engine Room Ventilation, Exhaust System
The operational conditions of the air inlet valves are Good ventilation of the engine room and suitable loca-
not altered substantially when using residual fuel. tion of the fresh air intake on the deck are important.
Sea water in the intake air might involve corrosive
attack and influence the overhaul intervals for the
Fuel Injection Pumps exhaust valves.
Assuming effective purification of the fuel oil, the The fresh air supply (ventilation) to the engine room
operation of the fuel injection pumps will not be very should correspond to approximately 1.5 times the
much affected. air consumption of the engines and possible boilers
in operation. Sub-pressure in the engine room will
The occurrence of increasing abrasive wear of plunger involve an increased exhaust temperature level.
and barrel can be a consequence of insufficient
purification of the fuel oil, especially if a fuel which The exhaust back-pressure measured after the tur-
contains residues from catalytic cracking is used. bochargers at full load must not exceed 250-300 mm
Water in the fuel oil increases the risk of cavitation in water column. An increase in the exhaust back-pres-
connection with pressure impulses occurring at the sure will also cause an increased exhaust valve tem-
fuel injection pump cut-off. A fuel with a high asphalt perature level, and increased fuel comsumption.
content has deteriorating lubricating properties and
can, in extreme cases, result in sticking of the fuel
injection pump plungers.
08028-0D/H5250/94.08.12
98.27 - ES0
MAN Diesel
Description Evaluation of Readings Regarding 502.02

Combustion Condition
General
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,
08028-0D/H5250/94.08.12
Compression too low air filter or charge

owing to leakage of air cooler (air side).
exhaust valve or piston
ring blow-by.
See also:
Engine Performance
and Condition 502.01
98.19 - ES0
MAN Diesel
Description
Condensate Amount 502.05
General
Fig. 1 Nomogram for calculation of condensate amount.
General Then normally, the air cannot absorb the same

amount of water as before.
There is always a certain amount of water in air.
When the air is saturated with aqueous vapour, the Condensation of water in the engine's charge air
humidity is said to be 100% and there is as much receiver is consequently dependent on the humidity
water in the air as it can absorb without condensing. and the temperature of the ambient air. To find out
The amount of water in kg/kg air can be found from if condensation in the charge air receiver will occur
08028-0D/H5250/94.08.12
the diagram. The ability to absorb water depends on the diagram can be used.
the pressure and temperature of the air.
Example:
Amount of Condensation Water in the Charge Diesel engine 1000 kW

Air Receiver Ambient air condition:
air temperature 35 C
Both higher pressure and lower temperature reduce relative air humidity 90 %
the ability to absorb water. A turbocharged diesel Charge air temperature 50 C
engine takes air from outside, compresses and Charge air pressure 2.6 bar
cools the air.
04.31 - ES2
MAN Diesel
502.05 Condensate Amount

Description
General
As a guidance, an air consumption of 8.2 kg/kWh (Le) Amount of Condensate Water in Air Tanks
at full load can be used for MAN B&W engines.
The volume of condensate in the air tank is determi-
Solution according to diagram: ned by means of the curve at the bottom to the right
of the diagram, representing an operating pressure
Water content of air (I) 0.033 kg/kg of 30 bar.
Max. water cont. of air (II) 0.021 kg/kg
Example:
Amount of condensate in charge air receiver.
Amount of condensate in air tank.
= (I-II) x le x P
= (0.033 - 0.021) x 8.2 x 1000 = 123 kg/h Volumetric capacity of tank (V) 4000 dm
Temperature in tank (T) 40 C=313K
Internal press. of tank (p) 30 bar
Draining of Condensation Water = 31 x 105 N/m(abs.)
Gas constant for air (R) 287 Nm/kg.K
This phenomenon will occur on all turbocharged Ambient air temperature 35 C
engines. For MAN B&W Four-stroke engine, there Relative air humidity 90 %
is no risk with a small amount of water in the charge Weight of air in tank
air receiver. But if the charge air receiver is filled with
water, there is a risk of getting water into the cylinder. pxV 31 x 105 x 4
This water have to be drained away. As standard a m= = = 138 kg
RxT 287 x 313
valve is mounted on the charge air receiver/cooler
on the engine. This valve is to be used for draining
of the water. If there is a great amount, the valve can Solution acc. to above diagram:
be left half-open. If the amount is small, the charge
air receiver can be drained periodically. 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
04.31 - ES2
MAN Diesel
Working Card 502-01.00
Page 1 (1) Engine Performance Data Edition 04H
L27/38
Safety precautions Special tools
Stopped engine Plate No Item No Note

Shut-off starting air
Shut-off cooling water 52000 134
Shut-off fuel oil 52000 146
Stopped lub. oil circul.
Description Hand tools
Measuring of engine performance data.

According to scheme "Performance L27/38".
Starting position
Engine is running.
Related procedure
Manpower Replacement and wearing parts

08028-0D/H5250/94.08.12
Working time : 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)
01.30 - ES0
MAN Diesel Performance L16/24, L21/31, L27/38 & L28/32H
M/V / Plant:
Eng. type: Eng. No:
T/C type: Serial No:
Fuel type: Viscosity:
Density: Date:
Load %
Air temp C
Running hours
RPM 1/min
T/C rpm 1/min
HT temp. C
HT press. bar
LT temp. C
LT press. bar
LO temp. C
LO press. before filter bar
LO press. after filter bar
LO press. T/C bar
FO temp. C
FO press. bar
CA temp. C
CA press. bar
Exh. before T/C C
Exh. after T/C C
L1 Phase C
L2 Phase C
L3 Phase C
Governor index
Power kW
Voltage V
Current A
Cos phi / kvAr
Crankcase press. mmWc
Exh. Index Pmax * Exh. Index Pmax *

C mm bar C mm bar
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4
Cylinder 5
Cylinder 6
Cylinder 7
Cylinder 8
Cylinder 9
* for L16/24 Pmax is not available.
Signature:
10064-1EX/H5810/02.9.20
MAN Diesel
Page 1 (3) Check of Leakages from Inspection Holes Edition 02H
L27/38
Stopped engine Plate no Item no Note

Shut-off cooling water
Shut-off fuel oil
Description
Check of leakages from inspection holes.
Hand tools
Starting position
Related procedure

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

Capacity : 1 man
Data

01.30 - ES0
MAN Diesel
502-05.00 Working Card
Edition 02H Check of Leakages from Inspection Holes Page 2 (3)
L27/38
Description
1) Leakages from cylinder head, see fig. 1.
If Then
Water leaks from the inspection hole The O-ring on the top of the liner has to be
replaced
Gas leaks from the inspection hole The sealing ring cylinder head/liner has to be
replaced
Fig 1 Inspection holes in the cylinder unit

08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Page 3 (3) Check of Leakages from Inspection Holes Edition 02H
L27/38
2) Leakages from HT cooling water pump, see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing
3) Leakages from LT cooling water pump, see fig. 2.
If Then
Water leaks from the inspection hole Check the rotating sealing
08028-0D/H5250/94.08.12
Fig 2 Inspection holes in the front-end box
01.30 - ES0
Trouble shooting
503/603
MAN Diesel
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
MAN Diesel
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
MAN Diesel
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
MAN Diesel
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
MAN Diesel
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 90-100C. Cont.
05.08- ES0
MAN Diesel
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
MAN Diesel
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
MAN Diesel
Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 03
L21/31
L27/38
Tabulated below are the remedial actions to be taken
if the following faults are observed:
Trouble Possible cause Trouble shooting
Oil leakage through cover nut. Missing or damaged O-ring Replace O ring.
(see Item 158, Plate 51515).
Seal face damaged. Replace cover assembly.
Excessive vibrations. Rotor out of balance owing to uneven

build-up of deposit on rotor walls
resulting from:
Missing or damaged O ring (see Item Replace O ring.

109, Plate 51515), allowing leakage.
O-ring seat on rotor joint faces Replace rotor assembly.

damaged.
Rotor assembly inadequately Tighten and bring to notice of maintenance

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

maged.
Dirt deposit not completely removed. Clean and bring to notice of maintenance
staff.
Rotor castings distorted through Replace rotor assembly.

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

wrong sequence. in section 515.
Bushes loose or worn in tube as- Fit new bearing tube assembly.
sembly.
08028-0D/H5250/94.08.12
99.25 - ES0
MAN Diesel
Description 503.06
Page 1 (2) Trouble Shooting Guide for Air Starter Edition 04
L21/31
L27/38
Trouble Possible Cause, see Plate 51309 Trouble Shooting
On pressing push-button, starter - Empty air receiver(s) Charge receiver(s)

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

does not respond, although air - Insufficient air pressure Increase pressure in receiver
flows through control circuit. - Push button stuck Remove and clean same
- Excessive length of main air Approach push-button to starter
pipework or install a solenoid valve near the
latter
Pinion revolves and advances, but - Ring gear and/or pinion burrs or Clean burrs or replace if necessary
does not engage the ring gear. damage
- Lack of clearance between pinion Replace pinion by a more adequate
and ring gear one. Check for distortion of ring
gear
Pinion revolves but does not - Follower Item 130 inoperative Disassemble, check, smoothen
advance. guide diameter, clean or replace if
rusted
- Insufficient air pressure Increase pressure in receiver
- Splined shaft Item 11 sticking Disassemble, clean, check spring
Item 13 and reassemble
- Excessive length of control pipe Approach push-button to the starter
or install a solenoid valve near the
latter
Pinion advances but does not - Pneumatic motor inoperative Disassemble, inspect rotor for
revolve foreign matters between teeth and
for possible wear of gears.
- Check valve Item 131 Clean and reassemble. Replace
worn parts
Disassemble, clean and reassem-
ble
Pinion engages gear ring, but will - Main valve Item 133 blocked Disassemble, clean and reassem-
08028-0D/H5250/94.08.12
not turn the engine ble or replace

- Rotors worn or blocked Disassemble, clean and reassem-
ble or replace rotors
- Main air pipework restricted or of Check all pipework and replace it if
insufficient bore it necessary
Starter starts working upon ope- - Incorrect connection of control Connect control pipes as per instal-
ning the flow valve of the feed line, pipes (with separate solenoid- lation instruction
although push-button (or solenoid valve)
valve) are not actuated. - Main valve Item 133 blocked and Disassemble, clean and replace
open joint if needed
00.13 - ES0
MAN Diesel
503.06 Description
Edition 04
Trouble Shooting Guide for Air Starter Page 2 (2)
L21/31
L27/38
Trouble Possible Cause, see Plate 51309 Trouble Shooting
Lack of starter power - Main pipework choked or is bore Check entire pipework for correct
is less than stipulated for the bore and replace if incorrect
starter
- Badly worn rotors Disassemble, replace and reassem-
ble
08028-0D/H5250/94.08.12
00.13 - ES0
MAN Diesel
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
MAN Diesel
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
MAN Diesel
Description 503.06
Page 1 (1) Trouble Shooting Guide for Air Starter Edition 06H
L27/38
Trouble Possible cause, see pl. 51309 Trouble shooting
On pressing push-button, starter does not - Empty air receiver(s) Charge receiver(s)
respond and no air flow seems to exist in - Flow valve(s) close Open flow valve(s)
control circuit. - Control circuit blocked Disconnect and clean out
On pressing push-button, starter does not - Leak in control duct Repair or replace
respond, although air flows through control - Insufficient air pressure Increase pressure in receiver
circuit. - Push button stuck Remove and clean same
- Excessive length of main air pipework Approach push-button to starter or install
a solenoid valve near the latter.
Pinion revolves and advances, but does - Ring gear and/or pinion burrs or damage Clean burrs or replace if necessary
not engage the ring gear. - Lack of clearance between pinion and Replace pinion by a more adequate one.
ring gear Check for distortion of ring gear
Pinion revolves but does not advance. - Follower Item 20 inoperative Disassemble, check, smoothen guide
diameter, clean or replace if rusted.
- Insufficient air pressure Increase pressure in receiver.
- Splined shaft Item 17 sticking Disassemble, clean, check spring Item 16
- Excessive length of control pipe and reassemble.
Approach push-button to the starter or
install a solenoid valve near the latter.
Pinion advances but does not revolve - Pneumatic motor inoperative Disassemble, inspect rotor for foreign
matters between teeth and for possible
wear of gears.
- Check valve Item 45 Clean and reassemble.
Replace worn parts.
Disassemble, clean and reassemble.
Pinion engages gear ring, but will not turn - Main valve Item 133 blocked Disassemble, clean and reassemble or
the engine. replace
- Rotors worn or blocked Disassemble, clean and reassemble or
replace rotors
- Main air pipework restricted or of Check all pipework and replace it if it
insufficient bore necessary
08028-0D/H5250/94.08.12
Starter starts working upon opening the - Incorrect connection of control pipes Connect control pipes as per installation
flow valve of the feed line, although push- (with separate solenoid valve) instruction
button (or solenoid valve) are not actuated. - Main valve Item 133 blocked and open Disassemble, clean and replace joint if
instruction needed
Lack of starter power - Main pipework choked or is bore is less Check entire pipework for correct bore
than stipulated for the starter and replace if incorrect
- Badly worn rotors Disassemble, replace and reassemble
02.37 - ES0-b/c
MAN Diesel
Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1)
Edition 03
General
Description The pump bearings are lubricated automatically with

oil from the lubricating oil system of the engine.
The built-on fresh water pumps in the high and low
temperature circuits are of the centrifugal type. They If the pump leaks and the shaft sealing rings are
are mounted in the front end box and are driven worn, it is recommended to replace the shaft seal,
through the gearing. see Working card 516-02.00.
Oil or water flows out of the inspec- Worn rotating sealing. See working card 502-05.00.
tion holes.
The pump does not work after start. Pump draws in air at suction side. Check packings and pipes for tightness.
The system is not filled-up. Check the level in the expansion tank.
Air cannot escape on delivery side. Vent the system.
Leaking shaft seal. Check the shaft seal.
Pump capacity drops after normal Air leakages from shaft seal. Overhaul the shaft seal.
operation.
Fouled impeller. Clean the impeller.
Pump does not give maximum Suction valve not fully open. Open the suction valve.
delivery.
Defective seals. Replace the seals.
Worn impeller and worn wear rings. Overhaul the pump.
Note: Running trouble with the pump, apart from

mechanical faults, is most often due to leaks in the
08028-0D/H5250/94.08.12
suction line. It is therefore essential that all packings

and gaskets are in order and that they are renewed
when necessary. Even a tiny hole in the suction line
will reduce the pump capacity.
98.20 - ES0
MAN Diesel
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 40C.
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
MAN Diesel
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
MAN Diesel
Description 503.20
Page 1 (6) Trouble Shooting / Electrical Failures Edition 09H
L27/38
Trouble Shooting If the conclusion of a trouble shooting indicates
that an exchange of a module is needed, please
This description is a trouble shooting guide for the fill-in the enclosed inspection report, and return the
automation system on the diesel engine type L27/38 module together with the inspection report to the
and L32/40. engine maker.
Further, please remember to inform the software no

General when ordering a new module.
This guide is a standard guide for engines, where

safety system is made by Allen-Bradley only. The Safety System
number of modules connected to the CPU module
variates from engine type to engine type. The in- The safety system is an independent system and
/outputs described in this guide, will be the same at consists of maker Allen-Bradley PLC hardware
all application. modules and MAN B&W software. Fig 1 describes
the hardware modules.
The following trouble shooting guide is an aid in iso-
lating troubles to the engine built-on safety system For wiring of the modules and sensors a reference
and monitoring system incl. the sensors connected is made to the electrical scheme which can be found
to these systems. in the operation manual, section 509.
CAUTION! The control system can be damaged The safety system consists of two Allen-Bradley
with the wrong voltage. When replacing a control PLC modules. The modules named 3P1 is the CPU
unit, check that the power supply is switched off module and the module named 5P1 is an I/O-mod-
during replacement and check the power supply for ule. Indication of individual input and output can be
the correct voltage before switching-on. found on the modules by yellow diodes. The refer-
ence number for each input and output can be found
Table 1.1 for the safety system and table 1.2 for the in the electrical scheme.
monitoring system are general guides for isolating
system problems. Each system check assumes that On the operation box individual indication of the shut-
the prior checks have been done properly. Table 1.3 downs (low lub. oil pressure, high cool. water temp.,
and 1.4 are system error messages which can be a overspeed and emergency stop) can be found.
guideline to the problem.
08028-0D/H5250/94.08.12
Fig 1 Hardware module.
06.22 - ES0
MAN Diesel
503.20 Description
Edition 09H Trouble Shooting / Electrical Failures Page 2 (6)
L27/38
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. 3P1. If it is alight the power supply for the PLC
modules are OK.
RUN/REM/PROG change-over Put the RUN/REM/PROG change-over switch in

switch on 3P1 in wrong position. RUN position. Check RUN LED on 3P1.
No software in the module. If no diodes on 3P1 and 5P1 - except the power diode,
are alight after having switched on the power supply,
the module is without software. The CPU 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 Out 1 is in failure or Check that diode Out 1 on CPU module is alight.
loose connections. If Out 1 is not alight check that Out 2 at 5P1 is not
alight. Check for loose wires on terminals VAC/DC
1 and Out 1 on 3P1, and 5P1.
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 output Out 8, Out 9, Out 10 and Out 11 on 3P1
are not alight. If one is alight, check the sensor and
wiring for short circuit. If Out 8, 9, 10, 11 on 3P1 is
not alight but the shutdown signals on the moni-
toring box is activated the problem is to be found
on the internal relays. Switch the power supply for
3P1 on and off several times. the relay contact will
then be OK again.
All shutdown LED are alight on the Connector is not correctly connected Check the connector J29 on the base module.
monitoring box. or internal failure in 3P1. No red LED must be alight on 3P1. Activate the
change-over switch RUN/REM/PROG. Exchange
the 3P1 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. 2 mm.
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly. Replace the pick-up.
Note! Diode Out 2 on 3P1 will be alight if actual speed
is above nominal speed. If actual speed is below, it
08028-0D/H5250/94.08.12
will be dark. At start LED In 0 will flash. At steady

speed LED In 0 will be permanently alight.
The alarm System & Power failure No program in CPU, or fault in Check that power supply is OK. (Green diode
is activated. CPU. must be alight). Switch on the RUN/REM/PROG
Diode Out 0 at 5P1 is not alight or CPU in stop mode. change-over switch. The problem could be related
diode Out 1 at 5P1 is not alight. to an internal component failure and the module
must be replaced. Observe that no red diode is
alight on 3P1.
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 Input 7 is not alight for 720 rpm engines,
and ON for 750 rpm engines. Version as described
at page one.
06.22 - ES0
MAN Diesel
Description 503.20
L27/38
If a replacement module is needed, the software ver- All sensors are connected to the base module and
sion must be informed at ordering. To find software the Operation Box (OB), Monitor for Temp. and
version, turn upper potentiometer to 3/4 position. Pressure Module (MTP) and Monitor for Exh. Gas
Observe diode no Out 3 for flashes. F.ex. three Temp. Module (MEG) are connected via interlink
flashes, a pause of 1.5 sec., and one more flash, bus connection.
means software version 3.2. The software version
can be with four numbers, ex. 3.1.2.1. (the software Interface to the alarm and monitoring system in the
version no. is also stated in the electrical scheme) control room is made by MODBUS or Interlink to the
output module.
The Monitoring System The software can be read on the label attached on
the Base Module or by pushing the lamp test button
The monitoring system monitors shows all relevant for 3 seconds. The software version number will be
pressures, temperatures and rpm on the engine. displayed in the operation box display.
The monitoring system consists of four hardware The software for engine type L27/38 will start with
modules as standard and a module as option for 3.xx, and the software for engine type L32/40 will
bearing temp. monitoring. The monitoring system start with 6.xx, f.ex. 6.4. Please make sure that the
hardware and software is developed by MAN B&W. dip switches SW1, SW2, SW5 and SW3 are in cor-
Fig 2 describes the hardware. rect position acc. to the plant related scheme. See
section 509.
Failure LED
2.5 A
Fuses OB ENGINE RPM.
0 1400
SI90
MTP H.T. WATER TEMP.
OUTLET ENGINE
TI12
0 60000 H.T. WATER PRESS.

PI10
INLET ENGINE
TC RPM. SI89
L.T. WATER TEMP.

TI01
0 40 INLET AIR COOL.
START AIR PI70 L.T. WATER PRESS.

PRESS. PI01
INLET AIR COOL.
LUB. OIL TEMP.

HOUR BAR TI22
INLET ENGINE
C LUB. OIL PRESS.

PI21
. . . . INLET FILTER
ALT. RPM.
LUB. OIL PRESS.
Dip Sensor power

PI22
OVERSPEED INLET ENGINE
Display LOW LUB. LUB. OIL PRESS.
switches LED
OIL PRESS. PI23
INLET TC
HIGH FRESH
WATER TEMP. FUEL OIL TEMP.
TI40
EMERGENCY INLET ENGINE
STOP
FUEL OIL PRESS.
PI40
INLET ENGINE
08028-0D/H5250/94.08.12
0 80
Push 3 sec. START STOP

3 SEC. Delay
LAMP TEST CHARGE AIR TEMP.
OUTLET COOL.
TI31
Software version REMOTE LOCAL

BLOCKING
RESET
CHARGE AIR PRESS.
OUTLET COOL.
0 4
PI31
will be indicated
in the display
AP HIGH H.T. WATER TEMP.
TAH 12.
LOW FUEL OIL PRESS.
PAL 40.
MEG 200 400 600
(Option) HIGH LUB. OIL TEMP.

TAH 21.
LOW START/STOP AIR PRESS.
PAL 70/71.
E
X
CYL.
1 TI60
H
HIGH/LOW EXH. GAS TEMP. OVERSPEED.
TDAH 60. SAH 81.
A CYL.
2 TI60
HIGH EXH. GAS TEMP. JET SYSTEM FAILURE. S
TC. OUTLET. TAH 61. SX 32. T

CYL.
3 TI60
HIGH EXH. GAS TEMP. POWER & SYSTEM FAILURE. G

TC. INLET. TAH 62. UX 95. A
CYL.
4 TI60
S
HIGH ALTERNATOR WINDING COMMON SHUTDOWN.
TEMP. TAH98 SS 86. T
CYL.
5 TI60
E
LOW L.T. WATER PRESS. START FAILURE.
PAL 01. SX 83.
M CYL.
6 TI60
LOW H.T. WATER PRESS. STOP FAILURE. E

PAL 10. SX 84. R
CYL.
7 TI60
A
LOW LUB. OIL PRESS. FUEL LEAKAGE.
PAL 22. LAH 42.
T CYL.
8 TI60
HIGH DIFF. PRESS. L.O. LOW L.O. LEVEL BASE R
FILTER. PDAH 21-22. FRAME. LAL 28. E

CYL.
9 TI60
LOW LUB. OIL PRESS. TC. HIGH L.O. LEVEL BASE

TC INLET TI62
PAL 23. FRAME. LAH 28.
LOW PRELUB. OIL PRESS. TURNING GEAR ENGAGED.

TC OUTLET TI61
PAL 25. ZS 75.
Fig 2 Hardware modules.
06.22 - ES0
MAN Diesel
503.20 Description
L27/38
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.
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. 2 mm.
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly.
Replace the pick-up. 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-
08028-0D/H5250/94.08.12
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.
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.
Cont.
06.22 - ES0
MAN Diesel
Description 503.20
L27/38
Cont. Table 1.2
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 Out 1 on the safety system module
is activated. possibilities 5P1. If it is alight, it is OK. No red LED must be alight
1) Power & system failure in the on 3P1. See also table 1.1. SUPPLY LED and RUN
safety system. 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 Out 0 at 5P1. If it is alight, it is OK.
6) Tacho failure. If 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
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
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
503.20 Description
L27/38
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
LED.
08028-0D/H5250/94.08.12
ERR-1 Indicates cable break or sensor failure on the corresponding input.
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.
06.22 - ES0
MAN
MANDiesel
Diesel
Electronic Device Inspection Report No.:

(to be attached to the component in failure) (date + no./initials, ex. 20001218-01/FIF)
Type: Plant Name:

Part No.: Engine No.:
(to be fill in by User, Engine Maker or Service Staff)
Serial No.: Engine Maker:

Software No.: Hours: Purchase Order No.:
(push Lamp test 3-5 sec and read display)
Fault Description
Fault Type: Claim Report No.:

Periodically Constant Warranty Non-warranty
Description:
Date: Signature:
Failure Type Defective Module Defective Parts F.type Remark

Name Co Name & No. Diagram No. Code
de
Defect Comp. A
Missing Comp. B
Reversed Comp. D
Printed Track C
Soldering E
(to be fill in by Producer or Test Engineer)
Adjustment F
Mechanical G
Water Damage H
Repair
Software Update I
Updating J
K
08028-0D/H5250/94.08.12
Special Repair / Exchange Price

Standard Repair / Exchange Price
Time Hours Exch. Cost
Remarks:
Assumed reason for the failure:

Design Production Installation External Influence
Date: Repaired by:
08050-1EX/H5810/00.12.18
Media specification
504/604
MAN Diesel
Description Quality of Lube Oil (SAE40) for 504.01

Page 1 (5) Heavy Fuel Oil Operation (HFO) Edition 10
L16/24, L21/31
L27/38, V28/32S
The specific power output offered by todays Die- Bright stocks, if contained, must neither adversely
sel engines and the use of fuels which more and affect the thermal nor the oxidation stability.
more often approach the acceptable limit in quality
increase the requirements placed on the lube oil The base oil must meet the limit values given in
and make it imperative that the lube oil is chosen Table 1, particularly as concerns its ageing tenden-
carefully. Medium-alkaline lube oils have proven cies.
to be suitable for lubricating the running gear, the
cylinders, the turbocharger and for the cooling of Medium-alkaline lube oil
the pistons. Medium-alkaline oils contain additives
which, amongst other things, provided them with a The finished oil (base oil with additives) must dem-
higher neutralising capacity than blended (HD) en- onstrate the following characteristics.
gine oils have.
Additives
No international specifications exist for medium-al-
kaline lube oils. An adequately long trial operation The additives must be dissolved in the oil and must
in compliance with the manufacturers instructions be of such a composition that an absolute minimum
is therefore necessary. of ash remains as residue after combustion, even
though the engine were run on distillate fuel tem-
Only lube oils, which have been approved by MAN porarily. The ash must be soft. If this prerequisite
Diesel, are to be used. These are listed in Table 5. is not complied with, increased deposits are to be
expected in the combustion spaces, especially the
Requirements exhaust valves and the inlet housing of the turbo-
chargers. Hard additive ash promotes pitting on
Base oil the valve seats, as well as burnt-out valves and in-
creased mechanical wear in the cylinder liners.
The base oil (medium-alkaline lube oil = base oil +
additives) must be a narrow distillation cut and must Additives must not facilitate clogging of the filter el-
be refined in accordance with modern procedures. ements, neither in their active nor in their exhaust-
ed state.
Properties/characteristics Unit Test method Limit values

Structure preferably parafnbasic
Behaviour in cold, still ows ASTMD2500 15
C
Flash point (as per Cleveland) ASTMD92 > 200
Ash content (oxide ash) ASTMD482 < 0.02
Coke residue (as per Conradson) ASTMD189 < 0.50
Aging tendency after being MAN Diesel

heated up to 135 C for 100 hrs. ageing cabinet *
08028-0D/H5250/94.08.12
Weight
nheptane insolubles ASTMD4055 or
% < 0.2
DIN 51592
Evaporation loss <2
Drop test (lter paper) Must not allow to recognize precipitation of
MAN Diesel test
resinous or asphaltlike ageing products
Table 1 Lube oil (HFO operation) - specified values

* in-house method
08.19 - ES1
MAN Diesel
504.01 Quality of Lube Oil (SAE40) for Description

Edition 10 Heavy Fuel Oil Operation (HFO) Page 2 (5)
L16/24, L21/31
L27/38, V28/32S
Detergency Lube oil selection
The detergency must be so high that coke and tar-

like residues from fuel combustion must not build- Engine SAEClass
up. The lube oil must be able to avoid fuel derived 16/24, 21/31, 27/38, 28/32S, 32/40,
deposits. 32/44, 40/54, 48/60, 58/64, 51/60DF 40
Dispersancy Table 2 Viscosity (SAE class) of lube oils
The dispersancy must be selected such that com-

mercially available lube-oil cleaning equipment can Neutralisation property (BN)
remove the detremental contaminations from the
used oil, i.e. the used oil must have good separat- Medium-alkaline lube oils having differently high
ing and filtering properties. levels of neutralisation capacity (BN) are available
on the market. According to the present-day state
Diesel-Performance of knowledge, operating conditions to be expected
and BN can be correlated as shown in Table 3. The
The Diesel performance (without taking the neu- operating resulting will in the essence be the deci-
tralisation ability into consideration) must, at least, sive criterion as to which BN will ensure the most
comply with MIL-L-21014 D resp. API-CD. economic mode of engine operation.
Neutralisation capacity Operation on low sulphur fuel
The neutralisation capacity (ASTM-D2896) must In order to meet the emission regulations, fuels
be so high that the acidic products of combustion with different sulphur content are used today. In en-
are neutralised at the lube oil consumption rate that vironmental sensitive areas (SECA) a low sulphur
is specific for the engine. The reaction time of the fuel must be used. Outside the SECA a fuel with
additives must be matched to the process in the a high sulphur content can be used. In this case
combustion chamber. Hints concerning the selec- the lube oil BN should be selected to meet the re-
tion of the BN are given in Table 3. quirements of the operation on high sulphur fuel.
Only for permanent operation on low sulphur fuel,
Evaporation tendency the lube oil with the lower BN should be selected.
Ultimately, the operating results are the decisive
The tendency to evaporate must be as low as pos- criterium as to which content of additives ensures
sible, otherwise the oil consumption is adversely the most economic mode of engine operation.
affected.
Cylinder lube oil
Further conditions
In the case of engines with separate cylinder lubri-
The lube oil must not form a stable emulsion cation, the pistons and the cylinder liner are sup-
08028-0D/H5250/94.08.12
with water. Less than 40 ml emulsion are ac- plied with lube oil by means of a separate oil pump.
ceptable in the ASTM-D1410 test after one hour. The oil supply rate is factory-set to conform to both
The foaming behaviour (ASTM-D892) must meet the quality of the fuel to be used in service and to
the following conditions: after 10 minutes < 20 ml. the anticipated operating conditions.
The lube oil must not contain agents to improve vis-
cosity index. Fresh oil must not contain any water or A lube oil as specified above is to be used for the
other contamination. cylinder and the lubricating circuit.
08.19 - ES1
MAN Diesel

L16/24, L21/31
L27/38, V28/32S
approx. BN (mg Engines / Operating conditions
KOH/g oil)
Marine Diesel Oil (MDO) of poor quality (ISOFDMC) or heavy fuel oil with a sulphur content
20
of <0.5 %.
23/30H and 28/32H in general. 23/30A, 28/32A and 28/32S under normal operating
conditions.
30 16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 and 58/64 and 51/60DF in pure HFO
mode only if fuel sulphur content is < 1.5 %.
51/60DF in alternating mode (HFO/Gas).
23/30A, 28/32A and 28/32S in case of severe operating conditions and in case of necessity
regarding oil life and engine cleanliness.
40
16/24, 21/31, 27/38, 32/40, 32/44CR, 40/54, 48/60 and 58/64 and 51/60DF in pure HFO
mode generally, provided the sulphur content is >1.5%.
32/40, 32/44CR, 40/54, 48/60, and 58/64 if BN 40 is inadequate in terms of oil life or engine
50
cleanliness (high sulphur content of the fuel, very low lube oil consumption.
Table 3 Determining the Base Number for operating conditions
Speed governor Lube-oil additives
In case of mechanic-hydraulic governors with sep- It is not allowed to add additives to the lube oil, or
arate oil sump, multi grade oil 5W-40 is preferably mixing the different makes (brands) of the lube oil,
used. If this oil is not available as refill, an oil 15W- as the performance of the carefully matched pack-
40 may exceptionally be used. In this context it is age of additives which is suiting itself and adapted
not important, if multi grade oils based on synthetic to the base oil, may be upset. Also, the lube oil
or mineral oil are used. company (oil supplier) is no longer responsible for
the oil.
The oil quality specified by the manufacturer is to
be used for the remaining equipment fitted to the Selection of lube oils / warranty
engine. For the engine L27/38 (propulsion) service
experience have shown that the operation temper- Most of the mineral oil companies are in close and
ature of the Woodward governor UG10MAS and permanent consultation with the engine manufac-
the corresponding actuator for UG723+ can ex- turers and are therefore in a the position to quote
ceed 93 C. In such case we recommend to use a the oil from their own product line that has been
synthetic oil like Castrol Alphasyn HG150. Engines approved by the engine manufacturer for the given
delivered later than March 2005 are already filled application. Independent of this release, the lube
08028-0D/H5250/94.08.12
with this oil. oil manufacturers are in any case responsible for
quality and performance of their products. If you
have further questions, we are more than willing to
provide you with further information.
08.19 - ES1
MAN Diesel
504.01 Quality of Lube Oil (SAE40) for Description

Edition 10 Heavy Fuel Oil Operation (HFO) Page 4 (5)
L16/24, L21/31
L27/38, V28/32S
Oil in service
There are no defined oil change intervals for MAN

Diesel medium-speed engines. The oil has to be
analysed on a regular basis. As long as the oil char-
acteristics are within the specified limits of Table 4
the oil is suitable for further use. An oil sample has
to be analysed every 1-3 months (see maintenance
plan). The quality of the oil can only be maintained
if the oil is cleaned by an appropriate device (e.g.
separator).
Limit value Method
Viscosity at 40 C 110-220 mm2/s ISO 3104 or ASTM D445
Base Number (BN) min. 50% of fresh oil BN ISO 3771
Flash Point (PM) min. 185 C ISO 2719
Water Content max. 0.2% (for a short period max. 0.5%) ISO 3733 or ASTM D1744
nHeptan Insoluble max. 1.5% DIN 51592 or IP 316
dependent upon the engine type and

Metal Content
operating condition
only for guidance

Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Si max. 10 ppm
Table 4 Limit value

08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel

L16/24, L21/31
L27/38, V28/32S
Examinations
We carry out the investigations on lube oil in our
laboratories for our customers. A representative
sample of about 0.5 litre is required for the exami-
nation.
Manufacturer Base Number [mg KOH/g]
20 30 40 50
AGIP Cladium 300 Cladium 400
BP Energol ICHFX 204 Energol ICHFX 304 Energol ICHFX 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 40XL 40 Taro 50XL 40

(TEXACO, CALTEX)
EXXON MOBIL Mobilgard M 430 Mobilgard M 440 Mobilgard M50

EXXMAR 30 TP 40 EXXMAR 40 TP 40
PETROBRAS Marbrax CCD420 Marbrax CCD430 Marbrax CCD440
REPSOL Neptuno NT 2040 Neptuno NT 3040 Neptuno NT 4040
SHELL Argina S 40 Argina T 40 Argina X40 Argina XL40
TOTAL Lubmarine Aurelia XL 4025 Aurelia XL 4030 Aurelia XL 4040 Aurelia XL 4055
Aurelia TI 4030 Aurelia TI 4040 Aurelia TI 4055
Table 5 Lubricating oils (SAE40), which have been approved for the use in MAN Diesel
fourstroke engines running on heavy fuel oil
Note!
MAN Diesel SE do not take any responsibility
for difficulties that might be caused by these
oils!
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description Quality of Lube Oil (SAE40) for Operation on 504.01

Page 1 (4) Gas Oil and Diesel Oil (MGO/MDO) and Biofuel Edition 11
L16/24, L21/31
L27/38, V28/32S
The specific power output offered by todays Die- Bright stocks, if contained, must neither adversely
sel engines and the use of fuels which more and affect the thermal nor the oxidation stability. The
more often approach the limit in quality increase base oil must meet the limit values as specified in
the requirements placed on the lube oil and make Table 1, particularly concerning the ageing stabil-
it imperative that the lube oil is chosen carefully. ity.
Blended lube oils (HD oils) have proven to be suit-
able for lubricating the running gear, the cylinder, Blended lube oils (HD-oils)
the turbocharger and for the cooling of the pistons.
Blended lube oils contain additives which, amongst The base oil for which additives have been mixed
other things, provide them with sludge carrying, (blended lube oil) must demonstrate the following
cleaning and neutralisation capabilities. characteristics:
Only lube oils, which have been released by MAN Additives

Diesel, are to be used. These are listed in Table 3.
The additives must be dissolved in the oil and must
Note! be of such a composition that an absolute minimum
For Dual-fuel engines which will be operated for of ash remains as residue after combustion. The
>40% of the time on Diesel oil fuel we recommend ash must be soft. If this prerequisite is not complied
to use a quality of lube oil with a Base Number (BN) with, increased deposits are to be expected in the
from 10-16 according to this specification. combustion chamber, especially at the outlet valves
and in the inlet housing of the turbochargers. Hard
Specifications additive ash promotes pitting on the valves seats,
as well as burnt-out valves and increased mechani-
Base oil cal wear.
The base oil (blended lube oil = basic oil + addi- Additives must not facilitate clogging of the filter el-
tives) must be a narrow distillation cut and must ements, neither in their active nor in their exhaust-
be refined in accordance with modern procedures. ed state.
Characteristic features Unit Test method Limit value

Structure preferably parafnbasic
Behaviour in cold, still ows ASTMD2500 15
C
Flash point (as per Cleveland) ASTMD92 > 200
Ash content (oxide ash) ASTMD482 < 0.02
Weight %
Coke residue (as per Conradson) ASTMD189 < 0.50
Ageing tendency after being MAN Diesel

heated up to 135 C for 100 hrs. ageing cabinet *
08028-0D/H5250/94.08.12
nheptane insolubles ASTMD4055

Weight % < 0.2
or DIN 51592
Evaporation loss Weight % < 2
Drop test (lter paper) Must not allow to recognise precipitation of
MAN Diesel test
resin or asphaltlike ageing products
Table 1 Lube oil (MGO/MDO) - specified values

* in-house method
08.19 - ES1
MAN Diesel
504.01 Quality of Lube Oil (SAE40) for Operation on Description

Edition 11 Gas Oil and Diesel Oil (MGO/MDO) and Biofuel Page 2 (4)
L16/24, L21/31
L27/38, V28/32S
Detergency Blended grade
The detergency must be so high that coke and tar- Blended lube oils (HD oils) corresponding to inter-
like residues from fuel combustion must not build- national specifications MIL-L 2104 or API-CD, and
up. having a Base Number (BN) of 10 16 mg KOH/g
are recommended by us (Designation for armed
Dispersancy forces of Germany: O-278).
The dispersancy must be selected such that com- The content of additives included in the lube oil de-
mercially available lube-oil cleaning equipment can pends upon the conditions under which the engine
remove the detrimental contamination from the is operated, and the quality of fuel used. If marine
used oil, i.e. the oil must have good separating and Diesel fuel is used, which has a sulphur content of
filtering properties. up to 2.0 weight % as per ISO-F DMC, and coke
residues of up to 2.5 weight % as per Conradson,
Neutralisation capacity a BN of approx. 20 is preferred. Ultimately, the op-
erating results are the decisive criterion as to which
The neutralisation capacity (ASTM-D2896) must content of additives ensures the most economic
be so high that the acidic products which result dur- mode of engine operation.
ing combustion are neutralised. The reaction time
of the additives must be matched to the process in Cylinder lube oil
the combustion chamber.
In the case of engines with separate cylinder lubri-
Evaporation tendency cation, the pistons and the cylinder liner are sup-
plied with lube oil by means of a separate oil pump.
The tendency to evaporate must be as low as pos- The oil supply rate is factory-set to conform to both
sible, otherwise the oil consumption is adversely the quality of the fuel to be used in service and to
affected. the anticipated operating conditions.
Further conditions A lube oil as specified above is to be used for the

cylinder and the lubricating circuit.
The lube oil must not form a stable emulsion with
water. Less than 40 ml emulsion are acceptable in Speed governor
the ASTM-D1410 test after one hour.
In case of mechanic-hydraulic governors with sep-
The foaming behaviour (ASTM-D892) must meet arate oil sump, multi grade oil 5W-40 is preferably
the following conditions: after 10 minutes < 20ml. used. If this oil is not available for topping-up, an oil
15W-40 may exceptionally be used. In this context
The lube oil must not contain agents to improve vis- it makes no difference whether multicoloured oils
cosity index. Fresh oil must not contain any water or based on synthetic or mineral oil are used. (Desig-
other contamination. nation for armed forces of Germany: O-236)
08028-0D/H5250/94.08.12
Lube oil selection The oil quality specified by the manufacturer is to

be used for the remaining equipment fitted to the
engine.
Engine SAEClass
16/24, 21/31, 27/38, 28/32S, 32/40,
32/44, 40/54, 48/60, 58/64, 51/60DF 40
Table 2 Viscosity (SAE class) of lube oils
08.19 - ES1
MAN Diesel
Description Quality of Lube Oil (SAE40) for Operation on 504.01

Page 3 (4) Gas Oil and Diesel Oil (MGO/MDO) and Biofuel Edition 11
L16/24, L21/31
L27/38, V28/32S
For the engine L27/38 (propulsion) service experi-
Approved SAE40 lube oils
ence have shown that the operation temperature of
the Woodward governor UG10MAS and the corre- Manufacturer Base Number
sponding actuator for UG723+ can exceed 93 C. In 10161) [mgKOH/g]
such case we recommend to use a synthetic oil like
AGIP Cladium 120 SAE 40
Castrol Alphasyn HG150. Engines delivered later
Sigma S SAE 40 2)
than March 2005 are already filled with this oil.
BP Energol DS 3154
Lube-oil additives
CASTROL Castrol MLC 40
Castrol MHP 154
It is not allowed to add additives to the lube oil, or
Seamax Extra 40
mixing the different makes (brands) of the lube oil,
as the performance of the carefully matched pack- CHEVRON Taro 12 XD 40
age of additives which is suiting itself and adapted (Texaco, Caltex) Delo 1000 Marine SAE 40
to the base oil, may be upset. Also, the lube oil
EXXON MOBIL Exxmar 12TP40
company (oil supplier) is no longer responsible for
Mobilgard 412 / MG 1SHC
the oil. Mobilgard ADL 40 2)
Delvac 1640
Selection of lube oils / warranty
PETROBRAS Marbrax CCD410
Most of the mineral oil companies are in close and
Q8 Mozart DP40
permanent consultation with the engine manufac-
turers and are therefore in a position to quote the oil REPSOL Neptuno NT 1540
from their own product line that has been approved
by the engine manufacturer for the given applica- SHELL Gadinia 40
Sirius FB 40 2)
tion. Independent of this release, the lube oil manu-
Sirius/Rimula X40 2)
facturers are in any case responsible for quality and Gadinia AL40
performance of their products. If any questions, we
are more than willing to provide you with further in- STATOIL MarWay 1540
formation. MarWay 1040
TOTAL Lubmarine Disola M4015

Oil in service
Table 3 Lubricating oils (SAE40) which have been approved
There are no defined oil change intervals for MAN for the use in MAN Diesel four-stroke engines running on gas oil
Diesel medium-speed engines. The oil has to be and Diesel oil
analysed on a regular basis. As long as the oil char-
acteristics are within the specified limits of Table 4,
the oil is suitable for further use. An oil sample has 1) If Marine Diesel fuel of poor quality (ISO-F-
to be analysed every 1-3 months (see maintenance DMC) is used, a Base Number (BN) of ap-
plan). The quality of the oil can only be maintained prox. 20 is of advantage.
08028-0D/H5250/94.08.12
if the oil is cleaned by an appropriate device (e.g. 2) If the sulphur content of the fuel is < 1 %.
separator).
MAN Diesel SE do not take any reponsibility for dif-
Examinations ficulties that might be caused by these oils.
We carry out the investigations on lube oil in our

laboratories for our customers. A representative
sample of about 0.5 litre is required for the exami-
nation.
08.19 - ES1
MAN Diesel
504.01 Quality of Lube Oil (SAE40) for Operation on Description

Edition 11 Gas Oil and Diesel Oil (MGO/MDO) Biofuel Page 4 (4)
L16/24, L21/31
L27/38, V28/32S
Limit value Method
Viscosity at 40 C 110-220 mm2/s ISO 3104 or ASTM D445
Base Number (BN) min. 50% of fresh oil BN ISO 3771
Flash Point (PM) min. 185 C ISO 2719
Water Content max. 0.2% (for a short period max. 0.5%) ISO 3733 or ASTM D1744
nHeptan Insoluble max. 1.5% DIN 51592 or IP 316
dependent upon the engine type and

Metal Content
operating condition
only for guidance

Fe max. 50 ppm
Cr max. 10 ppm
Cu max. 15 ppm
Pb max. 20 ppm
Sn max. 10 ppm
Al max. 20 ppm
Si max. 10 ppm
For biofuel operation:

max 12% FT-IR
biofuel content
Table 4 Limit value
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description
Page 1 (1) Lubricating Points 504.05
Edition 03
General
Lubricating Oil Types Used in the Engine
Description Lub. Oil Type
Engine system lubricating oil SAE 40 oil according to lubricating oil specification on page 504.01.
Turbocharger Engine system lubricating oil.
Governor See governor instructions in section 509.
Alternator (only for GenSet) See special instructions in section 518 or separate instructions.
Hydraulic tools Hydraulic oil or turbine oil (with a viscosity of about SAE 20).
08028-0D/H5250/94.08.12
04.35 - ES0
MAN Diesel
Description
Page 1 (1) Lubricating Oil in Base Frame 504.06
Edition 03H
L27/38
Type L27/38 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.
Min. level alarm H1 (mm) 325 325 325 325 325
Min. level H2 (mm) 335 335 335 335 335
Max. level H3 (mm) 425 425 425 425 425

08028-0D/H5250/94.08.12
Max. level alarm H4 (mm) 440 440 440 440 440
Min. litre (H2) 1150 1314 1477 1639 1802
Max. litre (H3) 1471 1679 1887 2096 2304
99.25 - ES0
MAN Diesel
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, @ 15C must be known
The following formula is used to calculate the in order to convert to the present lubricating oil
SLOC: temperature in the base frame. The following formula
is used to calculate :
SLOC [g/kWh] =
lubricating oil [kg/m3] =
(lubricating oil added - A1 - A2 [dm ]) * lubricating oil [kg/m ]
3 3
run.hrs period * PMCR [kW] lubricating oil @15C [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
MAN Diesel
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] [dm] [dm] [C] [g/kWh]
08028-0D/H5250/94.08.12
06.25 - ES0
MAN Diesel
Description
Quality of Heavy Fuel Oil (HFO) 504.20
Page 1 (10) edtion 08
General
Prerequisites Several international specifications for heavy fuel
oils are existing. The most important specifications
MAN Diesel four-stroke engines can be operated are ISO 8217-2005 and CIMAC-2003. These two
on any crude-oil based heavy fuel oil meeting the specifications are more or less equivalent. Table
requirements listed in Table 3-24, Page 3-37 , pro- 2 CIMAC Recommendations for residual fuels for
vided the engine and the fuel treatment plant are diesel engines (as bunkered) shows the specifi-
designed accordingly. In order to ensure a well-bal- cations CIMAC-2003. All qualities of these specifi-
anced relation between the costs for fuel, spare cations up to K700 can be used provided the fuel
parts and maintenance and repair work, we recom- treatment system is designed for these fuel grades
mend bearing in mind the following points. e.g. fuels with a maximum density of 1010 kg/m3
can only be used with modern separation.
Heavy fuel oil (HFO)
Important
Provenance/refining process
Fuel oil characteristics as stated in analysis results
The quality of the heavy fuel oil is largely deter- - even if they meet the above mentioned require-
mined by the crude oil grade (provenance) and the ments - may be not sufficient for estimating the
refining process applied. This is the reason why combustion properties and the stability of the fuel
heavy fuel oils of the same viscosity may differ con- oil. This means that service results depend on oil
siderably, depending on the bunker places. Heavy properties which cannot be known beforehand.
fuel oil normally is a mixture of residue oil and distil- This especially applies to the tendency of the oil to
lates. The components of the mixture usually come form deposits in the combustion chamber injection
from state-of-the-art refining processes such as system, gas passages and turbines. It may, there-
visbreaker or catalytic cracking plants. These proc- fore, be necessary to rule out some oils that cause
esses may have a negative effect on the stability of difficulties.
the fuel and on its ignition and combustion proper-
ties. In the essence, these factors also influence the Blends
heavy fuel oil treatment and the operating results of
the engine. The admixing of engine oils (ULO:used lube oil), of
non-mineral oil constituents (such as coal oil) and
Bunker places where heavy fuel oil grades of stand- of residual products from chemical or other proc-
ardised quality are offered should be given prefer- esses (such as solvents, polymers or chemical
ence. If fuels are supplied by independent traders, waste) is not permitted. The reasons are, for ex-
it is to be made sure that these, too, keep to the ample: the abrasive and corrosive effects, the ad-
international specifications. The responsibility for verse combustion properties, a poor compatibility
the choice of appropriate fuels rests with the en- with mineral oils and, last but not least, the nega-
gine operator. tive environmental effects. The order letter for the
fuel should expressly mention what is prohibited,
Specifications as this constraint has not yet been incorporated in
the commonly applied fuel specifications.
08028-0D/H5250/94.08.12
Fuels that can be used in an engine have to meet

specifications to ensure a suitable quality. The limit- The admixing of engine oils (ULO: used lube oil)
ing values for a heavy fuel oil are listed in Table 1 to the fuel involves a substantial danger because
Fuel oil specifications and associated characteris- the lube oil additives have an emulsifying effect
tic values. and keep dirt, water and catfines finely suspended.
Therefore, they impede or preclude the necessary
Please note the entries in the last column of Table cleaning of the fuel. We ourselves and others have
1 Fuel oil specifications and associated character- made the experience that severe damage induced
istic values, because they provide important back- by wear may occur to the engine and turbocharger
ground information. components as a result.
08.19 - ES1
MAN Diesel
504.20 Quality of Heavy Fuel Oil (HFO)

Description
edtion 08 Page 2 (10)
General
A fuel shall be considered to be free of used lube The admixing of chemical waste materials (such as
oil (ULO) if one or more of the elements Zn, P and solvents) to the fuel is for reasons of environmen-
Zn are below the specific limits (Zn: 15 ppm; P: tal protection prohibited by resolution of the IMO
15 ppm; Ca: 30 ppm). Marine Environment Protection Committee of 1st
January 1992.
Fuelsystem related characteristic values

Viscosity mm2/s max.
700 Viscosity/injection viscosity
(at 50 C) (cSt)
Viscosity max.
55 Viscosity/injection viscosity
(at 100 C)
Density g/ml max.
1.010 Heavy fuel oil treatment
(at 15 C)
Flash point C min.
60 Flash point (ASTMD93)
Pour point max.

Low temperature behaviour
(summer)
30 (ASTM D97), and Pump
ability
Pour point max.

Low temperature behaviour
(winter)
30 (ASTM D97), and Pump
ability
Enginerelated characteristic values

Carbon max.
residues 22 Combustion properties
(Conradon)
Sulphur % wt. 5
Sulphuric acid corrosion
4.5 in marine operation
Ash
0.20 Heavy fuel oil treatment
Vanadium mg/kg
600 Heavy fuel oil treatment
Water % vol.
Sediment % wt.
0.1
(potential)
Supplementary characteristic values
Aluminium mg/kg max.
08028-0D/H5250/94.08.12

and silicon
Asphalts % wt. 2/3 of carbon residues
Combustion properties
(Conradson)
Sodium mg/kg Sodium < 1/3 vanadium,
Heavy fuel oil treatment
sodium < 100
Cetane number of lowviscosity constituent minimum
Ignition quality
35
Fuel free of admixtures not based on mineral oil, such as coal oils or vegetable oils;
free of tar oil and lubricating oil (used oil), free of any chemical waste and of solvents or
polymers
Table 1 Fuel oil specications and associated characteristic values
08.19 - ES1
08028-0D/H5250/94.08.12
Characteristics Unit Limit CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC CIMAC Test method
A30 B30 D80 E 180 F 180 G 380 H 380 K 380 H 700 K 700 reference
08.19 - ES1
Table 2
Description
Page 3 (10)
Density at 15 C kg/m3 max. ISO 3675 or
MAN Diesel
960.0 975.0 980.0 991.0 991.0 1010.0 991.0 1010.0

ISO 12185
Kinematic mm2/s1) max.

viscosity 30.0 80.0 180.0 380.0 700.0 ISO 3104
at 50 C
min.2)
22.0 ISO 3104
Flash point C max.

60 60 60 60 60 ISO 2719
Pour point (upper) C max.

winter quality max. 0 24 30 30 30 30 ISO 3016
summer quality 6 24 30 30 30 30 ISO 3016

Carbon residue % max.
(m/m) 10 14 15 20 18 22 22 ISO 10370
Ash % max.
0.10 0.10 0.10 0.15 0.15 0.15 ISO 6245
(m/m)
Water % max.
(V/V) 0.5 0.5 0.5 0.5 0.5 ISO 3733
Sulfur 3) % max. ISO 14596

(m/m) 3.5 4.00 4.50 4.50 4.5
or ISO 8754
Vanadium mg/kg max. ISO 14596
150 350 200 500 300 600 600
CIMAC Recommendations for residual fuels for diesel engines (as bunkered)
or IP 501
Total sediment % max. ISO
potential (m/m) 0.10 0.10 0.10 0.10 0.10
Quality of Heavy Fuel Oil (HFO)
103072
Aluminium plus mg/kg max.
silicon 80 80 80 80 80 ISO 10478
Used lubricating The fuel shall be free of ULO. A fuel shall be considered to be free of ULO if one ore more of the elementsl Zinc,
oil (ULO) Phosphorus and Calcium are below or at the specied limits. All three elements must exceed the same limits
before a fuel shall be deemed to contain ULO.
Zinc mg/kg 15 IP501 or IP470

Phosphorus mg/kg 15 IP501 or IP500
Calcium mg/kg 30 IP501 or IP470
1) 1 mm2/s = 1cSt
2) Fuels with density close to the maximum, but with very low viscosity, may exhibit poor ignition quality.
edtion 08
504.20
3) A sulphur limit of 1,5% mm will apply in SOx Emission Control Areas designated by the IMO, when its relevant Protocol comes into force. There may be local variations.
General
MAN Diesel

Description
General
Leaked oil collectors The specified injection viscosity of 12-14mm2/s (for
GenSets 16/24, 21/31, 23/30H, 27/38 and 28/32H:
Leaked oil collectors into which leaked oil and resi- 12 - 18 cSt) and/or fuel oil temperature upstream
due pipes as well as overflow pipes of the lube oil of the engine should be adhered to. Only then will
system, in particular, must not have any connection an appropriate atomisation and proper mixing,
to fuel tanks. Leaked oil collectors should empty and hence a low-residue combustion be possible.
into sludge tanks. Besides, mechanical overloading of the injection
system will be prevented. The specified injection
Supplementary remarks viscosity and/or the necessary fuel oil temperature
upstream of the engine can be seen from the vis-
The following remarks are thought to outline the re- cosity/temperature diagram.
lations between heavy fuel oil grade, heavy fuel oil
treatment, engine operation and operating results. Heavy fuel oil treatment
Selection of heavy fuel oil Trouble-free engine operation depends, to a large

extent, on the care which is given to heavy fuel oil
Economic operation on heavy fuel oil with the limit treatment. Particular care should be taken that in-
values specified in Table 1, is possible under nor- organic, foreign particles with their strong abrasive
mal service conditions, with properly working sys- effect (catalyst residues, rust, sand) are effectively
tems and regular maintenance. Otherwise, if these separated. It has shown in practice that with the
requirements are not met, shorter TBOs (times aluminium and silicon content > 15 mg/kg abrasive
between overhaul), higher wear rates and a higher wear in the engine strongly increases.
demand in spare parts must be expected. Alterna-
tively, the necessary maintenance intervals and the The viscosity and density will influence the clean-
operating results expected determine the decision ing effect, which has to be taken into consideration
as to which heavy fuel oil grade should be used. when designing and setting the cleaning equip-
ment.
It is known that as viscosity increases, the price ad-
vantage decreases more and more. It is therefore Settling tank
not always economical to use the highest viscosity
heavy fuel oil, which in numerous cases means the The heavy fuel oil is precleaned in the settling tank.
lower quality grades. This precleaning is all the more effective the lon-
ger the fuel remains in the tank and the lower the
Heavy fuel oils ISO-RM A/B 30 or CIMAC A/B 30 viscosity of the heavy fuel oil is (maximum preheat-
ensure reliable operation of older engines, which ing temperature 75 C to prevent formation of as-
were not designed for the heavy fuel oils that are phalt in the heavy fuel oil). One settling tank will
currently available on the market. ISO-RMA 30 or generally be sufficient for heavy fuel oil viscosity
CIMAC A30 with a low pour point should be pre- below 380mm2/s at 50 C. If the concentration of
ferred in cases where the bunker system cannot be foreign matter in the heavy fuel oil is excessive,
heated. or if a grade according to ISO-F-RM, G/H/K380 or
08028-0D/H5250/94.08.12
H/K700 is preferred, two settling tanks will be re-

Viscosity/injection viscosity quired, each of which must be adequately rated to
ensure trouble-free settling within a period of not
Heavy fuel oils if having a higher viscosity may be less than 24 hours. Prior to separating the content
of lower quality. The maximum permissible viscosity into the service tank, the water and sludge have to
depends on the existing preheating equipment and be drained from the settling tank.
the separator rating (throughput).
08.19 - ES1
MAN Diesel
Description
General
Separators pable of separating water up to a heavy fuel oil density
of 1.01 g/ml at 15 C.
A centrifugal separator is a suitable device for ex-
tracting material of higher specific gravity, such as Table 3, shows the demands made on the separa-
water, foreign particles and sludge. The separators tor. These limit values which the manufacturers of
must be of the self-cleaning type (i.e. with automati- these separators take as a basis and which they
cally induced cleaning intervals). also guarantee.
Separators of the new generation are to be used ex- The manufacturer specifications have to be ad-
clusively; they are fully efficient over a large density hered to in order to achieve an optimum cleaning
range without requiring any switchover, and are ca- effect.
Marine and stationary appli-

cation; connected in parallel
1 separator for
100% throughput
1 separator (standby) for

100% 100% 100% throughput
Figure 1 Heavy fuel oil cleaning/separator arrangement
Layout of the separators is to be in accordance with lected, it can be expected that the results given in
the latest recommendations of the separator manu- Table 3, for water and inorganic foreign particles in
facturers, Alfa Laval and Westfalia. In particular, the the heavy fuel oil are reached at the entry into the
density and viscosity of the heavy fuel oil are to be engine.
taken into consideration. Consulting MAN Diesel is
required if other makes of separators come up for The results obtained in practical operation reveal
discussion. that adherence to these values helps to particularly
keep abrasive wear in the injection system and in
If the cleaning treatment prescribed by MAN Die- the engine within acceptable limits. Besides, opti-
sel is applied, and if the correct separators are se- mal lube oil treatment must be ensured.
08028-0D/H5250/94.08.12
Denition Particle size Quantity
Inorganic foreign particles < 20 mg/kg

< 5 m
incl. catalyst residues Al+Si content <1 5 mg/kg
Water < 0.2 % by volume
Table 3 Obtainable contents of foreign matter and water (after separation)
08.19 - ES1
MAN Diesel

Description
General
Water Ash
Attention is to be paid to very thorough water sep- Heavy fuel oils with a high ash content in the form
aration, since the water is not a finely distributed of foreign particles such as sand, corrosion and
emulsion but in the form of adversely large droplets. catalyst residues, promote the mechanical wear in
Water in this form promotes corrosion and sludge the engine. There may be catalyst fines (catfines)
formation also in the fuel system, which has an ad- in heavy fuel oils coming from catalytic cracking
verse effect on the delivery and atomisation and processes. In most cases, these catfines will be
thus also on the combustion of the heavy fuel oil. aluminium silicate, which causes high wear in the
If the water involved is sea water, harmful sodium injection system and in the engine. The aluminium
chloride and other salts dissolved in the water will content found multiplied by 5 - 8 (depending on
enter the engine. the catalyst composition) will approximately cor-
respond to the content of catalyst materials in the
The water-containing sludge must be removed from heavy fuel oil.
the settling tank prior to each separating process,
and at regular intervals from the service tank. The Homogeniser
venting system of the tanks must be designed in
such a way that condensate cannot flow back into If a homogeniser is used, it must not be installed
the tanks. between the settling tank and the separator on any
account, since in that case, harmful contaminants,
Vanadium/sodium and in particular seawater, cannot be separated out
sufficiently.
Should the vanadium/sodium ratio be unfavour-
able, the melting temperature of the heavy fuel oil Flash point (ASTMD-93)
ash may drop into the range of the exhaust valve
temperature which will result in high-temperature National and international regulations for transport,
corrosion. By precleaning the heavy fuel oil in the storage and application of fuels must be adhered to
settling tank and in the centrifugal separators, the in respect of the flash point. Generally, a flash point
water, and with it the water-soluble sodium com- of above 60 C is specified for fuels used in Diesel
pounds can be largely removed. engines.
If the sodium content is lower than 1/3 of the vadi- Low temperature behaviour (ASTM D-97)
um content, the risk of high-temperature corrosion
will be small. It must also be prevented that sodium Pourpoint
in the form of sea water enters the engine together
with the intake air. The pour point is the temperature at which the fuel
is no longer fluid (pumplike). Since many of the low-
If the sodium content is higher than 100 mg/kg, an viscosity heavy fuel oils have a pour point greater
increase of salt deposits is to be expected in the than 0 C, too, the bunkering system has to be pre-
combustion space and in the exhaust system. This heated unless fuel in accordance with CIMAC A30
08028-0D/H5250/94.08.12
condition will have an adverse effect on engine op- is used. The entire bunkering system should be de-
eration (among others, due to surging of the turbo- signed so as to permit preheating of the heavy fuel
charger). oil to approx. 10 C above the pour point.
Under certain conditions, high-temperature corro-

sion may be prevented by a fuel additive that raises
the melting temperature of the heavy fuel oil ash
(also refer to Additives to heavy fuel oils.
08.19 - ES1
MAN Diesel
Description
General
Pump ability Preheating of the charge-air in the part-load range
and output reduction for a limited period of time
Difficulties will be experienced with pumping if the are possible measures to reduce detrimental influ-
fuel oil has a viscosity higher than 1,000mm2/s (cSt) ences of fuel of poor ignition qualities. More effec-
or a temperature less than approx. 10 C above the tive, however, are a high compression ratio and the
pour point. Please also refer to Low temperature in-service matching of the injection system to the
behaviour (ASTM D-97). ignition qualities of the fuel oil used, as is the case
in MAN Diesel trunk piston engines.
Combustion properties
The ignition quality is a key property of the fuel. The
An asphalt content higher than 2/3 of the carbon reason why it does not appear in the international
residue (Conradson) may lead to delayed combus- specifications is the absence of a standardised
tion, which involves increased residue formation, testing method. Therefore, parameters such as the
such as deposits on and in the injection nozzles, Calculated Carbon Aromaticity Index (CCAI) are
increased smoke formation, reduced power and in- resorted to as an aid, which are derived from de-
creased fuel consumption, as well as a rapid rise of terminable fuel properties. We have found this to
the ignition pressure and combustion close to the be an appropriate method of roughly assessing the
cylinder wall (thermal overloading of the lube oil ignition quality of the heavy fuel oil used.
film). If the ratio of asphaltenes to carbon residues
reaches the limit value 0.66, and the asphaltene A test instrument utilising a constant-volume
content also exceeds 8 %, additional analyses of combustion technology (FIA fuel ignition analy-
the heavy fuel oil by means of thermogravimetric ser) has been developed and is currently be-
analysis (TGA) must be performed by MAN Diesel ing evaluated at a number of testing laboratories.
to evaluate the usability. This tendency will also be The ignition quality of a fuel is determined as an ig-
promoted by the blend constituents of the heavy nition delay in the instrument that is converted to an
fuel oil being incompatible, or by different and in- instrument-related cetan number (FIA-CN or ECN).
compatible bunkering being mixed together. As a It has been observed that fuels with a low FIA ce-
result, there is an increased separation of asphalt tan number or ECN could, in some cases, lead to
(also see Compatibility). operational problems.
Ignition quality As the fluid constituent in the heavy fuel oil is the
determining factor for its ignition quality and the vis-
Cracked products which nowadays are preferred as cous constituent is decisive for the combustion qual-
low-viscosity blend constituents of the heavy fuel ity, it is the responsibility of the bunkering company
oil in order to achieve the specified reference vis- to supply a heavy fuel oil grade of quality matched
cosity may have poor ignition qualities. The cetane to the Diesel engine. Please refer to Figure 2.
number of these constituents should be > 35. An in-
creased aromatics content (above 35 %) also leads
to a decrease in ignition quality.
08028-0D/H5250/94.08.12
Fuel oils of insufficient ignition qualities will show

extended ignition lag and delayed combustion,
which may lead to thermal overloading of the oil
film on the cylinder liner and excessive pressures in
the cylinder. Ignition lag and the resultant pressure
rise in the cylinder are also influenced by the final
temperature and pressure of compression, i.e. by
the compression ratio, the charge-air pressure and
charge-air temperature.
08.19 - ES1
MAN Diesel

Description
General
16/24 1
20/27
21/31 32/44CR
V D CCAI 23/30 32/36 40/54
1 800 800 25/30 32/40 48/60
27/38 40/45 52/55B
28/32 52/55A 58/64
820
810
840
820
2
860
830
3 880 A
840
4 900
5 850
920
940 860
10 2
960 870 B
20
980 880
30
50 1000 890
100 1020
900
200 C
1040
400 910
1000
920
5000
930
20000
50000
Figure 2 Nomogram for the determination of CCAI assignment of CCAI ranges to engine types
V Viscosity mm/s (cSt) at 50 C

D Density [kg/m] at 15 C
CCAI Calculated Carbon Aromaticity Index
08028-0D/H5250/94.08.12
A Normal operating conditions

B Difficulties may be encountered
C Problems encountered may increase up to engine damage after a short time of operation
1 Engine type
2 The combining straight line across density and viscosity of a heavy fuel oil results in CCAI.
CCAI can also be calculated with the aid of the following formula:
CCAI = D - 141 log log (V+0.85) - 81
08.19 - ES1
MAN Diesel
Description
General
Sulphuric acid corrosion The use of fuel additives during the guarantee pe-
riod is rejected as a matter of principle.
The engine should be operated at the cooling water
temperatures specified in the operating manual for Additives currently in use for Diesel engines are
the respective load. If the temperature of the com- listed in Table 4, together with their supposed ef-
ponent surface exposed to the acidic combustion fect on engine operation.
gases is below the acid dew point, acid corrosion
can no longer be sufficiently prevented even by an
alcaline lubricating oil. Precombustion Dispersants/stabilisers
Emulsion breakers
If the lube oil quality and engine cooling meet the Biocides
respective requirements, the BN values (see Qual-
ity of lube oil (SAE40) for heavy fuel oil operation Combustion Combustion catalysts (fuel
(HFO)) will be adequate, depending on the sulphur economy, emissions)
concentration in the heavy fuel oil. Postcombustion Ash modier (hot corrosion)
Carbon remover (exhaust
Compatibility
system)
The supplier has to guarantee that the heavy fuel Table 4 Additives to heavy fuels Classication/
oil remains homogenous and stable even after effects
the usual period of storage. If different bunker oils
are mixed, separation may occur which results in
sludge formation in the fuel system, large quantities Low sulphur HFO
of sludge in the separator, clogging of filters, insuf-
ficient atomisation and highresidue combustion. From an engine manufacturers point of view there
is no lower limit for the sulphur content of HFO. We
In such cases, one refers to incompatibility or insta- have not experienced any trouble with the currently
bility. The heavy fuel oil storage tanks should there- available low sulphur HFO, that are related to the
fore be emptied as far as possible prior to rebunker- sulphur content or specific to low sulphur HFO.
ing in order to preclude incompatibility. This may change in the future if new methods are
applied for the production of low sulphur HFO (de-
Blending heavy fuel oil sulphurization, uncommon blending components).
MAN Diesel will monitor developments and inform
If, for instance, heavy fuel for the main engine and our customers if necessary.
gas oil (MGO) are blended to achieve the heavy
fuel oil quality or viscosity specified for the auxil- If the engine is not operated permanently on low
iary engines, it is essential that the constituents are sulphur HFO, then the lubricating oil should be se-
compatible (refer to Compatibility above). lected according to the highest sulphur content of
the fuels in operation.
Additives to heavy fuel oils
08028-0D/H5250/94.08.12
MAN Diesel engines can be economically operated

without additives. It is up to the customer to decide
whether or not the use of an additive would be ad-
vantageous. The additive supplier must warrant
that the product use will have no harmful effects on
engine operation.
08.19 - ES1
MAN Diesel

Description
General
Examinations Analyse samples
Sampling The samples received from the bunkering company

are frequently not identical with the heavy fuel oil
To be able to check as to whether the specification bunkered. It is also appropriate to verify the heavy
indicated and/or the stipulated delivery conditions fuel oil properties stated in the bunker documents,
have been complied with, we recommend a mini- such as density, viscosity. If these values should de-
mum of one sample of each bunker fuel to be re- viate from those of the heavy fuel oil bunkered, one
tained, at least during the guarantee period for the runs the risk that the heavy fuel oil separator and
engine. In order to ensure that the sample is rep- the preheating temperature are not set correctly for
resentative for the oil bunkered, a sample should the given injection viscosity. The criteria for an eco-
be drawn from the transfer pipe at the start, at half nomic engine operation with regard to heavy fuel oil
the time and at the end of the bunkering period. and lubricating oil may be determined with the help
Sample Tec, supplied by Messrs Mar-Tec, Ham- of the MAN Diesel Fuel and Lube Analysis Set.
burg is an appropriate testing kit for taking samples
continuously during the bunkering. Our department for fuels and lube oils (Augsburg
Works, Department GQC) will be glad to furnish
further information if required.
Analysis of fuel oils are carried out by our chemical

laboratory for customers. For examination a sample
of approx. 0.5 litre is required.
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description
Quality of Marine Diesel Fuel (MDO) 504.20
General
Other designations Specification
Diesel Fuel Oil, Diesel Oil, Bunker Diesel Oil, Ma- The usability of a fuel depends upon the engine
rine Diesel Fuel. design and available cleaning facilities as well as
on the conformity of the key properties with those
Marine Diesel Oil (MDO) is offered as heavy distil- listed in the table below which refer to the condition
late (designation ISO-F-DMB) or as a blend of distil- on delivery.
late and small amounts of residual oil (designation
ISO-F-DMC) exclusively for marine applications. The key properties have been established to a
The commonly used term for the blend, which is of great extent on the basis of ISO 8217-2005 and
dark brown to black colour, is Blended MDO. MDO CIMAC-2003. The key properties are based on the
is produced from crude oil and must be free from test methods specified.
organic acids and any non-mineral oil products.
Property/feature Unit Test method Designation

Specication ISOF DMB DMC
Density at 15 C kg/m3 ISO 3675 900 920
Cinematic viscosity at 40 C mm2/s cSt ISO 3104 >2.5 < 11 >4 < 14
Pour Point winter quality ISO 3016 <0 <0
summer quality C <6 <6
Flash point Pensky Martens ISO 2719 > 60 > 60

Total content of sediments % by weight ISO CD 10307 0.10 0.10
Water content % by weight ISO 3733 < 0.3 < 0.3
Sulphur content % by weight ISO 8754 < 2.0 < 2.0
Ash content % by weight ISO 6245 < 0.01 < 0.03
Coke residue (MCR) % by weight ISO CD 10370 < 0.30 < 2.5
Cetane number ISO 5165 > 35 > 35

Copperstrip test ISO 2160 <1 <1
Vanadium content DIN 51790T2 0 < 100
mg/kg
Content of aluminium and silicon ISO CD 10478 0 < 25
1)
Visual inspection
Other specications:
08028-0D/H5250/94.08.12
British Standard BS MA 100 1987 Class M2 Class M3

ASTM D 975 2D 4D
ASTM D 396 No. 2 No. 4
Table 1 Marine Diesel Oil (MDO) key properties to be adhered to
1)
With good illumination and at room temperature, appearance
of the fuel should be clear and transparent.
08.19 - ES1
MAN Diesel
504.20 Quality of Marine Diesel Fuel (MDO) Description

General
Supplementary information Sea water, in particular, tends to increase corrosion

in the fuel oil system and hot corrosion of exhaust
At transshipment facilities and in transit MDO is valves and in the turbocharger. It is also the cause
handled like residual oil. Thus, there is the possibil- of insufficient atomization and thus poor mixture
ity of oil being mixed with high-viscosity fuel oil or formation and combustion with a high proportion of
Interfuel, for example with remainders of such fuels combustion residues.
in the bunkering boat, which may adversely affect
the key properties considerably. Solid foreign matter increase the mechanical wear
and formation of ash in the cylinder space.
The fuel shall be free of used lubricating oil
(ULO). A fuel shall be considered to be free of If the engine is mainly run on Blended MDO i.e.
ULO if one or more of the elements Zn, P and ISO-F-DMC, we recommend to provide a centrifu-
Ca are below the specified limits (Zn: 15 ppm; gal separator upstream of the fuel oil filter. Sepa-
P: 15 ppm; Ca: 30 ppm). rator throughput 65 % with relation to the rated
throughput. Separating temperature 40 to 50 C.
The Pour Point indicates the temperature at which Solid particles (sand, rust, catalyst fines) and water
the oil will refuse to flow. The lowest temperature can thus largely be removed and the intervals be-
the fuel oil may assume in the system, should lie tween cleaning of the filter elements considerably
approx. 10 C above the pour point so as to ensure extended.
it can still be pumped.
Investigations
A minimum viscosity at the fuel injection pump is re-
quired to ensure a sufficient lubricity. Therefore the Fuel analyses are carried out in our chemical labo-
temperature of the fuel must never exceed 60 C. ratory for our customers. For examination a sample
of approx. 0.5 litre is required.
If Blended MDOs (ISO-F-DMC) of differing bunker-
ing are being mixed, incompatibility may result in
sludge formation in the fuel system, a large amount
of sludge in the separator, clogging of filters, insuf-
ficient atomization and a large amount of combus-
tion deposits. We would therefore recommend to
run dry the respective fuel storage tank as far as
possible before bunkering new fuel.
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description
Quality of Gas Oil / Diesel Fuel (MGO) 504.20
General
Other designations Specification
Gas oil, Marine Gas Oil (MGO), High Speed Diesel Suitability of the fuel depends on the conformity
Oil. with the key properties as specified hereunder, per-
taining to the condition on delivery.
Diesel fuel is a medium class distillate of crude oil
which therefore must not contain any residual com- On establishing the key properties, the standards
ponents. of DIN EN 590 and ISO 8217-2005 (Class DMA),
as well as CIMAC-2003 were taken into considera-
tion to a large extent. The key property ratings refer
to the testing methods specified.
Property/feature Unit Test method Characteristic value
Density at 15 C 820.0
kg/m3 ISO 3675
890.0
1.5
Cinematic viscosity / 40 C mm2/s (cSt) ISO 3104
6.0
Filter ability1)
in summer 0
DIN EN 116
in winter C 12
Flash point AbelPensky in closed

ISO 1523 60
crucible
Distillation range up to 350 C % by volume ISO 3405 85
Content of sediment (Extraction method) % by weight ISO 3735 0.01
Water content % by volume ISO 3733 0.05
Sulphur content ISO 8754 1.5
Ash ISO 6245 0.01

% by weight
Coke residue (MCR) ISO CD 10370 0.10
Cetane number ISO 5165 40 2)
Copperstrip test ISO 2160 1
Other specications:
British Standard BS MA 1001987 M1

08028-0D/H5250/94.08.12
ASTM D 975 1D/2D
Table 1 Diesel fuel oil (MGO) key properties to be adhered to
1)
Determination of lter ability to DIN EN 116 is comparable to
Cloud Point as per ISO 3015.
2)
L/V 20/27 engines require a cetane number of at least 45
08.19 - ES1
MAN Diesel
504.20 Quality of Gas Oil / Diesel Fuel (MGO) Description

General
Supplementary information A minimum viscosity at the fuel pump is required to

ensure a sufficient lubricity. The required maximum
Using fuel oil temperature to keep the viscosity before the fuel
pump above 2 mm2/s is dependent on the fuel vis-
If, in case of stationary engines a distillate intended cosity. But in all cases the temperature of the fuel
for oil firing (for instance Fuel Oil EL to DIN 51603 before the injection pump must not exceed 50 C.
or Fuel Oil No 1 or No 2 according to ASTM D-
396, resp.), is used instead of Diesel fuel, adequate Investigations
ignition performance and low-temperature stability
must be ensured, i.e. the requirements as to prop- Fuel analysis are carried out in our chemical labo-
erties concerning filter ability and cetane number ratory for our customers at cost price. For examina-
must be met. tion a sample of approx. 0.5 litre is required.
08028-0D/H5250/94.08.12
08.19 - ES1
MAN Diesel
Description 504.27
Page 1 (4) Analysis Data Edition 02
General
Comments on Analysis Data for Fuel Oils Asphaltenes also influences the lubricating properties
of the fuel oil and, in extreme cases, high asphalteness
Carbon Residue content may lead to fuel injection pump sticking.
The carbon residue of a fuel oil indicates its coke- Fuel oils with a high asphalteness content will have
forming tendency and can be used to determine the a tendency to form sludge, especially if the water
tendency to form deposits in the combustion chamber content is also high. The asphaltenes content of a
and gasways. The higher the carbon residue value, fuel oil is influenced by pre-treatment. The heaviest
the higher the fouling tendency. semi-solid asphaltenes, and asphaltenes bound to
water as sludge, can be separated by centrifuging.
Some changes in the combustion process, requir-
ing adjustment of the maximum pressure, may also
be attributed to a high carbon residue content. The Diesel Index
value is measured by standardized tests, such as
the Conradson or Ramsbottom tests which give Diesel index is a calculated value to determine the
similar results. ignition quality of a fuel oil. The ignition quality is re-
lated to the hydrocarbon composition, paraffin being
The non-vaporized residue from the carbonizing test of high quality, n-heptanes of moderate quality and
consists of carbonaceous material and inorganic im- aromatics of low quality.
purities and is expressed as percentage weight of the
fuel sample tested. Carbon residue and asphaltenes With certain exceptions the properties of the aniline
content generally move in parallel, both in relation to point and the specific gravity reflect the hydrocarbon
the carbon-to-hydrogen ratio, with increasing values composition of a fuel oil, and are therefore used in
for a higher ratio. the following simple formula as an expression of
ignition quality:
The carbon-to-hydrogen ratio and thus also the
carbon residue depends on the source of the crude Diesel index = (aniline point F x API gravity) x
oil and the type of refinery processing used. 0.01.
The effect of carbon residue is impossible to coun- The aniline point is the lowest temperature at which
teract by pre-treatment of the fuel oil, as centrifuging equal volumes of the fuel and aniline become just
only influences solid inorganic contaminants and miscible. The test relies on the fact that aromatic
hard asphalts, which are only small amounts of the hydrocarbons mix completely with aniline at compara-
percentage weight called carbon residue. tively low temperatures, whereas paraffins require
considerably higher temperatures before they are
completely miscible.
Asphaltenes
A high aniline point thus indicates a highly paraffinic
Asphaltenes is defined as the part of a fuel oil sam- fuel, and consequently a fuel oil of good ignition qual-
ple which is insoluble in heptane. The content of ity. Similarly, a high API gravity number denotes a
08028-0D/H5250/94.08.12
asphalteness is expressed as percentage weight of low specific gravity and high paraffinicity, and again
the fuel oil sample tested. a good ignition quality.
Asphaltenes, which is aromatic, slow-burning, semi- The diesel index provides a reasonable idea of the
solid hydrocarbon compounds dispersed in the fuel ignition quality, but generally gives figures slightly
oil, has a similar effect on the combustion process above the cetane number.
to the carbon residue, the main impact being fouling
of gasways. The stability of the fuel oil is related to Fuel oils with poor ignition quality and a low diesel
the asphaltenes content. index might in particular cause problems in starting
diesel engines and running at low load.
02.16 - ES0 - G
MAN Diesel
504.27 Description
Edition 02 Analysis Data Page 2 (4)
General
In addition to starting difficulties, a prolonged ignition Especially if the weight ratio of sodium to vanadium
delay may give rise to alternations in the maximum exceeds 1:3, ash with a very low melting point and
pressure, leading to increased mechanical or ther- stiction temperature is formed, giving rise to high
mal load. temperature corrosion of exhaust valves and deposit
formation in turbochargers.
Furthermore, fuel oils with poor ignition quality may
cause retarded combustion and subsequent fouling It is possible to reduce the tendency for formation
of gasways. of detrimental vanadium-sodium ash by effective
centrifuging, which will remove sodium salts to-
gether with water. If a very low content of sodium is
Sulphur ensured, a relatively high vanadium content might
be acceptable.
Sulphur is present in fuel oil, mainly as organic
compounds, the amount present being expressed
as percentage weight of an oil sample tested. If free Water
sulphur is present it may cause corrosion in the fuel
system. The main problem caused by sulphur is low The water content of fuel oil is measured by a
temperature corrosion. During combustion, sulphur standardized distillation test and is expressed as
oxides are produced in the form of gases. Since percentage volume of the sample tested. Water in
humidity is also present sulphur and sulphuric acid the fuel oil may lead to several detrimental effects
may be formed on components in the combustion on the fuel oil system, and corrosion and cavitation
chamber and in the gasways, where the temperature of fuel injection pumps and fuel valves, and cause
is below that of the dew point for sulphuric acid. fouling of exhaust systems and turbochargers.
The detrimental effect of sulphur in fuel oil is coun- Due to its content of sodium, salt water in combina-
teracted by maintaining an adequate temperature of tion with vanadium contributes to the formation of
the combustion chamber components and by using low-melting corrosive ash, which attacks exhaust
alkaline lubricating oil to neutralize the sulphuric acid valves and turbochargers. When it disturbs the fuel
produced during combustion. atomization, water will lead to poor combustion,
resulting in higher heat load on the combustion
chamber components.
Vanadium and Sodium
It is possible to reduce the water content of a fuel oil
Vanadium and sodium are constituents of the ash primarily by centrifuging, and this should be done
content. The amounts of these are measured by to the widest possible extent in order to avoid the
analyzing the residue from the combustion test used detrimental effects of water in the fuel oil.
for determination of the ash content. The amount of
vanadium and sodium present is expressed in ppm,
parts per million, by weight in relation to the fuel oil Ash
sample being tested for ash content. Vanadium de-
08028-0D/H5250/94.08.12
rives from the crude oil itself and, being oil soluble, Ash content is a measure of the non-combustible
cannot be removed from the fuel oil by conventional material present in the fuel oil. The ash content is
pre-treatment. Sodium derives from the crude oil, and determined by a combustion test and it is expressed
also from contamination with salt water during storage as a percentage weight residue from complete com-
and transport of the fuel oil. Sodium is water- soluble bustion of the oil sample tested.
and, regardless of derivation, tends to combine with
the water present in the fuel oil. Ash-forming materials are present in the fuel oil as
natural components of crude oil and due to external
Owing to its water solubility, it is possible to remove contamination of the fuel oil.
or reduce the amount of sodium present in the fuel
oil. During combustion, corrosive ash is formed from
vanadium and sodium.
02.16 - ES0 - G
MAN Diesel
Description 504.27
Page 3 (4) Analysis Data Edition 02
General
Ash-forming materials exist both as solid contami- Viscosity of Marine Gas Oil (MGO) and Marine
nants and in soluble compounds. The solid contami- Diesel Oil (MDO) are expressed in centistokes (cSt)
nants may lead to abrasive wear in the fuel injection at 40 C.
system. Ash formed during combustion may lead to
abrasive as well as corrosive wear of combustion Viscosity is an important parameter in connection with
chamber components and give rise to formation of pumping, pre-treatment and injection of fuel oil, since
detrimental deposits. It is therefore essential, to the the possibility and efficiency of these processes to a
greatest possible extent, to reduce the amount of large extent depend on adequate viscosity.
ash-forming materials by centrifuging.
Adjustment of viscosity to adequate values is possible
Solid contaminants such as sand, rust, certain by taking advantage of the interdependence between
metal oxides and catalyst fines can be removed by the temperature and viscosity index of the fuel oil.
centrifuging, and the same goes for water-soluble
salts such as sodium. The nominal viscosity of a fuel oil is the factor de-
termining the preheating temperatures necessary to
Some of the components included in the ash content obtain adequate viscosity for pumping, centrifuging
have been found to be particularly harmful and are and injection of the fuel oil, and thus also the factor
therefore stated individually in the analysis data. determining the capacity of the preheating equipment
in the fuel oil system.
Silicium and Aluminium Oxides

Density
Residual fuels produced by refineries using fluid
catalytic cracking may be contaminated by catalyst Density is defined as the mass of a unit volume
particles in the form of silicium and aluminium oxides. and is expressed in g/cm at a temperature of 15C
Any catalyst particles are shown by the ash content (59F).
value. Separate values for silicium oxide content and
aluminium oxide content are measured by analyzing Specific gravity is the ratio of the mass of a given
the ash content. volume of liquid at 60F (15.6C) and the mass of
an equal volume of water at the same temperature.
The amount of silicium and aluminium oxides is ex- For a given liquid, the specific gravity will generally
pressed in ppm in relation to the weight of the original give the same numerical value as the density.
fuel oil sample being tested for ash content.
API gravity is an arbitrary scale calibrated in de-
As catalyst particles are very hard and abrasive, grees and related to specific gravity by the following
they can cause extreme mechanical wear of the fuel formula:
injection system, cylinder liners and piston rings. 141.5
API gravity = specific gravity/50F + 131.5
Catalyst particles, being solid and insoluble, can be
removed from the fuel oil. The guidelines for dimen-
08028-0D/H5250/94.08.12
sioning the centrifuge size are based on the fact As the formula indicates, the API gravity is in inverse
that approx. 1/3 of the catalyst particles in terms of proportion to density and specific gravity.
weight is removed.
Density is an important parameter in the centrifuging
process, where separating water and water-dissolved
Viscosity impurities from the fuel oil is based on the difference
in densities. If the density of the fuel oil approaches
Basically viscosity is a measure of the internal friction that of water, centrifuging thus becomes less effec-
or resistance of a liquid to flow. tive, necessitating a reduced flow rate and therefore
increased centrifuge capacity.
02.16 - ES0 - G
MAN Diesel
504.27 Description
Edition 02 Analysis Data Page 4 (4)
General
The water separation ability of fuel oil is increased Pour Point
by preheating the fuel oil prior to centrifuging since
the densities of fuel oil and water change with the The pour point is the lowest temperature at which an
temperature at different rates, thus making it possible oil will flow or can be poured. The pour point is meas-
to optimize density differences. ured under specific test conditions. Fuel oil must be
stored, handled and pumped at temperatures above
To some extent the quality of a fuel oil can be judged the pour point to avoid wax crystallization, which may
by the density, since this is directly proportional to the result in precipitation in storage tanks, blocking of
carbon-to-hydrogen ratio, which again is in direct pro- filters and pipe lines and prevention of pumpability.
portion to aromativity, carbon residue and asphaltene Normally, the pour point of residual fuel oil does not
content, but in reverse ratio to calorific value. create any problems, since the temperature needed
to reduce the viscosity to pumpable levels will be
adequately in excess of the pour point.
Analysis Data for Fuel Oils

Flash Point
Carbon Residue % weight
Asphaltenes % weight The flash point of an oil is defined as the temperature
Diesel Index at which it gives off sufficient vapour to create an
Engine- FIA
Relevant Ash % weight
inflammable mixture with air. This mixture will ignite
Properties Sulphur % weight or flash under the influence of an open flame, but
Water % volume will not support combustion itself. The flash point of
Vanadium ppm fuel oil is normally tested by the Pensky-Martens
Sodium ppm closed-up method.
Silicium Oxide ppm
Aluminium Oxide ppm
In order to provide a sufficient margin of safety from
Viscosity cSt/50C fire risk during storage, handling and transportation,
Installation- Density g/ml fuel oils for shipboard use must meet the classifica-
Relevant Flash Point C tion societies' requirements of flash point, limited to
Properties Pour Point C
a minimum of 60C (140F).
Table 2 Analysis data for fuels.
08028-0D/H5250/94.08.12
02.16- ES0 - G
MAN Diesel
Description 504.30
Page 1 (2) Fuel Oil Cleaning Edition 01
General
Purification Recommendations Especially for fuels above 180 cST/50C (1500 sec.
RW/100F) the highest possible temperature of 98C
Fuel oils are always contaminated and should there- (208F) 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 15C 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 15C Purifier / Purifier of the above results and recommendations serious
conditions below 0.991 consideration should be given to installing new equip-
ment in accordance with today's fuel qualities and
High content Series operation flow recommendations.
of catalyst fines Purifier + Clarifier
Table 1. Cleaning of HFO.
97.40 - ES0
MAN Diesel
504.30 Description
Edition 01 Fuel Oil Cleaning Page 2 (2)
General
To determine centrifuging capacity we generally

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

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

city of centrifuge.
08028-0D/H5250/94.08.12
97.40 - ES0
MAN Diesel
Description
Page 1 (5) Freshwater System Treatment 504.40
Edition 02
General
Protection against Corrosion in Freshwater Cleaning agents emulsified in water as well as slightly
Cooling System alkaline cleaning agents can be used for the degrea-
sing process, whereas ready-mixed cleaning agents
The engine fresh water must be carefully treated, which involve the risk of fire must obviously not be
maintained and monitored so as to avoid corrosion used. For descaling with acid, especially products
or the formation of deposits which can result in insuf- based on amino-sulphonic acid, citric acid, and tar-
ficient heat transfer, it is necessary to treat the cooling taric acid are recommendable, as these acids are
water. MAN B&W recommend that this treatment is usually obtainable as solid substances, easily soluble
carried out according to the following procedure: in water, and do not emit poisonous vapours.
The cleaning agents should not be directly admixed,

Clean the cooling water system. but should be dissolved in water and then added to
the cooling water system.
Fill up with deionized or distilled cooling water
(for example from the freshwater generator) Normally, cleaning can be executed without any dis-
with corrosion inhibitor added. mantling of the engine. We point out that the water
should be circulated in the engine to achieve the
Carry out regular checks of the cooling water best possible result.
system and the condition of the cooling wa-
ter. As cleaning can cause leaks to become apparent in
poorly assembled joints or partly defective gaskets,
inspection should be carried out during the cleaning
Observance of these precautions, and correct venting process. The acid content of the system oil should
of the system, will reduce service difficulties caused also be checked immediately after cleaning, and 24
by the cooling water to a minimum. hours afterwards.
Cleaning of the Cooling Water System Cooling Water - Inhibitors
Before starting the inhibition process, any existing The filling-up with cooling water and the admixture
deposits of lime or rust, or any oil sludge, should be of the inhibitor is to be carried out directly after the
removed in order to improve the heat transfer and to cleaning in order to prevent formation of rust on the
ensure uniform protection of the surface by means cleaned surfaces.
of the inhibitor.
Raw Water
The cleaning should comprise degreasing to remove
oil sludge, and descaling with acid afterwards to The formation of lime stone on cylinder liners and in
remove rust and lime deposits. cylinder heads may reduce the heat transfer, which
will result in unacceptably high temperatures in the
Ready-mixed cleaning agents, specially made for material.
08028-0D/H5250/94.08.12
cleaning the cooling water system, can be obtained

from companies specializing in cooling water treat- Therefore, it is recommended that deionized or distil-
ment. These companies offer assistance and control led water (for example from the freshwater genera-
of the treatment in all major ports. A number of these tor) is used as cooling water. However, on account
companies are mentioned on the enclosed list. We of its lack of hardness, this water will be relatively
point out that the directions given by them should corrosive, and a corrosion inhibitor should therefore
be closely followed. It is of particular importance to always be added.
flush the system completely after cleaning.
00.11- ES1
MAN Diesel
504.40 Freshwater System Treatment Description

Page 2 (5)
Edition 02
General
If deionized or distilled water cannot be obtained, Checking of the Cooling Water System and
normal drinking water can be used in exceptional the Cooling Water during Service
cases. If so, the total hardness of the water must
not exceed 9 dH (German hardness degrees). The If the cooling water is contaminated during service,
chloride, chlorine, sulphate, and silicate contents sludge or deposits may form. The condition of the
are also to be checked. These contents should not cooling water system should therefore be regularly
exceed the following values: checked, especially if deionized or distilled water is
not used. If deposits are found in the cooling spaces,
Chloride 50 ppm (50 mg/litre) these spaces or, if necessary, the entire system
Chlorine 10 ppm (10 mg/litre) should be cleaned.
Sulphate 100 ppm (100 mg/litre)
Silicate 150 ppm (150 mg/litre) According to experience, a zinc galvanized coating
in the freshwater cooling system is often very suscep-
There should be no sulphide and ammonia content. tible to corrosion, which results in heavy formation of
Rain water must not be used, as it may be heavily sludge, even if the cooling water is correctly inhibited.
contaminated. The initial descaling with acid will, to a great extent,
remove the galvanized coating. Generally, therefore,
It should be noted that softening of water does not we advise against the use of galvanized piping in the
reduce its sulphate and chloride contents. freshwater cooling system.
Corrosion Inhibitors The quality of the cooling water is to be checked re-

gularly, if possible once a week. Basically the inhibitor
To protect freshwater cooling systems in marine concentration, the pH value and the chloride concen-
diesel engines against corrosion, various types of tration should be in accordance with limits stated by
inhibitors are available. inhibitor manufacturer. For this purpose the inhibitor
manifactures normally supply simple test kits.
Generally, only nitrite-borate based inhibitors
are recommended. As a general guidance values the pH value should be
7-10 measured at 20 C and the chloride concentra-
A number of the products marketed by major compa- tion should not exceed 50 ppm (50 mg/litre).
nies are specified on the enclosed list, together with
the necessary dosages and admixing procedures. The water sample for these tests is to be taken from
We recommend that these directions are strictly the circulating system, and not from the expansion
observed. tank or the pipe leading to it.
Treatment of the cooling water with inhibting oils is not The concentration of inhibitor must under no
recommended, as such treatment involves the risk of circumstances be allowed to fall below that
oil adhering to the heat transmitting surfaces. recommended by the producer, as this would
increase the risk of corrosion.
Chromate inhibitors must not be used in plants
08028-0D/H5250/94.08.12
connected to a freshwater generator. A clear record of all measuring results should be kept,
so that the actual condition and trend of the system
Evaporated cooling water is to be replaced with may be currently ascertained and evaluated.
noninhibited water, whereas a loss of water through
leakage must be replaced with inhibited water. A sudden or gradual increase in the chloride content
of the cooling water may be indicative of salt water
When overhauling individual cylinders, a new dosage leakages. Such leakages are to be traced and repai-
of inhibitor must, if necessary, be added im-mediately red at the first opportunity.
after completing the job.
00.11- ES1
MAN Diesel
Description
Edition 02
General
A chloride content in the cooling water higher than The cooling water system must not be kept under
the 50 ppm specified might, in exceptional cases pressure.
be tolerated. However, in that case the upper limit
specified by the individual inhibitor supplier must Check, and repair any leaks.
not be exceed.
Drain the system and fill up completely with clean
A clear record of all measuring results should be kept, tap water, in order to flush out any oil or grease from
so that the actual condition and trend of the system the tank.
may be currently ascertained and evaluated.
Circulate the water for 2 hours, and drain again.
A sudden or gradual decrease in pH value, or an
increase of the sulphate content, may indicate ex-
haust gas leakage. The pH value can be increased Descaling with Acid Solution
by adding inhibtor; however, if major quantities are
necessary, the water should be replaced. Fill up with clean tap water and heat to 70-75 C.
Every third month a cooling water sample should be Dissolve the necessary dosage of acid compound
sent ashore for laboratory analysis, in particular to in a clean iron drum with hot water.
ascertain the contents of inhibtor, sulphate, and iron,
as well as the total salinity of the water. Fill the drum half up with water and slowly add the
acid compound, while stirring vigorously. Then fill the
drum up completely with hot water while continuing
Cleaning and Inhibiting Procedure to stir (e.g. using a steam hose).
The engine must not be running during the cleaning Be careful - use protective spectacles and
procedure, as this may involve the risk of overheating gloves.
when draining.
For engines which have been treated before the trial
trip, the lowest concentration recommended by the
Degreasing supplier will normally be sufficient.
Use clean tap water for filling-up. The cooling water For untreated engines, a higher concentration - de-
in the system can be used, if it does not contain pending on the condition of the cooling system - will
inhibitors. normally be necessary.
Heat the water to 60 C and circulate the water Drain some water from the system and add the acid
continuously. solution via the expansion tank.
Drain to lowest water level in expansion tank. The cooling water system must not be put under
pressure.
08028-0D/H5250/94.08.12
Add the amount of degreasing chemical specified

by the supplier, preferably from the suction side of Keep the temperature of the water between 70 C
the freshwater pump. and 75 C, and circulate it constantly. The duration
of the treatment will depend on the degree of foul-
Drain to lowest water level in the expansion tank ing. Normally, the shortest time recommended by
directly afterwards. the supplier will be sufficient for engines which are
treated before the trial trip. For untreated engines,
Circulate the cleaning chemical for the period speci- a longer time must be reckoned with. Check every
fied by the supplier. hour, for example with pH-paper, that the acid in the
solution has not been used up.
00.11- ES1
MAN Diesel
504.40 Freshwater System Treatment Description

Page 4 (5)
Edition 02
General
A number of descaling preparations contain colour Adding of Inhibitors
indicators which show the state of the acid solution.
If the acid content is exhausted, a new acid solution Fill up the cooling water system with water from the
can be added, in which case, the weakest recom- evaporator to the lowest water level in the expan-
mended concentration should be used. sion tank.
The solubility of acids in water is often limited. Weight out the quantity of inhibitors specified by the
Therefore if, in exceptional cases, a large amount is supplier and dissolve in a clean iron drum with hot
required, descaling can be carried out in two stages water from the evaporator.
with a new solution of compound and clean water.
Normally the supplier will specify the maximum Add the solution via the expansion tank to the system.
solubility. Then fill up to normal water level with water from the
evaporator.
After completing the descaling, drain the system and
flush with water. Acid residues can be neutralized Allow the engine to run for not less than 24 hours to
with clean tap water containing 10 kg soda per ton ensure that a stable protection of the cooling surfa-
of water. Circulate the mixture for 30 minutes, then ces is formed.
drain and flush the system.
Subsequently, test the cooling water with a test
The cooling water system must not be put under kit (available from the inhibitor supplier) to ensure
pressure. that an adequate inhibitor concentration has been
obtained.
Continue to flush until water used is neutral (pH
approx. 7). This should be checked every week.
The acid content of the system oil is to be checked

directly after the descaling with acid, and again 24
hours afterwards.
08028-0D/H5250/94.08.12
00.11- ES1
MAN Diesel
Description
Edition 02
General
Nitrite-borate corrosion inhibitors
for cooling water treatment
Maker's minimum
Company Name of Inhibitor Delivery Form Recommended
Dosage*
Castrol Limited Castrol Powder 3 kg/1000 l

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

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

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

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

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

Marine Chemicals Rocor NB Liquid Liquid 10 l/1000 l
Oslo, Norway
* Initial dosage may be larger
The list is for guidance only and must not be consid- The suppliers are listed in alpabetical order.
08028-0D/H5250/94.08.12
ered complete. We undertake no responsibility for

difficulties that might be caused by these or other Suitable cleaners can normally be supplied by
water inhibitos/chemicals. these firms.
00.11- ES1
Cylinder head
505/605
MAN Diesel
Description
Cylinder Head 505.01
L27/38
Cylinder Head Air Inlet and Exhaust Valves
The cylinder head is of cast iron with an integrated The valve spindles are made of heat-resistant material
charge air receiver, made in one piece. It has a bore- and the spindle seats are armoured with welded-on
cooled thick walled bottom. It has a central bore for hard metal.
the fuel injection valve and 4 valve cross flow design,
with high flow coefficient. Intensive water cooling of All valve spindles are fitted with valve rotators which
the nozzle tip area makes it possible to omit direct turn the spindles each time the valves are activated.
nozzle cooling. The valve pattern is turned about 20 The turning of the spindles ensures even temperature
to the axis and achieves a certain intake swirl. levels on the valve discs and prevents deposits on
the seating surfaces.
The cylinder head is tightened by means of 4 nuts and
4 studs which are screwed into the engine frame. The The cylinder head is equipped with replaceable valve
nuts are tightened by means of hydraulic jacks. seat rings. The exhaust valve seat rings are water
cooled in order to assure low valve temperatures.
The cylinder head has a screwed-on top cover. It has
two basic functions: oil sealing of the rocker chamber The seat rings are made of heat-resistant steel. The
and covering of the complete head top face. seating surfaces are hardened in order to minimize
wear and prevent dent marks.
08028-0D/H5250/94.08.12
99.17 - ES0
MAN Diesel

Page 1 (4) Dismantling of Cylinder Unit from Engine Edition 04H
L27/38

Stopped lub. oil circul. 52001 107
Press Blocking - Reset 52000 334
52000 060
Description and hydraulic tools according

to working card 520-01.06
Dismantling of cylinder unit from engine for in-
spection and/or overhaul.
Starting position Hand tools
Engine stopped and cooled down. Unbraco top.

Ratchet.
Extension.
Related procedure
Valve rotator 505-01.15

Disassembly of cylinder unit 505-01.01
Fuel injection valve 514-01.10
Function of hydraulic tools 520-01.05
Application of hydraulic tools 520-01.06
Working time : 2 hour Plate no Item no Qty/

Capacity : 2 men
08028-0D/H5250/94.08.12
Data

01.30 - ES0
MAN Diesel

Edition 04H Dismantling of Cylinder Unit from Engine Page 2 (4)
L27/38
Preparing before Dismantling 9) Disconnect the 2 clamps for locking the charge
air connections by removing the locking bolts
1) Drain off the water from the engine. for the clamps.
2) Take off the top cover. 10) Push the charge air connections inside the
cylinder head which are to be removed.
3) Take off the side covers on both sides of the
engine. 11) Turn the piston to top position.
4) Remove the exhaust gas cover.

Removal of Connecting Rod Shaft
Disassembling of Connectings 12) Mount the turning bracket between the marine
head and counter weight, see fig 2.
5) Disconnect the clamp for connecting cylinder
head and exhaust gas receiver. 13) Loosen the piston rod shaft by means of the
hydraulic jacks, see working card 506-01.25.
6) Disconnect the fuel oil high pressure pipe.
14) Remove the piston rod shaft nuts by hand.
7) Disconnect the 4 clamps for locking the FW
connection between the cylinder heads by
removing the locking bolts for the clamps.
8) Push the FW connections inside the cylinder

heads, which are to be removed.
08028-0D/H5250/94.08.12
Fig 1 Push the cooling water connection and charge air con- Fig 2 Mount the turning bracket between the marine head
nections inside the cylinder heads, which are to be removed and counterweight
01.30 - ES0
MAN Diesel

Page 3 (4) Dismantling of Cylinder Unit from Engine Edition 04H
L27/38
Mounting of Support Tools 16) Remove the cylinder head nuts by means of the
hydraulic jacks, see working card 520-01.05.
15) Mount the fixing tool for locking the connecting
rod shaft to the cylinder liner by means of the 17) Mount the lifting tool on the cylinder head.
mounting bolt, see fig 3.
Removal of Cylinder Unit from Engine
18) Carefully lift the cylinder unit out of the en-

gine.
Lifting tool
Note! Be careful not to scratch the thread on the
hydraulic bolts when lifting the cylinder unit.
19) Pull out the push rods from the engine

frame.
20) Land and fasten the cylinder unit upon the

Cylinder unit special work table, or on the floor upon wooden
supports and remove the lifting tool.
Fixing tool Fixing tool
Fig 3 Mounting of fixing tool

08028-0D/H5250/94.08.12
Fig 4 Hydraulic tools for dismounting of cylinder head nuts
01.30 - ES0
MAN Diesel

Edition 04H Dismantling of Cylinder Unit from Engine Page 4 (4)
L27/38
Cylinder unit
Work table
Fig 5 Cylinder unit placed in work table
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Page 1 (3) Disassembly of Cylinder Unit Edition 03H
L27/38

52000 082
Description
Hand tools
Dismounting of cylinder head, water jacket,
cylinder liner and piston for inspection/over- Measuring tools.
haul. Allen key, 8 mm.
Ratchet.
Extension.
Starting position Serrated fork.
Dismantling of cylinder unit 505-01.00
Related procedure
Reconditioning of valve spindle

seat and valve seat ring 505-01.10
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35
Piston 506-01.10
Inspection and honing of
cylinder liner 506-01.35
Separation/assembly of piston
and connecting rod and fitting
of piston rings 506-01.05

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

03.05 - ES0
MAN Diesel
Edition 03H Disassembly of Cylinder Unit Page 2 (3)
L27/38
Before starting to dismantle the cylinder unit, it must Removal of Cylinder Head
be placed on the working table.
6) Remove the four allen screws keeping the
cooling water jacket to the cylinder head.
Removal of Piston and Connecting Rod
Shaft 7) Mount the lifting tool on the cylinder head, see
fig 2.
1) Turn the unit upside down.
8) Remove the cylinder head by means of the
2) Remove the supporting tool from the cylinder lifting tool .
liner and piston rod shaft.
3) Mount the eye bolt at the bottom of the piston

rod shaft.
Lifting tool
4) Pull out the piston and the connecting rod shaft

with the aid of the eye bolt and tackle.
5) Turn the unit back to it's starting position.
Cylinder head
Fig 2 Removal of cylinder head
Removal of Cylinder Liner from the Water

Jacket
9) Lift the cylinder liner out of the water jacket by

means of the lifting tool as shown in fig 3.
10) Remove the flame ring from the cylinder liner

by means of the tool as shown in fig 4. Use a
used/scrapped piston ring.
08028-0D/H5250/94.08.12
Fig 1 Removal of piston and piston rod
03.05 - ES0
MAN Diesel
Page 3 (3) Disassembly of Cylinder Unit Edition 03H
L27/38
Lifting tool for Removal device

cylinder liner for flame ring
Flame ring
Scrapped
piston ring
Fig 4 Removal of flame ring
Cylinder liner
Lifting tool
Fig 3 Removal of cylinder liner from water jacket

08028-0D/H5250/94.08.12
03.05 - ES0
MAN Diesel
Page 1 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 04H
L27/38

Press Blocking - Reset
Dismounting of inlet and exhaust valve, inspec-

tion of valve guide and mounting of inlet and
exhaust valve.
Starting position
Related procedure
Reconditioning of valve spindle seat

and valve seat ring 505-01.10

08028-0D/H5250/94.08.12

Capacity : 1 man
Data
01.30 - ES0
MAN Diesel
Edition 04H Inspection of Inlet Valve, Exhaust Valve and Valve Guide Page 2 (3)
L27/38
Dismantling of Inlet and Exhaust Valve
Spindles
1) Land and fasten the cylinder head upon a spe-

cial work table and remove the lifting tool.
Or as an Alternative:
Land the cylinder head on the floor upon wood-

en supports and remove the lifting tool.
2) Turn back the rocker arm and remove the valve

bridge over the valve spindles.
3) Install the tool for mounting of valves (B), see

fig 1.
4) Compress valve springs by tightening nut A,

see fig 2.
Fig 2 Mounting of compression tool
Fig 1 Mounting of compression tool

08028-0D/H5250/94.08.12
5) Remove cone rings, see fig 3.
6) Release springs again by loosening nut A. Fig 3 Removal of cone rings valve spring pressed down
7) Remove a valve rotator and springs.
8) Push out the valve spindle.
9) Repeat point 4 - 8 to remove other valve

spindles.
01.30 - ES0
MAN Diesel
Page 3 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 04H
L27/38
Too much clearance also means insufficient
guidance of the valve spindle, and thus bad
alignment between the spindle head and the
valve seat ring.
12) Change the O-ring inside the valve guide, see

working card 505-01.20.
Mounting of Valve Spindle
13) For mounting the valve spindle, follow the

instructions in point 3-8 in reverse order.
Fig 4 Valve spring reliefed complete
Inspection of Valves/Valve Seats
If the valve seat is burnt or scarred, it should be ground

using a valve seat grinder, please see working card
505-01.10.
Inspection of Valve Guide
Too much clearance between the valve spindle and

the valve guide may cause:
Fig 5 Measurement of valve guide for wear
- increased lub. oil consumption.
- fouling up of the valve guide and thus give the
risk of the sticking of the valve spindle.
08028-0D/H5250/94.08.12
10) Clean the valve guide.
11) Inspect and measure for wear.
If the inner diameter of the valve guide mea-

sured below the O-ring exceeds the tolerance,
please see page 500.35, the valve guide must
be replaced. Please see working card 505-
01.20.
01.30 - ES0
MAN Diesel
Working Card Reconditioning of Valve Spindle Seat 505-01.10

and Valve Seat Ring
L21/31, L27/38
L21/31CR

Description
Reconditioning of valve spindle seat and valve

seat ring, with special grinding machine.
Valve spindle has been removed 505-01.05 All the hand tools and new stones are included
in the tools box for grinding machine.
Related procedure
Inspection of inlet valve,

exhaust valve and valve guide 505-01.05
Replacement and wearing parts

Manpower
08028-0D/H5250/94.08.12
Plate no Item no Qty/

Working time : 3 hours
Capacity : 1 man
Data

03.37 - ES0
MAN Diesel
505-01.10 Reconditioning of Valve Spindle Seat Working Card

Page 2 (2)
Edition 04 and Valve Seat Ring
L21/31, L27/38
L21/31CR
Reconditioning of Valve Seat Ring However, when seat "S" is ground to such an extent
that recess "R" disappears, see fig 1, the valve seat
Reconditioning of valve seat rings by machining is ring must be scrapped and a new one must be instal-
carried out by means of a grinding machine, the led, please see working card 505-01.35
pilot spindle of which must be mounted in the valve
spindle guide. For operation of the grinding machine, This is only valid for the exhaust valve seat. The
see separate instructions. inlet valve seat has no recess due to less wear of
the inlet valve seat.
Grinding of Valve Seats

Reconditioning of Valve Spindle
Grinding of valve seat rings should be carried out in
the following order: Reconditioning by machining is carried out with the
valve spindle being rotated in a turning lathe and a
1) Grind the seating surface with a feed at an special grinding machine mounted on the tool post
angle "A" of 30 0.05 of the turning latch.
0
2) Continue grinding until a clean and uniform Grinding of Valve Spindle

surface is obtained.
For operation of the grinding machine, see separate
3) Carry out final grinding with a feed in direction instructions.
from inside to outwards. Normally, the best
surface quality is obtained this way. 1) Grind the seating surface with a feed at an
0
angel "A" of 30 0.1
Scraping of Valve Seat Rings

2) Continue grinding until a clean and uniform
Normally, the valve seat ring can be reconditioned surface is obtained.
several times.
3) Check height "H"1 upon completion of the
grinding, see fig 2.
"H"1 must be no less than indicated on page

0.05
"A" 30 0
500.35.
"R" If less, the spindle must be scrapped.
"S"
08028-0D/H5250/94.08.12
0
"A" 30 0.1
"H"1
Fig 1 Valve seat ring Fig 2 Valve spindle
03.37 - ES0
MAN Diesel

Page 1 (2) Valve Rotator Edition 05
L21/31, L27/38
L21/31CR

Shut-off fuel oil
Dismantling, inspection and mounting of valve Small screwdriver.

rotator. Ring and open-end spanner, 24 mm.
Starting position
Valve spindle has been removed 505-01.05
Related procedure


Manpower
08028-0D/H5250/94.08.12
Working time : 1/2 hour

Capacity : 1 man
Data

03.05 - ES0
MAN Diesel

Edition 05 Valve Rotator Page 2 (2)
L21/31, L27/38
L21/31CR
Procedure 3) Watch the indicator mark on top of the valve
rotator and see that it moves a little each time
Valve rotators are installed on all 4 valves in the the valve is activated. See fig 1.
cylinder head. The function of the valve rotators is of
greatest importance for the lifetime of the valves. 4) Stop the engine, an re-install the valve covers
Non-functioning valve rotators must be exchanged. with new seals.
At every overhaul of the cylinder head, the valve

rotators must be checked.
Indicator mark
Function Test
1) Remove the valve covers from the cylinder

heads.
2) Start the engine and let it run idle speed to

avoid oil splash.
Fig 1 Valve rotator
08028-0D/H5250/94.08.12
03.05 - ESO
MAN Diesel
Working Card
Replacement of Valve Guide 505-01.20
L21/31, L27/38
L21/31CR

Shut-off fuel oil
Dismantling and mounting of valve guide for inlet Hammer / Lead hammer.
and exhaust valve. Liquid Nitrogen (LN2) or equivalent.
E7 reamer, 16 mm (L21/31)
H7 reamer, 20 mm (L27/38)
Starting position
Valve spindle has been removed 505-01.05
Related procedure

Manpower
08028-0D/H5250/94.08.12

Capacity : 1 man Plate no Item no Qty/
50501 076 4/cyl

Data 50501 088 4/cyl

07.17
MAN Diesel
505-01.20 Replacement of Valve Guide Working Card

L21/31, L27/38
L21/31CR
When to Replace the Valve Guide 7) Insert a new O-ring in the top of the valve guide, see
fig 3.
If the diameter exceeds the max. limit, see page
500.35, the valve guide must be replaced. Tool for valve guides is not a part of the standard tool kit.
Dismounting of Valve Guide
1) Remove the old valve guide, through the top of

the cylinder head using a drift inserted through
the valve seat, see fig 1.
This is easiest if the cylinder head is inverted,
as shown on fig 1.
Fig 2 Mounting of valve guide
Fig 1 Dismounting of valve guide
Mounting of Valve Guide
2) Clean the bore in the cylinder head carefully.

08028-0D/H5250/94.08.12
3) The new valve guide must be cooled down

to approx. -70C with liquid nitrogen (LN2) or
equivalent.
4) Insert the valve guide in the bore, see fig 2.
5) Ensure that the valve guide is fully seated, if

necessary by light blows to the drift.
6) After the guide has been fitted and has returned

to room temperature, it is essential that it be
reamed to final size using the specified reamer.
Please see page 500.35 for tolerances. Fig 3 Inserting a new O-ring in the valve guide
07.17
MAN Diesel
Page 1 (2) Check / Adjustment of Safety Valve Opening Pressure Edition 01H
L27/38

Shut-off cooling water Calibrated high pressure testing equipment
Shut-off fuel oil (not supplied)
Dismantling, inspection, reassembling and

presure testing of safety valve.
Starting position
Engine stopped. Respective side covers on

engine manoeuvre side dismounted.
Related procedure
Indicator valve 505-01.26

08028-0D/H5250/94.08.12

Capacity : 1 man
50501 338 1/cyl
Data

01.36 - ES0
MAN Diesel
Edition 01H Check / Adjustment of Safety Valve Opening Pressure Page 2 (2)
L27/38
For safety reasons, the safety valves are normally 5) Mount the safety valve with a new gasket.
checked/adjusted at an authorised workshop in con-
nection with overhaul of cylinder heads. 6) Mount the side covers.
However, it is possible to check/adjust the valves on
board if calibrated high pressure testing equipment
is available.
Note: In connection with check of safety valves, do not

increase the test pressure to more than 250 bar.
1) Dismount the safety valve.
2) Connect the safety valve to a calibrated high

pressure testing device.
3) Slowly increase the pressure until the safety

valve blows off. Observe the blow-off pressure
and compare with the factory setting.
4) If necessary, adjust the blow off pressure, see

fig 1.
a) Remove lead seal (2) and securing wire

(3).
b) Loosen and remove locking screw (4).
c) Adjust the blow off pressure by turning

the outer bushing (1).
d) Repeat step 3) until the correct blow off

pressure is reached.
e) Drill a securing bore for locking screw

(4).
f) Mount locking screw (4).
g) Secure locking screw with locking wire Fig 1 Safety valve

08028-0D/H5250/94.08.12
and lead seal.
01.36 - ESO
MAN Diesel

Page 1 (2) Indicator Valve Edition 05
L21/31, L27/38
L21/31CR

Shut-off fuel oil
Shut-off cooling oil
Dismounting, inspection and mounting of indi- Ring and open-end spanner 10 mm

cator valve. Ring and open-end spanner 27 mm
Steel brush
Starting position
Related procedure

Man power
Plate No Item No Qty./
Capacity : 1 man
Molykote HSC
Data

05.32 - ES0
MAN Diesel

Edition 05 Indicator Valve Page 2 (2)
L21/31, L27/38
L21/31CR
Description 5) Shortly open the valve and close it again.
Under normal working conditions the indicator valves 6) Observe if ther is a leakage from the indicator
require very little maintenance. However, to minimize valve.
toxic gasses in the engine room and to keep the
engine and engine room clean, it is necessary to 7) If the indicator is leaking, stop the engine
keep the indicator valves tight. and replace the indicator valve.
Also, when taking combustion pressures/diagrams, By replacement of indicator valve all parts have to
it is important that the mechanical connection bet- be fully cleaned and greased with molykote HSC
ween the indicator valve and the indicator is tight so to prevent that the parts will seize.
that the parts are not overheated and damaged. It is
therefore important that the valve connecting surface
is in good condition.
Warning!
In connection with check of indicator valves, be
aware of hot surfaces and possible discharge of
hot gasses.
The insulation glove has to be placed over the

indicator valve at any time when the engine is running,
to prevent that fuel and oil will cause fire when in
contact with hot surfaces. Exception will be taken
when measuring the max. pressure.
Check of Indicator Valve
See fig 1.
1) Visually inspect the valve cone for damage.
2) Ensure that all indicator valves are closed.

Fig 1 Indicator valve.
3) Start and run the engine.
4) Observe that the indicator valve is not

leaking.
05.32 - ES0
MAN Diesel

Page 1 (2) Replacement of Valve Seat Ring Edition 04
L27/38, L21/31
L21/31CR

Shut-off fuel oil
Replacement of valve seat ring for inlet and Hammer.

exhaust valve. Loctite, 648.
Lub. oil.
Starting position
Inlet and exhaust valves have been

removed 505-01.05
Related procedure
Mounting of valve spindles 505-01.10
Man power Replacement and wearing parts

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

Capacity : 1 man
50501 123 2/cyl.
50501 172 2/cyl.
Data 50501 184 2/cyl.

03.36 - ES0
MAN Diesel

Edition 04 Replacement of Valve Seat Ring Page 2 (2)
L27/38, L21/31
L21/31CR
Dismounting of Valve Seat Rings 4) The valve seat ring is easy removed by turning
the handle.
When reconditioning of a valve seat ring no longer is
possible due to dimensions exceeding the scrapping
criteria, the valve seat ring has to be replaced. Mounting of Valve Seat Rings
Dismounting of a valve seat ring is carried out by 5) Prior to mounting of a new valve seat ring, the
means of a special extractor tool set comprising the bore must be cleaned thoroughly and inspected
components, see fig 1. for marks. Marks that can hinder mounting of
the valve seat ring must be removed.
6) Cool down the valve seat ring to a max. of

-25 C before mounting, otherwise the O-ring
can be damaged.
Valve seat ring

Coat with
loctite 648
Fig 1 Extraction of valve seat ring O-ring

Coat with oil
or mounting
paste
Dismounting of a Valve Seat Ring is Carried

out According to the Following Procedure
Fig 2 Coat with oil/loctite
1) Weld approx. 5 seconds at 3 places around
the old valve seat ring with electrode.
2) Wait 60 seconds while the seat is cooling down 7) Place the O-ring on the valve seat ring and
and the shrink fit compression is relieved. coat with oil/loctite as shown in fig 2, just before
positioning it in the bore.
3) Mount the extraction tool and pull out the used
08028-0D/H5250/94.08.12
valve seat ring. (If the waiting time is not ob- 8) Prior to mounting of the valve spindle, the
served the tool might be damaged). valve seat ring must be grind to ensure correct
centering at the valve guide and the valve seat
ring. This can be done according to working
card 505-01.10.
03.36 - ESO
MAN Diesel
Working Card Inspection of Cylinder Head 505-01.45

Page 1 (2)
and Water Jacket Cooling Water Space Edition 03
L21/31, L27/38
L21/31CR

Shut-off fuel oil
Inspection of cylinder head cooling water Steel brush.

space.
Starting position
The cylinder head dismantled

from engine 505-01.00
Related procedure

08028-0D/H5250/94.08.12
Manpower
Working time : hour
Capacity : 1 man
Data

03.05 - ES0
MAN Diesel
505-01.45 Inspection of Cylinder Head Working Card

Page 2 (2)
Edition 03
and Water Jacket Cooling Water Space
L21/31, L27/38
L21/31CR
Inspection of Cylinder Head Cooling Water
Space
1) Inspect the cooling water inlet and outlet of the

cylinder head, see fig 1.
2) Remove all possible deposits.
3) If necessary, clean the cooling water inlet and

cooling water outlet, see fig 1, with a steel
brush.
Flush the cooling water space after cleaning.
4) If the cylinder head cooling water space,

contrary to expectation, is blocked with deposits,
please contact MAN Diesel for further instruc-
tions.
Inspection of Water Jacket Cooling Water Fig 1 Cooling water spaces to be inspected
Space
5) Inspect the cooling water connections and the

cooling water space, see fig 1.
6) Remove all possible deposits.
Flush the cooling water space after cleaning.
08028-0D/H5250/94.08.12
03.05 - ES0
MAN Diesel
Workinag Card 505-01.50
Page 1 (3) Assembly of Cylinder Unit Edition 04H
L27/38

Description
Mounting of cylinder head, water jacket, cylinder

liner and piston after inspection/overhaul.
Cylinder unit, dismantled 505-01.01
Related procedure
Mounting of cylinder unit in engine 505-01.55

Inspection of valve roller guides 508-01.00

Manpower
50501 111 1/cyl
Working time : 1 1/2 hours 50501 135 2/cyl
08028-0D/H5250/94.08.12
Capacity : 1 man 50501 196 1/cyl

50610 031 1/cyl
50610 043 1/cyl
Data 50610 055 1/cyl
50610 092 1/cyl
Data for pressure and tolerance (Page 500.35) 50601 093 1/cyl
Data for torque moment (Page 500.40) 50601 103 2/cyl
Declaration of weight (Page 500.45) 50601 127 1/cyl
01.30 - ES0
MAN Diesel
Edition 04H Assembly of Cylinder Unit Page 2 (3)
L27/38
Preparing before Mounting
1) Place the water jacket on the table.
2) Place a new o-ring on the cylinder liner and

slightly lubricate with oil.
3) Mount the cylinder liner, with a new flame ring,

in the water jacket by means of the lifting tool
for the liner, see fig 1.
Flame ring Tool
Fig 2 Marking on the cylinder liner
Mounting of Cylinder Head

.
Cylinder liner 8) Place a new o-ring at the bottom of the cylinder
head and slightly lubricate with oil.
Fig 1 Mounting of new flame ring 9) Mount the cylinder head by means of the lifting
tool (plate 52000, item no 38).
10) Mount the four allen screws in the cylinder head

Note: Be sure the marking on the cylinder liner is and tighten up all the screws, please see page
aligned with the water jacket. 500.40.
4) Fit a new sealing ring on the cylinder liner.

Mounting the Piston
08028-0D/H5250/94.08.12
5) Place a new o-ring on the top of the cylinder

liner. Before mounting the piston turn around the cylinder
unit.
6) Place a new sealing for the push rods on the
water jacket. Note: After an overhaul the cylinder liner must always
be honed and the piston must be fitted with new
7) Place a new o-ring for the cooling water con- piston rings, see Working Card 506-01.35.
nection on the water jacket.
01.30 - ES0
MAN Diesel
Page 3 (3) Assembly of Cylinder Unit Edition 04H
L27/38
11) Mount the piston guide bush around the cylinder
liner.
12) Screw an eye bolt in the bottom of the piston

rod and lift the piston and piston rod.
13) Lubricate the piston rings and the cylinder liner

with oil.
14) Slowly lower the piston into the cylinder liner.
Note:Make sure that the AS mark at the top of the

piston is placed to the exhaust gas side.
15) Mount the locking tools for the piston rod and
cylinder liner.
16) Remove the lifting eye bolt from the piston

rod.
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel

Page 1 (4) Mounting of Cylinder Unit in Engine Edition 03H
L27/38

and hydraulic tools according

Description to working card 520-01.06
Mounting of cylinder unit after inspection and/or

overhaul.
Cylinder unit is completely assembled. Lub. oil and copaslip.

Valve gear of respective cylinder is in the proper
position (valve closed).
Control of the surface of the engine.
Related procedure
Adjustment of valve clearance 508-01.10

Working time : 2 hours Plate no Item no Qty/

Capacity : 2 men
08028-0D/H5250/94.08.12
50501 135 1
50501 243 1
Data 51630 033 8
51230 027 4
01.30 - ES0
MAN Diesel

Edition 03H Mounting of Cylinder Unit in Engine Page 2 (4)
L27/38
Preparing before Mounting Mounting of the Piston Rod and Marine
Head
Before the cylinder unit is mounted in the engine, be
sure to clean the joint faces carefully. 4) Make sure the crank throw is in the top position.
This must be checked on the flywheel.
Placing of the Cylinder Unit in Engine 5) Slowly land the piston rod on the top of the
marine head.
1) Place a sealing ring around the push rods on
the frame. NOTE: Be careful not to scratch the thread on the
hydraulic bolts.
2) Mount a new o-ring for the lub.oil connection
to the rocker arms. 6) Remove the locking tool for the piston rod and
the cylinder liner. (plate 52000 item 212).
3) Lower the cylinder unit slowly into the engine
by means of the lifting tool; (plate 52000 item Note: Check that the marks AS are placed at the
038). same side on both the piston rod and the marine
head against the exhaust side.
Tightening of the Piston Rod
7) Lubricate threads and the contact face of the

Lifting tool hydraulic bolts with molycote paste or the
like.
8) Mount the nuts and tighten them firmly with a

tommy bar.
Cylinder unit
For tightening hydraulic piston rod bolts, please
see working card 506-01.25.
Tightening of Cylinder Head Nuts
9) Coat the cylinder stud threads and contact

faces with copaslip or the like.
Fixing tool
10) Fit the cylinder head nuts and make sure that
they run easily and that they bear on their entire
contact surfaces.
11) Tighten the nuts lightly with a tommy bar.

08028-0D/H5250/94.08.12
12) Place the spacer ring around the nuts with a

slot in such a position that the tommy bar can
be used.
Fig 1 Lifting tool
01.30 - ES0
MAN Diesel

Page 3 (4) Mounting of Cylinder Unit in Engine Edition 03H
L27/38
13) Tighten the hydraulic jacks and make sure Mounting of the Push Rods
that the cylinder of the jacks bears firmly on
the spacer ring. Tighten up all the nuts, see 14) Loosen and remove the bolt on the top of the
description 500.40. For usage of the hydraulic rocker arm shaft.
tools, please see working card 520-01.05.
15) Push out the rocker arm shaft and remove the
Note: If new studs or nuts are fit, the nuts must be rocker arms.
tightened and loosened three times, in order to com-
pensate for deformation of the thread and in order 16) Place the push rods on the rollers.
to ensure a safe minimum load of the studs through
the tightening. 17) Remount the rocker arms and rocker arm
shaft.
18) Fit and tighten the bolt on the top of the rocker
arm shaft again.
Assembling of Connections
Mount the exhaust clamp between the cylinder head

and the exhaust pipe.
Note: Turn clamps correctly as they are not sym-

metrical, see fig 4.
08028-0D/H5250/94.08.12
Fig 2 Hydraulic tools for mounting of cylinder head nuts Fig 3 Correct mounting of clamps
01.30 - ES0
MAN Diesel
Edition 03H Mounting of Cylinder Unit in Engine Page 4 (4)
L27/38
19) Place new O-rings at the water connections Ventilation
and push the connections into the cylinder
head. The GenSet is self-ventilating. This means that it
is not necessary for the engine to vent the system
20) Secure the water connections with clamps and before start.
tighten bolts on the clamp.
However, to avoid problems in the ships installation,
21) Place new O-rings on the charge air connection we recommend ventilating. This can be done in the
and push the connections into the next cylinder following way:
head.
24) Open connection G1, L.T. fresh water - inlet.
22) Secure the charge air connection with a clamp
and tighten the bolts on the clamp. 25) Bleed air from the venting screws on the charge
air cooler.
23) Mount the high-pressure fuel oil pipe; please
see working card 514-01.05. 26) Bleed air from the venting screws on the water
jacket drain cock, or by the connection F3,
venting to expansion tank.
27) Open connection G2, L.T. fresh water - out-

let.
28) Check for leakage.
Adjustment of Valve Clearance
29) Adjust the valve clearance, see working card

508-01.10.
30) Mount the side and top covers.
Fig 4 Clip on/off

08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Head 50501-05H
L27/38
040
015 410
052
076
064 088 292
302
314
206
027
338
351
172
184
123
111 196
243
135
363
08028-0D/H5250/94.08.12
375 422
363
135 218
See plate 50610
02.11 - ES0
MAN Diesel
Plate
50501-05H Cylinder Head Page 2 (2)
L27/38
Item Item
no Qty Designation Benvnelse no Qty Designation Benvnelse
015 2/C Guide for Styr for 422 1/C Cylinder head incl. Cylinderdksel inkl.
valve bridge ventilbro items 015, 027, 040, items 015, 027, 040,
052, 064, 076, 088, 123, 052, 064, 076, 088, 123,
027 1/C Cylinder head Cylinderdksel 172, 184, plate 50502 172, 184, plate 50502
items 010, 022, 130, items 010, 022, 130,
040 1/C O-ring O-ring 178, 191, 201, 213, 237, 178, 191, 201, 213, 237,
249, 250, 262, 274 249, 250, 262, 274
052 1/C Sleeve Foring
064 2/C O-ring O-ring
088 4/C Valve guide Ventilstyr
123 2/C Valve seat ring, Ventilsdering,

inlet indstrmning
184 2/C Valve seat ring, Ventilsdering,

exhaust udstdning
206 4/C Screw Skrue
218 1/C Water guide jacket Klekappe
292 1/C Conn. socket Forbindelsesstykke
302 1/C Threaded socket Gevindstuds
314 1/C Union nut Omlbermtrik
338 1/C Gasket Pakning
351 1/C Safety valve Sikkerhedsventil
375 1/C Connecting piece Forbindelsesstykke
410 1/C Indicator valve Indikatorventil

08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se ogs side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgngelig som en del af et reservedelsst.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
02.11 - ES0
MAN Diesel
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-04H
L27/38
08028-0D/H5250/94.08.12
03.44 - ES0
MAN Diesel
Plate
50502-04H Valve Spindles and Valve Gear Page 2 (2)
L27/38
Item Item
010 1/C Rocker arm, exhaust Vippearm, udstds, 274 2/C Valve spindle, inlet Ventilspindel, indsugn.
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 046, 058, 071, 083 490 24/C Spring Fjeder
083
500 24/C Ball Kugle
022 1/C Rocker arm, inlet Vippearm, indsugning
complete, incl. item komplet inkl. item 034, 512 4/C Spring washer Fjederskive
034, 046, 071, 083, 046, 071, 083, 105
105 524 4/C Retainer ring Lsering
034 2/C Bolt Bolt
046 2/C Bearing bush Leje
058 1/C Rocker arm, exhaust Vippearm, udstds
071 4/C Nut Mtrik
083 2/C Adjusting screw com- Justrbar skrue komplet

plete, incl. item 095, inkl. item 095, 117,
117, 142 142
095 2/C Circlip Fjederring
105 1/C Rocker arm, inlet Vippearm, indsugning
117 2/C Thrust piece Trykstykke
130 2/C Valve bridge com- Ventilbro komplet, inkl.

plete, incl. item 071, item 071, 129, 154,
129, 154, 166 166
142 2/C Adjusting screw Justrbar skrue
154 2/C Adjusting screw Justrbar skrue
166 2/C Valve bridge Ventilbro
178 4/C Conical ring 2/2 Konisk ring 2/2
191 4/C Rotocap complete Rotationsgiver, kom-

plet
201 4/C Spring Fjeder
213 1/C Screw Skrue

08028-0D/H5250/94.08.12
249 1/C Shaft Aksel
262 2/C Valve spindle, Ventilspindel, udstds

exhaust
03.44 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Head, Top Cover 50510-03H
L27/38
08028-0D/H5250/94.08.12
99.15 - ES0
MAN Diesel
Plate
50510-03H Cylinder Head, Top Cover Page 2 (2)
L27/38
Item Item
026 5/C Screw Skrue
038 5/C Washer Skive
051 1/C Top cover Topdksel
08028-0D/H5250/94.08.12
99.15 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Unit 50515-08H
L27/38
011
08028-0D/H5250/94.08.12
06.44 - ES0
MAN Diesel
Plate
50515-08H Cylinder Unit Page 2 (2)
L27/38
Item
no Qty Designation Where to find in the engine instruction book
011 1/C Cylinder unit, complete Plate 50515 Item 011

consisting of:
1/C Cylinder head Plate 50501
1/C Valve spindle and valve gear Plate 50502
1/C Piston and connecting rod Plate 50601
1/C Cylinder liner Plate 50610
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder
06.44 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Unit 50515-09H
L27/38
011
08028-0D/H5250/94.08.12
06.44 - ES0
MAN Diesel
Plate
50515-09H Cylinder Unit Page 2 (2)
L27/38
Item
011 1/C Cylinder unit, complete Plate 50515 Item 011

consisting of:
1/C Cylinder head Plate 50501
1/C Valve spindle and valve gear Plate 50502
1/C Piston and connecting rod Plate 50601
1/C Cylinder liner Plate 50610
08028-0D/H5250/94.08.12
06.44 - ES0
Piston/connecting rod
506/606
MAN Diesel
Description 506.01
Page 1 (2) Piston, Connecting Rod and Cylinder Liner Edition 03H
L27/38
Piston
The piston, which is oil-cooled and of the composite

type, has a body made of nodular cast iron and a
crown made of forged deformation resistant steel. It
is fitted with 2 compression rings and 1 oil scraper
ring in hardened ring grooves.
Fig. 2 Connecting rod
The piston pin is fully floating and kept in position in

the axial direction by two circlips.
Connecting Rod
Fig. 1 Piston
The connecting rod is of the marine head type.
By the use of compression rings with different barrel- The joint is above the connecting rod bearing. This
shaped profiles and chrome-plated running surfaces, means that it is not nessesary to open the big-end
the piston ring pack is optimized for maximum sealing bearing when pulling the piston. This is of advantage
effect and minimum wear rate. for the operational safety (no positional changes/no
new adaption), and this solution also reduces the
The piston has a cooling oil space close to the piston height dimension required for piston assembly /
crown and the piston ring zone. The heat transfer, removal.
and thus the cooling effect, is based on the shaker
08028-0D/H5250/94.08.12
effect arising during the piston movement. The Connecting rod and bearing body consist of CrMo
cooling medium is oil from the engine's lubricating steel. They are die-forged products.
oil system.
The bearing shells are identical to those of the crank-
Oil is supplied to the cooling oil space through chan- shaft bearing. Thin-walled bearing shells having an
nels from the oil grooves in the piston pin bosses. Oil AISn running layer are used.
is drained from the cooling oil space through ducts
situated diametrically to the inlet channels. The bearing caps and bearing blocks are bolted
together by waisted bolts.
98.27 - ES0
MAN Diesel
506.01 Piston, Connecting Rod and Cylinder Liner Description

L27/38
Cylinder Liner
The cylinder liner is made of special centrifugal cast

iron and fitted in a bore in the engine frame. The
liner is clamped by the cylinder head and rests by
its flange on the water jacket.
The liner can thus expand freely downwards when

heated during the running of the engine. The liner
is of the flange type and the height of the flange is
identical with the water cooled area which gives a
uniform temperature pattern over the entire liner sur-
face. The lower part of the liner is uncooled to secure
a sufficient margin for cold corrosion in the bottom
end. There is no water in the crankcase area.
The gas sealing between liner and cylinder head

consists of an iron ring.
To reduce bore polishing and lube oil consumption

a slip-fit-type flame ring is arranged on the top side
of the liner.
Fig. 3 Cylinder liner
08028-0D/H5250/94.08.12
98.27 - ES0
MAN Diesel
Working Card Separation/Assembly of Piston and 506-01.05
Page 1 (3)
Connecting Rod and Fitting of Piston Rings Edition 06H
L27/38

Separation of piston and connecting rod for in- Wooden wedge, 2 pieces.
spection or/and overhaul. Wooden support.
Assembly of piston and connecting rod after Wire.
inspection or/and overhaul.
Starting position
Related procedure
Inspection or/and overhaul of piston 506-01.10

Inspection or/and overhaul of
connecting rod 506-01.15
Inspection of connection rod big-end
bearing 506-01.16
Assembly of cylinder unit 505-01.50

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

Capacity : 1 man
50601 093 3
50601 127 1
Data

06.29 - ES0
MAN Diesel
506-01.05 Separation/Assembly of Piston and Working Card
Page 2 (3)
Edition 06H
Connecting Rod and Fitting of Piston Rings
L27/38
Separation of Piston and Connecting Rod
The piston rings should only be fitted to the piston
1) Take out the securing ring (Seeger circlips) with by the use of a special tool; the so-called piston ring
the plier (Plate 52000, Item 177). Push out the opener.
piston pin and lift the connecting rod away.
If the rings are opened further than necessary, there
is a risk of overstressing which means that the rings
Assembly of Piston and Connecting Rod will become permanently distorted and will not fit to
the cylinder liner's inner running surface.
2) Lubricate the piston pin before assembling.
The piston rings should be installed with the identi-
3) For assembly of piston and connecting rod, fication mark which is stamped into the ring close to
see point 1, but in the opposite direction. the ring joints, facing upwards, see fig 2.
Fittings of Piston Rings
Before fitting the coil spring loaded scraper ring, the
coil spring is dismantled from the ring by removal of
the joint pin. The coil spring is placed and assembled
in the ring groove. The scraper ring then is fitted in
the groove in such a way that the ring joint is ap-
Joint pin for proximately 180 offset to the spring joint.
coil spring Joint coil spring to be
placed opposite to ring joint
Ascertain correct assembling by checking the back
clearance. The back clearance is sufficient when the
face of the ring is below the groove edge when the
ring is pressed against the bottom of the groove.
When installed on the piston, the rings should be

Ring joint
pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring
Fig 1 Joint coil spring to be placed opposite to ring joint and groove.
Adequate clearance is present if the feeler gauge

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

the piston rings should be turned into positions off-
setting the ring joint 180 to each other.
08028-0D/H5250/94.08.12
06.29 - ES0
MAN Diesel
Working Card Separation/Assembly of Piston and 506-01.05
Page 3 (3)
Connecting Rod and Fitting of Piston Rings Edition 06H
L27/38
Piston Ring
no 1, 2 and 3:
Marked with ident.
no "1606 GOE TOP".
Scraper Ring:
Marked with ident.
no "0297".
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.
Fig 2 Marking of piston and scraper ring
06.29 - ES0
MAN Diesel
Working Card
Page 1 (4) Piston 506-01.10
Edition 04H
L27/38

Cleaning and inspection of piston. Replacement Tools for cleaning of piston, steel brush,
of piston ring, scraper ring and control of ring scraper etc.
grooves. Torque spanner.
Starting position
Piston has been dismantled from

Related procedure
Mounting of piston and


08028-0D/H5250/94.08.12

Capacity : 1 man
Data

06.25 - ES0
MAN Diesel
506-01.10 Piston
Working Card
Page 2 (4)
Edition 04H
L27/38
Inspection of Piston Mounting of Piston Crown
(MAHLE and KOLBENSCHMIDT) Piston type MAHLE
1) Remove the piston and scraper rings. Note: Always use new bolts when assembling the
piston.
2) Clean the piston on the outside and on the
inside. 8) Lubricate the threads and bearing surface with
molycote-paste G-n Plus.
3) Inspect the piston ring and scraper ring grooves
for wear, see page 3. 9) Tighten the piston bolts with a torque of 50 Nm
in the piston head.
Check of Piston Bolt Tension 10) Tighten the nuts crosswise with 60 Nm.
Piston type MAHLE
11) Loosen the nuts again.
4) Apply a torque spanner to the piston bolts,
adjusted to 50 Nm. 12) The tightening of the piston bolts with a torque
of 50 Nm in the piston head must be control-
5) Turn the torque spanner. led.
Note: It may turn out that the bolts do not turn dur- 13) Pretighten the nuts crosswise with joint moment
ing the test: of 20 Nm.
14) Turn the nuts further 120 degrees.

If Then
Check the piston bolt tension, see check of pis-
the bolts do not the tension is ok ton bolt tension.
turn during the test
the bolts can loosen the bolts and Check of Piston Bolt Tension
turn during the test tighten as described Piston type KOLBENSCHMIDT
in the process of
"Mounting of piston 4) Apply a torque spanner to the piston bolts,
crown" adjusted to 54 Nm.
5) Turn the torque spanner.

Inspection of Piston Crown
Piston type MAHLE Note: It may turn out that the bolts do not turn during
the test:
08028-0D/H5250/94.08.12
For cleaning and inspection of the piston crown, it

must be disassembled.
If Then
6) Loosen the bolts and remove the piston
crown. the bolts do not the tension is ok
turn during the test
7) Carefully clean the piston skirt, piston crown
and piston bolts. the bolts can loosen the bolts and
turn during the test tighten as described
in the process of
Mounting of piston
crown
06.25 - ES0
MAN Diesel
Working Card
Page 3 (4) Piston 506-01.10
Edition 04H
L27/38
Inspection of Piston Crown
Piston type KOLBENSCHMIDT
For cleaning and inspection of the piston crown, it

must be disassembled.
6) Loosen the bolts and remove the piston

crown.
7) Carefully clean the piston skirt, piston crown

and piston bolts.
Mounting of Piston Crown

Piston type KOLBENSCHMIDT
Note: Always use new bolts when assembling the

piston.
8) Lubricate the threads and bearing surface with

molycote-paste G-n Plus.
9) Tighten the piston bolts with a torque of 40 Nm

in the piston head.
10) Tighten the nuts crosswise with 67 Nm.
11) Loosen the nuts again.
12) The tightening of the piston bolts with a torque

of 40 Nm in the piston head must be control-
led.
13) Pretighten the nuts crosswise with joint moment

of 20 Nm.
14) Turn the nuts further 90 degrees.
Check the piston bolt tension, see check of pis-

08028-0D/H5250/94.08.12
ton bolt tension.
06.25 - ES0
MAN Diesel
506-01.10 Piston
Working Card
Page 4 (4)
Edition 04H
L27/38
The piston crown must be scrapped if: Note: At each piston overhaul:
- The piston and the scraper ring must be

A) The wear limit on the testing mandrel is ex- replaced.
ceeded, see fig. 1A
- The cylinder liner must be honed accor-
ding to the instructions.
or
- For position and fittings of piston rings,
B) The clearance between the new piston/scraper please see working card 506-01.05
ring and the ring groove is exceeded, see fig.
1B.
Piston type Piston and oil New ring Piston type Piston and oil New ring
Ring grooves. Ring grooves.
scraper ring. grooves. scraper ring. grooves.
Max. wear limit. Max. wear limit.
"MAHLE" Nominal size. Tolerances. "KOLBEN- Nominal size. Tolerances.
(mm) (mm)
(mm) (mm) SCHMIDT" (mm) (mm)
Piston ring +0.20 Piston ring

6 6 6.42 6 6.17 +0.03 6.42
1 +0.17 1

6 6 6.42 6 6.12 +0.03 6.42
2 +0.12 2

6 6 6.42 6 6.12 +0.03 6.42
3 +0.12 3
+0.06
Scraper ring 8 8 8.42 Scraper ring 8 8.04 0.03 8.42
+0.04
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 on the testing mandrel is ex-

ceeded, the specified max. wear limits are ex-
ceeded, and the piston must be scrapped.
0.45 mm
08028-0D/H5250/94.08.12
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.
Fig 1 Wear limits for ring grooves
06.25 - ES0
MAN Diesel
Working Card
Page 1 (4) Connecting Rod 506-01.15
Edition 07
L21/31, L27/38

Press Blocking - Reset and hydraulic tools according
Description
Cleaning, inspection and test measurement of

connecting rod.
Connecting rod has been Inside micrometer (140 mm).

dismantled from piston 506-01.05 Feeler gauge 0.15 - 0.20 mm.
Related procedure
Mounting of piston and


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

Capacity : 1 man
Data

07.17 - ES0
MAN Diesel
506-01.15 Connecting Rod

Working Card
Page 2 (4)
Edition 07
L21/31, L27/38
Cleaning of Piston Rod and Marine Head If bolts/nuts Then
1) Clean all machined surfaces on the piston rod have seizures in renew the bolts/screws
and marine head. threads or pittings on
contact surface
2) Degrease the joint faces, holes, piston rod and
marine head screws with a volatile solvent and cannot be turned onto renew the bolts/screws
blow dry with working air. bottom position by hand
Visual Inspection of Faces
3) Inspect the joint faces.
Damages, in the form of visible wear marks

and pittings or even cracks, may be in the joint
faces due to relative movements between the
surfaces.
Wear marks and cracks are visible, but not

perceptible with a fingernail. Pittings and impact
marks are both visible and perceptible.
Note: Handle the piston rod and marine head with

care. In case of damaged joint faces caused by
improper handling, the marine head bearing caps
can no longer be tightened without ovalness of the
big-end bore. Fig 1 Point of measurement
4) Register observed damages in the scheme

Marine Head Inspection for historic use only. Measurement of Big-end Bore
Please see page 4.
For check of ovalness, the upper and lower bearing
5) Carefully smooth single raised spots in the joint caps have to be assembled without bearing shells.
faces caused by pitting and impact marks with
a filesmall. Note: The ident. No on the upper and lower bearing
caps and the piston rod must always be the same,
see fig 3.
Inspection of Piston rod and Marine Head
bolts 8) Mount the upper and lower bearing caps by
08028-0D/H5250/94.08.12
means of the hydraulic bolts.

6) Inspect the hydraulic nuts for seizures in the
threads and pittings on the contact surfaces 9) Tighten the bolts with the prescribed pressure,
of the screwheads. please see working card 506-01.25.
7) Turn the hydraulic nuts onto bottom position Note: Connecting rod must be installed.
of the bolts.
10) Measure five different diameters in the groove
of the boring, see fig 1.
11) Register the measurements in the scheme

Marine Head Inspection. Please see page
4.
07.17 - ES0
MAN Diesel
Working Card
Page 3 (4) Connecting Rod 506-01.15
Edition 07
L21/31, L27/38
12) Calculate the maximum ovalness as the diffe- cified maximum ovalness is exceeded, contact MAN
rence between largest and smallest diameter Diesel for overhaul.
measured.
For marine head No 1 in the example, the maximum
13) Check if maximum ovalness is exceeded, ovalness is 0.02 mm and thus reuse is acceptable.
please see page 500.35.
For marine head No 2 in the example, the maximum
ovalness is 0.125 mm and therefore the marine head
If Then is rejected.
maximum ovalness is renew the complete

exceeded marine head, piston Inspection of Piston Rod Bush
rod, screws and
bearing shells 14) Inspect the surface of the piston pin and the
piston rod bush.
maximum ovalness is reuse the marine head
not exceeded 15) Measure the clearance between the piston pin
and bush.
Example of Measurement Results 16) Check if max. clearance is exceeded, see page
500.35.
The example, see fig 2, shows measurements and
damage observations for two marine heads in the If the specified clearance is exceeded, contact
scheme Marine Head Inspection (in case the spe- MAN Diesel for replacement.
Inspection of Bearing Shells for Big-end

Marine Head Inspection for L21/31 and L27/38
Criteria for replacement of connecting rod big-end
Cylinder No 1 2 3
bearing, see working card 506-01.16.
Marine head ident. No
Running hours for marine head
A - 0.5 - 3.0
0.01 mm
1/100 mm B + 1.0 - 7.0
Nominal C - 1.0 - 5.0
diameter
L21/31 = 200 mm D + 5.5
L27/38 = 262 mm E + 0.5 + 3.5
Ovalness: Diff. between min./max. 2.0 12.5
Tightening for measurement see

instruction. Wear Wear Wea
Cracks Cracks Cra
Corrosion/ Corrosion/ Cor

08028-0D/H5250/94.08.12
Pitting Pitting Pitt

A
B
Impact mark Impact mark Im
C
D Remarks: Remarks: Rem

E
To be To be
reused rejected
Marine head
Ident. No
Max ovalness = 0.06 mm
Note! The ident. No on the

marine head and on the bearing
cap must always be the same.
Fig 2 "Marine Head Inspection" Fig 3 The ident. No on the marine head must always be
the same
07.17 - ES0
08028-0D/H5250/94.08.12
07.17 - ES0
Working Card
Page 4 (4)
Plant/Ship: Engine Type:

Marine Head Inspection for L21/31 and L27/38 Engine No: Running Hours:
Sign.: Insp. Date:
Cylinder No 1 2 3 4 5 6 7 8 9
Marine head ident. No
Running hours for marine head
A
0.01 mm
1/100 mm B
Nominal C
diameter
L21/31 = 200 mm D
L27/38 = 262 mm
E
Ovalness: Diff. between min./max.
Connecting Rod
Tightening for measurement see

instruction. Wear Wear Wear Wear Wear Wear Wear Wear Wear
Cracks Cracks Cracks Cracks Cracks Cracks Cracks Cracks Cracks
Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/ Corrosion/
Pitting Pitting Pitting Pitting Pitting Pitting Pitting Pitting Pitting
A
B
Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark
C
D Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks:
E
Marine head
Ident. No
Max ovalness = 0.06 mm
L21/31, L27/38
MAN Diesel
506-01.15
Note! The ident. No on the
Edition 07
marine head and on the bearing
cap must always be the same.
MAN Diesel
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:
Stopped engine Plate no. Item no. Note.

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:
Working time : 1/4 Hour Plate no. Item no. Qty. /

Capacity : 1 man
Data:

02.06 - ES0
MAN Diesel
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 surfaces 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
MAN Diesel

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
MAN Diesel

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
MAN Diesel

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
MAN Diesel

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
MAN Diesel

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
MAN Diesel

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
MAN Diesel
Page 1 (5) Removal / Mounting of Marine Head from Engine Edition 01
L21/31, L27/38

Description
Removal of marine head from engine.
Engine out of operation.
Related procedure

Capacity : 2 men
08028-0D/H5250/94.08.12
Data

03.27 - ES0
MAN Diesel

Edition 01 Removal / Mounting of Marine Head from Engine Page 2 (5)
L21/31, L27/38
Condition : Piston and connecting rod has

been removed and the fixation tool is installed, see
fig. 1.
Fixation tool
Fig. 1 Fixation of connecting rod bearing
1) Turn the crank through to about TDC.
2) Install the brackets in the lower end of the

crankcase opening, see fig. 2.
08028-0D/H5250/94.08.12
Fig. 2 Bracket installed
03.27 - ES0
MAN Diesel
L21/31, L27/38
3) Place the guide beam on the brackets and

secure it by means of the screws, see fig. 3.
Guide beam
Bracket
Fig. 3 Placing of guide beam

08028-0D/H5250/94.08.12
03.27 - ES0
MAN Diesel

Edition 01 Removal / Mounting of Marine Head from Engine Page 4 (5)
L21/31, L27/38
4) Turn the crankshaft to the position shown in

fig. 4 and remove the nuts by means of the
hydraulic tool.
Fig. 4 Removal of nuts

08028-0D/H5250/94.08.12
03.27 - ES0
MAN Diesel
L21/31, L27/38
5) Install the slide piece as shown in fig. 5 and 8) Remove the bearing shells from each marine
remove the bracket. head half.
6) Turn the crankshaft to make the marine head

rest against the beam, see fig. 5. Mounting of Marine Head
7) Pull out the two halves of the marine head. Mounting is carried out in reverse order of the
above.
Slide piece
Fig. 5 Marine head with slide piece

08028-0D/H5250/94.08.12
03.27 - ES0
MAN Diesel
Working Card Hydraulic Tightening of Piston Rod 506-01.25
and Marine Head Screws
L27/38

52000 202
52000 334
Description
Tightening procedure for connecting rod bolts.

Check of connecting rod bolts, tightening con-
dition.
Hand tools
Starting position
Piston, connecting rod, bearing shells and

bearing cap preassembled.
Related procedure
Manpower Plate no Item no Qty/
Working time : hour

Capacity : 2 men
08028-0D/H5250/94.08.12
Data

02.39 - ES0
MAN Diesel
506-01.25 Hydraulic Tightening of Piston Rod Working Card
L27/38
The following sequence is the same for both the Measuring Instruction for Extension of Hy-
piston rod screws (item 211) and the marine head draulic Tightened Bolts
screws (item 152), see plate 50601.
4) Mount the two dial gauge on the hydraulic tools,
1) Mount the hydraulic tightening bolts and be fig 2.
sure that the studs are screwed home. Tighten
the nuts by hand. Note: For a correct measuring the dial gauge
has to be mounted with the magnetic bracket
2) Mount the hydraulic tools, fig 1, on both con- on the housing of the hydraulic tool.
necting rod bolts.
5) Tension both bolts simultaneously to a pressure
Be aware of the max. lifting height of the tool and of :
adjust the distance between the piston and the cyl-
inder before adding pressure to the tool, please see connecting rod screw : 100 bar
working card 520-01.05. marine head screw : 600 bar
3) Connect the hoses and pressure pump to the by use of the hydraulic tightening tool.
hydraulic tool.
Tightening order
08028-0D/H5250/94.08.12
Hydraulic tool
Fig. 1 Hydraulic tool for tightening of connecting rod screws
02.39 - ES0
MAN Diesel
Working Card Hydraulic Tightening of Piston Rod 506-01.25
L27/38
6) Set the dial gauges to "0". 11) Tension the bolts to a pressure of :
7) Check by feeler gauge 0.01 mm. It is not allowed connecting rod screw : 100 bar
that there is clearance between the assembled marine head screw : 600 bar
components.
again.
8) Load the bolts to the specified pressure, see
description 500.40. 12) Read elongation of the screw l on the dial
gauge and compare with the value in table.
9) Tension both the nuts hand-tight.
Note: The bolts should be tightened to the
10) Release the pressure. specified tensioning pressure, not according
to the elongation. The elongation only serves
as a means of control. In case of excessive
deviations, repeat the tensioning procedure
and check the measuring instruments and /
or pressure gauges.
13) Release the pressure and remove the hydraulic

tensioning tools.
Note: For general instruction about hydraulic

tightening, please see working card 520-
01.05.
Fig. 2 Hydraulic tool for tightening of connecting rod screws

08028-0D/H5250/94.08.12
02.39 - ES0
MAN Diesel

Page 1 (4) In-situ Inspection of Connecting Rod Big-end Bearing Edition 03H
L27/38

Shut-off fuel oil
Stopped lub. oil circul. and hydraulic tools according
Press Blocking - Reset to working card 520-01.06
Description
In-situ inspection and/or replacement of connec-

ting rod big-end bearing.
Dismounting and mounting.
Crankcase opened. Open-end spanner, 24 mm.
Related procedure
Inspection of connecting rod

big-end bearing 506-01.16
Tightening and check of connecting
rod screws 506-01.25

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

Capacity : 1 man
Data

01.30 - ES0
MAN Diesel

Edition 03H In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (4)
L27/38
Removal of the Connecting Rod Bearing
Cap
1) Turn the crankshaft into the top position.
2) Mount the holder on the marine head. Please

see fig 1.
3) Loosen the two marine head nuts with the

hydraulic tools.
4) Remove the nuts and bolts. Support pipes
5) Mount the supporting pipes. Please see fig

2.
6) Remove the upper screws of the holder.
7) Lowering the lower marine head cap by means

of the pipes until the pipes rest at the frame,
see fig 2.
8) Remove the bearing shell.
Fig 2 Mounting of the supporting pipes
Mounting of the Inspection Bracket
9) Mount the inspection bracket. Please see fig

3.
10) Slowly turn the crankshaft clockwise until

the marine head is resting on the inspection
bracket.
Holder Holder
11) Fix the marine head and inspection bracket

08028-0D/H5250/94.08.12
with screw.
Hydraulic device
Fig 1 Mounting of holders on the marine head
01.30 - ES0
MAN Diesel

Page 3 (4) In-situ Inspection of Connecting Rod Big-end Bearing Edition 03H
L27/38
Cleaning of Components before Mounting
15) Carefully clean the joint faces, the bore and

the bearing shells.
Mounting of Upper Bearing Shell
16) The bearing shell is placed in the bore, and the

contact surfaces of the shells must be parallel
to the contact surface of the marine head and
Inspection
bracket
the bearing cap respectively.
17) Coat the journal with clean lubricating oil.
18) Slowly turn the crankshaft anti-clockwise until

it rests in the marine head.
19) Remove the inspection bracket.
Screw for fitting

marine head and
inspection bracket
Fig 3 Mounting of the inspection bracket
Removal of the upper Marine Head Bearing

Shell
12) Slowly turn the crankshaft clockwise until it

is possible to remove the upper marine head
bearing shell. Please see fig 4.
08028-0D/H5250/94.08.12
13) Remove the upper marine head bearing

shell.
Inspection of Bearing Shells
14) Inspect the bearing shells; please see working

card 506-01.16.
Fig 4 Removal of the upper marine head bearing shell
01.30 - ES0
MAN Diesel

Edition 03H In-situ Inspection of Connecting Rod Big-end Bearing Page 4 (4)
L27/38
Mounting of Lower Bearing Shell Mounting of Bearing Cap
20) Turn the crankshaft anti-clockwise until it is in 23) Lift the lower bearing cap by means of the pipes
the top position. and mount the upper screws of the holder.
21) The bearing shell is placed in the bore, and the 24) Mount the two bolts and nuts for hydraulic
contact surfaces of the shells must be parallel tightening of the marine head.
to the contact surface of the marine head and
the bearing cap respectively. 25) Mount the hydraulic tool and tighten the nuts
according to working card 506-01.25.
22) Coat the journal with clean lubricating oil.
26) Remove the holder from the marine head.
08028-0D/H5250/94.08.12
01-30 - ES0
MAN Diesel
Page 1 (4) Inspection and Honing of Cylinder Liner Edition 03H
L27/38

Inspection and honing of cylinder liner with ho- Drilling machine 60-180 rpm.
ning brush. Honing oil.
Gas oil.
Starting position
Piston and connecting rod

removed 506-01.00
Related procedure
Grinding of seal face on cylinder

head and cylinder liner 506-01.45

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

03.43 - ES0
MAN Diesel
Edition 03H Inspection and Honing of Cylinder Liner Page 2 (4)
L27/38
Measurement of Cylinder Diameter Honing the Cylinder Liner
While the piston is removed from the cylinder, the Renovation is made in the workshop.
latter is measured to record the wear. The measure-
ments are taken by means of an inside micrometer, Prior to honing, deposits of coke and possible wear
with measuring points at TDC-position for the up- edges at the top of the liner must be removed by
permost piston ring, halfway down, and at the bot- scraping.
tom of the cylinder liner, see fig 1 and page 4.
A used flame ring must be used during the honing
process.
The used flame ring must be cleaned in water. Sub-

sequently, the flame ring is remounted in the cylin-
der before carrying out the honing process.
80-160 rpm.
Fig 1 Measuring points
The measurements normally should be taken in

both transverse and in longitudinal direction.
When measuring, take care that the measuring tool

has approximately the same temperature as the Fig 2 Flex-honer in cylinder liner
08028-0D/H5250/94.08.12
liner. When the wear of a cylinder liner exceeds the

value indicated on page 500.35, i.e. when it be-
comes too troublesome to maintain adequate serv- Note: Upon completion of the honing process
ice conditions, the cylinder liner in question should the used flame ring is discarded. A new flame ring
be replaced. is always mounted in the cylinder when replacing
the piston rings.
03.43 -ES0
MAN Diesel
page 3 (4) Inspection and Honing of Cylinder Liner Edition 03H
L27/38
The honing is made by means of a flex-honer with
grain fineness 80-120. A revolution speed between
80 and 160 rpm is chosen.
In order to achieve a required angle between hon-

ing grooves, see fig 3, the vertical speed is adjust-
ed to about 1 m/sec. which corresponds to about 2 60
sec. for one double movement (the flex- honer is led
from below up and down in 2 sec.)
The procedure must be continued until the cylinder

wall is covered by honing grooves and the surface
has a slightly matt appearance without any signs
of glaze. Fig 3 Angle between honing grooves
During the honing it is important to lubricate freely

with honing oil or cutting oil.
After the honing, the liner is carefully cleaned with

gas oil. Make sure that all abrasive particles are re-
moved.
08028-0D/H5250/94.08.12
03.43 - ES0
MAN Diesel
Edition 03H Inspection and Honing of Cylinder Liner Page 4 (4)
L27/38
08028-0D/H5250/94.08.12
03.43 - ES0
MAN Diesel
Working Card Grinding of Seal Face on 506-01.45
Cylinder Liner and Cylinder Head
L27/38

Shut-off fuel oil
Grinding of seal face on cylinder liner, cylinder Grinding paste.

head and engine frame by hand with grinding tool
and grinding paste.
Starting position
Related procedure
Assembling of cylinder unit 505-01.50

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

03.43 - ES0
MAN Diesel
506-01.45 Grinding of Seal Face on Working Card
Page 2 (2)
Edition 03H
Cylinder Liner and Cylinder Head
L27/38
Note: The grinding tool, see fig 1, is used for
both grinding the groove in the sealing surface on
the cylinder head (1), the cylinder liner flange (2)
and the surface of the engine frame (3).
If severe damage or corrosion is observed, a ma-

chining of the sealing faces may be required.
2. Cylinder liner
Fig 3 Grinding tool at engine frame
1. Cylinder head 3. Engine frame
Fig 1 Grinding tool
1) Loosen the sealing ring in liner flange and take

it out.
2) Face-grind the sealing grooves in the cylinder

liner flange, see fig 2, the surface of the engine
frame, see fig 3 and the sealing surface on the
cylinder head, see fig 4 with the use of grinding
paste and the grinding tool.
Fig 4 Grinding tool at cylinder head
3) Move back and forth the tool and lift it out from
time to time.
08028-0D/H5250/94.08.12
4) After grinding, carefully remove all traces of

abrasives and grinding compound.
5) When having ground the contact faces between

cylinder head and cylinder liner, it must be ob-
served that the sealing minimum height above
the cylinder liner is according to 500.35.
Fig 2 Grinding tool at cylinder liner
03.43 - ES0
MAN Diesel
Working Card Dismantling of Piston and Cylinder Liner 506-01.50

Page 1 (4)
at Low Overhaul Height Edition 06H
L27/38

and hydraulic tools according
Description
Dismounting of cylinder unit for inspection and/or

overhaul.
Engine stopped and cooled down.
Related procedure
Inlet and exhaust valve - overhaul and

regrinding of spindel and valve seat 505-01.10
Inspection of piston 506-01.10
Cylinder liner 506-01.35
Separation of piston and
08028-0D/H5250/94.08.12
Working time : 2 1/2 hours Plate no Item no Qty/

Capacity : 2 men
Data

07.35 - ES0
MAN Diesel
506-01.50 Dismantling of Piston and Cylinder Liner Working Card

at Low Overhaul Heights
L27/38
Preparing before Dismantling 10) Push the charge air connections inside the
cylinder head which are to be removed.
1) Drain off the water from the engine.
11) Remove the cylinder head nuts by means of the
2) Take off the top cover. hydraulic jacks, see working card 520-01.05.
3) Take off the side covers on both sides of the 12) Remove the bolts, which hold the cylinder head
engine. and water jacket together, see fig 2.
4) Remove the exhaust gas cover. Note: This means that the cylinder head now
can be removed from the cylinder unit.
Disassembling of Connectings
5) Disconnect the clamp for connecting cylinder

head and exhaust gas receiver. Bolts to be removed
6) Disconnect the fuel oil high pressure pipe.
7) Disconnect the 4 clamps for locking the FW

connection between the cylinder heads.
8) Push the FW connections inside the cylinder

heads, which are to be removed.
9) Disconnect the 2 clamps for locking the charge

air connections by removing the locking bolts
for the clamps, see fig 1.
Bolts to be removed
Fig 2 Remove bolts, which hold the cylinder head and water
jacket together
13) Mount the lifting tool on the cylinder head.
14) Lift the cylinder head and land it carefully on

wooden support.
08028-0D/H5250/94.08.12
15) Remove the push rods by hand.
Fig 1 Push the cooling water connection and charge air con-
nections inside the cylinder heads, which are to be removed
07.35 - ES0
MAN Diesel
Working Card Dismantling of Piston and Cylinder Liner 506-01.50

Page 3 (4)
at Low Overhaul Height Edition 06H
L27/38
Removal of Piston and Piston Rod, Cylinder 18) Loosen the four bolts for the piston rod by
Liner and Water Jacket means of the hydraulic tools and remove the
nuts.
16) Turn the piston into top dead centre.
19) Mount the tool for lifting the piston, see fig 4.
17) Mount the turning bracket to the marine head
and counterweight, see fig 3.
Fig 4 Lifting tool for piston
20) Carefully lift the piston and piston rod out of the
cylinder liner and land it on wooden support.
Fig 3 Turning bracket mounted to the marine head and

counterweight
08028-0D/H5250/94.08.12
07.35 - ES0
MAN Diesel
506-01.50 Dismantling of Piston and Cylinder Liner Working Card

at Low Overhaul Heights
L27/38
21) Mount the lifting tool for the cylinder liner, see fig
5 and lift the cylinder liner out of the engine.
Lifting tool for
22) Mount the eye bolt in water jacket and lift it cylinder liner
off the engine.
Cylinder liner
Lifting tool
08028-0D/H5250/94.08.12
Fig 5 Lifting tool for cylinder liner
07.35 - ES0
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod 50601-20H
L27/38
296
306
127
081
019
176
032
318
331
056
188
188
211
211
272
140
139 284
08028-0D/H5250/94.08.12
152
164
06.29 - ES0
MAN Diesel
Plate
50601-20H Piston and Connecting Rod Page 2 (2)
L27/38
Item Item
019 1/C Piston pin Stempelpind
032 2/C Retaining ring Sikringsring
056 1/C Bush for connecting Plejlstangsbsning

rod
081 1/C Piston 2/2, Stempel 2/2,

incl. item 176, 318, inkl. item 176, 318,331
331
127 1/C Oil scraper ring Olieskrabering
139 1/C Connecting rod Plejlstangsleje 2/2

bearing 2/2
140 4/C Cylindrical pin Cylindrisk stift
152 2/C Screw Plejlstangsskrue

for connecting rod
164 2/C Nut Mtrik
176 4/C Bolt Bolt
188 4/C Nut Mtrik
211 4/C Screw for Plejlstangsskrue

connecting rod
272 1/C Connecting rod shaft, Plejlstangsskaft,

incl. item 056 inkl. item 056
284 1/C Marine head, Marinehovede,

complete incl. item komplet inkl. item
140, 152, 164, 188, 140, 152, 164, 188,
211 211
296 3/C Piston ring Stempelring
306 1/C Set of piston rings and St af stempelringe og

oil scraper ring, incl. olieskrabering, inkl. item
item 127 and 296 127 og 296
318 4/C Distance sleeve Afstandsskive
331 4/C Nut Mtrik

08028-0D/H5250/94.08.12
06.29 - ES0
MAN Diesel
Plate
L27/38
296
306
127
081
019
176
032
318
331
056
188
188
211
211
272
140
139 284
08028-0D/H5250/94.08.12
152
164
06.29 - ES0
MAN Diesel
Plate
L27/38
Item Item

rod

331

bearing 2/2

for connecting rod
164 2/C Nut Mtrik
176 4/C Bolt Bolt
188 4/C Nut Mtrik

connecting rod


140, 152, 164, 188, 140, 152, 164, 188,
211 211

item 127 and 296 127 og 296
331 4/C Nut Mtrik

08028-0D/H5250/94.08.12
06.29 - ES0
MAN Diesel
Plate
L27/38
296
306
127
081
019
176
032
318
331
056
188
188
211
211
272
140
139 284
08028-0D/H5250/94.08.12
152
164
06.29 - ES0
MAN Diesel
Plate
L27/38
Item Item

rod

331

bearing 2/2

for connecting rod
164 2/C Nut Mtrik
176 4/C Bolt Bolt
188 4/C Nut Mtrik

connecting rod


140, 152, 164, 188, 140, 152, 164, 188,
211 211

item 127 and 296 127 og 296
331 4/C Nut Mtrik

08028-0D/H5250/94.08.12
06.29 - ES0
MAN Diesel
Plate
L27/38
296
306
127
081
019
176
032
318
331
056
188
188
211
211
272
140
139 284
08028-0D/H5250/94.08.12
152
164
06.29 - ES0
MAN Diesel
Plate
L27/38
Item Item

rod

331

bearing 2/2

for connecting rod
164 2/C Nut Mtrik
176 4/C Bolt Bolt
188 4/C Nut Mtrik

connecting rod


140, 152, 164, 188, 140, 152, 164, 188,
211 211

item 127 and 296 127 og 296
331 4/C Nut Mtrik

08028-0D/H5250/94.08.12
06.29 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Liner 50610-11H
L27/38
08028-0D/H5250/94.08.12
06.29 - ES0
MAN Diesel
Plate
50610-11H Cylinder Liner Page 2 (2)
L27/38
Item Item
018 1/C Cylinder liner Cylinderforing
031 1/C Sealing ring Ttningsring
092 1/C Flame ring Flammering
08028-0D/H5250/94.08.12
06.29 - ES0
Camshaft
507/607
MAN Diesel
Description
Camshaft and Camshaft Drive 507.01
L27/38
Camshaft and Camshaft Drive
The inlet and exhaust valves as well as the fuel pumps The lubricating oil pipes for the gear wheels are
of the engine are actuated by two camshafts. equipped with nozzles which are adjusted to apply
the oil at the points where the gear wheels are in
Due to the two-camshaft design an optimal adjust- mesh.
ment of the gas exchange is possible without inter-
rupting the fuel injection timing. It is also possible
to adjust the fuel injection without interrupting the
gas exchange.
The two camshafts are located in the engine frame.

On the exhaust side, in a very high position, the valve
camshaft is located to allow a short and stiff valve
train and to reduce moving masses.
The injection camshaft is located at the service side

of the engine.
Both camshafts are designed as cylinder sections

and bearing sections in such a way that disassembly
of single cylinder sections is possible through the
side openings in the crankcase.
The two camshafts and the governor are driven by

the main gear train which is located at the flywheel
end of the engine. They rotate with a speed which
is half that of the crankshaft.
The camshafts are located in bearing bushes which

are fitted in bores in the engine frame; each bearing
is replaceable and locked in position in the engine
frame by means of a locking screw. Fig. 1 Twin camshafts
The gear wheel for driving the camshaft as well as

a gear wheel connection for the governor drive are
screwed on to the aftmost section.
08028-0D/H5250/94.08.12
98.27 - ES0
MAN Diesel
Page 1 (2) Check of Camshaft and Camshaft Drive Edition 05H
L27/38

Shut-off fuel oil
Checking of gear wheels, bolted connections and Unbraco top, 14 mm.

lubricating system. Ratchet.
Extension.
Top, 24 mm.
Serrated fork.
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : 1 man
51106 142 1/cyl
Data

02.47 - ES0
MAN Diesel
Edition 05H Check of Camshaft- and Camshaft Drive Page 2 (2)
L27/38
1) Dismount the covers which give access to the 3) Check all screws, nuts and bolted connections,
gear wheels, camshaft and crankcase. including locking devices everywhere in the
gear wheel housing, camshaft housing and
2) Examine all gear wheels for cracks, wear and crankcase to check that they have not worked
deformations while turning the engine to enable loose. Tightening torques, please see page
inspection all over the circumference of the 500.40.
gear wheels.
4) Examine all lubricating oil spray pipe nozz-
les.
5) Mount the covers.
08028-0D/H5250/94.08.12
02.47 - ES0
MAN Diesel
Page 1 (3) Inspection and Replacement of Camshaft Bearing Edition 04H
L27/38
Stopped engine Plate no Item no Note.

Shut-off cooling water Hydraulic tools according to
Shut-off fuel oil Working Card 520-01.06
Description
Hand tools
Check of roller path of cams and check of cam-
shaft bearing. Screwdriver.
Replacement of camshaft bearing. Supporting tool for camshaft bearing.
Starting position
Cover for camshaft and gear wheel has been

removed.
Related procedure
Camshaft and camshaft drive 507-01.00

Man power
08028-0D/H5250/94.08.12

Capacity : 2 men Plate no Item no Qty/
50705 350 1/eng.

Data 50705 648 1/eng.

02.41 - ES0
MAN Diesel

Edition 04H Inspection and Replacement of Camshaft Bearing Page 2 (3)
L27/38
To Check Roller Path of Cams Note: To prevent the lower rocker arm from
1) While turning the engine, examine the cam pushing downward at the camshaft section to be
discs and in particular, check the roller path of removed, place a screwdriver in the sloth of the
all cams for cracks, crackles and ruffle. Also rocker arm and lift the lower rocker arm free from
examine the rollers of the lower rocker arms. the camshaft section, see fig 1.
Note: If there are flat spots on the roller and if some

of the rollers may be blocked, the roller must be
replaced by a new one, please see working card
508-01.00.
To Check Camshaft Bearings

2) The wearing surface of the camshaft bearings
cannot be checked without dismounting the cam-
shaft. However, abnormal wear of one or more
bearings will become apparent in the form of
burrs of white metal at the circumference of the
camshaft journal, and in that case the bearing
will in no doubt be discoloured, as well.
The bearing clearance is measured with a

feeler gauge, please see data sheet 500.35.
To Replace Camshaft Bearing for Injection

or Valve Camshaft
If one or several of the camshaft bearings should
be replaced, the camshaft must be wholly or partly
dismantled.
3) The camshaft sections are marked in relation

Fig 1 Place a screwdriver in the sloth of the lower rocker arm
to each other.
4) Dismantle the camshaft section for (towards

engine front) of the bearing that is to be repla-
ced. 7) Remove the spur wheel and the bearing plate,
see fig 2 so the camshaft can be moved towards
5) Place a screwdriver between the camshaft the alternator.
sections forward of the bearing and push the
08028-0D/H5250/94.08.12
camshaft forward. Remember to mark the spur wheel. It must be

placed exactly at the same spot. Otherwise,
6) Dismantle the same camshaft section at the the timing will be changed.
front end and remove the camshaft section
from the engine. 8) Dismantle the camshaft section aft (towards
the alternator) of the bearing that is to be
replaced.
9) Place a screwdriver between the camshaft sec-

tions aft of the bearing and push the camshaft
aft towards the alternator.
02.41 - ES0
MAN Diesel
Page 3 (3) Inspection and Replacement of Camshaft Bearing Edition 04H
L27/38
Mounting of the Camshaft Bearing
15) For fitting the bearing it must be cooled down

with CO2 to -90 C below crankcase tempera-
ture.
16) Insert the bearing in the frame. Make sure that

the oil bores in the bearing shell are turned 90
according to the oil bores in the frame.
Note: Check that the bearing is placed in the

middle of the frame.
17) Coat all the journals of the camshaft section

with clean lubricating oil and push the camshaft
into position, making sure that the marks on
the flanges coincide.
18) Assemble the sections and fit the bolts (coated

with molycote or similar).
19) Tighten the nuts with a torque spanner, see

data sheet 500.40.
Fig 2 Removing of spur wheel and the bearing plate
10) Dismantle the same camshaft section at the

aft end and remove the camshaft section from
the engine.
The bearing to be removed is now free.
11) Mount the supporting tool for removing the

camshaft bearing, see fig 3.
08028-0D/H5250/94.08.12
12) Turn the nut clockwise until the bearing is

removed from the frame hole.
13) Remove the supporting tool.

1 Tool
2 Bearing
Inspection of Sleeve and Oil Bore
14) Check that the oil bore for the bearing is free Fig 3 Supporting tool for removing the camshaft bearing
for oil flow. Inspect the camshaft journal for
seizures.
02.41 - ES0
MAN Diesel

Page 1 (4) Adjustment of Camshaft for Valve and Injection Timing Edition 07H
L27/38

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

camshaft in relation to crankshaft).
Starting position
Camshaft assembled as per timing order, mounted

in frame and roller gear house.
If intermediated gearwheel must be changed, the
generator must be dismounted.
Related procedure

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

Capacity : - man
Data

02.41 - ES0
MAN Diesel

Edition 07H Adjustment of Camshaft for Valve and Injection Timing Page 2 (4)
L27/38
If the gearwheels have been dismantled, a nominal
adjustment of the camshaft compared to the crank-
shaft (timing) must be made.
Mounting of the Intermediate Spur Gear

Wheels
1) Turn the crankshaft to top dead centre for the

last cylinder (the cylinder nearest to the coupling
side).
2) Mount the upper intermediate spur gear-

wheel.
3) Mount the lower intermediate spur gear wheel

so that the marks on the lower intermediate spur
gearwheel are corresponding with the mark on
the crankshaft gearwheel, see fig 1 E2, and
at the same time turn the upper intermediate
spur gearwheel so that the small holes in the
circumference of the two intermediate spur
gearwheel are corresponding, see fig 2.
Fig 2 Position of small holes in the circumference of the two

intermediated gearwheels
08028-0D/H5250/94.08.12
Fig 1 Marks on gearwheels
Fig 3 13 teeth counter-clockwise from the joint of the gear-

Note: The punch mark on the crankshaft gearwheel wheel
is placed between teeth 12 and 13 counting counter
clockwise from the joint of the gearwheel, see fig
3.
02.41 - ES0
MAN Diesel

Page 3 (4) Adjustment of Camshaft for Valve and Injection Timing Edition 07H
L27/38
4) Tighten up the intermediate spur gearwheels, Check / Adjustment of Injection Timing
please see page 500.40.
16) Turn the engine to approx. 20 before ignition
top dead centre for cylinder no 1. cylinder
Adjusting of the Valve Camshaft numbering, see page 500.11.
5) Turn the valve camshaft until the mark on 17) Un-screw both plugs on front and backside
the spur gearwheel for the valve camshaft is of the fuel pump for cylinder no 1, see page
corresponding with the marks for the upper 500.11.
intermediate spur gearwheel, see fig 1 E1.
18) Use a flashlight and a mirror to light through
Tighten up the spur gearwheel, see page the pump from the back, see fig 4.
500.40.
19) Look through the pump from the front side
and at the same time turn the engine until the
Adjusting of the Injection Camshaft when plunger in the barrel cuts off the light from the
Gear Wheel is dismantled flashlight.
6) Turn the engine to max. 9.5 BTDC for cylinder

no 1, see stamp mark on flywheel.
7) Un-screw both plugs on front and backside

of the fuel pump for cylinder no 1, see page
500.11.
8) Use a flashlight and a mirror to light through

the pump from the back, see fig 4.
9) Look through the pump from the front side and

at the same time turn the camshaft until the
plunger in the barrel cuts off the light from the
flashlight.
10) Mount the gearwheel for the camshaft.
11) Make sure that the punch mark at the gear-

wheel for the camshaft corresponds with the
punch mark at the intermediate gearwheel.
08028-0D/H5250/94.08.12
12) If re-adjustment of the camshaft is needed,

then loosen the gearwheel and adjust (tighten
one bolt).
13) Check injection timing from step 8.
14) If timing of the fuel camshaft is OK, then tighten

the bolts on the gearwheel.
15) Mount the plugs for the fuel pump.

Fig 4 Use a flashlight and a mirror to light through the pump
02.41 - ES0
MAN Diesel
Edition 07H Adjustment of Camshaft for Valve and Injection Timing Page 4 (4)
L27/38
Note: Check the stamp on the flywheel. This now 21) Check injection timing from step 16.
must be max. 9.5 BTDC.
22) If timing of the fuel camshaft is OK, then tighten
20) If re-adjustment of the camshaft is needed, the bolts on the gearwheel.
then loosen the gearwheel and adjust (tighten
one bolt). 23) Mount the plugs for the fuel pump.
08028-0D/H5250/94.08.12
02.41 - ES0
MAN Diesel
Plate
Page 1 (2) Intermediate Wheel 50701-03H
L27/38
08028-0D/H5250/94.08.12
99.15 - ES0
MAN Diesel
Plate
50701-03H Intermediate Wheel Page 2 (2)
L27/38
Item Item
012 1/E Stepped spur gear, Tandhjul, komplet

complete incl. item inkl. item 024, 048,
024, 048, 061 061
024 1/E Spur gear Tandhjul
036 1/E Spur gear, complete Tandhjul, komplet

incl item 061, 120 inkl. item 061, 120
061 2/E Control drive bearing Lejebsning
073 2/E Bolt Bolt
085 4/E Axial bearing ring Lejering
097 2/E Axle Aksel
107 2/E Washer Skive
119 2/E Nut Mtrik
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine Qty/E = Qty/Motor
99.15 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft (Injection Camshaft) 50705-21H
L27/38
278 266
362
362
278
266
673
291
266 636
278 291
590 589
600
362
291
685
697
5 cyl.
313* 301 374 386
386 374
6 cyl.
Item nos for 408 433
bearing disks 398 421 445
7 cyl.
08028-0D/H5250/94.08.12
457 470 469

469 470 457
8 cyl.
494 421 528
482 504 516 541
9 cyl.
553 433 577 565
565 577 433 553
06.33 - ES0
MAN Diesel
Plate
50705-21H Camshaft (Injection Camshaft) Page 2 (2)
L27/38
Item Item
266 Screw Skrue 469 2/E Bearing disk, Lejesle,

160/E 5 cyl. engine 5 cyl. motor 7 cyl. engine 7 cyl. motor
192/E 6 cyl. engine 6 cyl. motor
224/E 7 cyl. engine 7 cyl. motor 470 2/E Bearing disk, Lejesle,
482 1/E Bearing disk, Lejesle,
278 Washer Skive 8 cyl. engine 8 cyl. motor
8 cyl. engine 8 cyl. motor
291 Cylindrical pin Cylindrisk stift
301 1/E Bearing plate, com- Lejeplade, komplet 541 1/E Bearing disk, Lejesle,
plete incl. item 313 inkl item 313 8 cyl. engine 8 cyl. motor
313* 4/E Expander plug Ekspansionsprop 553 2/E Bearing disk, Lejesle,
362 1/C Camshaft part Styreakselsektion
piece 565 2/E Bearing disk, Lejesle,
5 cyl. engine 5 cyl. motor 577 2/E Bearing disk, Lejesle,
5 cyl. engine 5 cyl. motor 589 1/E Axial bearing disk Aksial lejesle
398 1/E Bearing disk, Lejesle, 590 1/E Bearing segment Lejesle, ende
6 cyl. engine 6 cyl. motor end
408 1/E Bearing disk, Lejesle, 600 1/E Spur wheel Cylindrisk tandhjul
636 1/E Flange Flange
421 Bearing disk Lejesle
1/E 6 cyl. engine 6 cyl. motor 673 16/E Bolt Bolt
685 2/E Screw Skrue
433 Bearing disk Lejesle
1/E 6 cyl. engine 6 cyl. motor 697 2/E Washer Skive

08028-0D/H5250/94.08.12

Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
06.33 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft (Valve Camshaft) 50705-22H
L27/38
266
278
291 014
278
266
014 720
266
732 707
230
278
719
242
014 254
685
697
301
313*
291
6 cyl.
063 087
Item nos for 051 075 099
bearing disks
7 cyl.
109 122 110
08028-0D/H5250/94.08.12
110 122 109
8 cyl.
146 075 183
134 158 171 195
9 cyl.
205 087 229 217
217 229 087 205
06.33 - ES0
MAN Diesel
Plate
50705-22H Camshaft (Valve Camshaft) Page 2 (2)
L27/38
Item Item
No Qty Designation Benvnelse No Qty Designation Benvnelse
014 1/C Camshaft part Styreakselsektion 230 1/E Axial bearing disk Aksial lejesle
piece
242 1/E Bearing segment Lejesle, ende
051 1/E Bearing disk, Lejesle, end
254 1/E Spur wheel Cylindrisk tandhjul
6 cyl. engine 6 cyl. motor 266 Screw Skrue
075 Bearing disk Lejesle 112/E 7 cyl. engine 7 cyl. motor
1/E 6 cyl. engine 6 cyl. motor 128/E 8 cyl. engine 8 cyl. motor
087 Bearing disk Lejesle 278 Washer Skive

099 1/E Bearing disk, Lejesle, 144/E 9 cyl. engine 9 cyl. motor
7 cyl. engine 7 cyl. motor 13/E 7 cyl. engine 7 cyl. motor
301 1/E Bearing plate, com- Lejeplade, komplet
122 2/E Bearing disk, Lejesle, plete incl. item 313 inkl item 313
313* 4/E Expander plug Ekspansionsprop
8 cyl. engine 8 cyl. motor 685 2/E Screw Skrue
146 1/E Bearing disk, Lejesle, 697 2/E Washer Skive

707 1/E Ring Ring
8 cyl. engine 8 cyl. motor 719 1/E Additional mass Inertimasse
171 1/E Bearing disk, Lejesle, 720 8/E Screw Skrue

732 1/E Cylindrical pin Cylindrisk stift


08028-0D/H5250/94.08.12


06.33 - ES0
MAN Diesel
Plate
5L27/38
266
278
291 014
278
266
014
266
266
291
230
278
707
242
014 254
685
697
301
313*
291
08028-0D/H5250/94.08.12
Item nos for

bearing disks
5 cyl.
026 038
038 026
06.33 - ES0
MAN Diesel
Plate
5L27/38
Item Item
014 1/C Camshaft part Styreakselsektion

piece
026 2/E Bearing disk Lejesle
038 2/E Bearing disk Lejesle
230 1/E Axial bearing disk Aksial lejesle

end
266 88/E Screw Skrue

plete incl. item 313 inkl item 313
685 2/E Screw Skrue
707 1/E Ring Ring
08028-0D/H5250/94.08.12
06.33 - ES0
MAN Diesel
Plate
6-7-8-9L27/38
266
278
291 014
278
266
014
266
266
291
230
278
707
242
014 254
685
697
301
313*
291 6 cyl.
063 087
051 075 099
Item nos for
bearing disks 7 cyl.
08028-0D/H5250/94.08.12
109 122 110

110 122 109
8 cyl.
146 075 183
134 158 171 195
9 cyl.
205 087 229 217
217 229 087 205
06.33 - ES0
MAN Diesel
Plate
6-7-8-9L27/38
Item Item
014 1/C Camshaft part Styreakselsektion 230 1/E Axial bearing disk Aksial lejesle
piece
051 1/E Bearing disk, Lejesle, end
6 cyl. engine 6 cyl. motor 266 Screw Skrue
075 Bearing disk Lejesle 120/E 7 cyl. engine 7 cyl. motor
087 Bearing disk Lejesle 278 Washer Skive

122 2/E Bearing disk, Lejesle, plete incl. item 313 inkl item 313
8 cyl. engine 8 cyl. motor 685 2/E Screw Skrue
146 1/E Bearing disk, Lejesle, 697 2/E Washer Skive

707 1/E Ring Ring




08028-0D/H5250/94.08.12


06.33 - ES0
Operating gear
508/608
MAN Diesel
Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition 03H
L27/38
Roller Guides Valve Actuating Gear
The fuel injection pumps and rocker arms for inlet The push rods for the inlet and exhaust valves are
and exhaust valves are operated by the cams on the activated by the camshaft via a cam follower.
camshafts through roller guides. The roller guides for
inlet and exhaust valves are located in bores in the The push rod movement is in the cylinder head
water jacket for each cylinder. transmitted to short rockers, and from these to a
guided, spring-loaded yoke. This yoke operates two
The roller runs on a bush fitted on a pin that is equal valves each.
pressed into the roller guide and secured by means
of a lock screw. The pillow supporting the rocking levers (the rocking-
lever casing) is bolted to the cylinder head.
Operating Gear for Fuel Injection Pumps Bearing bushes, ball pans and yokes are lubricated
by means of a fitting in the pillow.
The injection pumps which are mounted directly on
the frame are activated via thrust pieces from the
roller guide. The roller guide is incorporated in the
fuel pump as one unit.
08028-0D/H5250/94.08.12
98.27 - ES0
MAN Diesel
Working Card Inspection of Valve Camshaft 508-01.00
Page 1 (2)
Lower and Upper Rocker Arms Edition 04H
L27/38

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

mounting of valve roller guides.
Starting position
Cylinder unit has been removed from engine and

dismantled.
Related procedure
Control and adjusting of valve

clearance 508-01.10

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

01.30 - ES0
MAN Diesel
508-01.00 Inspection of Valve Camshaft Working Card

Edition 04H Lower and Upper Rocker Arms Page 2 (2)
L27/38
1) Remove the locking screw from the upper
rocker arm shaft.
2) Push out the shaft and remove the upper rocker

arms for the inlet and outlet valves.
3) Blow clean the lubricating ducts in the bush

and the roller with air.
4) Examine the shaft, push rod and ball cup for

damage and replace if necessary. Roller
Replacement of Roller and Shaft Pin for the Roller pin

Lower Rocker Arms
5) Remove the lock screw for the lower rocker Locating pin
arm shaft.
6) Push out the lower rocker arm shaft.
Fig 2 Remove the locating pin for the roller shaft
7) Remove the locating pin for the roller shaft of

the lower rocker arm, see fig 2.
8) Push out the roller shaft.
The roller and shaft can now be replaced.
9) After replacement mount the lock screw with

loctite 275.
Mounting of Valve Camshaft Lower and Up-

per Rocker Arms
10) Assemble the rocker arms and shaft in the

opposite direction.
08028-0D/H5250/94.08.12
11) Mount the locking screws for the lower and

upper rocker arm shafts.
Lock screw for

the lower rocker arm shaft
Fig 1 Lower and upper rocker arm
01.30 - ES0
MAN Diesel
Page 1 (2) Control and Adjusting of Valve Clearance Edition 12H
L27/38

Shut-off fuel oil
Description Hand tols
Control and/or adjusting of valve clearance.
Starting position
Cover for rocker arm is removed.
Related procedure

08028-0D/H5250/94.08.12
Capacity : 1 man
Data
See also plate 50502.
04.04 - ES0
MAN Diesel
Edition 12H Control and Adjusting of Valve Clearance Page 2 (2)
L27/38
1) Turn the engine so that the roller, rests on the Control of Inlet and Exhaust Valve
circular part of the cam, i.e. the inlet valves and Clearance
the exhaust valves are closed.
At overhaul adjusting of valve bridge can be done
2) Check clearance between valve bridge and before rocker arms are mounted.
valve spindle, please see page 500.35. Cold
condition. 4) Loosen the nut on the valve bridge 1.
3) Check that the feeler gauges marked "cor- 5) Adjust the screw until the valve bridge have
rect" can be inserted into the clearances at contact with both valves.
both inlet and exhaust valves. Also check that 6) Tighten the nut on valve bridge with the correct
it is not possible to insert the gauges marked torque, see description 500.40.
"incorrect".
If the valve clearance is incorrect please con-
tinue to 4 7) Place the correct feeler gauge marked correct
between rocker arm and valve bridge, see fig
2.
8) Adjust the valve clearance by the screw and

tighten the nut.
9) Tighten the nut on valve bridge with the correct

torque, see description 500.40.
Fig 1 Loosen the adjustment screw on the rocker arm and Fig 2 Feeler gauge
08028-0D/H5250/94.08.12
valve bridge
04.04 - ES0
MAN Diesel
Plate
Page 1 (2) Roller Guide and Push Rods 50801-05H
L27/38
08028-0D/H5250/94.08.12
02.33 - ES0
MAN Diesel
Plate
50801-05H Roller Guide and Push Rods Page 2 (2)
L27/38
Item Item
016 4/C Ball seat Kuglesde
028 2/C Push rod Stdstang

incl item 016 inkl. item 016
100 4/C Screw Skrue
124 1/C Bracket Konsol
136 1/C Shaft Aksel
148 2/C Bearing bush Lejebsning
161 2/C Roller pin Aksel
185 2/C Bush Bsning
197 2/C Roller Rulle
220 2/C Rocker arm, complete Svingarm, komplet

incl. item 161, 185, inkl. item 161, 185,
197 197
08028-0D/H5250/94.08.12
02.33 - ES0
Control/safety
509/609
MAN Diesel
Description 509.01
Page 1 (7) Safety, Control and Monitoring System Edition 13
General
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
Continuous analogue monitoring base module (BM)
Independent safety system operation box (OB)
Easy installation monitoring of temperatures/pressures
Simple operation panel (MTP)
Instrumentation complete monitoring of exhaust gas temperature
No maintenance panel (MEG)
Prepared for CoCoS monitoring of bearing temperature panel
Redundant safety system (MBT), option
bearing temperature display (BTD), op-
tion
In order to fulfil all classification society requirements oil mist detector, option
the engine is equipped with monitoring sensors for Instrumentation (sensors, wiring, junction
all medias as standard. If just one classification boxes)
society require one specific measuring point it is Manometers and thermometers
standard on the engine. Also a built-on safety system Output module (OM), option
is standard. Alarm panel (AP), option
08028-0D/H5250/94.08.12
Fig 1 Monitoring and safety system.
05.18 - NG - ES1
MAN Diesel
509.01 Description
Edition 13 Safety, Control and Monitoring System Page 2 (7)
General
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 GenSets 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.
automatically stop (shutdown) in case of:
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 safety system The base module is the centre of the monitoring
module inside the terminal box. system.
The base module, the OB-module, the MTP-module

Governor and the MEG-module are designed by MAN B&W
Diesel A/S, Holeby specifically for this engine type.
The engine speed is controlled by a hydraulic governor
or electronic controller with hydraulic actuator. Apart from the electrical main connection to the
alternator the ship yard only has to perform the fol-
Information about the design, function and opera- lowing electrical connection:
tion of the governor is found in the special governor
instruction book. 24 VDC supply to the safety system.
08028-0D/H5250/94.08.12
Cable connection to/from power management

The governor is mounted on the flywheel end of the system.
engine and is driven from the camshaft via a cylindri- 24 VDC supply to the base module.
cal gear wheel and a set of bevel gears. Modbus communication or interlink to output
module.
Regulating Shaft The vessels alarm and monitoring system in the

main switch board can be connected to the base
The governor's movements are transmitted through module by means of a 3-wire MODBUS communi-
a spring-loaded pull rod to the fuel injection pump cation link. For further information, please see the
regulating shaft which is fitted along the engine. description "Communication from the GenSet".
05.18 - NG - ES1
MAN Diesel
Description 509.01
General
In situations where the vessels system cannot oper- Indication of:
ate a MODBUS communication unit, MBD-H offers Engine rpm
an output module (OM) to be installed in the vessels TC rpm
control room. Starting air pressure
Display for digital read out
By means of the OM it is possible to connect all dig- Indication of software version
ital and analogue signals to the vessels monitoring
system in a conventional manner. Shutdowns indication:
overspeed
Communication between the base module (BM) and low lub. oil pressure
the output module (OM) takes place via a 3-wire high fresh water temp.
interlink bus (RS485). emergency stop / oil mist
In the base module all the alarms are generated and Please note that the local stop push button must be
delay and cut-off at standstill is done. Set points and activated at least 3 sec. before the engine will stop.
special conditions can be found in "Operation Data
& Set Points, B 19 00 0".
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.
Operating Box Module (OB)
This module includes the following possibilities:
Operation of: Fig 2 Operation box module (OB).

engine start
engine stop
08028-0D/H5250/94.08.12
remote mode The manual start button must be activated until ig-
local mode nition, takes place. If the engine have been without
blocking/reset mode prelubrication in more than 20 minutes the engine
lamp test can not be electrical started.
arrow up - shift upwards through measure-
ments for display The push buttons REMOTE - LOCAL - BLOCKING is
arrow down - shift downwards through only related to the start function. In case of BLOCK-
measurements for display ING the engine can not be started from local or from
remote (switchboard).
05.18 - NG - ES1
MAN Diesel
509.01 Description
General
The stop function is not depended of the REMOTE

- LOCAL - BLOCKING position.
On the local operating box module the pressure,

temperature and rpm are illustrated by means of a
display: an LED indicates whether it is the working
hours, alternator, pressure, temperature or rpm
which is measured.
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.
If the lamp test button is activated for more than 3

sec. the software version will be displayed.
Fig 4 Monitor temp./press. (MTP)
If there is a deviation, the bargraph in question will

start to illuminate the segments upwards or down-
wards, depending on rising or falling measurements,
see fig 4.
It must be mentioned that the latter does not apply to

the charge air temperature and charge air pressure,
because they will vary with the engine load.
Monitoring of Exhaust Gas Temperature

Panel (MEG)
Fig 3 Monitoring of temperature/pressure module (MTP). 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.
08028-0D/H5250/94.08.12
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 5 Monitoring of exhaust gas temperature module (MEG).
05.18 - NG - ES1
MAN Diesel
Description 509.01
General
For emergency operation in case of totally black-out By performing an offset adjustment equalisation of the
on the 24 V DC supply the engine is equipped with temperature when the engine is adjusted correctly the
manometers for: operator will get the impression that the temperatures
then are identical when the pumps etc are adjusted
Lub. oil pressure correctly. If a deviation of the temperatures occurs,
Cooling water pressure it is because of problems with the combustion or the
Fuel oil pressure fuel pumps just as the operator is used to.
and thermometers for: The equaliser function is activated by pressing the

arrow push buttons on the OB panel for minimum
Cooling water temp. three seconds. A menu occurs and by pressing ar-
Fuel oil temp. row push buttons up/down the following options are
available:
"NO" (Nothing happens and you return to

normal mode)
"YES" (Equalisation is completed if pos-
sible. New offsets are calculated)
"RESET" (All offset values are re-zeroed)
The chosen option is accepted by pressing "BLOCK-

ING" or "lamp test". If equalisation cannot be com-
pleted, "Err-2" will show up for two seconds and
afterwards it returns to normal mode again. In case
that a temperature deviation is above 40o C it will not
be possible to complete an equalisation and "Err-2"
will be indicated. The 40o C deviation is from the "real"
readings, and not from the "manipulated" readings.
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.
Fig 6 Monitor exh. gas temperature (MEG). Monitoring of Bearing Temperature, MBT
(option)
Equaliser Function for Exhaust Gas Tem- The temperature shown on the MBT module is
perature indicated with segments illuminated from the left
to the right. The number of segments illuminated
08028-0D/H5250/94.08.12
An equaliser function has been introduced to take depends on the actual temperature of the bearing
into consideration the old learning that the exhaust temperature.
temperature values must be identical on a four-stroke
diesel engine.
On the engine type L16/24, L27/38 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 ship's crew will
adjust the fuel pumps improperly to obtain identical
exhaust temperature values for each cylinder and
this is of course not desirable.
05.18 - NG - ES1
MAN Diesel
509.01 Description
General
Output Module (option)
For alarm systems which cannot be communicated

through the MODBUS protocol, an output module
has been designed. This module includes conven-
tional output signals (4-20 mA) for all analogue
measuring values, signals for limit values, and in-
formation signals from the safety system.
The output module will be delivered in a separate

box (IP56) with the dimensions (H/L/W): 380 x 380
x 155 mm.
Alarm Panel (option)
An alarm panel with 24 alarm points can be con-

nected to the system. The alarm panel can be in-
stalled on the engine or in the engine control room,
see fig 7. The dimensions for the panel are (H/L/W):
Fig 7 Monitoring of bearing temperature (MBT), option. 144 x 96 x 35 mm.
It is important that all alarms leads to prompt in-

Display for Bearing Temperature Display, vestigation and remedy of the error. No alarm is
BTD (option) insignificant. It is therefore important that all engine
crew members are familiar with and well trained in
On the bearing temperature display the excact meas- the use and importance of the alarm system.The
uring value for each individual bearing temperautre most serious alarms are equipped with slowdown
can be read. Furthermore an indication of high and/or shutdown functions.
bearing temperature alarm and very high bearing
temperature shutdown are indicated.
08028-0D/H5250/94.08.12
Fig 9 Alarm panel.

Fig 8 Display for bearing temperature (BTD), option.
05.18 - NG - ES1
MAN Diesel
Description 509.01
General
Instrumentation The temperature sensors are placed at the measur-
ing point.
Pressure measurements are generated from the
pressure transmitters.
Data
The exhaust gas temperatures are generated by
NiCr/Ni thermo sensors. Power supply : 24 VDC -20 to +30%,
max ripple 10%
Temperatures are generated by PT100 sensors. Power consumption : < 2 amp
Ambient temp. : -20oC to 70oC
The above transmitters and sensors are specially External
designed for installation on diesel engines. communication links : MODBUS ASCII / RTU or
interlink (RS422 / RS485)
The pressure sensors are placed centrally at the
front of the engine, facilitating easy access for
maintenance and overhauls, and minimizing wire
connections.
08028-0D/H5250/94.08.12
05.18 - NG - ES1
MAN Diesel
Description 509.10
Page 1 (2) Lambda Controller Edition 06
L21/31
L27/38
Purpose At 50% load change the system will be activated for
about 3-8 seconds.
The purpose of the lambda controller is to prevent
injection of more fuel in the combustion chamber than If the system is activated for more than 10 seconds
can be burned during a momentary load in-crease. the air supply will be shutoff and a "Jet system failure"
This is carried out by controlling the relation between signal will be generated.
the fuel index and the charge air pressure.
Fuel Oil Limitation during Start Procedure

Advantages
During the start procedure the controller is activated
The lambda controller has the following advan- as an index limiter.
tages:
Hereby, heavy smoke formation is avoided during
- Reduction of visible smoke in case of sud- start, and the regulating device cannot overreact.The
den momentary load increases. fuel limiter function stops when the engine reaches
the nominal RPM.
- Improved load ability.
The jet system is released at 50 RPM during the
- Less fouling of the engine's exhaust gas starting procedure.
ways.
- Limitation of fuel oil index during starting Air Consumption

procedure.
Jet air consumption at sudden step loads:
The above states that the working conditions are
improved under difficult circumstances and that the
maintenance costs for an engine, working with many Air cons. =
(step load % - 25) x N
and major load changes, will be reduced. (Nm)
111
N = Number of cylinders.
Principles of Functioning
Fig 1 illustrates the controller's operation mode. In At 50% step load for L21/31 and L27/38 the air
case of a momentary load increase, the regulating consumption will be as follows:
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), whereby the electri- Cyl. no. 5 6 7 8 9
cal circuit will be closed.
Thus the solenoid valve (4) opens. The jet system Nm3 1.12 1.35 1.57 1.80 2.02
is activated, the turbocharger accelerates and in-
08028-0D\H5250\94.08.12
creases the charge air pressure, thereby pressing

the piston (3) backwards in the lambda cylinder (5).
When the lambda ratio is satisfactory the jet system
will be de-activated.
04.15 - ES1
MAN Diesel
509.10 Description
Edition 06 Lambda Controller Page 2 (2)
L21/31
L27/38
08028-0D\H5250\94.08.12
Fig 1 Lambda controller incl. start limitation
04.15 - ES1
MAN Diesel
Description
Communication from the GenSet 509.55
General
System Layout All signals can be wired up from the OM-mod-

ule to the ships alarm & monitoring system.
Fig 1 shows the system layout. The modules BM, OB,
MTP, MEG and safety system are all placed on the 3) A simple alarm panel (AP) with 24 LED chan-
engine. More detailed information on each module nels can be installed in the control room. This
and sensors can be read in the description "Safety, solution only serves digital alarms.
Control and Monitoring System".
If the alarm system can communicate with MODBUS
ASCII or RTU, there is no need for the OM-module
Communication or AP. All signals can be communicated by the
MODBUS.
Communication from the BM-module to the ships
alarm & monitoring system can be done in three In the following please find a description of the MOD-
ways: BUS protocol and addressing of the signals.
1) In the BM-module there is a MODBUS ASCII

or RTU interface communication. MODBUS Protocol (BM)
2) An output module (OM) can be placed in The BM has a standard MODBUS ASCII and RTU
the control room switchboard or alarm disk. interface which may be selected, by means of a DIP
Communication from the BM-module to the switch on the BM, to be either:
OM-module is made via the 3 wire module
interlink bus. RS422 5 wire (Rx+, Rx-, Tx+, Tx-, GND) or
RS485 3 wire (Rx+/Tx+, Rx-/Tx-, GND)
In the OM-module all the signals are converted
into 4-20 mA signals and digital outputs.
08028-0D/H5250/94.08.12
Fig 1 System overview: "monitoring system & safety system"
06.44 - ES1
MAN Diesel
509.55 Communication from the GenSet

Description
General
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
06.44 - ES1
MAN Diesel
Description
General
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, 4, 5 and 6).
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, 4, 5 and 6 which
[DATA] = [bb][1. word][2. word]....[n. word] specifies the block I/Os registers addresses and how
[bb]=Byte, stating number of subsequent the 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.
06.44 - ES1
MAN Diesel

Description
General
MODBUS Timeout However the implementation of the protocol in the
GenSet Base Module is able to handle much smaller
To prevent lock up of the protocol, ie. a breakdown timeouts (response times), which may be required
on the connection, a number of timeouts are to in order to obtain an acceptable worst-case I/O
be built in, as specified in the MODBUS protocol scan time:
specification:
Base Module, max. time between characters in a
MODBUS specification max. time between charac- frame:5 ms
ters in a frame: 10 ms
Base Module, max. time between receipt of frame
MODBUS specification max. time between receipt and answer: 100 ms
of frame and answer: 1 second
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
Description
General
In the tables below each signal has a importance h) "Safety system failure" consists of following
statement with following meaning: signals: Power supply failure and internal watch
dog alarm.
Required by the classification society or MAN i) "Safety sensor cable failure" means cable fail-
B&W. ure on one or more of following sensors: lub. oil
Recommended by MAN B&W. pressostate PSL22, cool. water ther-mostate
"Nice to have". TSH12, speed pick-up SE90-2 or emergency
stop switch ZS82 (as option TSH29/27 for
In the tables below some signals have a remark with L27/38 or LSH92 for L27/38 and L32/40)
following meaning: j) "Local shutdown" only consists of the shut-
a) Required by American Bureau of Shipping, downs (PSL22, TSH, SSH81, and ZS82) in the
ABS. safety system.
b) Required by Bureau Veritas, BV. k) For L27/38, L21/31 and L32/40 the signal
c) Required by Jugoslavenski Register & DnV. ZS82, also includes high oil mist shutdown,
d) Required by Registro Italiano Navale, RINA. LSH92 if it is installed (option).
e) Required by Nippon Kaiji Kyokai, NKK & DnV. l) Oil mist (LSH/LAH92) is standard for 7, 8, 9 cyl.
f) Bureau Veritas, Lloyds Register of Shipping L27/38 (for marine application) and L32/40. For
and ABS demand alarm point for low/high 5, 6 cyl. L27/38 and L21/31 it is an option.
heavy fuel oil temp. Normally this is placed m) Required by Det Norske Veritas, DnV.
at yard side as an common alarm for all aux. n) For L16/24 engine type TC rpm range is 0-
engines. The signal can also be generated from 80000.
iTI40. o) Not accepted by all classification societies.
g) "Common shutdown" consists of following p) For GenSets with high voltage alternators.
signals: PSL22, TSH12, SSH81 and ZS82
(as option TSH29/27 for L27/38 or LSH92 for General) All alarm signals are already performed
L27/38 and L32/40). Furthermore it consist with necessary time delay. F.ex. lub. oil level
also of the redundant shutdowns performed in alarms (LAL/LAH28) includes 30 sec. alarm
the Base Module. delay. Start air alarm (PAL70) includes 15 sec.
alarm delay. No further delay are needed.
Table 3 (Block scanning)
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
oPAL70 Starting air press. low 4009 Digital Required
08028-0D/H5250/94.08.12
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 b)
oLAH28 High oil level base frame 4010 Digital Recommended
iZS75 Microswitch, turning gear engaged 4011 Digital Recommended b)
oSAH81 Overspeed alarm 4012 Digital Recommended
oTAD60 Exh. gas temp. high or low 4013 Digital Recommended m)
oTAH61 TC temp. outlet, high 4014 Digital Recommended
oTAH62 TC temp. inlet, high 4015 Digital Recommended m)
Cont.
06.44 - ES1
MAN Diesel

Description
General
Cont. of table 3
iTI12 HT water temp. outlet 4016 Integeter 12 Bit Recommended m) 0-200 C

iTI21/22 Lub. oil temp. inlet 4017 Integeter 12 Bit Recommended a) + m) 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 a) 0-200 C
iTI98-2 Alternator winding temp. 2 401A Integeter 12 Bit Recommended a) 0-200 C
iTI98-3 Alternator winding temp. 3 401B Integeter 12 Bit Recommended a) 0-200 C
iPI10 HT water press. inlet 401C Integeter 12 Bit Recommended a) + m) 0-6 bar
iPI22 Lub. oil press inlet engine 401D Integeter 12 Bit Recommended a) + m) 0-10 bar
iPI40 Fuel oil press. inlet 401E Integeter 12 Bit Recommended 0-16 bar
iPI70 Starting air pressure 401F Integeter 12 Bit Recommended a) 0-40 bar
oSX86-2 Safety sensor cable failure 4020 Digital Recommended i)
oSX83 Start failure 4021 Digital Recommended
Table 3 MODBUS block 1 (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 k)+l)
iSSH81 Overspeed stop 4045 Digital Nice to have
oZS96 Local indication 4046 Digital Nice to have
oZS97 Remote indication 4047 Digital Nice to have
oSA99 (Spare) 4048 Digital
oSS90A Engine running 4049 Digital Nice to have
iTE60-1 Exh. gas temp., cylinder 1 404A Integer 12 Bit Nice to have c) 0-800 C
iTE60-2 Exh. gas temp., cylinder 2 404B Integer 12 Bit Nice to have c) 0-800 C
iTE60-3 Exh. gas temp., cylinder 3 404C Integer 12 Bit Nice to have c) 0-800 C
iTE60-4 Exh. gas temp., cylinder 4 404D Integer 12 Bit Nice to have c) 0-800 C
iTE60-5 Exh. gas temp., cylinder 5 404E Integer 12 Bit Nice to have c) 0-800 C
iTE60-6 Exh. gas temp., cylinder 6 404F Integer 12 Bit Nice to have c) 0-800 C
iTE60-7 Exh. gas temp., cylinder 7 4050 Integer 12 Bit Nice to have c) 0-800 C
iTE61 Exh. gas temp. outlet TC 4053 Integer 12 Bit Nice to have d) 0-800 C
iTE62 Exhaust gas temp. inlet TC 4054 Integer 12 Bit Nice to have e) 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
08028-0D/H5250/94.08.12
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 TC press. 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 TC RPM pickup 405C Integer 12 Bit Nice to have n) 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, low 4061 Digital Nice to have
06.44 - ES1
MAN Diesel
Description
General
oSAH89 High TC rpm 40C2 Digital Nice to have m)

oTAH62-2 High exh. gas temp. before TC 40C3 Digital Nice to have m)
oTAH12-2 High cooling water temp. 40C4 Digital Nice to have m)
oTAH60-1 High exh. gas temp cyl. 1 40C5 Digital Nice to have m)
oTAH60-6 High exh. gas temp cyl. 6 40CA Digital Nice to have m)
oTAH60-7 High exh. gas temp cyl. 7 40CB Digital Nice to have m)
oTAH60-8 High exh. gas temp cyl. 8 40CC Digital Nice to have m)
oTAH60-9 High exh. gas temp cyl. 9 40CD Digital Nice to have m)
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 l)
Table 5 MODBUS block 3 (mutiple i/o) register addressing.
Individual scanning
oZS57 Earth connector & diff. protection 4090 Digital Nice to have p)
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
509.55 Description
Edition 09 Communication from the GenSet Page 8 (10)
General
Following signals are only available as option for engine type L27/38.
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 High bearing temp. shutdown 401CH Digital Nice to have
oTSH29/27A Common alarm main bearing temp. 401DH Digital Nice to have
oTSH29/27B Common alarm main bearing temp. 401EH Digital Nice to have
oUX29/27 Common cable failure 401FH Digital Nice to have
Table 6 MODBUS block 4 (mutiple i/o) register addressing.
Table 7 (Individual scanning of control signals)

Running hours C141 32 bit word 2 registers

08028-0D/H5250/94.08.12
Start via MODBUS C1C1 Digital o)

Stop via MODBUS C201 Digital o)
Start counter C241 32 bit word 2 registers
In fig 8 and 9 some examples of wiring are illustrated.

See also description "Guidelines for cable and wi-
ring" for further information.
06.44 - ES1
MAN Diesel
Description 509.55
Page 9 (10) Communication from the GenSet Edition 09
General
Engine type L16/24, L21/31, L27/38 or L32/40
08028-0D/H5250/94.08.12
Fig 8 MODBUS communication (RS 485 and RS 422).
06.44 - ES1
MAN Diesel

Description
General
Engine type L27/38 incl. bearing surveillance module
Fig 9 MODBUS communication (RS 485).
Comment: Always connect each engine with

separate serial cable to the alarm system. Do not
connect all auxiliary engines on one serial cable
connection.
08028-0D/H5250/94.08.12
06.44 - ES1
MAN Diesel
Working Card Functional Test and Adjustment of Safety, 509-01.00
Page 1 (2)
Alarm and Monitoring Equipment Edition 03H
L27/38

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
Working time : - hours Plate no Item no Qty/

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

99.11 - ES0
MAN Diesel
509-01.00 Functional Test and Adjustment of Safety, Working Card
Alarm and Monitoring Equipment
L27/38
Maintenance of Monitoring and Safety has to be under constant observation until it can be
Systems stopped.
One of the most important parameters of preventive It is recommended that all functions are tested every
work is that the alarm system, as well as the shutdown three months according to the mentioned working
and overspeed devices, are functioning 100%. cards.
If some of these functions are out of operation, they To check these functions, use the working cards
must be repaired immediately. If this is not possible mentioned under related procedure on page 1.
because of the current working situation, the engine
08028-0D/H5250/94.08.12
99.11 - ES0
MAN Diesel

Page 1 (3) Function Test of Shutdown Edition 07
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.
Starting position
Functional test and adjustment of safety

alarm and monitoring equipment 509-01.00
Related procedure

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

04.29 - ES0
MAN Diesel

Edition 07 Function Test of Shutdown Page 2 (3)
General
It is of the utmost importance that the shutdown
function is working properly.Therefore, the shutdown
function must be tested at regular intervals according
to the planned maintenance programme 500.25.
Function Test of Overspeed Shutdown
1) Start the engine locally and keep it at no load,

at nominal rpm:
Engine Type rpm
L16/24 1000 or 1200

L27/38 720 or 750
L21/31 900 or 1000
V28/32S 720 or 750
2) Take a large spanner and put it on the link bet-

ween fuel-rack and governor. Slowly force the
engine rpm over the setpoint, see Description
500.30 and the overspeed will release.
Fig 1 Pressure controller
Warning: Do not raise the speed over 120% of no-
minal speed because this could damage the
valves and pistons.
Function Test of Low Lubricating Oil Pres-
The engine must stop. sure Shutdown
3) Reset the overspeed shutdown on the operation 4) Start the engine and keep it at no load.
box.
5) Mount the manometer/test pump on the test
valve outlet, situated right under the pressostate
Adjustment PSL 22, fig 1.
Correct detection of RPM (counting of teeths) de- 6) Close oil pressure valve, fig 1.
pends on the size of the gap between the movable
flywheel and the front of the pick-up sensor. If no or 7) Relieve the pressure slowly and check that the
08028-0D/H5250/94.08.12
wrong signal is detected by the sensor, the measuring switch changes back to the pressure stated as
gap must be adjusted or cleaned. the shutdown point, see 500.30.
The gap is expected to be 2.0 mm 0.3 mm (the The engine must stop.
pitch of the thread on the pick-up is 1.0 mm). The
number of teeth relative speed values/limits can be Note: If adjustment is needed, turn the screw clock-
found in the Engine Automatic diagram, section 509 wise or anticlockwise, see fig 2.
and description 500.30 in section 500.
8) Disconnect the manometer/test pump.
The overspeed shutdown limits can not be adjusted
by the user.
04.29 - ES0
MAN Diesel

Page 3 (3) Function Test of Shutdown Edition 07
General
9) Open the oil pressure valve on the pressure
block.
Protection
cap
10) Reset the low lubricating oil pressure shutdown
on the operation box.
Function Test of High Fresh Water

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

out according to the following procedure.
Fig 3 Thermostate
15) The sensor is mounted again.
16) Reset the high H.T. water temperature shut-

down on the operation box.
Alarm System
Fig 2 Adjustment of pressostate and thermostate
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
11) Take the sensor out of the pocket. all engine crew members are
familiar with and well trained in the use and impor-
12) Test the sensor in a water bath, which is con- tance of the alarm system.
trolled by the temperature or a special testing The most serious alarms are equipped with slowdown
device. and/or shutdown functions.
13) Start the engine and keep it at no load.
14) Raise the temperature until the switch chan-

ges and check that it happens at the stated
shutdown point, see 500.30.
08028-0D/H5250/94.08.12
The engine must stop.
Note: If adjustment is needed, remove the thermostat

cover. Locking screw pos. 5, fig 3, is loosened, and
the range can be set with the spindle, pos. 1, while
the scale, pos. 2, is read at the same time.
04.29
MAN Diesel
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

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

02.20 - ES0
MAN Diesel
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
MAN Diesel
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

Capacity : 1 man
Data

04.06 - ES0
MAN Diesel
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
MAN Diesel
Page 1 (2) Adjustment and test of tacho and proximity sensors Edition 01
L21/31

Shut off starting air
Shut off cooling water
Shut off fuel oil
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

04.04 - ES0
MAN Diesel
Edition 01
Adjustment and test of tacho and proximity sensors Page 2 (2)
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
MAN Diesel
Page 1 (3) Adjustment of Lambda Controller Edition 10H
L27/38

Shut off starting air
Shut off cooling water
Shut off fuel oil
Adjustment of lambda controller. Adjustablle spanner, 10"-12".
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

01.41 - ES0
MAN Diesel
Edition 10H
Adjustment of Lambda Controller Page 2 (3)
L27/38
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 on the regulating arm
is min. 1 mm, see fig 1.
Fig 3 Lambda Controller
2) Turn the lever (fig 2) of the governor a few

times to full load with an adjustable spanner
(spring between governor and fuel rack full
com-pressed). Check that the fuel index is 28
at the fuel pump.
3) In case of large deviation from index 28 ad-

Fig 1 Check of free space
justment is done by turning the regulating arm
(4), fig 3. Finally adjustment is done at the
adjustment screw (3), fig 3.
4) Adjustment completed.
Adjustment of the Stop Screw
5) Remove pipe for charge air pressure.

08028-0D/H5250/94.08.12
6) Supply air pressure until the piston rod reaches

its upper position.
7) Turn the lever (fig 2) of the governor to full load

with an adjustable spanner. Adjust the stop
screw (fig 2) to 110 % load (stationary 100%)
according to the test bed, plus 1.5 index. Use
the index arm on the fuel injection pump nearest
to the lambda controller as the control for the
index.
8) Adjustment completed.
Fig 2 Adjustment of the stop screw
01.41 - ES0
MAN Diesel
Page 3 (3) Adjustment of Lambda Controller Edition 10H
L27/38
Adjustment of Start Index, only if mounted
After adjustment of the lambda index the start index

must be adjusted.
Force the piston by the screw on the back, see fig 4.

Check that the index is 18 mm. Adjustment is made
on the self-locking nut on the back of the lambda
controller, see fig 4.
Note : In case of start failure due to wear of the fuel

pump, the start index must be raised to a higher level
by turning the self-locking nut anticlockwise. Fig 4 Adjustment of start index
08028-0D/H5250/94.08.12
01.41 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 50901-07H
L27/38
08028-0D/H5250/94.08.12
02.37 - ES0
MAN Diesel
Plate
50901-07H Governor and Governor Drive Page 2 (2)
L27/38
Item Item
033 1/E Plug screw Propskrue
045 1/E Gasket Pakning
069 4/E Screw Skrue
070 1/E O-ring O-ring
082 1/E Castle nut Kronemtrik
094 1/E Split pin Split
141 1/E Shim (set 0.1 - Mellemlg (st 0,1 -

0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)
153 1/E Disc Skive
165 1/E Ball bearing Kugleleje
177 1/E Bevel gear wheel Konisk tandhjul
212 1/E Housing Hus
236 2/E Pin Stift
261 1/E Screw Skrue
273 1/E Axle journal Akseltap
285 1/E Bush Bsning
307 1/E Gear wheel Tandhjul
319 1/E Screw Skrue
320 1/E Wear disc Slidskive
332 1/E Key Feder
356 /I Silastene Silastene
393 1/E Synchronizing motor Synchroniseringsmo-

tor
403 1/E Governor Regulator

08028-0D/H5250/94.08.12
415 4/E Screw Skrue
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
02.37 - ES0
MAN Diesel
Plate
L27/38
393
For governor,
see special
instruction book
403
415
141
153
165
190 177
200
356
069 094
082
070
427
045 212
033
08028-0D/H5250/94.08.12
236
319
332 320
297
273 307
261 285
05.38 - ES0
MAN Diesel
Plate
L27/38
Item Item
069 4/E Screw Skrue

0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)
153 1/E Disc Skive
212 1/E Housing Hus
236 2/E Pin Stift
261 1/E Screw Skrue
285 1/E Bush Bsning
319 1/E Screw Skrue
332 1/E Key Feder
393 1/E Synchronizing motor Synchroniseringsmo-

tor
403 1/E Governor, Europa Regulator, Europa

08028-0D/H5250/94.08.12
415 4/E Screw Skrue
05.38 - ES0
MAN Diesel
Plate
L27/38
403
For UG-Actuator,
415
see special
instruction book
141
153
165
190 177
200
356
069 094
082
070
427
045 212
033
08028-0D/H5250/94.08.12
236
319
332 320
297
273 307
261 285
06.04 - ES0
MAN Diesel
Plate
L27/38
Item Item
069 4/E Screw Skrue

0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)
153 1/E Disc Skive
212 1/E Housing Hus
236 2/E Pin Stift
261 1/E Screw Skrue
285 1/E Bush Bsning
319 1/E Screw Skrue
332 1/E Key Feder
403 1/E Actuator, Woodward Aktuator, Woodward
415 4/E Screw Skrue

08028-0D/H5250/94.08.12
06.04 - ES0
MAN Diesel
Plate
Page 1 (2) Regulating Device 50902-05H
L27/38
399 280
387 409
434* Pick-up, see plate 50907/276
410
375 292
302
255 243 279

135 674
172 159
160 231 686
147 674 267
088 184 206

196 218
08028-0D/H5250/94.08.12
111
123
064
314 338 363 027 040 076 088
326 351 015 039 052
06.05 - ES0
MAN Diesel
Plate
50902-05H Regulating Device Page 2 (2)
L27/38
Item Item
015 Bearing bracket, com- Konsol, komplet inkl. 279 1/C Ball joint Kugleled
plete incl. bush bsning
6/E 5 cyl. engine 5 cyl. motor 280 5/E Nut Mtrik
8/E 7 cyl. engine 7 cyl. motor 292 1/E Bracket Konsol
10/E 9 cyl. engine 9 cyl. motor 302 4/E Screw Skrue
027 Screw Skrue 314 1/E Shaft, 5 cyl. engine Aksel, 5 cyl. motor
14/E 6 cyl. engine 6 cyl. motor 326 1/E Shaft, 6 cyl. engine Aksel, 6 cyl. motor
18/E 8 cyl. engine 8 cyl. motor 338 1/E Shaft, 7 cyl. engine Aksel, 7 cyl. motor
351 1/E Shaft, 8 cyl. engine Aksel, 8 cyl. motor
039 1/E Setting ring Justerring
363 1/E Shaft, 9 cyl. engine Aksel, 9 cyl. motor
040 1/E Spring pin Fjederstift
375 4/E Lock washer Lseskive
052 1/E Sleeve Bsning
387 1/E Cylinder, complete Cylinder, komplet
064 1/E Lever Arm
399 4/E Screw Skrue
076 1/E Screw Skrue
409 1/E Stop screw Stopskrue
410 1/E Lever, complete Arm, komplet
111 1/E Screw Skrue
434* 1/E Repair kit for item Reservedelsst til item
123 1/E Nut Mtrik 387, 387, bestende af:
consisting of: 1 stk. fjeder
135 2/C Bult strap Bjle 1 pc spring 2 stk. pakning til stempel
2 pcs gasket f/piston 2 stk. pakning til ende-
147 1/C Clamping piece Spndestykke 2 pcs end cover dksel
gasket 1 stk. kombineret
159 1/C Screw Skrue 1 pc combined scraper skrabe- og ttningsring
and sealing ring 1 stk pakning uden krave
160 2/C Spring pin Fjederstift 1 pc gasket without col-
lar
172 1/C Spring pin Fjederstift
674 2/C Nut Mtrik
184 1/C Sleeve Bsning
686 1/C Nut Mtrik
206 1/C Screw Skrue
218 2/C Screw Skrue
231 2/C Self locking nut Selvlsende mtrik

08028-0D/H5250/94.08.12
243 1/C Screw Skrue
255 1/C Tension spring Trkfjeder
267 1/C Articulated head Svinghoved
06.05 - ES0
MAN Diesel
Plate
Page 1 (5) Instruments 50907-20
L27/38
Length Item
Fig. Range Code
L mm L1 mm no
70 - 120C 99 82 TSH 12 012

L1
L
Thermostat
1 - 10 bar 90 30 PSL 22 036
L
08028-0D/H5250/94.08.12
L1
Pressure control
08.08 - ES0
MAN Diesel
Plate
50907-20 Instruments Page 2 (5)
L27/38
Length Item
Fig. Range Code
L mm L1 mm no
0 - 4 bar 90 30 PT 23 048
PT 31
0 - 6 bar 90 30 PT 10 085
PT 01
L
0 - 10 bar 90 30 PT 21 132
0 - 10 bar 90 30 PT 22
0 - 16 bar 90 30 PT 40 156
L1
PT 70 168
0 - 40 bar
Pressure transmitter
Female plug - see item 288
110 SE 90-1 181

0 - 20 kHz SE 90-2
Pick-up
55 SE 89 203
0 - 1 kHz
08028-0D/H5250/94.08.12
Pick-up
08.08 - ES0
MAN Diesel
Plate
L27/38
Length Item
Fig. Range Code
L mm L1 mm no
0 - 1 kHz 22 ZT 88 276
Pick-up
0 - 160C 63 110 TE/TI 12 359

L1
L
Thermometer
0-160C 63 174 TE/TI 40 396

L1
08028-0D/H5250/94.08.12
Thermometer
(Female plug - see item 288)
08.08 - ES0
MAN Diesel
Plate
50907-20 Instruments Page 4 (5)
L27/38
Length Item
Fig. Range Code
L mm L1 mm no
0 - 200C 300 TE 01 360
0 - 200C 80 TE 21 372
TE 31
L
Temperature sensor
0 - 800C 129 9000 TE 60 431

L1
0 - 800C 69 9000 TE 61 443

TE 62
Temperature sensor
7000 TE 29 479
08028-0D/H5250/94.08.12
Temperature sensor
08.08 - ES0
MAN Diesel
Plate
L27/38
Length Item
Fig. Range Code
L mm L1 mm no
0-6 bar 52.5 57 PI 10 480
0-16 bar 52.5 57 PI 22 492

PI 40
Manometer
L1 26.5 50 288
Female plug with cable relief
0-120C 90 100 TI 10 311

08028-0D/H5250/94.08.12
Thermometer
08.08 - ES0
MAN Diesel
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-03H
L27/38
08028-0D/H5250/94.08.12
02.11 - ES0
MAN Diesel
Plate
50920-03H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
L27/38
Item Item
049 4/E Screw Skrue
050 2/E Nut Mtrik
062 1/E Plate Plade
098 1/E Pipe for level switch Rr for nivaeukontakt
108 1/E Level switch Niveaukontakt
121 1/E Pipe for level switch Rr for nivaeukontakt
169 1/E Dipstick, complete Pejlestok, komplet

182 2/E Red. adaptor Red. adapter
194 /I Glue Lim
204 1/E Cable union Kabelforskruning
216 1/E Terminal box Klemkasse
228 2/E Screw Skrue
241 1/E Parts for terminal Dele for klemrkke

strip
253 2/E Screw Skrue
265 1/E Pipe Rr
277 2/E Angle union Vinkelforskruning
289 1/E Pipe Rr
290 1/E Pipe Rr
300 1/E Pipe Rr

08028-0D/H5250/94.08.12
02.11 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-07
L21/31, L27/38
V28/32S
A-A 058
022 010
034
416
046
404
C C
333 178
345 333
286 357
C-C
382 369
08028-0D/H5250/94.08.12
394 370
06.47 - ES0
MAN Diesel
Plate
50925-07 Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L21/31, L27/38
V28/32S
Item Item
010 1/E Fuel oil leakage Br.olielkagealarm

alarm
058 1/E Hose connection Slangeforbindelse
178 1/E Repair kit for Reparationsst for

running in filter indkrselsfilter
286 4/E Screw Skrue
345 1/E Packing ring Pakningsring
416 /I Glue Lim
08028-0D/H5250/94.08.12
06.47 - ES0
MAN Diesel
Plate
Page 1 (2) Monitoring Box 50935-20H
L27/38
Front view
015
505 027
To check software version

push lamp test for 3-5 sec.
The display will indicate
the software no.
039
135
292
302
314
338
351
Inside view Diagnose led
064
196
375
184
387
399
08028-0D/H5250/94.08.12
409
410
495
471
363
Led sensor
power
07.44 - ES0
MAN Diesel
Plate
50935-20H Monitoring Box Page 2 (2)
L27/38
Item Item
015 1/E Operation box (OB) Operation box (OB)

without oil mist de- uden olietgedetektor
tector
027 1/E Monitor temp./press. Monitor temp./tryk

(MTP) (MTP)
039 1/E Monitor exh. gas Monitor udst.gastemp.

temp. (MEG) (MEG)
064 1/E Base module (MB) Basemodul (MB)
135 1/E Panel (A1) Panel (A1)
184 1/E 5 pol connector 5 pol stik
196 3/E Resistor 120R Modstand 120R
292 19/E Cable union M16 Kabelforskruning M16
302 20/E Nut M16 Mtrik M16
314 1/E Hose connection Slangeforskruning
363 1/E Conduit Ledningskanal
471 2/E Fuse Sikring
495 1/E 5 pol double 5 pol dobbelt stik

connector
505 1/E Operation box (OB) Operation box (OB)

with oil mist detector med olietgedetektor
08028-0D/H5250/94.08.12
07.44 - ES0
MAN Diesel
Plate
Page 1 (2) Terminal Box 50936-18H
L27/38
Front view
453
465
477
489
490
500
536
To check software version:

Turn upper potentiometer to
3/4 position. 095
Observe diode no. Out 1 for
flashes. 345
F.ex. four flashes a pause of
1.5 sec. and one more flash Inside view 573
mean software version 4.1.
585
225 0
1
4
5
AC/DC OUT
2 6
3 7
DC INPUTS
ISOLATED RELAY
Allen-Bradley
250
0 4 8 12
1 5 9 13
2 6 10 14
3 7 11 15
DC/RELAY OUT
394 0
1
2
3
4
5
6 10
7 11
8
9
404
416
428
08028-0D/H5250/94.08.12
142
441 GND
GND
Label:
-X1 -X1 -X1 Safety system 3P1-5P1
-F4/0
-F4/1
-F4/7
-F4/8
548 GND
274
154
561
07.45 - ES0
MAN Diesel
Plate
50936-18H Terminal Box Page 2 (2)
L27/38
Item Item
095 1/E Safety system, Sikkerhedssystem,

Base unit Base unit
142 3/E Terminal, earth Jordklemme
154 6/E End stop Endestop
274 7/E End plate Endeplade
345 1/E Output module Outputmodul
394 4/E Fuse terminal Sikringsklemme
416 4/E Fuse 2A Sikring 2A
441 17/E Terminal 1 Klemme 1
536 1/E Panel A2 Panel A2
548 32/E Terminal double Klemme, dobbelt
573 1/E Processor unit (CPU) Processor unit (CPU)
585 1/E End cap Endestykke

08028-0D/H5250/94.08.12
07.45 - ES0
MAN Diesel
Plate
Page 1 (2) Digital Load Sharing & Speed Control 50945-03
General
08028-0D/H5250/94.08.12
04.03 - EO0-ny
MAN Diesel
Plate
50945-03 Digital Load Sharing & Speed Control Page 2 (2)
General
Item Item
021 1/E Digital load sharing & Digital speed

speed control control
08028-0D/H5250/94.08.12
Qty/Q = Qty/Plant Qty/Q = Qty/Anlg
04.03 - EO0-ny
MAN Diesel
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
MAN Diesel
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
MAN Diesel
Plate
Page 1 (2) Output Module 50947-05
L16/24
L21/31
L27/38
083
201 225
213 237
262
274
095
105
OUTPUT MODULE 117
130
142
250
08028-0D/H5250/94.08.12
J11 J13 J6 J7 J2 J3 J1 J14
J12 J4 J5 J8 J9 J10
07.33 - EO0
MAN Diesel
Plate
50947-05 Output Module Page 2 (2)
L16/24
L21/31
L27/38
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 Mtrik
225 2/E Cable union Kabel forskruning
237 2/E Nut Mtrik
262 2/E Cable union Kabelforskruning
274 2/E Nut Mtrik
08028-0D/H5250/94.08.12
07.33 - EO0
MAN Diesel
Plate
Page 1 (2) APM Motor Control 50948-01
General
08028-0D/H5250/94.08.12
98.13 - EO0
MAN Diesel
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
MAN Diesel
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
MAN Diesel
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, bl
035 4/E Lamp holder Lampefatning
047 6/E Glow lamp Gldelampe
059 4/E Head, black Trykknap, sort
060 4/E Body Krop
072 4/E No contact block Sluttekontakt
084 10/E Auxillary relay Hjlperel
096 10/E Socket Sokkel
106 1/E Bridge rectifier Ensretterbro
118 1/E Transformer Transformer
131 12/E Fuse terminal Sikringsholder
08028-0D/H5250/94.08.12
98.16 - EO0-ny
MAN Diesel
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
MAN Diesel
Plate
50956-01 Converter Page 2 (2)
General
Item Item
021 1/E Coverter Converter
033 1/E Cable, length 1.8 m Kabel, lngde 1.8 m
045 1/E Cable, length 10 m Kabel, lngde 10 m
08028-0D/H5250/94.08.12
07.37 - ES0
MAN Diesel
Plate
Page 1 (2) Oil Mist Detector 50960-02
L21/31
L27/38
059
08028-0D/H5250/94.08.12
07.37 - ES0
MAN Diesel
Plate
50960-02 Oil Mist Detector Page 2 (2)
L21/31
L27/38
Item Item
059 1/E Oil mist detector Olietgedektor
08028-0D/H5250/94.08.12
07.37 - ES0
MAN Diesel
Plate
Page 1 (2) Oil Mist Detector 50960-01H
L27/38
08028-0D/H5250/94.08.12
00.40 - ES0
MAN Diesel
Plate
50960-01H Oil Mist Detector Page 2 (2)
L27/38
Item Item
011 Housing Hus

023 Screw Skrue

035 4/E Screw Skrue
08028-0D/H5250/94.08.12
00.40 - ES0
Crankshaft
510/610
MAN Diesel
Description
Crankshaft and Main Bearings 510.01
L27/38
Crankshaft and Main Bearings Vibration Damper
The crankshaft, which is a one-piece forging, is sus- A vibration damper is mounted on the crankshaft
pended in underslung bearings. The main bearings to limit torsional vibrations. The damper consists of
are of the rillenlager type, which are coated with a a primary and a secondary part. Between these,
running layer. To attain a suitable bearing pressure groups of leaf spring packs are arranged, which are
and vibration level the crankshaft is provided with clamped at their outer ends.
counterweights, which are attached to the crankshaft
by means of two hydraulic screws. These spring packs form, together with the primary
and secondary members, chambers which are filled
At the flywheel end the crankshaft is fitted with a with oil. If the exterior member vibrates in relation
gear wheel which, through two intermediate wheels, to the inner member, the leaf springs are bent and
drives the camshafts. force oil from one chamber into another, retarding
the relative movement of the two parts and thus
Also fitted here is a coupling flange for the connec- damping the torsional vibration. In order to protect
tion of an alternator. At the opposite end (front end) the leaf springs against overloading, their deflection
there is a gear wheel connection for lube oil and is limited by buffers.
water pumps.
The elasticity is determined by careful choise of the
Lubricating oil for the main bearings is supplied leaf springs, the damping factor by the gap between
through holes drilled in the engine frame. From primary and secondary members.
the main bearings the oil passes through bores in
the crankshaft to the big-end bearings and thence
through channels in the connecting rods to lubricate
the piston pins and cool the pistons.
08028-0D/H5250/94.08.12
02.17 - ES0
MAN Diesel
Page 1 (7) Checking of Main Bearings Alignment (Autolog) Edition 14H
L27/38
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off fuel oil
Description:
Checking of main bearings alignment (autolog).
Starting position: Hand tools:
Turning gear in engagement. (If mounted).

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

Capacity : 2 men
Data:

05.26 - ES0
MAN Diesel
Edition 14H Checking of Main Bearings Alignment (Autolog) Page 2 (7)
L27/38
Procedure
1) Remove the side covers from the crank ca-

sing.
2) Turn the crankshaft to bring the crank web for

cylinder no 1 to position X, see fig 8.
3) Place the dial gauge in the punch marks in the

counterweight, see fig 1.
4) Adjust the dial gauge to 0.
5) Turn the crankshaft to position P, T, S and Y and

read the dial gauge in each position and fill in
the form Checking of Main Bearing Alignment
(Autolog), page 6 and 7. Fig 1 Placing of dial gauge
6) Repeat the procedure on the remaining crank

webs.
7) Compare the values to earlier values taken

after the sea trial.
8) Please contact us if the values exceed the

values shown in this Working Card.
08028-0D/H5250/94.08.12
05.26- ES0
MAN Diesel
L27/38
Deflection of crankshaft in 1/100 mm. (0.01 mm).
Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig 4
Left side P 2 0 2 0 -1 2
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Bottom stop Y 2 -1 0 1 0 2 Right side - left side

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

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

"Closing" of the crankthrow is considered Start in position X.
negative. Turn anti clockwise
Fig 7 Fig 8
05.26 - ES0
MAN Diesel
510-01.00 Checking of Main Bearings Alignment (Autolog) Working Card

L27/38
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 displa-
ced 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 exceed + or 8/100 mm
08028-0D/H5250/94.08.12
05.26 - ES0
MAN Diesel

L27/38
Vertical deflection of crank throw nearest flywheel
Flexible coupling between diesel engine and driven machine
- New or recently overhauled engine, norminal + 8/100 - 20/100 mm

- New or recently overhauled engine, max. + 15/100 - 23/100 mm
- Operating engine, check alignment immediately + 22/100 - 25/100 mm
Flexdisc between diesel engine and driven machine
- New or recently overhauled engine, max. + 0/100 - 35/100 mm
Vertical deflection of crank throws remaining
Flexible coupling between diesel engine and driven machine
- New or recently overhauled engine, norminal + or 8/100 mm

- New or recently overhauled engine, max. + or 15/100 mm
- Operating engine, check alignment immediately + or 22/100 mm
Flexdisc between diesel engine and driven machine
- New or recently overhauled engine, norminal + or 8/100 mm

- New or recently overhauled engine, max. + or 15/100 mm
08028-0D/H5250/94.08.12
- Operating engine, check alignment immediately + or 22/100 mm
05.26 - ES0
MAN Diesel
510-01.00 Checking of Main Bearings Alignment (Autolog) Working Card

L27/38
Process/Proces I.D. no.
Plant/Anlg Page of/Side af
Engine Type/Motortype Engineer/Operatr Date/Dato
Instruction/Instruktion
Top
Right side Left side
Bottom end/ Bottom start/

1/100 mm Bund slut Bund start
Right side
Cyl. no 1 2 3
Left side
Remarks/Bemrkninger
08028-0D/H5250/94.08.12
05.26 - ES0
MAN Diesel

L27/38
Component/Komponent Type I.D. no.
Process/Proces Page of/Side af
Test place/ Test bed/prvehal Cold/Kold

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

side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
05.26 - ES0
MAN Diesel
Page 1 (4) Inspection of Main and Guide Bearing Shells Edition 10H
L27/38

Shut-off fuel oil 52001 036 (Extra tool)
Description
Dismantling, inspection and/or replacement and

mounting of main and guide bearing shells.
Engine out of operation Allen key, 12 mm

Socket spanner, 36 mm
Lead hammer
Silastene
Copaslip
Related procedure
Criteria for replacement of bearings, 506-01.16


08028-0D/H5250/94.08.12

Capacity : 2 men
Data

Data for tightening torque (Page 500.40)
05.10 - ES0
MAN Diesel
Edition 10H Inspection of Main and Guide Bearing Shells Page 2 (4)
L27/38
Dismantling of Main Bearing
1) Dismantle the crankcase covers on both sides

of the engine fore and aft of the main bearing
in question.
2) Turn the engine until the crank is in a convenient

possition for carrying out the work.
3) Install the hydraulic tool on the side tie rods for

the main bearing cap to be lowered. Loosen
and remove the nuts (1), see fig 1. Leave the
rods in to avoid that the main bearing cap
drops down when removing the nuts for the
main bearing cap.
Seen from above
To pump
To pump
Fig 2 Installing lifting tool on main bearing cap
1 2 2 1
7) Slacken the tackle until the lifting tool is resting

Fig 1 Hydraulic tools mounted on tie rods against the engine frame.
8) Remove the lower bearing shell from the bear-

ing cap.
4) Install the hydraulic tool on the tie rods for the
main bearing cap inside the crankcase. Loosen 9) Press the tool for turning the upper bearing
and remove the nuts (2), see fig 1. half out into the lubricating oil bore in the crank
journal, see fig 3.
5) Install the lifting tool for the main bearing cap,
08028-0D/H5250/94.08.12
see fig 2 10) Turn the upper bearing half out by turning the
crankshaft.
6) Place a tackle above the handles of the two
lifting tools. Connect it to the handle and pull
tight to carry the weight of the main bearing
cap an screw the side stay bolts out.
05.10 - ES0
MAN Diesel
Working Card
Inspection of Main and Guide Bearing Shells 510-01.05
L27/38
16) Lift the bearing cap into position by means of
the tackle and screw the side studs in by hand.
Turning out Add some liquid sealing compound to the nuts
bearing to seal against the frame and screw on the nuts
but do not tighten.
17) Fit the nuts on the tie rods for the main bearing
cap in the crankcase.
18) The lifting tool for the main bearing cap can
now be removed.
Turning in 19) Mount the hydraulic jacks according to

bearing
Working Card 520-01.06.
20) Tighten the tie rods with a pressure of, see

Data for tightening torque description 500.40,
step 1 and turn the nuts against the frame.
21) Tighten the side tie rods with a pressure of see

step 1 and turn the nuts against the bearing
Fig 3 Using turning-out tool cap.
22) Tighten the tie rods with a pressure of, see

Mounting of Main Bearing step 2 and turn the nuts against the frame.
11) Carefully wash the new bearing in diesel fuel 23) Tighten the side tie rods with a pressure of see
to remove the preservation. Data for tightening torque description 500.40,
12) Add oil to the bearing surface of the upper cap.
bearing shell and slide it by hand into position
as far as possible. Make sure that the bear- 24) Release the pressure completely and rise the
ing is placed in the middle of the longitudinal pressure once again on the tie rods to, see
direction of the bearing bore. Data for tightening torque description 500.40,
13) If the bearing cannot be brought into correct cap.
position by hand, the tool for turning out the
bearing can be used to turn in the bearing. 25) Release the pressure and remove the hydraulic
make sure the joint faces of the bearing shell tools.
08028-0D/H5250/94.08.12
and the frame are in line.

26) Release the pressure completely and rise
14) Add oil to the bearing surface of the lower the pressure once again on the side tie rods
bearing shell and place it in the main bearing to, see Data for tightening torque description
cap. Make sure the joint faces of the bearing 500.40, step 2 and turn the nut against the
shell and the bearing cap are in line. engine frame.
15) Add molykote paste to the surface around the 27) Release the pressure and remove the hydraulic
hole for the side tie rods on the main bearing tools.
cap.
05.10 - ES0
MAN Diesel
Edition 10H Inspection of Main and Guide Bearing Shells Page 4 (4)
L27/38
Dismantling of guide bearing
All 4 thrust ring halves are identical.
Check or replacement of the thrust rings is carried out,

when checking or replacing the aft main bearing.
Before lowering the aft main bearing cap, as described

under "Dismantling of main bearing", the crankshaft
must be moved a little axially to make sure there is
noe axial force on the fore or aft thrust rings.
Lower thrust ring

Dismantling of thrust rings
28) When lowering the main bearing cap, care Fig 4 Guide bearing
must be taken that the lower thrust rings do
not drop into the oil pan.
29) The fore and aft upper thrust rings have come
down a little at the same time as the main bear-
ing cap was lowered and can easily be turned
out while the main bearing cap is resting in the
lifting tools.
Installation of thrust rings
30) The upper fore and aft thrust rings can easily
be turned in if the crankshaft is in the right axial
position.
31) Leave the two halves hanging over the main
journal with the joint faces in horizontal posi-
tion.
32) Add some grease to the back of the lower

thrust rings and place the thrust rings on the
main bearing cap. Make sure the guide flaps
are located in the grooves machined in the
bearing cap.
08028-0D/H5250/94.08.12
33) Lift the bearing cap and assemble as described

under "Mounting of main bearing".
34) For min./max. axial guide bearing clear-

ance and min./max. radial main bearing, see
description 500.35.
05.10 - ES0
MAN Diesel

Page 1 (3) Vibration Damper Edition 04H
L27/38

Shut-off fuel oil
Starting position
Related procedure


08028-0D/H5250/94.08.12
Working time : 4-8 hours Plate no Item no Qty /

Capacity : 1 man
See plate 51004.
Data

02.49 - ES0
MAN Diesel

Edition 04H Vibration Damper Page 2 (3)
L27/38
Maintenance Note: If it is inevitable to separate outer part from
inner part, please pay attention to the marking on
When the angle of twist between the damper's in- these parts.
ner
and outer parts does not exceed the permissible After disassembly, please check all individual
and the damper is supplied with sufficient oil (under parts.
pressure) from the engine then the sleeve-spring
packets will not be endangered. Prior to installing the spring packages and the bolts
please check, whether the outer part can be turned
The recommended inspection interval is 32,000 easily with respect to the inner part.
operating hours. At this interval it is recommended
to renew the complete sleeve-spring packet (keys
and bolts). Mounting of the sleeve-spring packets
4) Position again the sleeve-spring packets so,
An earlier inspection is necessary when unusual that there is a through control groove at the
noise radiates from the neighbourhood of the damper inner side of the radial gap.
or if metal deposits, which would indicate sleeve-
spring wear. 5) Check with the bolts that the lateral surfaces
of the butt rims are clean and smooth.
If, during the life of the damper, a sleeve spring fracture
occurs the complete sleeve-spring packet must Note: If any burrs have been formed, they must be
be replaced not only the individual spring. removed.
To provide access to the damper, the front end box Note: It is important that during assembly, the with
must be removed. Further the hydraulic nuts and the MoS2 greased sleeve-spring packets together with
gearwheel must be dismounted. their respective central bolster are replaced in their
original position.
Manual inspection of the Vibration Damper It is possible that "polished" areas on the side plates or
inspection covers respectively are visible:This will not
1) Remove the side plates or the inspection negatively influence the working of the damper.
co-vers to gain access to the sleeve spring
packets. Further inspections of the damper can be made in
conjunction with any major maintenance work that
2) Remove the central bolster and use a hook to has to be done on the engine.
extract the sleeve spring packets.
If however, for example, the oil supply to the damper
3) Strip down the sleeve-spring. Clean and check is for som reason interrupted, it is necessary to in-
each sleeve for cracks. spect the damper.
Small "polished" areas on the surfaces of the sleeves

08028-0D/H5250/94.08.12
are normal and therefore replacement is not required.

Any cracked sleeve cannot be individually re-
placed: the complete sleeve-spring packet must
be renewed.
02.49 - ES0
MAN Diesel
L27/38
During any damper inspection, it is important to check The damper should be inspected if, on any bearing in
the oil supply and thoroughly clean the oil supply the crankshaft or gearbox, damage occurs that can
lines. The lubrication properties of the oil are severly be attributed to water content in the oil. Oil-shudge
reduced when the water content, especially salt-water can, due to the centrifugal effect, be deposited in the
is high. To prevent corrosion of the sleeves the water damper's spring chamber. This can have an adverse
content in the oil should not exceed 0.1 Vol %. effect on the damper.
Vibration damper, gearwheel and front end box is

mounted in reverse order of dismounting.
Fig 1 Installation / inspection condition of vibration damper.

08028-0D/H5250/94.08.12
02.49 - ES0
MAN Diesel

L27/38

Shut-off fuel oil
Inspection
Starting position
Related procedure
Working time : x hours Plate no Item no Qty /

08028-0D/H5250/94.08.12
Capacity : 1 man
See plate 51004
Data

02.37 - ES0
MAN Diesel
L27/38
- Grease carefully all O-rings (850 ,851) and
Damper dismounting
the appropriate grooves with Klber PETAMO
GHY 133N or equivalent
- Withdraw the crankshaft bolts (do not remove
- Insert O-rings (850 and 851) into the appropri-
them)
ate grooves in flange (5) and side plate (7)
- Mount the lifting appliances (730) onto the
- Coat inner-star (9) running surface of O-ring
damper and suspend the damper on the
(850) carefully with Klber PETAMO GHY
crane.
133N paste or equivalent
- Remove the crankshaft bolts
- Coat rest of inner-star (9) with ANTICORIT
- Insert forcing bolts into the damper inner
OHK 380A or equivalent
star (9) and push back the damper from the
- Apply MOLYKOTE 1000 paste or equivalent to
crankshaft flange slowly and evenly
the threads of the damper main bolts (750)
Attention ! Do not damage or injure the
centering shoulders and sealing surfaces
Assembly
during dismounting !
- Place flange plate (5) onto the centering table
- Rest damper onto lateral plate (5). (damper
(O-rings are visible)
centre line vertical)
- Place spring assembly (1, 2, 3) onto the flange
plate (5)
Disassembly of the damper
- Insert inner-star (9)
Attention ! Open damper main bolts (750) only - Place lateral plate (7) onto spring assembly
if it is required (e.g. for a total spring inspection) (1, 2, 3)
The concentricity setting of the damper outer - Center flange plate (5), spring assembly (1, 2,
member will be lost, if no centering shoulders 3) and lateral plate (7) according to the permis-
exist between the spring assembly (1,2,3) and sible concentricity values as stated on Fig 1.
lateral plates (5, 7)
NOTE ! An excess of 30% of the stated circu-
- Rest damper onto lateral plate (5). (damper
larity value is still permissible, if no unbalance
centre line vertical)
problems arise from that.
- Remove damper main bolts (750)
- Remove lateral plate (7)
- Apply enough LOCTITE (type see assembly
- Remove spring assembly (1, 2, 3)
drwg.) onto both sides of the disk spring
- Remove inner star (9)
(810).
Now a complete inspection of the damper can
be carried out. Attention ! The disk springs (810) and the
apropriate seat-engaging surfaces must be
Attention ! The exchange of damaged or worn dry and free of grease (oil)
spring packs(1) requires dismounting and refit-
ting of the clamping ring (3). Such work is to be - Mount the damper main bolts (750) according
carried out only at the manufacturers works or to the following mounting instructions:
by a Geislinger service specialist
- Surfaces must be cleaned (degreased).
- Enough specified Loctite must be applied to
08028-0D/H5250/94.08.12
Assembly of the damper

both sides of all marked disc springs (wash-
ers), see Fig 1.
- Tighten bolts according to table (tolerance
Preparations prior to assembly
+10%).
- Clean every single part carefully.
Attention! Values for tightening torques or initial
Attention ! All oil supply and venting holes
tightening torques are valid only if the stated
must be clean and free of dirt
thread and disc spring treatment according to
- Exchange all seals (O-rings...)
table is applied!
- Exchange all disc springs (810) of the damper
main bolts (750)
02.37 - ES0
MAN Diesel
L27/38
If twist angle is stated: Apply enough LOCTITE 243 onto both sides of
the disk springs (810) and mount the damper
- Tighten bolt until disc spring rests just flat on main bolts (750)
flange or with stated initial tightening torque.
Check the concentricity settings (Repeat the as-
- Then turn bolt head further through the stated sembly of the damper outer member again if the
twist angle. permissible concentricity values are exceeded.
Twist angle Thread Disc spring

Inspection
42 Molycote Loctite 243
Oil quality / engine oil change

- Check the concentricity settings, see Fig 1
again. Check the oil quality at regular intervals. Bad oil
quality or a water mix - especially seawater - with
Attention ! An excess of 30% of the stated circularity the engine oil can cause damage to the damper.
value is still permissible, if no unbalance problems That reduces the life time of the damper rapidly.
arise from that. Exceeding this limit requires remount-
ing and correction to obtain better values. Carry out the required activities according to chapter
14 if bad oil quality is present or an oil change is to
Remove damper main bolts (750) be carried out.
Exchange disc springs (810) and clean the

apropriate seat-engaging surfaces. All seat-
engaging surfaces must be dry and free of
grease (oil))
0.2 C
0.1 C
Loctite
Item
08028-0D/H5250/94.08.12
No
Fig 1 Damper
02.37 - ES0
MAN Diesel

L27/38
Total inspection of the damper
Carry out a total inspection according to the
0.1 x d
- given inspection intervals
- and the inspection instructions
Permissible wear of the damper items
O-ring d
The total wear must not exceed 10 % of the rope

diameter d (see fig 2). Fig 2 O-ring
The total wear is the sum of

- the wear of the O-ring
- the depth of the run-in grooves on inner star
INSPECTION INTERVALS AND INSTRUCTIONS

Inspection intervals in service hours based on normal service conditions
28.000 30.000 40.000 60.000

kind of inspection kind of inspection
dismount damper. carry out a 30.000 service hours inspection

separate damper inner member from damper.
outer member (do not disassemble damper carry out additionally :
spring assembly).
clean all parts, especially oil supply.- and disassemble damper outer member
venting holes. service or replacement of spring packs and in-
replace all accessible rubber seal rings. ner star, see Fig 3
replace all disc springs and lockwashers of
the dismounted bolts. ATTENTION !
check the permissable wear according to A disassembly of the damper outer member is to
"Permissible wear of the damper items. be carried out by a Geislinger service station or by
parts which are exposed to wear may have to Geislinger
be refurbished or exchanged if required
If an inspection should show that more than 50% of the wear limits have been consumed wi-
08028-0D/H5250/94.08.12
thin one inspection interval only, the following inspection interval is to be reduced in time by
assuming a linear wear rate
The inspection intervals are depending on the different specific

operating conditions.
NOTE:
Regular inspection and supervision of the damper allows for advanced planning and the orde-
ring of spare parts in time !
02.37 - ES0
MAN Diesel

L27/38
+ the depth of the run-in grooves on the lateral The further the measuring wedge can be pressed
plates ( 5 or 7 ) between the spring blades the greater is the wear of
the inner star groove and the spring blades.
- O-Ring nominal diameter d = 8 mm
NOTE: Half wedge length means half wear, three-
Inner star groove - inner ends of the spring quarters wedge length means three-quarters wear,
blades and so on.
Replace inner star and spring packs if the measuring
The total wear inner star groove / inner ends of spring
wedge can be pressed between the spring blades
blades - must not exceed the value w as stated in
over the total wedge length.
Fig 5.
Testing tool
Operating Conditions
A measuring wedge is to be used as a testing tool.The
- Required oil pressure at oil inlet of damper:
measuring wedge is to be produced by the customer
according to torsional vibration calculation
if no measuring wedge is supplied by Geislinger.
- Permissible ambient temperature:
Use the following sketch to produce a measuring
-20C bis 120C
wedge.
The thickness of the central shim, the wear dimen- measuring wedge
spring pack
sion w and the width of the measuring wedge B
are stated on in Fig 5.
Measuring wear
Measure approximately every fourth spring pack
Place the measuring wedge between the inner

inner star
ends of the spring blades resting the wedge on the
groove bottom.
Press by hand or use a soft hammer to force the

measuring wedge along the inner star groove, until Fig 3 Measuring wear
the spring tips rest on both groove faces.
08028-0D/H5250/94.08.12
Fig 4 Testing
02.37 - ES0
MAN Diesel
L27/38
Trouble Shooting
Inspection condition Corrective measure
Pressure oil supply with the prelubricating Dismount damper; check oil supply holes on
pump; No oil escapes from one or more ventig the damper and on the crankshaft; free oil
holes. discharge must be guaranteed.
Total wear of the O-ring (850) does not exceed Exchange O-ring(s); smooth and polish the
the permissible value of wear. run-in grooves
Total wear of the O-rings (850) exceeds the Exchange O-ring(s) and exchange or repair
permissible value of wear. worn parts. (Clarify repair with Geislinger or a
Geislinger service station).
The total wear at the spring tips (engagement Exchange inner star (9) and spring assembly
with inner star grooves) exceeds the permissi- (1, 2, 3).
ble value "w" (see Fig 5).
Bad oil quality / oil change or higher water con- Remove venting screw /756) (if existing).
tent in the engine oil as permitted. Drain damper totally (drain hole in 6 o'clock
Effect: no damage to the engine bearings. position).
Fill up damper with fresh engine oil and drain
damper again; repeat flushing several times.
Bad oil quality or higher water content in the Carry out a 28.000 - 30.000 service hours
engine oil as permitted. inspection according to "Total inspection of the
Effect: damage to the engine bearings. damper".
Type a w
D85/2/1 1.5 0.38

08028-0D/H5250/94.08.12
D94/1/1 2 0.5
D94/2/1 2 0.58
Fig 5 Wear of springs and inner star groove
02.37 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 51001-10H
L27/38
141 165
177
189
273
190
285
200
190
104
094
082
224
070
075
212
033
08028-0D/H5250/94.08.12
045
057
236 069
08.14 - ES0
MAN Diesel
Plate
51001-10H Crankshaft Page 2 (2)
L27/38
Item Item
033 1/E Crankshaft, Krumtap,




070 2/C Cylindrical pin, 25 Cylindrisk stift, 25
075 2/C Cylindrical pin, 30 Cylindrisk stift, 30

(optional) (option)
082 4/C Nut Mtrik
094 4/C Bolt Bolt
104 2/C Counterweight Kontravgt
189 4/E Screw Skrue
190 1/E Gearwheel 2/2 Tandhjul 2/2
224 Plug screw Propskrue

236 1/E Screw Skrue

08028-0D/H5250/94.08.12
08.14 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 51001-11H
5L27/38
141 165
177
189
190
200 273
285
190
094
224 082
070
212
104
248
021
236
08028-0D/H5250/94.08.12
07.40 - ES0
MAN Diesel
Plate
51001-11H Crankshaft Page 2 (2)
5L27/38
Item Item
021 1/E Crankshaft Krumtap
082 4/C Nut Mtrik
094 4/C Bolt Bolt
104 9/E Counterweight Kontravgt
189 4/E Screw Skrue
190 1/E Gearwheel 2/2 Tandhjul 2/2
236 1/E Screw Skrue
248 1/E Counterweight Kontravgt
08028-0D/H5250/94.08.12
07.40 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 51003-14H
L27/38
010
022
105
034
046
071
083
130
142 095
08028-0D/H5250/94.08.12
Crankshaft see plate 51001
05.17 - ES0
MAN Diesel
Plate
51003-14H Flywheel with Gear Rim Page 2 (2)
L27/38
Item Item
010 1/E Flywheel, Svinghjul





071 16/E Bolt Bolt
083 1/E Gear rim Tandkrans
105 32/E Nut Mtrik
142 1/E Nut Mtrik
08028-0D/H5250/94.08.12
05.17 - ES0
MAN Diesel
Plate
Page 1 (2) Vibration Damper with Attachment 51004-19
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
51004-19 Vibration Damper with Attachment Page 2 (2)
L27/38
Item Item
016 1/E Vibration damper Svingningsdmper
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Item Item
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Item Item
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Item Item
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Item Item
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Item Item
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Crankshaft
016
see plate 51001
161
053
041
161
08028-0D/H5250/94.08.12
06.02 - ES0
MAN Diesel
Plate
L27/38
Item Item
053 8/E Bolt Bolt
161 16/E Nut Mtrik
08028-0D/H5250/94.08.12
06.02 - ES0
Engine frame/Oil pan
511/611
MAN Diesel
Description
Engine Frame and Base Frame 511.01
L27/38
Engine Frame The main bearings for the underslung crankshaft are
carried in heavy supports by tierods from the interme-
The monobloc cast iron engine frame is designed diate frame floor, and are secured with the bearing
to be very rigid. All the components of the engine caps.These are provided with side guides and held in
frame are held under compression stress. The frame place by means of studs with hydraulically tightened
is designed for an ideal flow of forces from the cylin- nuts. The main bearing is equipped with replaceable
der head down to the crankshaft and gives the outer shells which are fitted without scraping.
shell low surface vibrations.
On the sides of the frame there are covers for ac-
Two camshafts are located in the engine frame. cess to the camshafts and crankcase. Some covers
The valve camshaft is located on the exhaust side are fitted with relief valves which will operate if oil
in a very high position and the injection camshaft is vapours in the crankcase are ignited (for instance in
located on the service side of the engine. the case of a hot bearing).
Base Frame
The engine and alternator are mounted on a rigid

base frame. The alternator is considered as an in-
tegral part during engine design. The base frame,
which is flexibly mounted, acts as a lubricating oil
reservoir for the engine.
08028-0D/H5250/94.08.12
Fig 1 Engine frame Fig 2 Main bearings
00.13 - ES0
MAN Diesel
Page 1 (2) Functional Test of Crankcase Safety Relief Valves Edition 08H
L27/38

Shut-off fuel oil
Functional test of crankcase safety relief val-

ves.
Starting position
Related procedure

08028-0D/H5250/94.08.12
Capacity : 1 man
51106 237 1/cover
51106 524 4/relief valve
Data 51106 740 1/relief valve

06.47 - ES0
MAN Diesel
Edition 08H Functional Test of Crankcase Safety Relief Valves Page 2 (2)
L27/38
Functional Testing 4) Remount the relief valve cover of the engine.
Functional testing of the crankcase safety relief

valves cannot be performed during operation of the Warning!
engine, but it must be checked during overhauls that If the safety relief valves are actuated, the engine
the valve flap is movable. must be stopped immediately, and it must not be
restarted until the cause and the fault are detected,
see also description 503.04, Ignition in Crankcase.
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, see fig 1:
1) Remove the relief valve cover from the en-

gine.
2) Place the cover on the floor with the pressure

area upwards.
3) Apply a weight at 20 kg on the pressure

area.
The relief valve must open under this pres-
sure. Fig 1 Cover with relief valve
08028-0D/H5250/94.08.12
06.47 - ES0
MAN Diesel
Plate
Page 1 (4) Frame with Main Bearings 51101-19H
L27/38
086
194 074
265 899
074
182
062
098
108
277 121
289
133
145
290 373
300
397 385
922
348
361
216 407
049 934
228 216
312
228
324 204 312

336 887
348
08028-0D/H5250/94.08.12
361
241 241
242
242
456
253
086 157
169
086
07.33 - ES0
MAN Diesel
Plate
51101-19H Frame with Main Bearings Page 2 (4)
L27/38
909
910
361
419
420
432
432 444
444
08028-0D/H5250/94.08.12
049
07.33 - ES0
MAN Diesel
Plate
Page 3 (4) Frame with Main Bearings 51101-19H
L27/38
Item Item
049 2/E Cylindrical pin Cylindrisk stift 216 Cross bolt Krydsbolt
062 4/C Tie rod Stavbolt 16/E 6 cyl. engine 6 cyl. motor
074 8/C O-ring O-ring 20/E 8 cyl. engine 8 cyl. motor
086 Nut Mtrik
34/E 5 cyl. engine 5 cyl. motor 228 Nut Mtrik
098 1/E Frame, Stativ,
5 cyl. engine 5 cyl. motor 241 Main bearing Hovedlejeskal
shell 2/2, Miba 2/2, Miba
108 1/E Frame , Stativ, 7/E 5 cyl. engine 5 cyl. motor
121 1/E Frame, Stativ, 10/E 8 cyl. engine 8 cyl. motor
133 1/E Frame, Stativ, 242 Main bearing Hovedlejeskal

8 cyl. engine 8 cyl. motor shell 2/2, Daido 2/2, Daido
145 1/E Frame, Stativ, 8/E 6 cyl. engine 6 cyl. motor
157 Main bearing cap Hovedlejedksel 11/E 9 cyl. engine 9 cyl. motor
7/E 6 cyl. engine 6 cyl. motor 253 4/E Thrust bearing ring Tryklejering
9/E 8 cyl. engine 8 cyl. motor 265 O-ring O-ring
169 1/E Main bearing cap, Hovedlejedksel, 16/E 7 cyl. engine 7 cyl. motor
axial aksial 18/E 8 cyl. engine 8 cyl. motor
182 Tie rod Stavbolt
12/E 5 cyl. engine 5 cyl. motor 277 4/C Nut Mtrik
16/E 7 cyl. engine 7 cyl. motor 289 4/C Stud Tap
20/E 9 cyl. engine 9 cyl. motor 290 Sealing ring Ttningsring
194 Crown nut Kronemtrik 7/E 6 cyl. engine 6 cyl. motor
Plug
08028-0D/H5250/94.08.12
20/E 9 cyl. engine 9 cyl. motor 300 Propskrue

204 Cylindrical pin Cylindrisk stift 7/E 6 cyl. engine 6 cyl. motor
07.33 - ES0
MAN Diesel
Plate
51101-19H Frame with Main Bearings Page 4 (4)
L27/38
Item Item
312 Protecting cap Beskyttelseshtte 909 Camshaft bearing Ventilstyreaksel-

14/E 5 cyl. engine 5 cyl. motor (valve camshaft) leje
910 Camshaft bearing Styreakselleje for
336 1/E Spray nozzle Sprjtedyse (injection camshaft) brndstofind-
sprjtning
348 4/E Spring lock Fjedersikring 6/E 5 cyl. engine 5 cyl. motor
361 Screw Skrue 8/E 7 cyl. engine 7 cyl. motor
20/E 8 cyl. engine 8 cyl. motor 922 Cu-gasket, M80 Kobberpakning, M80
373 1/E O-ring O-ring 8/E 7 cyl. engine 7 cyl. motor
385 1/E Cover Dksel 10/E 9 cyl. engine 9 cyl. motor
397 Cu-gasket, M60 Kobberpakning, M60 934 Plug, M80 Propskrue, M80
407 Plug, M60 Propskrue, M60

419 1/C Connecting piece Forbindelsesstykke
432 2/E Plug Prop
456 2/E Tie rod Stavbolt
887 /I Loctite 270 Loctite 270
899 4/C Ring Ring

08028-0D/H5250/94.08.12
07.33 - ES0
MAN Diesel
Plate
Page 1 (2) Front-end Box 51103-18H
L27/38
720
408
014 732
398
409
Cooling water pumps,

see plate 51610
744
Charge air cooler,

see plate 51201
756
134
122
386 612
600
158 697
278 171 707
985 697 720 732
997 685
099 349
349
099
051
768
171
08028-0D/H5250/94.08.12
158
291 099 793
997 781 803
349 Lubricating oil pump,
see plate 51501
266 051
254 362 Lubricating oil cooler,
see plate 51506
999 350 099
06.41 - ES0
MAN Diesel
Plate
51103-18H Front-end Box Page 2 (2)
L27/38
Item Item
014 1/E Front-end box Front-end box 756 1/E Packing ring Pakningsring
051 8/E Washer Skive 768 2/E Cover Dksel
099 28/E Spring washer Fjederskive 781 4/E Screw Skrue
122 1/E Plug screw Propskrue 793 1/E O-ring O-ring
134 1/E Packing ring Pakningsring 803 1/E Cover Dksel
158 8/E Sleeve Bsning 985 8/E Sleeve Bsning
171 8/E Retaining ring Sikringsring 997 8/E O-ring O-ring
254 14/E Screw Skrue 999 2/E Gasket (1-string) Pakning (1-streng)
266 1/E Housing Hus
278 4/E Thermostatic Termostatelement

element for HT for HT klevand
cooling water

element for LT for LT klevand
cooling water
350 16/E Screw (1-string) Skrue (1-streng)
362 2/E Cover (1-string) Dksel (1-streng)
398 1/E Intermediate piece Mellemstykke
612 4/E Screw Skrue

08028-0D/H5250/94.08.12
720 18/E Closing screw Skrue
06.41 - ES0
MAN Diesel
Plate
L27/38
Mounting of charge air

cooler, see plate 51235
Charge air pipes,

see plate 51230
Lubricating oil filter,

see plate 51502
840
852
864
099
038
051
146 205
876 183
985
997
349 171
986
099
099
888
038 911
08028-0D/H5250/94.08.12
109
099
038
923
06.41 - ES0
MAN Diesel
Plate
L27/38
Item Item
099 18/E Spring washer Fjederskive
109 1/E Cover Dksel

element for lub. oil for smreolie
171 4/E Retaining ring Sikringsring
183 1/E Cover Dksel
349 4/E Screw Skrue
864 1/E Closing piece Lsestykke
888 12/E Thrust washer Trykskive
923 1/E Cover Dksel
986 /I Loctite 243 Loctite 243
08028-0D/H5250/94.08.12
06.41 - ES0
MAN Diesel
Plate
L27/38
Centrifugal by-pass filter, 445

see plate 51515
087+ 218 935
099 217+ 445
242+ 577 516
541 433 528
959 099 494
636 469 504
960 553 457
673
661
648 482
972 984 470
229 719 301
624 075 996 697
528 195 038 947
063 196
099
026 408
08028-0D/H5250/94.08.12
06.16 - ES0
MAN Diesel
Plate
L27/38
Item Item
026 1/E Cover Dksel 624 4/E Screw Skrue
038 4/E Screw Skrue 636 1/E Thrust piece Trykstykke
063 4/E Nut Mtrik 648 1/E Covering plate Dkselplade
075 2/E Washer Skive 661 1/E Screw Skrue
087+ 4/E Screw Skrue 673 1/E Nut Mtrik
099 8/E Spring washer Fjederskive 697 1/E O-ring O-ring
195 4/E Stud Tap 719 1/E Spring Fjeder
196 /I Loctite 638 Loctite 638 935 1/E Intermediate piece Mellemstykke
217+ 1/E Flange Flange 947 1/E Intermediate piece Mellemstykke
218 /I Packing silicone Packing silicone 959 1/E O-ring O-ring

paste paste
960 1/E Cover Dksel
972 1/E Casing Hus
242+ 4/E Nut Mtrik
984 1/E Piston Stempel
996 1/E Retaining ring Sikringsring
+ To be used if cen- + Anvendes hvis ikke
433 10/E Screw Skrue trifugal by-pass filter centrifugal by-pass
is not mounted filter er monteret
457 1/E Bracket for by-pass Konsol for centrifugal

centrifugal filter by-pass filter
469 4/E Screw Skrue
494 1/E Cover Dksel
516 4/E Screw Skrue
528 8/E Spring washer Fjederskive

08028-0D/H5250/94.08.12
541 1/E Spring Fjeder
553 1/E Piston Stempel
06.16 - ES0
MAN Diesel
Plate
Page 1 (3) Covers on Frame 51106-24H
L27/38
441
740 512 453

524
490
500
201
166
154
250
249
573
585
250
249
225
237
250
249
620
5 cyl.
249
08028-0D/H5250/94.08.12
6 cyl. 250
7 cyl. 298 237
8 cyl. 274 178
9 cyl. 776
788
When ordering crankcase 250
cover, please see this
diagram for cover type. 262
06.40 - ES0
MAN Diesel
Plate
51106-24H Covers on Frame Page 2 (3)
L27/38
404
250 166
249
250
249
See
diagram
249
250
249
250
201 237
619
298
286
5 cyl. 1 2 3 1 2
249 6 cyl. 3 1 2 3 1 2
250 7 cyl. 1 2 3 1 2 1 2
1 2 3 1 2 3 1 2
08028-0D/H5250/94.08.12
8 cyl.
249 274
9 cyl. 3 1 2 3 1 2 3 1 2
When ordering camshaft cover,

please use this diagram to ensure
250 308 correct cover type.
Type 1 - item 597
Type 2 - item 607
Type 3 - item 154
06.40 - ES0
MAN Diesel
Plate
L27/38
Item Item
154 Cover Dksel 490 4/D Lock washer Lseskive

8/E 6 cyl. engine 6 cyl. motor 500 4/D Screw Skrue
10/E 8 cyl. engine 8 cyl. motor 512 4/D Self locking nut Selvlsende mtrik
524 4/D Washer Skive
573 2/E Warning plate Advarselsplade
178 1/E Cover Dksel
585 /I Adhesive Lim
201 Cover Dksel
5/E 5 cyl. engine 5 cyl. motor 597 Cover Dksel
225 Cover with Dksel med
relief valve reliefventil 607 Cover Dksel
237 2/C O-ring O-ring 619 1/E O-ring O-ring
249 Screw Skrue 620 1/E Cover Dksel

152/E 6 cyl. engine 6 cyl. motor 740 1/D O-ring O-ring
788 2/E Screw Skrue
250 Washer Skive
262 1/E Cover Dksel
286 1/E Cover Dksel

08028-0D/H5250/94.08.12
308 1/E Cover Dksel
404 1/C Cover Dksel
441 1/D Cover Dksel
453 1/D Relief valve Sikkerhedsventil
Qty/D = Qty/Cover Qty/D = Qty/Dksel
06.40 - ES0
MAN Diesel
Plate
L27/38
764 752
823 823
847 847
835 835
859 859
860 860
872 872
884 884
896 896
752
166
154
250
249
573
585
250
249
752
237
250
249
620
08028-0D/H5250/94.08.12
249
250
298 237
274 764
788 776
250
262
06.38 - ES0
MAN Diesel
Plate
51106-28H Covers on Frame Page 2 (3)
L27/38
441
740 512 453

524
490
500
404
250 166
249
250
249
See
diagram
249
250
249
225
250
201 237 619
298
286
5 cyl. 1 2 3 1 2
08028-0D/H5250/94.08.12
249 6 cyl. 3 1 2 3 1 2
5 cyl. 7 cyl. 1 2 3 1 2 1 2
250
6 cyl. 8 cyl. 1 2 3 1 2 3 1 2
249 274
7 cyl. 9 cyl. 3 1 2 3 1 2 3 1 2
8 cyl. When ordering camshaft cover,
please use this diagram to ensure
9 cyl. 250 308 correct cover type.
Type 1 - item 597
When ordering crankcase
cover, please see this Type 2 - item 607
diagram for cover type. Type 3 - item 154
06.38 - ES0
MAN Diesel
Plate
L27/38
Item Item
154 Cover Dksel 512 4/D Self locking nut Selvlsende mtrik
8/E 6 cyl. engine 6 cyl. motor 524 4/D Washer Skive
10/E 8 cyl. engine 8 cyl. motor 573 2/E Warning plate Advarselsplade
585 /I Adhesive Lim
597 Cover Dksel
201 Cover Dksel 2/E 5 cyl. engine 5 cyl. motor
225 Cover with Dksel med 607 Cover Dksel

relief valve reliefventil 2/E 5 cyl. engine 5 cyl. motor
620 1/E Cover Dksel
249 Screw Skrue
129/E 5 cyl. engine 5 cyl. motor 740 1/D O-ring O-ring
175/E 7 cyl. engine 7 cyl. motor 752 Cover, oil splash Dksel, oil splash
250 Washer Skive 7/E 8 cyl. engine 8 cyl. motor
181/E 7 cyl. engine 7 cyl. motor 764 1/E Cover, oil splash Dksel, oil splash
262 1/E Cover Dksel 788 2/E Screw Skrue
274 2/E O-ring O-ring 823 1/D Gasket Pakning
286 1/E Cover Dksel 835 1/D Screw Skrue
298 2/E O-ring O-ring 847 1/E Oil collecting pan Olieopsamlingsskl
308 1/E Cover Dksel 859 1/D Protection sheet Beskyttelsesplade
404 1/C Cover Dksel 860 1/D Seal ring Ttningsring

08028-0D/H5250/94.08.12
441 1/D Cover Dksel 872 1/D Socket Studs
453 1/D Relief valve Sikkerhedsventil 884 2/D Screw Skrue
490 4/D Lock washer Lseskive 896 /I Loctite 242 Loctite 242
500 4/D Screw Skrue
Qty/D = Qty/Cover Qty/D = Qty/Dksel
06.38 - ES0
MAN Diesel
Plate
Page 1 (2) Cover on Frame 51106-23H
L27/38
548
022
142
130 105
117
561
083
095
010
034
08028-0D/H5250/94.08.12
129
Crankshaft see plate 51001
06.18 - ES0
MAN Diesel
Plate
51106-23H Cover on Frame Page 2 (2)
L27/38
Item Item
010 1/E Cover Dksel
083 1/E Cover Dksel
105 8/E Screw Skrue
129 1/E Sealing ring Ttningsring
130 1/E Cover Dksel
142 4/E Screw Skrue
548 4/E Lock disc Lseskive
08028-0D/H5250/94.08.12
06.18 - ES0
MAN Diesel
Plate
Page 1 (2) Base Frame - One Bearing 51111-07H
L27/38
080
175
126
138
092
151
163
Level switch in oil sump,

018 see plate 50920
031
043
055
079 067
08028-0D/H5250/94.08.12
06.18 - ES0
MAN Diesel
Plate
51111-07H Base Frame - One Bearing Page 2 (2)
L27/38
Item Item
018 1/E Base frame, Bundramme,





079 7/E Screw Skrue
080 4/E Screw Skrue
092 4/E Nut Mtrik
126 Screw Skrue

138 Disc Skive


08028-0D/H5250/94.08.12
06.18 - ES0
MAN Diesel
Plate
Page 1 (2) Base Frame - Two Bearings 51111-08H
L27/38
080
329
175
126
138
092
151
163
Level switch in oil sump,

018 see plate 50920
031
043
055
079 067
08028-0D/H5250/94.08.12
06.18 - ES0
MAN Diesel
Plate
51111-08H Base Frame - Two Bearings Page 2 (2)
L27/38
Item Item





079 7/E Screw Skrue
080 4/E Screw Skrue
092 4/E Nut Mtrik
126 Screw Skrue

138 Disc Skive

329 6/E Screw Skrue

08028-0D/H5250/94.08.12
06.18 - ES0
MAN Diesel
Plate
Page 1 (2) Covering 51120-01H
L27/38
066
054 078 A
3 x M10 to be drilled in
cover when mounting
091
101 150
113
017
208 125
221 137
233
029 149
030
125
B
137
08028-0D/H5250/94.08.12
base frame when mounting
162
B
042
cooler when mounting 198
029 125 029
030 137 174 186
base frame when mounting
06.40 - ES0
MAN Diesel
Plate
51120-01H Covering Page 2 (2)
L27/38
Item Item
017 1/E Guard for cooler Skrm for kler

042 1/E Guard Skrm
054 1/E Guard Skrm
066 2/E Screw Skrue
091 3/E Screw Skrue
113 1/E Guard Skrm
149 1/E Guard Skrm
150 2/E Bracket Holder
162 1/E Distance piece Afstandsstykke
174 1/E Guard Skrm
186 1/E Nut Mtrik
198 1/E Guard Skrm


6, 7 cyl. engine 6, 7 cyl. motor

08028-0D/H5250/94.08.12
06.40 - ES0
Turbocharger
512/612
MAN Diesel
Description
Turbocharger System 512.01
L27/38
Fig. 1 Diagram for Compressed Air System
Turbocharger System through the cooler, the end covers being designed with
partitions which cause the cooling water to turn.
The turbocharger system of the engine, which is a
constant pressure system, consists of an exhaust The cooling water for the low temperature stages of
gas receiver, a turbocharger, a charging air cooler the charge air is controlled by the scavenging pres-
and a charging air receiver. sure to ensure sufficient scavenging temperature for
burning HFO. A water mist catcher can be adopted
The turbine wheel of the turbocharger is driven by after the air cooler as an option.
the engine exhaust gas, and the turbine wheel drives
the turbocharger compressor, which is mounted on From the exhaust valves, the exhaust gas is led
the common shaft. The compressor draws air from through to the exhaust gas receiver where the
the engine room through the air filters. pulsatory pressure from the individual cylinders is
equalized and passed on to the turbocharger as a
08028-0D/H5250/94.08.12
The turbocharger forces the air through the char- constant pressure, and further to the exhaust outlet
ging air cooler to the charging air receiver. From the and silencer arrangement.
charging air receiver the air flows to each cylinder
through the inlet valves. The exhaust gas receiver is made of pipe sections,
one for each cylinder, connected to each other by
The charging air cooler is a compact two-stage tube- means of compensators to prevent excessive stress
type cooler with a large cooling surface. The high in the pipes due to heat expansion.
temperature water is passed through the first stage
of the charging air cooler and the low temperature To avoid excessive thermal loss and to ensure a
water is passed through the second stage. At each reasonably low surface temperature the exhaust gas
stage of the cooler the water is passed two times receiver is insulated.
01.36 - ES0
MAN Diesel
Description Cleaning the Turbocharger In Service 512.05

Page 1 (1)
Water Washing of Compressor Edition 01
General
Compressor Chemical cleaning will not improve the cleaning

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

water before the compressor wheel will reduce the
fouling rate considerably, and consequently prolong
the intervals between dismantling necessary for
mechanical cleaning.
94.26 - ES0U-G
MAN Diesel
Description Cleaning the Turbocharger in Service 512.10

Page 1 (3)
Dry Cleaning - Turbine Edition 02H
L23/30H
V28/32S
Description Cleaning System
The tendency to fouling on the gas side of turbo- The cleaning system consists of a cleaning agent
chargers depends on the combustion conditions, container (2) with a capacity of approx. 0.5 liters and
which are a result of the load and the maintenance a removable cover. Furthermore the system consists
condition of the engine as well as the quality of the of an air valve (3), a closing valve (1) and two snap
fuel oil used. on connectors.
Fouling of the gas ways will cause higher exhaust The position numbers (2) and (3) indicate the system's
gas temperatures and higher wall temperatures of "blow-gun". Only one "blow-gun" is used for each
the combustion chamber components and will also engine plant. The blow-gun is working according to
lead to a higher fuel consumption rate. the ejector principle with pressure air (working air)
at 5-7 bar as driven medium. Injection time approx.
Tests and practical experience have shown that radi- 2 min. Air consumption approx. 5 Nm3/2 min.
al-flow turbines can be successfully cleaned by the
dry cleaning method.
This cleaning method employs cleaning agents con-

sisting of dry solid bodies in the form of granules. A
certain amount of these granules, depending on the
turbocharger size, is, by means of compressed air,
blown into the exhaust gas line before the gas inlet
casing of the turbocharger.
The injection of granules is done by means of wor-

king air with a pressure of 5-7 bar.
On account of their hardness, particularly suited

blasting agents such as nut-shells, broken or artifi-
cially shaped activated charcoal with a grain size of
1.0 mm to max. 1.5 mm should be used as cleaning
agents.
1 Closing valve 2 Container
The solid bodies have a mechanical cleaning effect 3 Air valve 4 working air inlet
which removes any deposits on nozzle vanes and 5 Exhaust pipe 6 Snap coupling
turbine blades.
Fig 1 Arrangement of dry cleaning of turbocharger - Turbine
Dry cleaning can be executed at full engine load and
does not require any subsequent operating period of
the engine in order to dry out the exhaust system.
Experience has shown that regular cleaning intervals

are essential to successful cleaning, as excessive
fouling is thus avoided. Cleaning every second day
during operation is recommended.
The cleaning intervals can be shorter or longer based

on operational experience.
97.08 - ES2
MAN Diesel
512.10 Cleaning the Turbocharger in Service Description

Page 2 (3)
Edition 02H Dry Cleaning - Turbine
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 Wrth 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 , Denmark
Tel.:(01) 29 97 00 Telex: 19038
6. "Crushed Nutshells"
Brigantine, Hong Kong
7. "Turbine Wash"
Ishikawajima-Harima Heavy Industries Co.

Ishiko Bldg., 2-9-7 Yassu, Chuo-Ku
Tokyo 104, Japan
Tel.: 03-2 77-42 91
97.08 - ES2
MAN Diesel
Description Cleaning the Turbocharger in Service 512.10

Page 3 (3)
Dry Cleaning - Turbine Edition 02H
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 B&W Diesel A/S

Stamholmen 161 DK-2650 Hvidovre
Tel.: +45 31 492501 Fax.: +45 31 494397
Telex: 31197 manbw dk
The list is for guidance only and must not be considered complete.
We undertake no responsibility that might be caused by these or other
products.
97.08 - ES2
MAN Diesel
Description
Control Air for Charge Air Blow off 512.38
L27/38
Functionality of SCR Valves at Charge Air

Inlet Cooler Small valve Big valve Outlet
The valves for the SCR system is mounted to keep

the exhaust gas temperature after TC above 310C, if
possible. This temperature is needed for the catalyst
to perform as intended.
The system exists of two different valves with a

opening area of 5 cm2 (small valve) and 10 cm2 (big
valve). The two valves openes and closed according
to the diagram shown below with the temperatures
written below.
The function is activated when engine is running and

deactivated when engine is stopped. Fig 1
Control of Valves for SCR Temperature
Small valve = Valve A

Big valve = Valve B
Valve pos.
B open
B close
A open
A close
08028-0D/H5250/94.08.12
t15L t15H t10L t10H t5L t5H Temp.
t15L = 309 C t15H = 312 C

t10L = 315 C t10H = 320 C
t 5L = 325 C t 5H = 330 C
Fig 2 Diagram of valve function
07.22 - ES0
MAN Diesel
Page 1 (4) Overhaul of Charging Air Cooler Edition 03H
L27/38

Overhaul of charging air cooler.
Starting position
Related procedure

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

Capacity : 2 men
51201 030 1/k
51201 113 1/k
Data 51201 150 1/k
51103 408 8/E
01.30 - ES0
MAN Diesel

Edition 03H Overhaul of Charging Air Cooler Page 2 (4)
L27/38
Overhaul of Charging Air Cooler
Charging air pipe
The charging air cooler normally is cleaned and
overhauled at the intervals indicated in the Planned
Maintenance Program, or if observations prove that
the cooler does not work adequately, see section
502.
Dismounting of Charging Air Cooler
1) Turn off the cooling water inlet and outlet val-

ves.
2) Remove the charging air pipe, see fig 1. Fig 1 Charging air pipe
3) Mount the lifting tool and tighten the four bolts, 6) Lift and pull the air cooler out of the cooler
see fig 2. housing and place it on a couple of wooden
planks on the floor.
4) Attach a tackle hook to the lifting tool and
slightly tighten the wire. 7) Remove screws (1), end cover (2), reversing
cover (5) and side plate (6), see fig 4.
5) Loosen and remove the bolts for the charging
air cooler, see fig 3.
08028-0D/H5250/94.08.12
Fig 2 Mounting of lifting tool
01.30 - ES0
MAN Diesel
Page 3 (4) Overhaul of Charging Air Cooler Edition 03H
L27/38
Cleaning and inspecting
8) Clean the cooler element on the water and air

sides.
After using cleaning agents, the manufacturing

recommendation must be followed.
Bolts
The greatest care must be taken when dis-

mantling, cleaning and mounting the cooler
element, as the thin fins of the tubes cannot
stand impacts and pressure.
Fig 3 Bolts for charging air cooler

08028-0D/H5250/94.08.12
1 Screw
2 End cover
3 Gasket
4 Gasket
5 Reversing cover
6 Side plate
Fig 4 Charging air cooler
01.30 - ES0
MAN Diesel

Edition 03H Overhaul of Charging Air Cooler Page 4 (4)
L27/38
Nevertheless, if the metal is bent, it should be
carefully straightened, as bent fins will increase O-ring
the pressure drop across the cooler consider-
ably.
Should one or more cooler tubes become

leaky it/they immediately must be made tight,
either by expanding the tube ends into the tube
plates or by blanking with plugs of the tube(s)
concerned.
It is important that the charging air cooler is not

leaky as any water that leaks in will be carried
together with the air into the cylinders where it
will damage valves, piston rings, and cylinder
liners.
9) Also clean the end cover and coat it on the Fig 5 O-ring at water connections
inside with an anti-corrosion agent.
10) Fouling and deposition in the pipes can be 12) Lift the air cooler by the lifting tool and carefully
removed with a hand or machine operated push it into its housing.
circular steel brush.
13) Mount the bolts for the air cooler, see fig 3.
Mounting of Charging Air Cooler 14) Mount the screws for the charge air pipe, see
fig 1.
11) Renew gaskets (3) for end cover and gasket
(4) for reversing cover before assembling end
cover (2), reversing cover (5) and side plate Out of Service Periods
(6). See fig 4.
At longer periods out of service, recommendations
Note: Before mounting the air cooler, the O-ring at for the entire system are followed. Please see sec-
the water connections must be replaced, see fig 5. tion 501.
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel

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
MAN Diesel

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
MAN Diesel
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
MAN Diesel

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
MAN Diesel
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
MAN Diesel

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
MAN Diesel

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
MAN Diesel
Plate
Page 1 (2) Charge Air Cooler 51201-15H
L27/38
902
353
125
113
A-A
A
030
162
137
149
029
017
150 042
08028-0D/H5250/94.08.12
066 054 902 078
06.44 - ES0
MAN Diesel
Plate
51201-15H Charge Air Cooler Page 2 (2)
L27/38
Item Item
017 2/K Side plate Sideplade
029 8/K Screw Skrue
030 1/K O-ring O-ring
042 8/K Screw Skrue
054 4/K Plug screw Propskrue
066 4/K Cu-washer Cu-skive
078 4/K Screw Skrue
113 1/K Gasket end cover Pakning endedksel
125 1/K End cover Endedksel
137 1/K Cooler block Klerblok
149 1/K Reversing cover Vendekammer
150 1/K Gasket Pakning

reversing cover vendekammer
162 1/E Charging air cooler, Charging air cooler,

complete komplet
353 22/K Screw Skrue
08028-0D/H5250/94.08.12
Qty/K = Qty/Cooler Qty/K = Qty/Kler
Qty./E = Qty./Engine Qty./E = Qty./Motor
06.44 - ES0
MAN Diesel
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-05H
L27/38
08028-0D/H5250/94.08.12
99.11 - ES0
MAN Diesel
Plate
51202-05H Exhaust Pipe Arrangement Page 2 (2)
L27/38
Item Item
012 1/E Cover Dksel
024 Gasket Pakning

036 Screw Skrue

048 Nut Mtrik

061 1/C Exhaust manifold Udstdsmanifold
073 Compensator Kompensator

097 1/C Clamping strap 2/2 Holder 2/2
107 2/C Screw Skrue
119 2/C Nut Mtrik
08028-0D/H5250/94.08.12
99.11 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Turbocharger 51203-08H
L27/38
08028-0D/H5250/94.08.12
99.25 - ES0
MAN Diesel
Plate
51203-08H Mounting of Turbocharger Page 2 (2)
L27/38
Item Item
018 Thrust washer Trykskive 210 Screw Skrue

6/E TC NR20/S TC NR20/S 9/E TC NR24/S TC NR24/S
12/E TC NR29/S TC NR29/S
222 3/E Screw Skrue
031 1/E Bracket Konsol
043 6/E Screw Skrue
246 O-ring O-ring
055 6/E Screw Skure 1/E TC NR24/S TC NR24/S
258 Screw Skrue
079 O-ring O-ring 4/E TC NR24/S TC NR24/S
2/E TC NR29/S TC NR29/S 271 Lock spring washer Lsefjederskive
080 1/E Discharge pipe for Afgangsrr for 4/E TC NR29/S TC NR29/S
TC NR20/S TC NR20/S
283 1/E Discharge pipe for Afgangsrr for
092 1/E Gasket Pakning TC NR24/S TC NR24/S
102 2/E Screw Skrue 295 1/E Discharge pipe for Afgangsrr for
TC NR29/S TC NR29/S
114 2/E Lock spring washer Lsefjederskive
126 O-ring O-ring

138 Screw Skrue

151 Lock washer Lseskive

163 1/E Seal ring Ttningsring
175 2/E Screw Skrue
199 Intermediate piece Mellemstykke

08028-0D/H5250/94.08.12
209 Clamp Holder

99.25 - ES0
MAN Diesel
Plate
Page 1 (2) Water Washing of Compressor Side 51205-01
General
08028-0D/H5250/94.08.12
94.01 - ES0S-G
MAN Diesel
Plate
51205-01 Water Washing of Compressor Side Page 2 (2)
General
Item Item
No. Qty. Designation Benvnelse No. Qty. Designation Benvnelse
019* 1/E Top cover with non- Topdksel med kon- 284* 1/E Straight male stud Ligeforskruning
return valve traventil coupling
020* 1/E O-ring for top cover O-ring for topdksel 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 Ventilsde 318 1/E Container complete, Beholder komplet, som
as shown on plate vist p plate
056* 1/E Spring for non-return Fjeder for kontraventil
valve
068* 1/E Cap screw for non- Omlber til kontraven-

return valve til
081 1/E Top cover with non- Topdksel 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
115 2/E Finger nut Fingermtrik
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 je 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 Hndtag med fleksibel

pipe and cap screw slange og omlber
235 1/E Filter insert Filterinsats
247 1/E Gasket for handle Pakning til hndtag
259 1/E Hand valve Hndventil

08028-0D/H5250/94.08.12
260 1/E Gasket for hand val- Pakning til hndventil

ve
272* 1/E Lance Lanse
Qty./E = Qty./Engine Antal/E = Antal/Motor
94.01 - ES0S-G
MAN Diesel
Plate
Page 1 (2) Drain Trap 51208-02H
L27/38
08028-0D/H5250/94.08.12
00.39 - ES0
MAN Diesel
Plate
51208-02H Drain Trap Page 2 (2)
L27/38
Item Item
015 1/E Drain trap, Vandudlader,

complete komplet
088 1/E Drain pipe Drnrr
135 4/E Screw Skrue
147 4/E Screw Skrue
159 4/E Nut Mtrik
160 2/E Screw Skrue
172 2/E Nut Mtrik
08028-0D/H5250/94.08.12
00.39 - ES0
MAN Diesel
Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 51210-01
L23/30H, L21/31,
L27/38, V28/32S
053
016 112 028 041 028 065 077
089 148
100
136
08028-0D/H5250/94.08.12
01.12 - ES0
MAN Diesel
Plate
51210-01 Blowgun for Dry Cleaning of Turbocharger Page 2 (2)
L23/30H, L21/31,
L27/38, V28/32S
Item Item
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
MAN Diesel
Plate
Page 1 (2) Charge Air Pipes 51230-02H
L27/38
255
351 NR29/S 267
363 292 218 279
375 279 147
206 243 159
375 218 160 088
363 172 326
160
184 172
387
172
135
351 NR24/S
363 292
375 267 111
206 399 434
363 218 446
375 172
159
184 172
387
NR20/S
363 280 088
375 255 052 015
206 231 027 027 039
375 172 040
363 363
08028-0D/H5250/94.08.12
218 471
147 422
184 458
387 338
172 409 027
410
064 040
00.38 - ES0
MAN Diesel
Plate
51230-02H Charge Air Pipes Page 2 (2)
L27/38
Item Item
015 1/E Flange Flange 326 1/E Covering sheet Dkplade
027 Seal ring Ttningsring 338 2/E Plug screw Propskrue

13/E 6 cyl. engine 6 cyl. motor 351 8/E Nut, NR24/S and Mtrik, NR24/s og
15/E 7 cyl. engine 7 cyl. motor NR29/s NR29/s
19/E 9 cyl. engine 9 cyl. motor 363 20/E Nut Mtrik
039 2/E Screw Skrue 375 3/E Gasket Pakning
040 Lock washer Lseskive 387 5/E Thrust washer Trykskive

8/E 6 cyl. engine 6 cyl. motor 399 1/E Diffuser, NR24/S Diffusor, NR24/s
10/E 8 cyl. engine 8 cyl. motor 409 2/E Packing ring Pakningsring
410 1/C Screw Skrue
052 1/C Intermediate piece Mellemstykke
064 1/C Safety clamp Sikkerhedsring
434 3/E Screw Skrue
088 1/E Pipe piece Rrstykke
446 1/E Water mist catcher Water mist catcher
135 2/E Screw Skrue
471 8/E Stud Tap
147 1/E Pipe piece, NR20/S Rrstykke, NR20/S
184 5/E Screw Skrue
218 1/E Compensator Kompensator
231 1/E Diffuser, NR20/S Diffusor, NR20/S
243 1/E Diffuser, NR29/S Duffusor, NR29/S
255 1/E Flange, NR20/S Flange, NR20/S

08028-0D/H5250/94.08.12
280 4/E Screw, NR20/S Skrue, NR20/S
292 8/E Screw, NR24/S and Skrue, NR24/S og

NR29/S NR29/S
00.38 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pipes TC 51231-05H
L27/38
NR20/S and NR24/S NR29/S
308
321 333
105 105
129 129
142 142
130 130
083
105
058 046
071
166
154
178
298
058
08028-0D/H5250/94.08.12
010 071
022
034
06.47 - ES0
MAN Diesel
Plate
51231-05H Lubricating Oil Pipes TC Page 2 (2)
L27/38
Item Item
010 1/E Steel pipe Stlrr
034 4/E Screw Skrue
058 4/E Pipe clamp Rrholder
071 8/E Screw Skrue
105 2/E Equal elbow Vinkelforskruning

coupling
130 2/E Straight male stud Ligeforskruning

coupling
142 1/E Plug Prop
308 1/E Restriction, NR20/S Restriktion, NR20/S
08028-0D/H5250/94.08.12
06.47 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Charge Air Cooler 51235-02H
L27/38
097
132
012
144
097
156
168
073 181
Charge air cooler,

see plate 51201
061
120
097
08028-0D/H5250/94.08.12
06.41 - ES0
MAN Diesel
Plate
51235-02H Mounting of Charge Air Cooler Page 2 (2)
L27/38
Item Item
107 /I Packing-silicone Silicone

paste
120 1/E Valve Ventil
132 1/E Connection pipe Forbindelsesrr
156 1/E Cover Dksel
168 2/E Locking spring Lsefjederskive

washer
181 2/E Screw Skrue
08028-0D/H5250/94.08.12
06.41 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Charge Air Cooler 51235-03H
L27/38
097
012
097
Charge air cooler,
see plate 51201
073
061
120
097
311
323 203
08028-0D/H5250/94.08.12
215
288
240
227
264 252
276
239 168
Control Air for
181 preheating valve,
see plate 51236
06.41 - ES0
MAN Diesel
Plate
51235-03H Mounting of Charge Air Cooler Page 2 (2)
L27/38
Item Item
107 /I Packing-silicone Silicone

paste
120 1/E Valve Ventil

washer
181 2/E Screw Skrue
203 1/E Bushing Bsning
239 4/E Screw Skrue
252 1/E Actuator Aktuator
276 4/E Screw Screw
311 1/E Slider Glider
08028-0D/H5250/94.08.12
06.41 - ES0
MAN Diesel
Plate
Page 1 (2) Control Air for Preheating Valve 51236-01H
L27/38
079
175
080
151
067
209
Control air pipe connected

to overspeed stop pipe.
079
126 114 199 102
151 199
067 199
043
031
08028-0D/H5250/94.08.12
138
126
055
018
151 163 126 187

092
06.43 - ES0
MAN Diesel
Plate
51236-01H Control Air for Preheating Valve Page 2 (2)
L27/38
Item Item
031 1/E Support Sttte
043 1/E Solenoid valve 5/2 Magnetventil 5/2
055 2/E Silencer Dmper
079 1/E Pipe Rr
080 1/E Pipe Rr
092 1/E Pipe Rr
102 1/E Pipe Rr
114 1/E Pipe Rr
126 3/E Screw Skrue
138 2/E Screw skrue
151 6/E Screw Skrue
163 1/E Screw Skrue
175 2/E Equal elbow coupling Vinkelforskruning

coupling

coupling
209 1/E Reducing stand pipe Reducerstykke
08028-0D/H5250/94.08.12
06.43 - ES0
MAN Diesel
Plate
Page 1 (3) Control Air for Charge Air Blow Off 51238-01H
L27/38
331 272 260
367
380 392
402
235
379
A
355
296 A
08028-0D/H5250/94.08.12
284 306 355 259
223 318 247 343
07.33 - ES0
MAN Diesel
Plate
51238-01H Control Air for Charge Air Blow Off Page 2 (3)
L27/38
211
140, 188 115 139 093

140, 188
081 032 020 103 056
093
081 211 068
019 176
140
08028-0D/H5250/94.08.12
414
426 044 127 164 152
127
07.33 - ES0
MAN Diesel
Plate
Page 3 (3) Control Air for Charge Air Blow Off 51238-01H
L27/38
Item Item
019 1/E Small valve (valve A) Lille ventil (ventil A) 331 1/E Straight coupling Ligeforskruning
020 1/E Big valve (Valve B) Stor ventil (valve B) 343 4/E Adjustable elbow Justbar
coupling vinkelforskruning
032 1/E Inlet pipe for valve Tilgangsrr for ventil
355 2/E Adjustable elbow Justbar
044 1/E Outlet pipe for valve Afgangsrr for ventil coupling vinkelforskruning
056 1/E Support Konsol 367 1/E Equal elbow coupling Vinkelforskruning
068 1/E Support Konsol 379 1/E Pipe section Rrsektion
081 2/E Packing ring Pakningsring 380 1/E Pipe section Rrsektion
093 3/E Packing ring Pakningsring 392 2/E Welding-on plate Svejseplade
103 2/E Screw Skrue 402 4/E Screw Skrue
115 16/E Screw Skrue 414 8/E Nut Mtrik
127 4/E Screw Skrue 426 8/E Screw skrue
140 20/E Nut Mtrik
176 2/E Screw Skrue
188 /I Glue for metal Lim
211 1/E Charge air manifold Ladeluftmanifold
247 2/E Solenoid valve 3/2 Magnetventil 3/2
260 1/E Pipe section Rrsektion

08028-0D/H5250/94.08.12
296 4/E Screw Skrue
306 1/E Equal tee coupling T-forskruning

coupling
Qty/I = Qty/Individual Qty/I = Qty/Individuel
07.33 - ES0
Compressed air system
513/613
MAN Diesel
Description 513.01
Page 1 (2) Compressed Air System Edition 09H
L27/38
General Starting System
The compressed air system on the engine consists of The engine is started by means of a built-on air
a starting system, starting control system and safety starter, which is a turbine motor with gear box, safety
system. Further, the system supplies air to the jet clutch and drive shaft with pinion. Further, there is a
system and the stop cylinders on each fuel injection main starting valve.
pump. On 8 and 9 cylinders engines air is supplied to
the oil mist detector through a reduction valve.
Control System
The compressed air is supplied from the starting air
receivers (30 bar). The air starter is activated electrically with a pneumatic
3/2-way solenoid valve. The valve can be activated
08028-0D/H5250/94.08.12
Working pressure for the air starter: manually from the starting box on the engine, and
min. 16 bar it can be arranged for remote control, manual or
max. 30 bar automatic.
To avoid dirt particles in the internal system, a dirt For remote activation the starting coil is connected
strainer equipped with a drain valve is mounted in so that every starting signal to the starting coil goes
the inlet line to the engine. through the safe start function which is connected to
the safety system mounted on the engine.
01.37 - ES0
MAN Diesel
513.01 Description
Edition 09H Compressed Air System Page 2 (2)
L27/38
Further, the starting valve also acts as an emergency Pneumatic Start Sequence
starting valve which makes it possible to activate the
air starter manually in case of power failure. When the starting valve is opened, air will be supplied
to the drive shaft housing of the air starter.
Safety System The air supply will - by activating a piston - bring the
drive pinion into engagement with the gear rim on
As standard the engine is equipped with an emer- the engine flywheel.
gency stop. It consists of one on-off valve, see
diagram, which activates the stop cylinder on each When the pinion is fully engaged, the pilot air will
fuel injection pump. flow to, and open the main starting valve, whereby
air will be led to the air starter, which will start to
Air supply must not be interrupted when the engine turn the engine.
is running.
When the RPM exceeds approx. 158, at which firing
has taken place, the starting valve is closed whereby
the air starter is disengaged.
08028-0D/H5250/94.08.12
01.37 - ES0
MAN Diesel
Description 513.01
Page 1 (2) Compressed Air System Edition 14H
L27/38
General Starting System
The compressed air system on the engine consists of The engine is started by means of a built-on air
a starting system, starting control system and safety starter, which is a turbine motor with gear box, safety
system. Further, the system supplies air to the jet clutch and drive shaft with pinion. Further, there is a
system and the stop cylinders on each fuel injection main starting valve.
pump. On 8 and 9 cylinders engines air is supplied to
the oil mist detector through a reduction valve.
Control System
The compressed air is supplied from the starting
air receivers (30 bar) through a reduction station, The air starter is activated electrically with a pneumatic
where from compressed air at 10 bar is supplied to 3/2-way solenoid valve. The valve can be activated
08028-0D/H5250/94.08.12
the engine. The reduction station should be located manually from the starting box on the engine, and
as near the starting air receiver as possible. it can be arranged for remote control, manual or
automatic.
Working pressure for the air starter:
min. 8 bar For remote activation the starting coil is connected
max. 10 bar so that every starting signal to the starting coil goes
through the safe start function which is connected to
To avoid dirt particles in the internal system, a dirt the safety system mounted on the engine.
strainer equipped with a drain valve is mounted in
the inlet line to the engine.
03.34 - ES0
MAN Diesel
513.01 Description
Edition 14H Compressed Air System Page 2 (2)
L27/38
Further, the starting valve also acts as an emergency Pneumatic Start Sequence
starting valve which makes it possible to activate the
air starter manually in case of power failure. When the starting valve is opened, air will be supplied
to the drive shaft housing of the air starter.
Safety System The air supply will - by activating a piston - bring the
drive pinion into engagement with the gear rim on
As standard the engine is equipped with an emer- the engine flywheel.
gency stop. It consists of one on-off valve, see
diagram, which activates the stop cylinder on each When the pinion is fully engaged, the pilot air will
fuel injection pump. flow to, and open the main starting valve, whereby
air will be led to the air starter, which will start to
Air supply must not be interrupted when the engine turn the engine.
is running.
When the RPM exceeds approx. 158, at which firing
has taken place, the starting valve is closed whereby
the air starter is disengaged.
08028-0D/H5250/94.08.12
03.34 - ES0
MAN Diesel

Page 1 (2) Air Filter Edition 02
General

Shut-off fuel oil
Shut-off nozzle cooling 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
MAN Diesel

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
MAN Diesel

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
08028-0D/H5250/94.08.12
51309 161 1 (spare part kit)
Data

02.35 - ES0
MAN Diesel

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 engines secured by four screws (25).
ring gear.
08028-0D/H5250/94.08.12
Fig 1 Turbine housing assembly
02.35 - ES0
MAN Diesel

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

08028-0D/H5250/94.08.12
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).
02.35 - ES0
MAN Diesel

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.
08028-0D/H5250/94.08.12
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.
02.35 - ES0
MAN Diesel

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

08028-0D/H5250/94.08.12
helical spline shaft (56). Planet gear disassembly
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).
02.35 - ES0
MAN Diesel

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.
08028-0D/H5250/94.08.12
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.
02.35 - ES0
MAN Diesel

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 of metal smearing in planet pin holes &
planet shaft holes and keyways. keyways not acceptable. Scoring on bearing diameter not to
Integrity of knurl connection. 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
08028-0D/H5250/94.08.12
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
02.35 - ES0
MAN Diesel

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).
08028-0D/H5250/94.08.12
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.
02.35 - ES0
MAN Diesel

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 measu-
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
08028-0D/H5250/94.08.12
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.
02.35 - ES0
MAN Diesel

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. Tang lock washer into retainer nut slot. the spur gear shaft (65).
Place O-ring (12) onto outer diameter of gearbox Press the helical shaft assembly into the spur gear
housing (48). shaft (65) until end of shaft protrudes from forward
end of drive housing.
Install carrier shaft assembly into aft side of gearbox
housing (48) and secure with four screws (44).Torque Maintain pressing force and install pinion onto drive
to 113 in-lbs. shaft (61). Secure with screw (79). Torque to 60 ft.
lb.
Drive Housing Install spacer between pinion (79) and drive housing
(72) before releasing pressure from helical shaft.
Drive reassembly
Final assembly
Install bearing (69), please see Fig 3, into forward
end of spur gear shaft (65) and secure with retaining Place turbine assembly (23) with aft end on a flat sur-
ring (70). face and install ring gear. Ensure notches on ring
gear are aligned with screw positions on turbine
Press bearing (66) onto spur gear shaft (65) and housing.
secure with retaining ring (67).
Thoroughly grease planet gears (34), ring gear (27),
Press bearing (68) into drive housing (72) until seated sun gear (30), spur gears (45, 65) using grease No
firmly into housing. 9-94121-002.
Press lip seal (75) into forward end of drive housing Rotate carrier shaft (35) slightly, and at the same time,
(72) and install O-ring into O-ring groove on drive align gearbox into the front of turbine housing (26).
housing.
Install six gearbox to turbine assembly screws (25)
Install spur gear assembly (65-67) into gearbox drive and torque 113 in-lbs.
housing (72) until firmly seated.
Install drive assembly (72) onto gearbox assembly
Install bearing (55) onto aft end of drive shaft as- (48) and secure with eight screws (73). Torque to
sembly (56-61) and secure with retaining ring (54). 113 in.lbs.
Lubricate drive shaft assembly using grease No
9-94121-002.
08028-0D/H5250/94.08.12
02.35 - ES0
MAN Diesel
L27/38

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 : 2 hours Plate No Item No Qty/

Capacity : 1 man
08028-0D/H5250/94.08.12
51309 133 1 (repair kit, main valve)

51309 172 1 (set of seals)
Data 51309 173 1 (repair kit, rotor)

02.37 - ES0
MAN Diesel
L27/38
Operation On putting into operation
Before putting into operation In case of manual start, operate the push-button
valve for very short periods only.
Check if the installation has been accomplished
in accordance with our instructions.
Complete Overhaul
Check the adjustment of the auto-start device
(if installed), to ensure: Strip the starter and clean all lines and pipe-
work.
the speed of the starter shaft never exceeds
the value of 2.500 rpm. Check rotors and advance mechanism; clean
same and replace worn or rusted parts.
the starter stops working, once the engine
hasattained a speed 1 to 1.5 times is igni- Check the driving pinion for wear and replace
tion speed. it if necessary.
Check that the air receiver is charged and that Revice all valves and replace joints.
the flow valve is opened.
Test for leaks and check that the control circuit Storage
is not chocked.
When leaving our works, the starters contain antirust
Check for correct meshing of the driving pinion oil to protect their inner parts. In spite o this, we must
with the flywheel gear ring by means of several recommended storage in a dry place.
short starter impulses.
08028-0D/H5250/94.08.12
02.37 - ES0
MAN Diesel

Page 1 (2) Emergency Starting Valve Edition 03H
L27/38

Shut-off fuel oil
Lubricating, disassembly and reassembly of Small screwdriver.

emergency starting valve in starting system.
Starting position
Related procedure
Working time : 1 hour Plate no Item no Qty./

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

00.43 - ES0
MAN Diesel
Edition 03H Emergency Starting Valve Page 2 (2)
L27/38
Emergency Starting Valve 2) Push the emergency start button with a screw-
driver, as shown in fig 1, until the engine igni-
The emergency starting valve is placed on the tur- tes.
bine starter and should be tested according to the
planned maintenance programme. 3) Release the button. The button is springloaded
and will automatically return to the start posi-
1) Switch the engine to "local" on the operating tion.
box panel.
Fig 1 Emergency starting valve

08028-0D/H5250/94.08.12
00.43 - ES0
MAN Diesel

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

02.20 - ES0
MAN Diesel

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
MAN Diesel
Page 1 (2) Electric Turning Gear Edition 01H
L27/38
V28/32S

Shut-off cooling water Please see related electric diagram
Shut-off fuel oil
Press (Blocking - Reset)
Description
Hand tools
Electric turning of engine.
Starting position
Indicator valve in cylinder head

are open 50501-05H
Related procedure
Manpower
08028-0D/H5250/94.08.12
Capacity : 1 man Plate no Item no Qty. /
Data

02.17 - E0O
MAN Diesel

Edition 01H Electric Turning Gear Page 2 (2)
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 engine in remote position.
the gear rim until the secured position is
reached.
Maintenance
2) Adjust the position switch in such a way that
the signal from the switch changes as soon as Lubrication of gear shaft to avoid rust on the shaft.
secured position is left.
3) Tighten the position switch in this position and Trouble tracing

check once more.
Motor is not running:
- Check the electrical system.

Engagement of turning gear
Turning gear shaft can not be moved easily:
Connect the remote push button panel to the turning
gear motor starter panel.
- Dismantle the shaft and clean for
rust. New lubrication to avoid rust.
Check the rotation of the gear before connection of
the gear to the engine. Forward, clockwise rotation
Turning gear in position, turning motor is running,
- gear turning handle.
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
Engine is not starting:
towards the flywheel, so the lock pin can lock in
turning position.
- Check the microswitch ZS 75 mount-
ed on the turning gear.
It can be necessary to turn the gear in steps for con-
nection to and from flywheel.
Note: During repair work, see note on plate 51325-
04H.
Note: Inform all staff working on the engine.
Press the warning push button before turning the

engine .
08028-0D/H5250/94.08.12
02.17 - E0O
MAN Diesel
Page 1 (2) Manual Turning Gear Edition 02H
L27/38

Shut-off fuel oil
Press (Blocking - Reset)
Manual turning of engine. Standard spanner with a long shaft
Starting position
Indicator valve in cylinder head

has to be open Plate 50501
Related procedure
Working time : 1/4 hour Plate no Item no Qty. /

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

03.13 - E0O
MAN Diesel

Edition 02H Manual Turning Gear Page 2 (2)
L27/38
Warning: The diesel engine can be started locally The turning gear will automatically try to find
on the emergency start arrangement eventhough this position once the nut (X) is loosened. It
the turning gear is engaged. might need a light turning of the nut (Y) in order
to reach the position 2 - blocking.
Note: Inform all staff working on the engine that
the turning gear is engaged.
Adjustment of the turning gear
1) Engine running position.

This is the stand-by position of the turning gear
when the engine is running.
Fig 3 Position 3 Engine turning position
3) Engine turning position.

The turning gear is made ready for turning by
loosening the 60 mm nut (X) until the nut is
approx. 23 mm from the end of the shaft.
The turning gear is pushed into engagement
with the gear rim on the flywheel and out of
blocking mode. The engine can now be turned
Fig 1 Position 1 Engine running position
by means of the 30 mm nut (Y).
Note: The turning gear must be fully

2) Engine blocking position. engaged during the entire turning of engine.
This is the blocking position of the engine when
the turning gear is engaged. When the new position of the engine is found
the turning gear will automatically try to return
to the blocking position.
When turning the engine is completed the
turning gear is dis-engaged by pulling back
the turning gear carefully by hand. Finally, the
60 mm nut (X) is tightened.
08028-0D/H5250/94.08.12
Trouble tracing
Turning gear shaft can not be moved easily:

- Dismantle the shaft and clean for rust.
New lubrication to avoid rust.
Engine is not starting:

- Check the microswitch ZS 75 mounted on the
Fig 2 Position 2 Engine blocking position turning gear.
03.13 - E0O
MAN Diesel
Plate
Page 1 (2) Air Starter 51309-09H
V28/32S
L27/38
08028-0D/H5250/94.08.12
07.51 - ES0
MAN Diesel
Plate
51309-09H Air Starter Page 2 (2)
V28/32S
L27/38
Item Item
1* 6/S Screw Skrue 76* 1/S Lip seal Ttningsring
3* 1/S Screw Skrue 78 1/S Pinion Tandhjul
7* 1/S Bearing spacer Lejering 79* 1/S Washer, pinion Skive, tandhjul
8* 2/S Bearing Leje 80* 1/S Screw Skrue
9* 1/S O-ring O-ring 160 1/E Air starter, complete Startemotor, komplet
Output gear ratio
10* 1/S Spring washer Fjederskive 11.7:1
13* 2/S O-ring O-ring 161 1/S Spare parts kit, com- Reservedelsst, be-
prising of item 1, 3, 7, stende af item 1, 3, 7,
14* 2/S Seal spacer Pakningsdse 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,
15* 2/S Lip seal Ttningsring 45, 50, 56, 61, 63, 64, 45, 50, 56, 61, 63, 64,
67, 69, 70, 72, 74, 76 67, 69, 70, 72, 74, 76
18* 8/S Screw Skrue
21* 1/S O-ring O-ring
22* 6/S Screw Skrue
36* 3/S Needle bearing Leje
39* 2/S Bearing Leje
45* 4/S Screw Skrue
50* 6/S Screw Skrue
56* 1/S Bearing Leje
61* 1/S Bearing, needle roller Leje
62a 1/S Shaft (LH) Aksel (LH)
62b 1/S Shaft (RH) Aksel (RH)
63* 2/S Thrust washer Trykskive
64* 1/S Retaining ring Sikringsring
67* 1/S Ball bearing Kugleleje

08028-0D/H5250/94.08.12
70* 1/S Bearing, needle roller Leje
74* 1/S Screw Skrue
Qty/E = Qty./Engine Qty./E = Qty/Motor
Qty./S = Qty./Starter Qty./S = Qty./Starter
07.51 - ES0
MAN Diesel
Plate
Page 1 (2) Air Starter 51309-11H
L27/38
08028-0D/H5250/94.08.12
02.34 - ES0 - b/c

MAN Diesel
Plate
51309-11H Air Starter Page 2 (2)
L27/38
Item Item
140 1/S Pinion Tandhjul
141 1/S Air starter, complete Startemotor, komplet
142 1/S Solenoid valve Magnetventil
143 1/S Strainer Filter
08028-0D/H5250/94.08.12
02.34 - ES0 - b/c

MAN Diesel
Plate
Page 1 (3) Air Starter (supplement for plate 51309-11H) 51309-12H
Serial no. > 01-0026 L27/38

08028-0D/H5250/94.08.12
02.34 - ES0 - b
MAN Diesel
Plate
51309-12H Air Starter (supplement for plate 51309-11H) Page 2 (3)
L27/38 Serial no. > 01-0026

Item Item
1 1/S Special circlip Clips 31 4/S Flat washer Skive
2* 1/S Retaining ring Sikringsring 32 4/S Stud Tap
3 1/S Needle bearing Nleleje 34 1/S Servo-limiter unit Servo-limiter unit
4 4/S Allen screw Skrue 35 1/S Servo supplement Servo supplement
5 4/S Special washer Skive 36 2/S Allen screw Skrue
6 1/S Front cover Fordksel 37* 8/S Washer Skive
7* 1/S Special joint Speciel samling 38 4/S Special bolt Bolt
8 1/S Bearing extrac. ring Lejering 39 2/S Flexible pipe Flexibelt rr
9 23/S Cylinder roller Cylinderrulle 40 1/S Silencer Lyddmper
10 1/S Bearing disc Lejeskive 41 4/S Stud Tap
12 1/S Special nut Mtrik 42 4/S Flat washer Skive
13 1/S Special washer Skive 43 4/S Nut Mtrik
14* 1/S Ring Ring 44* 1/S Secondary rotor Secondary rotor
15 1/S Hauling crown ccw Rotordksel 45 1/S Check valve Checkventil
16 1/S Spring Fjeder 46 1/S Elastic pin Elastisk tap
17 1/S Splined shaft ccw Fjedrende aksel 47* 1/S Membrana Membran
18 1/S Guide cylinder Styrecyllinder 48 1/S Plug Prop
19* 1/S O-ring O-ring 49* 1/S Special nut Mtrik
20 1/S Follower Medflger 50* 1/S Lip seal Ttningsring
21 2/S Allen screw Skrue 51* 1/S Main valve Hovedventil
22 2/S Special washer Skive 52* 1/S O-ring O-ring
23 1/S Motor body ccw Motorhus 53* 1/S Distributor Fordeler
24* 1/S Primary rotor Primary rotor 54* 1/S Bushing Bsning
25 1/S Valve body ccw Ventilhus 55* 1/S O-ring O-ring
26 1/S Silencer Lyddmper 56* 1/S O-ring O-ring
27 1/S Bend Bjning 57* 1/S Seal shell Dksel

08028-0D/H5250/94.08.12
28 1/S Flat washer Skive 58* 1/S Special washer Skive
29 1/S Special nut Mtrik 59* 1/S Special nut Mtrik
30 4/S Special nut Mtrik 60 1/S Spring Fjeder
02.34 - ES0 - b
MAN Diesel
Plate
Serial no. > 01-0026 L27/38

Item Item
61 4/S Stud Tap
64 1/S Plug joint Ttningsprop
67 1/S Inlet nozzle Indstrmningsdyse
69 4/S Special washer Skive
70 4/S Allen screw Skrue
71 1/S Special pipe 6x4 Rr 6x4
72 1/S Elastic pin Elastisk tap
75 1/S Front labyrinth seals Ttning
81 2/S Rod Stang
133 1/S Repair kit for main Reservedelsst for

valve, comprising item hovedventil indehold-
49, 50, 51, 52, 53, 54, 55, ende item 49, 50, 51,
56, 57, 58, 59 52, 53, 54, 55, 56, 57,
58, 59
172 1/S Set of seals, compri- Ttningsst, indehold-

sing item 2, 7, 14, 19, ende item 2, 7, 14, 19,
37, 47, 50, 52, 55, 56, 37, 47, 50, 52, 55, 56,
66, 68, 74, 77, 82 66, 68, 74, 77, 82
173 1/S Repair kit, compris- Reservdelsst, inde-

ing item 172, 24, 44, holdende item 172, 24,
08028-0D/H5250/94.08.12
76, 83 44, 76, 83
02.34 - ES0 - b
MAN Diesel
Plate
Serial no. > 02-0101 L27/38

08028-0D/H5250/94.08.12
02.34 - ES0 - c
MAN Diesel
Plate
51309-13H Air Starter (supplement for plate 51309-11H) Page 2 (3)
L27/38 Serial no. > 02-0101

Item Item
1 4/S Allen screw Skrue 32 4/S Stud Tap
2 4/S Special washer Skive 34 1/S Servo-limiter unit Servo-limiter unit
3 1/S Front cover Fordksel 35 1/S Servo supplement Servo supplement
4* 1/S Retaining ring Sikringsring 36 2/S Allen screw Skrue
5 1/S Needle bearing Nleleje 37* 8/S Washer Skive
6 1/S Special circlip Clips 38 4/S Special bolt Bolt
7* 1/S Special joint Speciel samling 39 2/S Flexible pipe Flexibelt rr
8 1/S Bearing extrac. ring Lejering 40 1/S Silencer Lyddmper
9 23/S Cylinder roller Cylinderrulle 41 4/S Stud Tap
10 1/S Bearing disc Lejeskive 42 4/S Flat washer Skive
11* 1/S Labyrinth sealing Labyrintttning 43 4/S Nut Mtrik
12 1/S Special nut Mtrik 44* 1/S Secondary rotor Secondary rotor
13 1/S Special washer Skive 45 1/S Check valve Checkventil
14* 1/S Ring Ring 46 1/S Elastic pin Elastisk tap
15 1/S Hauling crown ccw Rotordksel 47* 1/S Membrana Membran
16 1/S Spring Fjeder 48 1/S Plug Prop
17 1/S Splined shaft ccw Fjedrende aksel 49* 1/S Special nut Mtrik
18 1/S Guide cylinder Styrecylinder 50* 1/S Lip seal Ttningsring
19* 1/S O-ring O-ring 51* 1/S Main valve Hovedventil
20 1/S Follower Medflger 52* 1/S O-ring O-ring
21 2/S Allen screw Skrue 53* 1/S Distributor Fordeler
22 2/S Special washer Skive 54* 1/S Bushing Bsning
23 1/S Motor body ccw Motorhus 55* 1/S O-ring O-ring
24* 1/S Primary rotor Primary rotor 56* 1/S O-ring O-ring
25 1/S Valve body ccw Ventilhus 57* 1/S Seal shell Dksel
26 1/S Silencer Lyddmper 58* 1/S Special washer Skive

08028-0D/H5250/94.08.12
27 1/S Bend Bjning 59* 1/S Special nut Mtrik
28 1/S Special nut Mtrik 60 1/S Spring Fjeder
30 4/S Special nut Mtrik 61 4/S Stud Tap
02.34 - ES0 - c
MAN Diesel
Plate
Serial no. > 02-0101 L27/38

Item Item
64 1/S Plug joint Ttningsprop
67 1/S Inlet nozzle Indstrmningsdyse
69 4/S Special washer Skive
70 4/S Allen screw Skrue
71 1/S Special pipe 6x4 Rr 6x4
72 1/S Elastic pin Elastisk tap
81 2/S Rod Stang
133 1/S Repair kit for main Reservedelsst for

valve, comprising item hovedventil indehold-
49, 50, 51, 52, 53, 54, 55, ende item 49, 50, 51,
56, 57, 58, 59 52, 53, 54, 55, 56, 57,
58, 59
172 1/S Set of seals, compri- Ttningsst, inde-

sing item 4, 7, 11, 14, hold-ende item 4, 7,
19, 37, 47, 50, 52, 55, 56, 11, 14, 19, 37, 47, 50,
66, 68, 74, 77, 82 52, 55, 56, 66, 68, 74,
77, 82
173 1/S Repair kit, compris- Reservdelsst, inde-

ing item 172, 24, 44, holdende item 172, 24,
76, 83 44, 76, 83
08028-0D/H5250/94.08.12
02.34 - ES0 - c
MAN Diesel
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
MAN Diesel
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 Skrm
190* 1/V O-ring O-ring
212 1/V Piston Stempel
224* 1/V Dampener, shock Dmper
236 1/V O-ring, cap O-ring
248* 1/V Spring Fjeder
273 1/V End cap Endedksel
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- Reserevedelsst,

prising item bestende af item
190, 200, 224, 248, 190, 200, 224, 248,
261, 285 261, 285
08028-0D/H5250/94.08.12
Qty./V = Qty./Valve Qty./V = Qty./Ventil
04.04 - ES0
MAN Diesel
Plate
Page 1 (2) Main Stop Valve 51315-03
L21/31,
L23/30H, L27/38
08028-0D/H5250/94.08.12
00.41 - EO0
MAN Diesel
Plate
51315-03 Main Stop Valve Page 2 (2)
L21/31,
L23/30H, L27/38
Item Item
042 1/E Stop valve, Stopventil,

complete komplet
066 1/V Gasket Pakning
078 1/V Gasket Pakning
08028-0D/H5250/94.08.12
Qty./V = Qty./Valve Antal/V = Antal/Ventil
00.41 - EO0
MAN Diesel
Plate
Page 1 (2) Solenoid Valve, 3/2 51318-01H
Generel
08028-0D/H5250/94.08.12
05.33 - EO0
MAN Diesel
Plate
51318-01H Solenoid Valve, 3/2 Page 2 (2)
L27/38
Item Item
001 1/E Solenoid valve, Magnetventil,

complete komplet
08028-0D/H5250/94.08.12
05.33 - ES0
MAN Diesel
Plate
Page 1 (2) Air Filter 51321-03
General
190
08.21 - ES0
MAN Diesel
Plate
51321-03 Air Filter Page 2 (2)
General
Item Item
190 1/E Filter complete Filter komplet
200 1/F Repair kit Reparationsst

(filter and O-ring) (filter og O-ring)
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
08.21 - ES0
MAN Diesel
Plate
Page 1 (2) Pressure Reduction Valve 51322-06H
L27/38
052
027
015 003
039
08028-0D/H5250/94.08.12
07.51 - ES0
MAN Diesel
Plate
51322-06H Pressure Reduction Valve Page 2 (2)
L27/38
Item Item
003 1/E Pressure reduction Magnetventil,

valve, complete komplet
015 1/E Filter Filter
027 1/E Manometer and pres- Manometer og magnet-

sure reduction valve ventil
040 1/E Repair kit Reparationsst

(filter and O-ring) (filter og O-ring)
052 1/E Manometer Manometer
08028-0D/H5250/94.08.12
07.51 - ES0
MAN Diesel
Plate
Page 1 (2) Pressure Reduction Valve 51322-04H
General
08028-0D/H5250/94.08.12
03.22 - ES0
MAN Diesel
Plate
51322-04H Pressure Reduction Valve Page 2 (2)
General
Item Item
no Qty. Designation Benvnelse no Qty. Designation Benvnelse
015 1/V Cover Dksel
027 10/V Screw Skrue
039* 2/V Filter Filter
040 1/V Tube incl. o-ring Rr, 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 Rrprop
196 1/V Repair kit, incl. item Reparationsst, 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 Reparationsst 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 Reparationsst for

item 206 item 206
Qty/E = Qty/Engine Antal/E = Antal/Motor
Qty/V = Qty/Valve Antal/V = Antal/Ventil
03.22 - ES0
MAN Diesel
Plate
Page 1 (2) Turning Gear with Attachment 51325-03
L21/31,
L27/38
08028-0D/H5250/94.08.12
All valves and fittings

has to be approved by
classification society.
99.15 - ES0
MAN Diesel
Plate
51325-03 Turning Gear with Attachment Page 2 (2)
L21/31,
L27/38
Item Item
011 1/E Nut Mtrik
023 1/E Shaft Aksel
047 2/E Screw Skrue
059 2/E Screw Skrue
060 1/E Position swich Position switch
072 1/E Stop piece Stopstykke
084 1/E Spur wheel Tandhjul
106 1/E Support Sttte
131 1/E Grease nipple Smrenippel
155 1/E Sliding piece Glidestykke
179 1/E Nut Mtriik
08028-0D/H5250/94.08.12
99.15 - ES0
MAN Diesel
Plate
Page 1 (2) Electric Turning Gear 51325-05H
V28/32S
L27/38
08028-0D/H5250/94.08.12
02.32 - EO0
MAN Diesel
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 Mtrik, 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 Stskrue

cap screw
670 1/E Shaft Aksel
682 1/E Lock pin Lsepind
694 1/E Pipe Rr
704 1/E Shaft Aksel
728 1/E Turning handle Trne hndtag
741 1/E Studs Studs
753 1/E Self-locking hex. nut Selvlsende mtrik
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
MAN Diesel
Plate
Page 1 (2) Overspeed Stop Valve 51327-01H
General

08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Plate
51327-01H Overspeed Stop Valve Page 2 (2)
General
Item Item
012 1/E Solenoid valve 3/2, Magnetventil 3/2,

complete komplet
024 1/E Coil Spole
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
99.03 - ES0
MAN Diesel
Plate
Page 1 (2) Arrangement of Jet System 51330-05H
L27/38
379
380
019 152 032 188
081 081
093 093
081
247 093
235
223
152
044
331
318
221
296 Cyl. 1
306
367

081 259 260 115 081

093 115 140 093
164
08028-0D/H5250/94.08.12
140 306 272 306

318 318
08.17 - ES0
MAN Diesel
Plate
51330-05H Arrangement of Jet System Page 2 (2)
L27/38
Item Item
019 1/E Pipe Rr

032 1/E Pipe Rr
044 1/E Pipe Rr

coupling

complete komplet
152 2/E Straight coupling Ligeforskruning
164 1/E Coil Spole
188 2/E Screw Skrue
221 1/E Pipe Rr

coupling
272 1/E Adjustable male stud Justerbar ligeforskru-

coupling ning

coupling
331 1/E Restriction Restriktion
379 1/E Pipe Rr

08028-0D/H5250/94.08.12
6 and 7 cyl. engine 6 og 7 cyl. motor
380 1/E Pipe Rr

08.17 - ES0
MAN Diesel
Plate
Page 1 (2) Arrangement of Jet System 51330-06H
L27/38
379
380
019 152 032 188
081 081
093 093 081
247 093
235
223
152
044
331
343
318
296 221
306

081 259 260 115 081

093 115 140 093
164
08028-0D/H5250/94.08.12
140 306 272 306

318 284 318
08.17 - ES0
MAN Diesel
Plate
51330-06H Arrangement of Jet System Page 2 (2)
L27/38
Item Item
019 1/E Pipe Rr 379 1/E Pipe Rr

5 and 6 cyl. engine 5 og 6 cyl. engine 7 and 8 cyl. engine 7 og 8 cyl. motor
032 1/E Pipe Rr 380 1/E Pipe Rr

9 cyl. engine 9 cyl. engine
044 1/E Pipe Rr

coupling

complete komplet
152 2/E Straight coupling Ligeforskruning
164 1/E Coil Spole
188 2/E Screw Skrue
221 1/E Pipe Rr

coupling
272 1/E Adjustable male stud Justerbar ligeforskru-

coupling ning
284 2/E Adapter Adapter

coupling

08028-0D/H5250/94.08.12

7, 8 and 9 cyl. engine 7, 8 og 9 cyl. motor
08.17 - ES0
MAN Diesel
Plate
Page 1 (2) Starting Air Receiver 51335-01H
General

08028-0D/H5250/94.08.12
99.15 - EO0
MAN Diesel
Plate
51335-01H Starting Air Receiver Page 2 (2)
General
Item Item
016 1/E Starting air receiver, Starteluftreceiver,

complete komplet
028 1/E Pressure gauge valve Manometerventil
053 1/E Starting valve Starteventil
065 1/E Backfilling valve Pfyldningsventil
077 1/E Air relief valve Afluftningsventil
089 1/E Auxiliary valve Hjlpeventil
090 1/E Drain valve Drnventil
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
99.15 - EO0
Fuel oil system
514/614
MAN Diesel
Description 514.01
Page 1 (2) Internal Fuel Oil System Edition 05H
L27/38
Fig. 1 Diagram for fuel oil system.
General It is adviced to install the filter every time the ex-

tern fuel pipe system has been dismantled, but it
The internal built-on fuel oil system as shown in fig. is important to remove the filter again when the
1 consists of the following parts: extern fuel oil system is considered to be clean for
any impurities.
the running-in filter
the high-pressure injection equipment
the waste oil system Fuel Injection Equipment
Each cylinder unit has its own set of injection equip-

Running-in Filter ment comprising injection pump unit, high-pressure
pipe and injection valve.
The running-in filter has a fineness of 50 microns
08028-0D/H5250/94.08.12
and is placed in the fuel inlet pipe. Its function is to The injection equipment and the distribution supply
remove impurities in the fuel pipe between safety pipes are housed in a fully enclosed compartment
filter and the engine in the running-in period. thus minimizing heat losses from the preheated fuel.
This arrangement reduces external surface tempera-
Note: The filter must be removed before ship delivery tures and the risk of fire caused by fuel leakage.
or before handling over to the customer.
The injection pump unit are with integrated roller
guide directly above the camshaft.
01.38 - ES0
MAN Diesel
514.01 Description
Edition 05H Internal Fuel Oil System Page 2 (2)
L27/38
The fuel quantity injected into each cylinder unit is A bore in the cylinder head vents the space below
adjusted by means of the governor, which maintains the bottom rubber sealing ring on the injection valve,
the engine speed at the preset value by a continuous thus preventing any pressure build-up due to gas
positioning of the fuel pump racks, via a common leakage, but also unveiling any malfunction of the
regulating shaft and spring-loaded linkages for each bottom rubber sealing ring due to leak oil.
pump.
The injection valve is for "deep" building-in to the Waste Oil System
centre of the cylinder head.
Waste and leak oil from the compartments, fuel valves
The injection oil is supplied from the injection pump and fuel pumps is led to a fuel leakage alarm unit.
to the injection valve via a double-walled pressure
pipe installed in a bore in the cylinder head. The alarm unit consists of a box with a float switch
for level monitoring. In case of a larger than normal
This bore has an external connection to lead the leak leakage, the float switch will initiate an alarm. The
oil from the injection valve and high-pressure pipe supply fuel oil to the engine is led through the unit
to the waste oil system, through the double walled in order to keep this heated up, thereby ensuring
pressure pipe. free drainage passage even for high-viscous wa-
ste/leak oil.
08028-0D/H5250/94.08.12
01.38 - ESo
MAN Diesel
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
6 6
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
MAN Diesel
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
MAN Diesel
Page 1 (4) Dismounting / Mounting of Fuel Injection Pump Edition 08H
L27/38

Shut-off fuel oil
Fuel injection pumps have to be removed to permit Reversing ratchet.

the necessary check, which also involves disas- Torque wrench 20-200 Nm.
sembly to a certain extent. It may also become Cross handle.
necessary to remove the pumps if com-ponents Annular extension, size 24.
have to be replaced. Hexagon key wrench with ball head, 6 A/F.
Set of open-end/ring spanners.
Set of hexagon bolt drivers.
Starting position Lifting tackle with rope.
Copaslip or similar.
Covering on the exhaust gas counterside remo- Acid-free grease.
ved.
Fuel injection pipe dismounted.
Injection pump cleaned and checked, fuel rack
completely pushed in as a precautionary measure
af protection (full load position).
Related procedure
Adjustment of camshaft for valve

and injection timing 507-01.20
Disassembly and assembly and repair
of fuel injection pump 514-01.06

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

Capacity : 1 men 51401 685 1/C
51401 457 1/C
51435 070 *8/C
Data 51435 344 *4/C
51435 356 4/C
Data for torque moment (Page 500.40) * see plate 51435 for max. amount.
02.36 - ES0
MAN Diesel
Edition 08H Dismounting / Mounting of Fuel Injection Pump Page 2 (4)
L27/38
Operating Sequence 1 - Dismounting of Fuel

Injection Pump
1) Turn the engine so that the follower of the

injection pump is at cam base circle position
(spring largely unloaded).
2) Close all the necessary shut-off valves (such

as for the fuel oil pipes, air ducts etc.).
3) Disconnect the air duct, leaked fuel oil pipe,

lub. oil pipe and sealing oil pipe (if fitted) from
the injection pump.
4) Remove the screw, (3) fig 1,on the two pumps

beside and press the fuel oil pipe away from
the actual fuel pump.
5) Unscrew the hexagon head bolt, (1) fig 1, be-

tween the fuel rack and the articulated head.
Caution
The position of the articulated head between
the knuckle lever and the rack has been ad-
justed and secured by the manufacturer. It is Fig 2 Removing a fuel injection pump
expressly pointed out that the articulated head
must not be disassembled and/or changing
the length as adjusted is only allowed for zero
position balancing the injection pump and the 6) As a protective precaution for the fuel rack,
governor. push it completely in (full load position).
7) Screw off the hexagon nuts, (2) fig 1.
8) Screw the holder, see fig 2, onto the injection

pump.
9) Insert the lever into the holder and connect it

with the bolt. Secure the bolt by means of the
spring plug.
10) Attach the rope to the lever by means of shackle

08028-0D/H5250/94.08.12
and suspend it from the lifting tackle.
11) Lift rope until the lever approximately has the

position, see fig 2.
12) Depress the lever to lift the injection pump far

enough to come clear of the bore hole.
Caution
During removal, take care that stud bolts are
not damaged.
Fig 1 Fuel injection pump as mounted
02.36 - ES0
MAN Diesel
Page 3 (4) Dismounting / Mounting of Fuel Injection Pump Edition 08H
L27/38
13) Keep the injection pump in this position and 21) Insert the lever in the holder and connect by
remove it sideways. means of the bolt. Secure the bolt by means
of spring plug.
14) Cover the resultant opening in the crank-
case. 22) Attach the rope to the lever by means of a
shackle and suspend from lifting tackle. Lift
15) To transport the pump away, let the lever loose, the injection pump.
see fig. 3.
23) Treat a new o-ring seal, (1) fig 3, with acid-free
16) Put the injection pump down on a clean grease and fit it in the ring groove. Take care
place. that it is evenly tensioned over the circumfer-
ence and not twisted.
17) Remove the tool completely.
24) Press the lever down to lift the injection
pump.
25) Push the injection pump under the change-air

pipe and over the bore hole.
Caution
Take care that the injection pump does not hit
any parts while being installed.
26) Release the pressure exerted on the lever,

lowering the injection pump into the bore.
Caution
In introducing the injection pump, take care
that stud bolts do not suffer damage.
27) Remove the tool completely.
28) Treat new o-ring seals (2) fig 4 and (4) fig 1,
with acid-free grease and fit them in the ring
grooves on the flange, taking care that they
are not twisted.
Fig 3 Transporting of dismounted fuel injection pump

08028-0D/H5250/94.08.12
Operating Sequence 2 - Installing of Fuel

Injection Pump
18) Clean the contact faces on the injection pump

and the crankcase.
19) Treat new o-ring seals, (1) fig 4, with acid-free

grease and fit them in the ring grooves on the
fuel oil orifice flanges, making sure not to twist
them.
20) Screw the holder onto the injection pump. Fig 4 Press the fuel pipesback into the pump
02.36 - ES0
MAN Diesel
514-01.05 Dismounting / Mounting of Fuel Injection Pump Working Card
L27/38
29) Press the fuel pipes back into the pump, fig 4, Caution
and fit the plug screw, (3) fig 1. The correct length of the articulated head be-
tween the knuckle lever and the fuel rack has
30) Treat the thread and contact face of the hexa- been adjusted and secured by the manufac-
gon nut with coperslip or the like and screw turer. It is expressly pointed out that changes
it hand-tight onto the stud bolts (do not drive to the length so adjusted are only allowed to
them home). be made for a balancing of the zero position
between the injection pump and governor.
31) Turn the engine (follower of the injection pump
aligns on cams). 37) Open all the shut-off valves that have been
closed in operating sequence 1.
32) Tighten the hexagon nut with specified torque,
please see description 500.40. 38) Verify that the fuel rack is in the "zero position"
end position when the complete fuel admis-
33) Connect the air pipe, the leaked fuel oil pipe, sion linkage is at "zero position" (compare fuel
the lub. oil pipe and the sealing oil pipe (if ap- rack position with that on the other injection
plicable) to the injection pump. pumps).
34) Mount the fuel inection pipe. 39) After putting into operation, determine the igni-
tion pressure by taking indicator diagrams.
35) Check and adjustment of injection timing,
please see working card 507-01.20. Note: Precise settings are very essential for the
output, combustion properties and trouble-free
36) Attach the articulated head to the fuel rack. operation of the engine.
08028-0D/H5250/94.08.12
02.36 - ES0
MAN Diesel
Working Card Disassembly and Assembly and Repair 514-01.06
of Fuel Injection Pump
L27/38

Injection pumps have to be disassembled indivi- Reversing ratchet.

dually or jointly at intervals specified in the main- Torque wrench 20-200 Nm.
tenance schedule. Dubious, worn and damaged Cross handle.
parts have to be replaced to ensure operational Screw driver insert, size 12 x 12.5.
reliability and efficiency. Screw driver insert, size 10 x 12.5.
Thickness gauge 0.05 - 1.0 mm.
Set of open-end/ring spanners.
Starting position Set of hexagon bolt drivers.
MoS2 lubricant.
Injection pump detached and cleaned on the Loctite 243 bonding agent.
exterior. Acid-free grease.
All the parts cleaned and checked for damage,
and replaced if necessary. Tappet and valve sup-
port assembled.
Related procedure
Dismounting/Mounting of Fuel
Injection Pump 514-01.05

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

Capacity : 1 men
51401 720 1/C
51401 744 1/C
Data 51401 504 1/C
51401 482 2/C
Data for pressure and tolerance (Page 500.35) 51401 697 2/C
Data for torque moment (Page 500.40) 51401 707 1/C
Declaration of weight (Page 500.45) 51401 110 1/C
02.11 - ES0
MAN Diesel
514-01.06 Disassembly and Assembly and Repair Working Card
L27/38
Operating Sequence 1 - Disassemble a Fuel

Injection Pump
1) Screw out the hexagon socket bolts (1), take

off the valve support and put down on clean
place, see fig 2.
2) See fig 1 (I). Screw the spindle back, place the

bridge diagonally onto the casing and attach
it by means of hexagon nuts.
3) Turn the spindle until the thrust pad contacts

the tappet, see fig 1 (II).
4) Turn the spindle to depress the tappet far

enough to unload the screw plug so the latter
can be removed, see fig 1 (III).
5) Turn the spindle back to unload the compres-

sion spring, see fig 1 (IV).
6) Remove the complete tool.
7) Disassemble the tappet together with the pump

plunger and put down on clean place.
Caution
Do not touch the pump plunger with your bare
hands. Protect the control edges on the pump
plunger from damage.
8) Measure the clearance (A), fig 2, of the pump

plunger between the thrust plate (2) and the
plunger base plate, note down and compare
with specified value, see description 500.35.
In case of exceeding values, please replace
wearing parts.
08028-0D/H5250/94.08.12
Fig 1 Unloading/loading of the compression spring in the fuel

9) Screw off the hexagon socket bolts (3) and injection pump
take the tappet (16) off.
10) Take the thrust plate out and pull the plunger
base plate (14) off the plunger.
02.11 - ES0
MAN Diesel
L27/38
Fig 2 Fuel injection pump
11) Take the compression spring out of the cas- 13) Screw out both baffle screws (6).
ing, disassemble the spring cup (4) and the
regulating sleeve (5). 14) Unscrew the hexagon socket screws (7) and
take the thrust ring (19) off.
08028-0D/H5250/94.08.12
12) Unscrew the cylinder and remove the regulator

rod, see fig 4.
02.11 - ES0
MAN Diesel
L27/38
15) Put the thrust plate onto the monobloc cylinder 18) Remove the monobloc cylinder from the casing
and fasten it in place, see fig 3. and put it down on a clean support.
16) Screw two hexagon head bolts into the thrust 19) Measure the axial and radial clearance of
plate down to contact with the casing. follower (8), fig 2, note down and compare
with the specified clearances, see description
17) Attach the monobloc cylinder to the casing by 500.35.
turning the hexagon head bolts. In case of exceeding values, please replace
wearing parts.
Note:Take care to avoid tilting of the monobloc cyl-
inder as it is being pulled out. Note:The replacement of followers should be entrust-
ed to a service base on MAN B&W personnel
as a matter of principle because the follower
bolt has been fitted in the tappet by freezing.
20) Check the complete valve support, (20) fig 2,

for tightness and verify that the individual parts
move easily. Disassemble the valve support if
necessary.
21) Clean all the parts with clean diesel oil and
check them for wear or damage.
Note:A pump element consists of the plunger and

monobloc cylinder. Plunger and monobloc cyl-
inder can only be replaced together because
they fit together.
08028-0D/H5250/94.08.12
Fig 3 Removing the monobloc cylinder Fig 4 Fuel injection pump top view
02.11 - ES0
MAN Diesel
L27/38
Operating Sequence 2 - Assemble a Fuel 27) Introduce the monobloc cylinder into casing,
Injection Pump taking note of the position of the cylindrical pin,
refer to fig 5.
22) Prior to assembly, slightly oil all the parts with
thin-bodied mineral oil. 28) Place the thrust plate, see fig 5, onto the mono-
bloc cylinder, mount the bridge over the thrust
Note: Metallic sealing and contact faces must plate on the casing, and screw the hexagon nut
be absolutely dry when assembled. down to contact with the thrust plate, see fig 5.
Screw the hexagon head bolt into the bridge.
23) Fit a new plunger packing in the ring groove,
see fig 4. 29) Force the monobloc cylinder into the casing
by turning the hexagon head bolt, making sure
Note: Alignment of the marks M/M is of great that the locating pin is between the cylindrical
importance. pins, see fig 5.
24) Fit the fuel rack in the casing. Note:When forcing the monobloc cylinder into the
casing, prevent it from tilting.
25) Apply loctite 243 to the thread of the cylinder
over length of 6 mm and screw home into the
casing with a new gasket fitted.
26) Treat new sealing rings (9) and o-ring seals (10
and 11) with acid-free grease and fit them in
ring groove, taking care that the o-ring seals
are evenly tensioned aver the circumference,
and not twisted.
08028-0D/H5250/94.08.12
Fig 5 Installing a new barrel
02.11 - ES0
MAN Diesel
Page 6 (6)
Edition 07H of Fuel Injection Pump
L27/38
30) Removel the tool. Note:Prior to installing the spring plate, verify once
again that the markings of the regulating sleeve
31) Put the thrust ring (2), fig 2, onto the monobloc and fuel rack match.
cylinder.
37) Fit the compression spring (13) in the cas-
32) Apply copaslip or the like to the threads and ing.
contact faces of the hexagon socket bolts, screw
home hand-tight and tighten to the specified 38) Put the plunger base plate (14) onto the pump
torque, please see description 500.40. For plunger (15). Insert the thrust plate (2) in the
order of tightening, see fig 6. plunger base plate.
Causion
Do not touch pump plungers with your bare
hands. Protect control edges on plungers
against damage.
39) Put the tappet (16) over the plunger base plate
and fasten it by four hexagon socket bolts
(3).
40) Measure the clearance (A), fig 2, of the pump

plunger between the thrust plate (2) and the
plunger base plate, note down and compare
with specified value, see description 500.35.
In case of exceeding values, please replace
1-8 Order of bolt tightening wearing parts.
9-19 Order of tightening
41) Carefully push the plunger and tappet into the
monobloc cylinder and/or casing, taking note
Fig 6 Order of tightening the fixing bolts for the monobloc of the position of the longitudinal groove in the
cylinder (left) and valve support (right)
tappet for the screw plug (17).
42) Screw the spindle back and place the bridge

33) Place the valve support onto the monobloc diagonally onto the casing and fasten it by
cylinder, taking note of the bore/cylindrical pin hexagon nuts, (see fig 1/I).
(12) position.
43) Turn the spindle until the thrust pad contacts
34) Apply copaslip or the like to the threads and the tappet (see fig 1/II).
contact faces of the hexagon socket bolts, screw
home hand-tight and tighten to the specified 44) Turn the spindle to depress the tappet far
08028-0D/H5250/94.08.12
torque in three steps, please see description enough to allow the screw plug equipped with
500.40. For ordering of tightening, see fig 6. a new gasket to be fitted (see fig 1/III).
35) Fit the regulating sleeve so that the markings 45) Force the tappet down by turning the spindle
(M), see fig 4, on the fuel rack and regulating far enough so that the screw plug equipped
sleeve coincide. with a new gasket can be fitted.
36) Install the spring plate through the regulating 46) Remove the complete tool.
sleeve into the casing.
47) Screw the baffle screws (6) complete with new
gaskets (18) into the casing specified.
02.11 - ES0
MAN Diesel
Working Card
Fuel Injection Valve 514-01.10
L27/38

Stopped pre. lub. pump 52000 497
Description
Dismounting, overhaul, pressure testing and

mounting of fuel injection valve.
Top cover on the cylinder head and front cover on Ring and open end spanner 12 mm
the fuel injection pump has been dismounted. Ring and open end spanner 24 mm
Socket spanner 24 mm
Clean kerosene or gas oil.
Antiseizure product.
(Copaslip, Molykote GN Plus or similar).
Related procedure
08028-0D/H5250/94.08.12

Manpower
Capacity : 1 man 51402 033 1/cyl
51402 104 1/cyl
51402 189 1/cyl
Data

Data for tightening torque (Page 500.40)
08.19 - ES0
MAN Diesel
514-01.10 Fuel Injection Valve Working Card

L27/38
The fuel injection valve is the single component that 3) Remove the high pressure fuel injection pipe,
has a very important influence on the diesel engine see fig. 1, pos. 12.
condition. The functioning and setting of the injection
valve influence the combustion process, the operating 4) Loosen the lock screw and lock washer and
data and the loading of the injection system. Various remove it from the cylinder head. See fig. 1
forms of operation and quality of fuel oil affect the pos. 9.
overhaul intervals. In some cases it may be neces-
sary to shorten the prescribed intervals. 5) Screw the high-pressure lance out from the
cylinder head. See fig. 1 pos. 8.
Dismounting
1) Loosen the hexagon nuts and screw them off,

see fig. 1 pos. 7. 2
2) Remove the bracket from the fuel injection

valve, see fig. 1, pos. 11.
1
11
2
1
4 8
10
3
12
9
1 Spindel
2 Nut
5 Fig 2 Tool for dismounting of fuel injection valve.

6
08028-0D/H5250/94.08.12
1 Adjusting spindle 7 Hexagon nut

2 Nut 8 High pressure lance
3 Pressure spring 9 Lock screw Dismount the fuel injection valve from the cyl-
4 O-ring 10 Setting screw inder head using of the special tool as shown
5 Nozzle nut 11 Fuel injection valve in fig 2.
6 Injector nozzle 12 Fuel injection pipe
6) Screw the threaded spindle of the tool onto the
injection valve until seated. See fig. 2 pos 1.
Fig 1 Fuel injection valve.
7) Pull the injection valve out by turning the hexa-
gon nut. See fig. 2 pos 2.
Note:The special tool is the only allowable tool for

this operation.
08.19 - ES0
MAN Diesel
Working Card Fuel Injection Valve 514-01.10

L27/38
8) Cover the hole into the cylinder by a cloth or 17) Pull out the injector needle and clean the nozzle
similar. holes of chared coke by means of the supplied
special drill, see fig. 3, with holder.
Dismantling 18) Clean carefully the injector body by placing

these in a cleaning liquid and then blow through
Note:Utmost cleanliness and care are required during the parts with dry air.
the disassembly of fuel injection valve.
9) Clean the complete injection valve with Inspection of the Parts

kerosene/MDO on the outside, remove coke
deposits by using a hard brush (not a steel Note:Nozzle body and nozzle neddle are matched
brush). For the injection nozzle, only use a by lapping and are therefore only interchange-
wooden scraper in order not to damage the able as one unit.
nozzle orifices. Clean the cylindrical projection
of the nozzle body with particular care. 19) Insert the injector needle into nozzle body.
As controle of parts is the needle pulled out to
10) Loosen the nut, see fig 1, pos 2. approx. one third of its sliding surface. At an
almost vertical position, the injector needle
11) Remove the setting screw (10). must quickly slide onto the tight seat by its
deadweight. This check-up has to be carried
12) Then release the pressure spring (3) by loosn- out for three almost uniformly distributed turn-
ing the adjusting screw (1) ing position of the needle.
13) Dismount all components. 20) However the best way, to check if the holes are
worn out is to control the flow rate of the nozzle
14) Loosen the nozzle nut (5). If it is jammed, then which only can be made at the manufacturers
the nozzle nut can be heated in hot oil. works on a special test stand.
15) Remove the injector nozzle (6). Be careful that

the the injector needle does not fall out. Reassembling
21) When all parts have been cleaned, overhauled

Cleaning and found in good order, assemble the fuel
injection valve in opposite order.
Do not damage the lapped surface.
16) All parts must be cleaned with kerosene or MDO

oil and a hard brush (not a steel brush).
08028-0D/H5250/94.08.12
Fig 3 Special drill.
08.19 - ES0
MAN Diesel
L27/38
Pay attention to the following: 22) Mount the fuel injection valve in the test tool.
The bracket to be in such a position that the
a. Lubricate the threads on the adjusting screw, nozzle of the injector is pointing downwards.
fig. 1, pos. 1, with lub. oil, and the threads of the
nozzle holder for the nozzle nut. The shoulder Check the nozzle holes.
of the nozzle which is in contact with the nozzle
nut, must be lubricated with an antiseizure 23) Loosen the spindle for spring, fig. 1, pos. 1, as
product. much as possible until blocking. Pump and seet
that all the jets are present and are uniform,
b. The sealing plane surface of body and nozzle fig. 4. If any hole is blocked or having, other
must be wiped dry with paper. spray angle clean the nozzle tip again.
c. Renew the O-rings, fig. 1, pos 4 or please see

plate 51402 item 104.
d. Tighten torque for nozzle nut. According to

Description 500.40.
Safety:
Conditions of Labour Safety Right Wrong
The fuel jets must not be touched under any cir-

Fig 4
cumstances as they hit through the skin tissue, and
cause blood poisoning. Urgently comply with the
regulations on fire prevention when handling inflam- Adjust the opening pressure
mable liquids.
24) Important! The hydraulic pressure has to be
increased slowly until the opening pressure is
Pressure Testing of Fuel Injection Valve reached, as otherwise faults will occur when
reading off the opening pressure. Please see
The most effective checking of the fuel injection Description 500.35. When the injection test is
valves is obtained through pressure testing, prefer- carried out for the first time on new nozzle ele-
ably carried out after each overhaul and also in case ments, the nozzle needle may be stuck due to
of irregularities in operation. The pressure testing is preservation and has to be loosened by flushing
carried out in the following way using the pressure it thoroughly. In the case of injection nozzles
testing apparatus supplied. that have already been used, collect the anti-
corrosion oil contaminated with fuel, and do
08028-0D/H5250/94.08.12
When testing injection valves of modern four-stroke not fill it back into the nozzle test bed.
engines, atomisation no longer is a test criterion, as
the nozzle's behaviour during engine operation can- 25) Important! With new nozzles, a drop in open-
not be dublicated by the pressure tester. ing pressure by 50-90 bar may already occur
A poor injection pattern does not permit to draw after a few operating hours.
conclusions on the nozzles performance in the en- This pressure drop does not represent a mal-
gine. It is fully operational, provided that the criteria function and is typical of all fuel injection valves.
with regard to opening pressure, tighteness and Opening should not be re-adjusted.
unclogged nozzle bores are fulfilled.
08.19 - ES0
MAN Diesel
Working Card
Fuel Injection Valve 514-01.10
L27/38
Decrease in opening pressure less than/more Mounting of the Fuel Injection Valve in Cyl-
than 90 bar? inder Head
Decrease in opening Continue with next step. 28) Before mounting the fuel valve, clean and
pressure than 90 bar:
inspect the valve sleeve in the cylinder head.
Decrease in opening Disassemble the injection If necessary, grind the seating face with the
pressure more than valve. grinding tool, see fig 6.
90 bar: Carry out a visual inspection
(spring broken)
If components are in good
order, continue with the next
step.
Tightness test
26) Then increase the pressure to 300 bar and

keep the pressure by working the lever slowly
downwards. When the pressure is kept at 300
bar, there must not be drop from the nozzle
tip for approx. 5 sec, see fig. 5.
Fig 6 Grinding tools
Right Wrong Drops

Mounting of the Injection Valve
Fig 5
29) Mount new o-rings on the valve.
30) Coat the O-rings at the injection valve with

Note:Be aware of diesel from the drain holes are graphite paste.
not running down to the nozzle tip. Place a
ragl around the valve below the high pressure 31) The injection valve has to be inserted into the
pipe. cylinder head. Care for the alignment of the
08028-0D/H5250/94.08.12
flueaded hole for the high-pressure lance con-

If the test conditions are not fulfilled it is nec- nection. The alignment of the injection valve
essary to dismantle the fuel valve. Follow the is checked by a visual inspection through the
procedure item 9 the fuel injection valve to borehole for the high pressure cone connection
determine the causes. by using a light source (flash light).
27) All connecting and attached points of the fuel 32) Mount the holder for fuel valve. Tighten the
injection valve must not leak. nuts by hand.
Note: Final tightening of fuel valve has to be done

after tightening of high pressure lance.
08.19 - ES0
MAN Diesel
L27/38
Assembly of the High Pressure Piping
High pressure lance
High pressure pipe 34) Renew the o-rings, see fig. 7, pos 1-2-3-4 and
coat the high-pressure connecting threds and
o-ring at the pump and at the high pressure
lance with lub. oil or graphite paste.
35) High pressure lance has to be inserted into

cylinder cover and tightened, according to
Description 500.40.
1 O-ring Note: Fuel injection valve has to be loosened before

2 O-ring
tightening high pressure lance.
3 O-ring
4 O-ring
5 Disk 36) Tighten locking bolt, see fig. 7, pos 6, according
6 Lock screw to Description 500.40.
7 Lock washer
37) The correct positioning of the sealing cone
Fig 7 Fuel injection pipe from the pressure pipe has to be checked at
the pump. The sleeve nuts has to be screwed
by hand on the high pressure lance and fuel
pump.
33) After assembly of high pressure pipings then
tighten the nuts according to description 38) Tighten the sleeve nut at the connecting socket,
500.40. according to Description 500.40.
39) Tighten the sleeve nuts at the high pressure

cone, according to Description 500.40.
08028-0D/H5250/94.08.12
08.19 - ES0
MAN Diesel
Page 1 (2) Check of Fuel Oil Piping System Edition 05
L21/31
L27/38

Shut-off fuel oil
Press buttom (Blocking - Reset)
Description
Hand tools
Check of fuel oil piping system.
Starting position
Engine is running.
Related procedure
Working time : hour Plate no Item no Qty. /

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

08.06 - ES0
MAN Diesel

Edition 05 Check of Fuel Oil Piping System Page 2 (2)
L21/31
L27/38
Fuel Oil System
1) Dismount the covers to the injection pumps. 5) Check flexible connections for leaks and da-
Blow through drain pipes from the pump bed. mages.
2) Examine the piping system for leaks. It is important that the flexible connections are free
3) Retighten all bolts and nuts in the piping sy-
stem. 6) Check for any leak of the O-ring for the fuel
injection pipe.
4) Move all valves in the piping system.
Lubricate valve spindles with graphite or si- Concerning fuel oil condition, see section 504.
milar.
08028-0D/H5250/94.08.12
08.06 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump 51401-05H
L27/38
421
457
230*
589* 577* 697
590* 612* 707
122 313* 110 482
301* 719 242
146* 229
482 398
600 242
636* 624 494 374
099* 349
504
648* 325
087
648* 661* 254
661* 720 685
109* 732
744 266
278
531 291
08028-0D/H5250/94.08.12
063*
014 051* 217
205
038* 183
673*
026*
06.29 - ES0
MAN Diesel
Plate
51401-05H Fuel Injection Pump Page 2 (2)
L27/38
Item Item
014 1/P Roller guide, com- Rullestyr, komplet inkl. 349 1/P Plug screw Propskrue
plete incl. item 026, item 026, 038, 051,
038, 051, 063, 673 063, 673 374 1/P Stop plate Stopplade
026* 1/P Roller Rulle 398 2/P Screw Skrue
038* 1/P Roller pin Rulletap 421 6/P Cylindrical screw Cylindrisk skrue
051* 1/P Roller guide Rullestyr 457 1/P O-ring O-ring
063* 1/P Threaded pin Gevindtap 482 2/P Packing ring Pakningsring
087 1/P Pump element, com- Pumpeelement, kom- 494 1/P Seal ring Ttningsring
plete incl. item 099, plet inkl. item 099, 109,
109, 636, 648, 661 636, 648, 661 504 1/P Seal ring Ttningsring
099* 1/P Barrel Cylinder 531 /I Loctite 620 Loctite 620
109* 1/P Plunger Stempel 565 1/C Fuel Injection Pump, Brndselspumpe,
complete as shown komplet som vist p
110 1/P O-ring O-ring on front page forsiden
122 1/P Pressure valve, com- Trykventil, komplet inkl. 577* 1/P Cylindrical pin Cylindrisk stift
plete incl. item 146, item 146, 230, 301,
230, 301, 313, 577, 313, 577, 589, 590, 589* 1/P Spring Fjeder
589, 590, 612 612
590* 1/P Pressure valve Trykventil
146* 1/P Distance sleeve Afstandsbsning
600 8/P Cylindrical screw Cylindrisk skrue
183 1/P Pressure plate Trykplade
612* 1/P Ball Kugle
205 1/P Thrust piece Trykstykke
624 1/P Thrust ring Trykring
217 4/P Screw Skrue
636* 1/P Cylindrical pin Cylindrisk stift
229 1/P Pump casing, Pumpehus,
incl. item 719 inkl. item 719 648* 2/P Ball Kugle
230* 1/P Connecting piece Forbindelsesstykke 661* 2/P Threaded pin Genvingtap
242 2/P Screw Skrue 673* 1/P Bush Bsning
254 1/P Control rack Reguleringsstang 685 1/P O-ring O-ring
266 1/P Control sleeve Kontrolbsning 697 2/P Sealing ring Ttningsring
278 1/P Spring plate Fjederplade 707 1/P O-ring O-ring
291 1/P Pump spring Pumpefjeder 719 2/P Cylindrical pin Cylindrisk stift
08028-0D/H5250/94.08.12
301* 1/P Pressure valve Fjeder for 720 1/P Seal ring Ttningsring
spring trykventil
732 1/P Cylinder Cylinder
313* 1/P Spring plate Fjederplade
744 1/P Seal ring Ttningsring
325 1/P Plug screw Propskrue
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
06.29 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve 51402-15H
L27/38
153
082 141
069 177
190
104
070 033
057 189
224*
116 236*
212 128*
248*
08028-0D/H5250/94.08.12
094
021
045
08.23 - ES0
MAN Diesel
Plate
51402-15H Fuel Injection Valve Page 2 (2)
L27/38
Item Item
021 1/V Injection nozzle Dyse
045 1/V Nozzle nut Dysemtrik
057 1/V Pressure bolt Bolt
069 1/V Adjusting spindle Justebar spindel
070 1/V Pressure spring Trykfjeder
082 1/V Nut Mtrik
094 2/V Cylindrical pin Cylindrisk stift
116 1/C Fuel injection valve, Brndselsventil, kom-

complete incl. item plet inkl. item 021, 033,
021, 033, 045, 057, 069, 045, 057, 069, 070,
070, 082, 094, 104, 189, 082, 094, 104, 189,
190, 212 190, 212
128* 1/V Nozzle holder Dyseholder
141 1/V Bracket Spndestykke
153 2/V Nut Mtrik
177 2/V Bolt Bolt
190 1/V Guide for spring Fjederstyr
212 1/V Nozzle holder, Dyseholder,

complete komplet
224* 1/V Bush Bsning
236* 1/V Cylindrical pin Cylindrisk stift
248* 1/V Bush Bsning

08028-0D/H5250/94.08.12
Qty/V = Qty/Valve Qty/V = Qty/Ventil
08.23 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pipe 51404-14H
L27/38
022
129 130
010 046
286 333
298
034
308
321 298
142 333
095 308
154 321
286
117
08028-0D/H5250/94.08.12
07.17
MAN Diesel
Plate
51404-14H Fuel Injection Pipe Page 2 (2)
L27/38
Item Item
010 1/C High pressure lance Hjtrykslanse
034** 1/C High pressure pipe Hjtryksrr bestende

consist of item 286, af item 286, 298, 308,
298, 308, 321, 333 321, 333
095 1/C Bolt Bolt
117** 1/C Fuel injection pipe, Hjtryksrr,

complete, consist of komplet, bestende af
item 010, 022, 034, 046, item 010, 022, 034, 046,
095, 129, 142, 154, 286, 095, 129, 142, 154, 286,
298, 308, 321 298, 308, 321
129 1/C Ring Ring
130 1/C Locking washer Lseskive
142 1/C Disk Mellemstykke
298* 2/C O-ring O-ring
308* 2/C Sleeve Bsning
321* 2/C Circlip Sikringsring
333* 2/C Nut Mtrik
08028-0D/H5250/94.08.12
* = Only available as part of a spare parts kit * = Kun tilgngelig som en del af et reservedelsst.
** = When ordering item 034 and 117 please order ** = Ved bestilling af item 034 og 117 venligst bestil
item 286 in addition ekstra af item 286
Qty/E = Qty./Engine Qty/E = Qty./Motor
07.17
MAN Diesel
Plate
Page 1 (2) Safety Filter 51415-03
General
08028-0D/H5250/94.08.12
03.18 - EO0
MAN Diesel
Plate
51415-03 Safety Filter Page 2 (2)
General
Qty. Designation Benvnelse Qty. Designation Benvnelse
1 1/E Fuel oil filter duplex, Brndselsoliespalte-

complete filter, komplet
2 2/F Screw plug Propskrue
3 2/F Gasket Pakning
10 6/F Bolt Bolt
11 2/F Cover Dksel
12 2/F O-ring O-ring
13 8/F Nut Mtrik
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 Mtrik
70 2/F Screw Skrue
72 2/F Nut Mtrik
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
03.18 - EO0
MAN Diesel
Plate
Page 1 (2) Ball Valve with Actuator 51425-01
General
015
027 039
Seen from A
08028-0D/H5250/94.08.12
040
07.17 - ES0
MAN Diesel
Plate
51425-01 Ball Valve with Actuator Page 2 (2)
General
Item Item
015 1/Q Solenoid valve Magnetventil
027 1/Q Actuator Actuator
039 1/Q Limit switch Grnseafbryder
040 2/Q Ball valve Kugleventil
08028-0D/H5250/94.08.12
07.17 - ES0
MAN Diesel
Plate
Page 1 (2) Butterfly Valve with Actuator 51425-02H
General
08028-0D/H5250/94.08.12
00.34 - ES0
MAN Diesel
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 Reservedelsst
08028-0D/H5250/94.08.12
00.34 - ES0
MAN Diesel
Plate
General
088
052
064
08028-0D/H5250/94.08.12
07.17 - ES0
MAN Diesel
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
MAN Diesel
Plate
General
015
027 039
Seen from A
08028-0D/H5250/94.08.12
040
07.17 - ES0
MAN Diesel
Plate
General
Item Item
08028-0D/H5250/94.08.12
07.17 - ES0
MAN Diesel
Plate
General
015
027 039
Seen from A
08028-0D/H5250/94.08.12
040
07.17 - ES0
MAN Diesel
Plate
General
Item Item
08028-0D/H5250/94.08.12
07.17 - ES0
MAN Diesel
Plate
General
088
052
064
08028-0D/H5250/94.08.12
07.18
MAN Diesel
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
MAN Diesel
Plate
Page 1 (2) Fuel Oil Arrangement 51430-07H
L27/38
240
252
492
335
264
323
276
406
384 240 418 372
264 252
276 347 215
360 288 431 227
012 396 239
036 240 443 359
024 252 455 480
048 264 097
276 467 107
168 479
181
144 119
156
120 061
132 085
Fuel oil leakage alarm,
see plate 50925 073
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
51430-07H Fuel Oil Arrangement Page 2 (2)
L27/38
Item Item
012 1/E Screw Skrue 323 2/E Welding coupling Svejseforskruning
024 2/E Washer Skive 335 1/E Reducing standpipe Reduceringsstandrr
036 1/E Screw Skrue 347 1/E Pipe, Rr,

fuel oil outlet afgang brndolie
048 2/E Spring lock Fjederls
359 1/E Non-return valve Kontraventil
061 1/E Pipe, Rr,
fuel oil inlet tilgang brndolie 360 1/E Pipe, Rr,
fuel oil outlet afgang brndolie
073 1/E Pipe, Rr,
fuel oil outlet afgang brndolie 372 1/E Pipe, drain Rr, drn
085 1/E Pipe, drain Rr, drn 384 1/E Adjustable tee Justerbar
coupling T-forskruning
097 3/E Packing Pakning
396 1/E Drain pipe Rr, drn
406 1/E Adjustable elbow Justerbar
119 1/E Bracket Konsol coupling vinkelforskruning
120 2/E Pipe clamp Rrholder 418 1/E Packing ring Pakningsring
132 4/E Screw Skrue 431 1/E Pipe Rr
144 1/E Pipe clamp Rrholder 443 1/E Straight male stud Ligeforskruning
coupling
156 2/E Screw Skrue
455 1/E Pipe Rr
168 1/E Adjustable elbow Justebar
coupling vinkelforskruning 467 6/E Pipe holder Rrholder
181 1/E Packing ring Pakningsring 479 6/E Slotted cheese head Krvskrue
screw
coupling 480 1/E Welding coupling Svejseforskruning
203 2/E Packing ring Pakningsring 492 1/E Flat steel bar Fladstl
227 4/E Screw Skrue
239 4/E Spring lock Fjederls
252 6/E Screw Skrue

08028-0D/H5250/94.08.12
288 1/E Pipe, Rr,

fuel oil inlet tilgang brndolie
06.22 - ES0
MAN Diesel
Plate
Page 1 (2) Pipes on Cylinder Section 51434-01H
L27/38
Connection on
Main pipe for Seen from A - A cylinder head
overspeed
Main pipe for drain
and leakage oil
502 551 526 514

742
754
766
778
Connection on
cylinder head
622 599 609 526
538 610 538 587 575 538 646 634 671 683
08028-0D/H5250/94.08.12
A A
56
56
56
563, 705, 717, 729, 730 538 658 695
07.05 - ES0
MAN Diesel
Plate
51434-01H Pipes on Cylinder Section Page 2 (2)
L27/38
Item Item
502 1/E Main pipe for over- Hovedrr for over- 634 1/C Equal tee coupling T-forskruning
speed, 5 cyl. engine speed, 5 cyl. motor
646 1/C Branch pipe, Stikrr,
514 Pipe clamp Rrholder cylinder section cylindersektion
5/E 6 cyl. engine 6 cyl. motor 658 1/C Branch pipe, Stikrr,
6/E 7 cyl. engine 7 cyl. motor cylinder section cylindersektion
8/E 9 cyl. engine 9 cyl. motor 671 1/E Adjustable elbow Justebar
coupling vinkelforskruning
526 Screw Skrue
16/E 5 cyl. engine 5 cyl. motor 683 1/E Branch pipe, Stikrr,
20/E 6 cyl. engine 6 cyl. motor cylinder section cylindersektion
28/E 8 cyl. engine 8 cyl. motor 695 1/E Straight male stud Ligeforskruning
32/E 9 cyl. engine 9 cyl. motor coupling
538 4/C Banjo coupling Banjoforskruning 705 1/E Main pipe for drain Hovedrr for drn
and leakage oil og lkageolie
551 1/C Branch pipe, Stikrr, 6 cyl. engine 6 cyl. motor
cylinder section cylindersektion
717 1/E Main pipe for drain Hovedrr for drn
563 1/E Main pipe for drain Hovedrr for drn and leakage oil og lkageolie
and leakage oil og lkageolie 7 cyl. engine 7 cyl. motor
729 1/E Main pipe for drain Hovedrr for drn
575 Pipe clamp Rrholder and leakage oil og lkageolie
6/E 7 cyl. engine 7 cyl. motor 730 1/E Main pipe for drain Hovedrr for drn
7/E 8 cyl. engine 8 cyl. motor and leakage oil og lkageolie
587 1/C Adjustable elbow Justerbar 742 1/E Main pipe for over- Hovedrr for over-
coupling vinkelforskruning speed, 6 cyl. engine speed, 6 cyl. motor
599 1/C Branch pipe, Stikrr, 754 1/E Main pipe for over- Hovedrr for over-
cylinder section cylindersektion speed, 7 cyl. engine speed, 7 cyl. motor
609 1/C Branch pipe, Stikrr, 766 1/E Main pipe for over- Hovedrr for over-
cylinder section cylindersektion speed, 8 cyl. engine speed, 8 cyl. motor
610 Banjo coupling Banjo forskruning 778 1/E Main pipe for over- Hovedrr for over-
4/E 5 cyl. engine 5 cyl. motor speed, 9 cyl. engine speed, 9 cyl. motor
622 Branch pipe, Stikrr,

cylinder section cylindersektion
08028-0D/H5250/94.08.12

07.05 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump Connections 51435-07H
L27/38
273
285 248 153
297 476 332 070 427 070
488 344 307 415 307
069
070
415
427
177 356 177

320 439
440 320
153
332
344
261 319 069 319
261
248 307 307 248

177
285
297
08028-0D/H5250/94.08.12
06.26 - ES0
MAN Diesel
Plate
51435-07H Fuel Injection Pump Connections Page 2 (2)
L27/38
Item Item
069 Insert pipe Rr 332 Lock screw Lseskrue

070 O-ring O-ring 344 Packing ring Pakningsring

153 2/E Cover Dksel 356 O-ring O-ring

177 Screw Skrue 24/E 6 cyl. engine 6 cyl. motor
72/E 9 cyl. engine 9 cyl. motor 415 Clamping holder Rrholder
248 2/E Intermediate piece Forbindelsesstykke 10/E 6 cyl. engine 6 cyl. motor
261 2/E Intermediate piece Forbindelsesstykke 14/E 8 cyl. engine 8 cyl. motor
427 Screw Skrue
285 16/E Screw Skrue 8/E 5 cyl. engine 5 cyl. motor
297 16/E Lock disc Lseskive 12/E 7 cyl. engine 7 cyl. motor
307 Intermediate piece Forbindelsesstykke 16/E 9 cyl. engine 9 cyl. motor
4/E 6 cyl. engine 6 cyl. motor 439 Screw Skrue
319 Intermediate piece Forbindelsesstykke 32/E 9 cyl. engine 9 cyl. motor
4/E 6 cyl. engine 6 cyl. motor 440 Lock disc lse plade
320 Plate Plade 32/E 9 cyl. engine 9 cyl. motor
12/E 6 cyl. engine 6 cyl. motor 452 1/E Seamless steel pipe Smls stlrr
08028-0D/H5250/94.08.12
16/E 8 cyl. engine 8 cyl. motor 464 2/E Straight male stud Ligeforskruning
18/E 9 cyl. engine 9 cyl. motor coupling
476 2/E Screw plug Propskrue
06.26 - ES0
Lubricating oil system
515/615
MAN Diesel
Description 515.01
Page 1 (3) Internal Lubricating Oil System Edition 06H
L27/38
Fig 1 Diagram for internal lubricating oil system.
General Quantities in litres for engine,

Engine type
incl. cooler, filters and pipes on engine
As standard the lubricating oil system is based on 5 1260
wet sump lubrication. 6 1450
7 1620
All moving parts of the engine are lubricated with 8 1810
oil circulating under pressure in a closed built-on 9 1990
system.
Table 1 Quantities for starting-up the engine incl. cooler, filters
The lubricating oil is also used for the purpose of and pipes on engine
cooling the pistons and turbocharger.
The standard engine is equipped with built-on:

System Flow
08028-0D/H5250/94.08.12
Engine driven lubricating oil pump.

Lubricating oil cooler. The lubricating oil pump draws oil from the oil sump
Lubricating oil thermostatic valve. and presses the oil through the cooler and filter to
Duplex lubricating oil filter. the main lubricating oil bore, from where the oil is
Prelubricating oil pump. distributed to the various lubricating points. From the
lubricating points the oil returns by gravity to the oil
sump.The oil pressure is controlled by an adjustable
Oil Quantities spring-loaded relief valve built in the system.
The approximate quantities of oil necessary for

a new engine, before starting up are given in the
table/below.
01.32 - ES0
MAN Diesel
515.01 Description
Edition 06H Internal Lubricating Oil System Page 2 (3)
L27/38
The main groups of components to be lubricated ad 6) Through a bore in the frame lub oil is led to
are: the first camshaft bearing and through bores in the
camshaft from where it is distributed to the other
1 Turbocharger camshaft bearings.
2 Main bearings, big-end bearing etc.
3 Camshaft drive
4 Governor drive Lubricating Oil Pump
5 Rocker arms
6 Camshaft The lubricating oil pump, which is of the helical gear
type, is mounted on the front end box of the engine
ad 1) For priming and during operation the turbo- and is driven by the crankshaft.
charger is connected to the lub. oil circuit of the
engine. The oil serves for bearing lubrication and
also for dissipation of heat. Lubricating Oil Cooler
The inlet line to the turbocharger is equipped with a As standard the lubricating oil cooler is of the plate
reduction valve in order to adjust the oil flow. type. The cooler is mounted on the front end box.
ad 2) Lubricating oil for the main bearings is sup-

plied through holes in the engine frame. From the Thermostatic Valve
main bearings it passes through bores in the crank-
shaft to the connecting rod big-end bearings. The thermostatic valve is a fully automatic 3-way
valve with thermostatic elements set at fixed tem-
The connecting rods have bored channels for sup- perature.
ply of oil from the big-end bearings to the small-
end bearings, which has an inner circumferential
groove, and a pocket for distribution of oil in the Built-on Full-flow Depth Filter
bush itself, and for supply of oil to the pin bosses
and the piston cooling. The lubricating oil filter is of the duplex paper car-
tridge type. It is a depth filter with a nominel fineness
From the front main bearings channels are bored in of 10-15 microns, and a safety filter with a fineness
the crankshaft for lubricating of the pump drive. of 60 microns.
ad 3) The lubricating oil pipes for the camshaft drive

gear wheels are equipped with nozzles which are Pre-lubricating
adjusted to apply the oil at the points where the
gear-wheels are in mesh. As standard the engine is equipped with an elec-
tric-driven prelub pump mounted parallel to the
ad 4) The lubricating oil pipe for the gear-wheels for main pump. The pump is arranged for automatic
the governor drive are adjusted to apply the oil at operation, ensuring stand-still of the prelubricating
08028-0D/H5250/94.08.12
the points where the gear-wheels are in mesh. pump when the engine is running, and running
during engine stand-still in stand-by position by the
ad 5) The lubricating oil to the rocker arms is led engine control system.
through bores in the engine frame to each cylinder
head. The oil continues through bores in the cylin-
der head and rocker arm to the movable parts to Draining of the Oil Sump
be lubricated at the rocker arm and valve bridge.
Further, lub oil is led to the movable parts in need It is recommended to use the separator suction pipe
of lubrication. for draining of the lubricating oil sump.
01.32 - ES0
MAN Diesel
Description 515.01
Page 3 (3) Internal Lubricating Oil System Edition 06H
L27/38
Crankcase Ventilation 4) The manifold is to be provided with drainage

arrangement.
The crankcase ventilation is not to be directly con-
nected with any other piping system. It is preferable The ventilation pipe should be designed to eliminate
that the crankcase ventilation pipe from each engine the risk of water condensation in the pipe flowing back
is led independently to the weather. The outlet is into the engine and should end in the open air:
to be fitted with corrosion resistant flame screen
separately for each engine. The connection between engine (C13) and
the ventilation pipe must be flexible.
However, if a manifold arrangements is used, its The ventilation pipe should be continuously
arrangements are to be as follows: inclined (min. 5 degrees).
A continuous drain has to be installed near
1) The vent pipe from each engine is to run the engine. The drain must not be lead back
indepently to the manifold, and be fitted with to the engine.
corrosion resistant flame screen within the Dimension of the flexible connection DN100.
manifold. Dimension of the ventilation pipe after the
flexible connection min. DN100.
2) The manifold is to be located as high as
practicable so as to allow substantial length
of piping separating the crankcase.
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
01.32 - ES0
MAN Diesel

Page 1 (3) Lubricating Oil Pump Edition 04H
L27/38

Shut-off fuel oil
Disassembly, overhaul and assembly of lubrica- Feeler gauge 0.1 mm, min length 40-50 cm.
ting oil pump. Feeler gauge 0.3 mm, min length 40-50 cm.
Feeler gauge 0.35 mm, min length 40-50 cm.
Starting position
Lubricating oil cooler. 515-06.00
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
51501 018 2/p

51501 102 4/p
Data

99.14 - ES0
MAN Diesel

Edition 04H Lubricating Oil Pump Page 2 (3)
L27/38
Preparing before Dismounting Mounting
For getting access to the lubricating oil pump, it is 8) Change the O-rings on the pump.
necessary to remove the lubricating oil cooler. Please
see working card 515-06.00. 9) Mount the pump using the bolts and tighten
these according to description 500.40.
Dismounting 10) Renew the O-rings for oil and water connec-
tions to the lub. oil cooler.
1) Remove the bolts which are holding the lub.
oil pump. 11) Mount the lub. oil cooler to the frame plate.
2) Use the spring bolts to push out the pump.
Overhaul
3) Remove the bolt (1) and the spur wheel (2),

see fig 1.
4) Remove the bolt (3) and the cover (4), see fig
1.
Take out the gear wheel shafts (5) and clean all parts
in gas oil and with a hard brush, (never use a steel 1 Bolt
brush). The parts are blown clean with working air. 2 Spur wheel
3 Bolt
4 Cover
5) Check the wear of the bearing bush. 5 Gear wheel shafts
6) If the bearing bush is to be removed, the exist-

ing bearing bush is plugged out by means of a Fig 1 Lubricating oil pump
mandrel. The bores are cleaned, see fig 2 and
the new bearing bush is mounted.
The bush is cooled down to -130C, the hous-
ing or cover has room temperature.
Note: Criteria for replacement of bearing bush, see

A, fig 3.
08028-0D/H5250/94.08.12
7) Mount the gear wheel shafts (5) the cover (4)

and the bolt (3), the spur wheel (2) and the
bolt (1), see fig 1. Tighten the bolts according
to page 500.40.
Note: Check that the oil pump can run easily when
the pump is assembled.
Fig 2 Bores to be cleaned
99.14 - ES0
MAN Diesel

Page 3 (3) Lubricating Oil Pump Edition 04H
L27/38
A min. 0.1 mm
max. 0.3 mm
If Then
feeler gauge 0.1-0.3 mm OK

can come into the pump
feeler gauge 0.1 mm Replace bearing bush

cannot come into the
pump
feeler gauge 0.35 mm Replace bearing bush

can come into the pump
Fig 3 Check of bearing bush

08028-0D/H5250/94.08.12
99.14 - ES0
MAN Diesel

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
MAN Diesel
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
MAN Diesel

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
MAN Diesel
Page 1 (3) Lubricating Oil Filter Edition 03H
L27/38

Shut-off fuel oil
Description
Hand tools
Replacement of paper filter element.
Cleaning of safety filter and filter housing. Open-end ring spanner, 19".
Allen key, 6 mm.
Allen key, 10 mm.
Starting position
Related procedure
Manpower
08028-0D/H5250/94.08.12
Working time : 1 hour

Capacity : 1 man Plate no Item no Qty. /
51502 013 2/E

Data 51502 971 2/E

08.25 - ES0
MAN Diesel
Edition 03H Lubricating Oil Filter Page 2 (3)
L27/38
Please note: Never open the filter while it is in use. 7) Dismantle the filter housing cap.
The filter to be cleaned must be out of operation.
8) Remove the inner safety element. Clean the ele-
ment with detergent. Check that it is intact.
Normal Running
9) Remove the outer elements.
1) The valve is in position 2 or 4, see fig 2, and
the element not in use is vented and ready to Note: Our filter elements are of the disposable type.
use (standby). Always change to new original filter.
10) Clean the filter housing and the cap.

Changing the Filter
Note: Be sure that sealing ring in bottom of front-
2) Switch to position 3, fig 2, and wait 5 minutes. end box is removed/replaced before installing new
Then continue to position 1 or 5, fig 2. filter cartridge.
3) Wait 2 minutes. 11) Check the seal in the cap. Change if needed.
4) Open the vent screw on the filter out of ser- 12) Assemble the filter in reverse order.
vice.
13) Switch to position 2 or 4 and vent the
5) Wait 20 minutes. exchanged element by means of the vent screw.
6) Dismantle the cover.
Vent screws
08028-0D/H5250/94.08.12
Fig 1 Vent screws
08.25 - ES0
MAN Diesel
Page 3 (3) Lubricating Oil Filter Edition 03H
L27/38
Pos.
Fig 2 Name plate for lubricating oil filter

08028-0D/H5250/94.08.12
08.25 - ES0
MAN Diesel
Page 1 (2) Lubricating Oil, Thermostatic Valve Edition 04H
L27/38

Shut-off fuel oil
Inspection of thermostatic valve and replacement

of elements.
Starting position
Related procedure

Capacity : 1 man
08028-0D/H5250/94.08.12
51103 146 2/E
Data

01.30 - ES0
MAN Diesel

Edition 04H Lubricating Oil, Thermostatic Valve Page 2 (2)
L27/38
Adjustment and Maintenance Check the Element
The thermostatic valve cannot be adjusted, and 10) Place the element in a bucket of water -12
under normal working conditions maintenance is not C below the nominal rating and stir the water
required. However, in some cases it is necessary to vigorously with the element for 5 minutes (the
replace the element. sliding valve should not be off its seat).
11) Next, place the element in water 10 C above the

nominal rating and stir vigorously for 5 minutes.
The element should not be fully stroked.
This is determined by immediately placing the element

back in the valve housing, and pushing the element
spider fully into its counterbore. If the resistance of
the sliding valve overtravel spring can be felt, the
element is fully stroked. Perform the last step quickly
before the element has cooled.
Note: do not use oil as the test bath.
On every high temperature elements, water and

1 Bolt glycol may be used.
2 Cover
3 Lock ring
4 Element
5 Sleeve
Fig 1 Lubricating oil thermostatic valve
Replacement of the Element
1) Unscrew the bolts (1) and remove the cover

(2), see fig 1.
2) Remove the lock ring (3).
3) Remove the sleeve and element (4 and 5).
4) Thoroughly clean the sleeve (5).
5) Replace it or check, see "check the ele-

ment".
08028-0D/H5250/94.08.12
6) Remount the element (4) by wriggling it some-

what over side.
7) Mount the sleeve (5)
8) Mount the lock ring (3).
9) Renew the gasket and mount the cover Fig 2 Placing of lubricating oil thermostatic valve
(2). Tighten the bolt (1) according to page
500.40.
01.30 -ES0
MAN Diesel

Page 1 (2) Check of Lubricating Oil Piping System Edition 03
L21/31
L27/38

Shut-off fuel oil
Check and examination of the lubricating oil

piping system.
Starting position
Engine is running.
Related procedure
Working time : hour Plate no Item no Qty /

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

02.20 - ES0
MAN Diesel

Edition 03 Check of Lubricating Oil Piping System Page 2 (2)
L21/31
L27/38
Checks to be Carried Out
1) Examine the external connections for leaks.
2) Retighten all bolts and nuts in the external

system.
3) Check flexible oil vapour discharge hose

connections for leaks and damages.
Note: It is important that the flexible connections

are free from paint and grease and in healthy con-
dition.
Concerning lubricating oil condition, see section

504.
08028-0D/H5250/94.08.12
02.20 - ES0
MAN Diesel
Page 1 (5) Lubricating Oil Cooler Edition 05H
L27/38

Separation, cleaning and assembling. Ring and open end spanner, 10 mm.
Replacement of plates and gaskets. Ring and open end spanner, 55 mm.
Ring and open end spanner, 30 mm.
Adjustable spanner.
Starting position
Cooling water and lub. oil have been drained

from cooler/engine. All external pipes are discon-
nected.
Related procedure

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

01.30 - ES0
MAN Diesel
Edition 05H Lubricating Oil Cooler Page 2 (5)
L27/38
Introduction Separation of Edge-clamped Frame
Cleaning of the cooler must take place, when the Mount the bolts, see fig. 1.
pressure drop on the oil and water side exceeds an
allowable value and/or if oil cannot be sufficiently Upon completion of the procedure Cooling and
cooled. Pressure Relief, separate the frame by retaining
two or four diagonally placed bolts.
Note: To prevent oil from dripping / flowing on the
prelubricating pump it is recommended to screen the Note: Take care that the pressure plate does not
pump before the lubricating oil cooler is separated. tilt!
Loosen the bolts uniformly and diagonally (max. 10

Separation mm at a time), then push the pressure plate towards
the end support. When the pressure plate is not tight
Cooling and Pressure Relief anymore, the plates can be removed.
Before opening the plate heat exchanger, it must Note: When using plate heat exchangers on board
be cooled down to below 40o C and be without ships, the pressure plate must be secured in order to
pressure! avoid danger during the movements of the ship.
The cooling must not exceed 10o C per minute.

The pressure drop must not exceed 10 bar per Cleaning
minute.
The capacity and corrosion resistance of the plate
Note: If these norms are exceeded, the guarantee heat exchangers depend on the cleanness of the
will cease to be valid. plates. Any coating on the plates can be removed
manually.
08028-0D/H5250/94.08.12
Fig 1 Mounting of oil cooler in front-end box
01.30 - ES0
MAN Diesel
L27/38
Manual Cleaning Control of Cleaning Fluid Concentrations
Clean the plates with a soft brush and a suitable Sodium hydroxide (NaOH) solution is titrated with
detergent. In case of dense coating of scale or 0.1 n hydro-chloric acid (HCI) with methyl orange
organic materials, the plates must be put in a bath or methyl red as an indicator.
with detergent.
Nitric acid (HNO3) solution is titrated with 0.1 n
Note: Never use a steel brush, metal scraper or sodium hydroxide (NaOH) with phenolphtalin as an
the like. indicator.
A high-pressure cleaner can be used with care, how- The concentration of the cleaning fluid in % can be
ever, never with sand or other abrasives added. calculated from the titration result using the follow-
ing formula:
Detergents Concentration = bxnxm %

a x 10
A detergent is suitable, if it removes any coating
on the plates without causing any damage to plates a : ml cleaning fluid taken out for titration
and gaskets. b : ml titration fluid used as a cover
n : the molecular concentration of titration fluid
Note: It is of great importance that decomposi- m : The molecular weight of the cleaning fluid
tion of the protective film on the stainless steel does (NaOH) the molecular weight 40, HNO3
not take place - the film preserves the corrosion molecular weight 63)
resistance of steel.
Do not use chlorine-containing agents such as Replacement of Plates and Gaskets

hydrochloricacid (HCI)!
Marking
Oil and fats are removed by using a water emulsify-
ing oil solvent, e.g. BP-system cleaner. The plates are marked with material codes and refer-
ence numbers at each end, plus codes for non-glued
Organic and greasy coatings are removed by using gaskets, if any, and stamped with letters V and H
sodium hydroxide (NaOH): at either end (fig 1).
- max. concentration 1.5% When facing the gasket, the plate is designated as
(1.5% concentration corresponds to 3.75 a left plate, when letter V turns upwards - and as a
l 30% NaOH per 100 l water). right plate when letter H turns upwards. Inlets and
- max. temperature 85o C. outlets of the V-plates are taking place through the
corner holes Nos 1 and 4. Inlets and outlets of the
Stone and lime/calcareous deposits are removed by H-plates take place through corner holes Nos 2
using nitric acid (HNO3): and 3.
- max. concentration 1.5%

08028-0D/H5250/94.08.12
(1.5% concentration corresponds to 1.75 l Replacement of Plates

62% HNO3 per 100 l water).
- max. temperature 65o C. Before mounting a spare plate in the plate stack,
please make sure that the spare plate is identical
Note: The nitric acid has an important constructive with the faulty one.
effect on the protective film of stainless steel.
01.30 - ES0
MAN Diesel

Edition 05H Lubricating Oil Cooler Page 4 (5)
L27/38
Note: The same corner holes must be opened and Apply a thin layer of glue on the gasket grooves of the plates
letters V and H must be placed properly. and press the gaskets down into the gasket grooves.
Replacement of Glued Gaskets
The insertion of the gaskets starts at both ends of the plate -
On Plate 51506 are stated gasket and glue quan- and continues with the straight sections along the edges.
tity.
The gluing process is most easily performed by placing
Please use a degreasing agent on the new gas- the gaskets and the plates on a table. After pressing the
kets. gaskets into the grooves of the plate, it is stacked.
The first plate after the end cover and the connector The plates with the gaskets are mounted in the frame which
grid must have gaskets in all grooves. The gaskets is lightly clamped. In the case of using rubber grooves,
must be cut according to the existing gaskets. they are assembled to the minimum measure stated on
the engine sign plus 0.2 mm per plate.
Loosen the glued gaskets by heating the plate in
water at 100o C. Clean the plates and remove the Heat up the plate heat exchanger to 90-100 C by means
coatings, if any. of water or steam.
Please note:
Cleaning of New Gaskets and Plates
- The temperature must be kept for 1 1/2-2
New gaskets and gasket grooves of the plates are hours.
cleaned with a cloth moistened with degreasing - The liquid pressure must be kept as low as
agent. The glued surfaces must be absolutely clean possible.
- without finger prints etc.
If there is no possibility of heating the plate heat exchanger,
Please use our cleaning fluid, which conforms to it must be placed in a place as warm as possible with con-
supplier's recommendations. nections dismounted.
Alternatively, please use: At 20 C the drying time will be approx. 48 hours. At 40

C, the drying time is approx. 24 hours.
- Trichloroethylene
- Chlorothene VG
- Acetone Serial number
- Methyl ethyl ketone (please state when
- Ethylacetat Material Code ordering single plates)
It is important that all degreasing agent be evapo-

rated, before glue is applied. Normally this will take 1 2
approx. 15 min. at 20o C.
Clean the new gaskets on the glued surfaces with

fine-grained sandpaper instead of the degreasing
08028-0D/H5250/94.08.12
agent supplied.
Four last digits Four last digits are ref.
H number of the plate.
are ref. number
Gluing of plate
or (only on plates for non-
V glued gasket)
Pliobond 25, which is a solvent-based nitrile rubber
glue (25% solids).The glue is applied with a brush in a Fig 2 Plate with serial No etc
thin layer on the backs of the gaskets and the gaskets
must be dried in a clean place free of dust.
01.30 - ES0
MAN Diesel

L27/38
Assembling
If the plates are dismounted, they must be properly

assembled according to plate item numbers.
The fixed cover has number 1 and serial numbers

for the subsequent plates, and intermediate frames,
if any, are numbered 2, 3, 4, 5 etc.
Serial numbers are stamped in the right top corner

of the plates. Further, please note that the gasket
side must face the fixed cover.
Fastening
Fasten the nuts crosswise until the movable cover

to the measure x at each nut. See fig 3.
Cyl x
Fig 3 Measuring x
5 66 mm
6 72 mm
7 72 mm
8 81 mm
9 88 mm
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel

Page 1 (3) Centrifugal Bypass Filter Edition 04
L21/31
L27/38

Shut-off fuel oil
Cleaning procedure, cleaning intervals. Big adjustable spanner.

Maintenance intervals and procedures. Tools for cleaning.
Starting position
With the engine stopped or filter isolated by

means of a valve.
Related procedure
Working time : 1 hour Plate No Item No Qty/

Capacity : 1 man
08028-0D/H5250/94.08.12
51515 301 1/Filter

51515 313 1/Filter
Data 51515 325 1/Filter

02.20 - ES0
MAN Diesel

Edition 04 Centrifugal Bypass Filter Page 2 (3)
L21/31
L27/38
Cleaning Procedure 4) Unscrew rotor top nut (026) and separate
rotor.
1) Isolate the filter by closing the valve for lubrica- 5) Remove sludge from inside the rotor by
ting oil inlet to the filter. means of a spatula and wipe clean. En-
sure that all rotor components are throughly
Note: Ensure the centrifuge has come to a com- cleaned and free from deposits of dirt before
plete stop before proleading reassembling the rotor.
2) Slacken cover clamp ring (266). Unscrew cover Note:Failure to do so could cause an out-of-balance
fixing nut and lift off cover (038). condition which will accelerate bearing and
spindle wear.
3) Lift off rotor assembly having allowed oil to
drain from nozzles. The rotor should be remo- 6) Remove stand tube (075) and clean.
ved and replaced on the spindle with extreme
care in order to ensure that the bearings are 7) Clean nozzle with brass wire. Examine top
not damaged. and bottom bearings in tube assembly.
If damaged or worn - replace tube assembly
complete. Examine O-ring and renew if da-
maged.
Rotor fixing nut
026 8) Place standtube, totaing it to ensure that it is
properly located in the recess in the rotorbase.
038 If the standtube shows any sign of damage
then it should be replaced.
9) Reassemble rotor complete and tighten top

nut.
075
Note:Ensure that rotor cover and rotor body are
always matched by balance number and pin
location. Do not interchange rotor cover.
266
10) Examine spindle journals. If damaged or

worn - replace with body assembly
complete.
11) Reassemble rotor complete checking that rotor

revolves freely.
026 Rotor top nut
Note: Check cover o-ring, - if damaged it must
038 Cover
075 Stand tube be replaced.
266 Cover clamp ring
08028-0D/H5250/94.08.12
Tighten cover fixing nut and secure safety

clamp. The clamp ring should be securely
Fig 1 Centrifugal bypass filter fitted at all times and the filter should not be
run without the clamp ring fitted.
12) Open for lubricating oil.
13) With filter running, check all joints for leakage.

Check for excessive vibration.
02.20 - ES0
MAN Diesel

Page 3 (3) Centrifugal Bypass Filter Edition 04
L21/31
L27/38
Maintenance - Bearings and Spindle 16) Re-apply dial gauge at 90 to previous posi-
tion and repeat.
All rotors are correctly balanced before leaving the
factory. An out-of-balance condition can occur as a 17) Turn rotor 90 and repeat.
result of an uneven build up of sludge in the rotor or
as a result of excessive bearing or spindle wear. The highest reading is the play in the bearing.
Dependent on the conditions, wear will eventually take The maximum clearances when new are 0.10 mm at
place on the spindle and bearings and these should top and 0.13 mm at bottom bearing. If the clearance
be replaced with factory fitted assemblies only. exceeds 0.30 mm top or 0.33 mm bottom then replace
with new bearing tube assembly.
To Check Bearing Clearances The spindle and body assembly and the rotor bear-
ing tube assembly are factory assembled items and
This is most easily done by applying a dial gauge should only be replaced with complete assemblies.
to the outside of the rotor opposite each bearing in
turn and measuring the total play, thus:
14) Apply dial gauge and measure play.
15) Turn rotor 90 and repeat measurement.

08028-0D/H5250/94.08.12
02.20 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pump 51501-07H
L27/38
08028-0D/H5250/94.08.12
06.32 - ES0
MAN Diesel
Plate
51501-07H Lubricating Oil Pump Page 2 (2)
L27/38
Item Item
018 2/P O-ring O-ring
031 1/E Lubricating oil pump, Smreoliepumpe, kom-

comp. 5-6 cyl. engine plet 5-6 cyl. motor
incl. item 055, 067, 079, incl. item 055, 067, 079,
092, 102, 114, 126, 151, 092, 102, 114, 126, 151,
175, 187, 199, 209 175, 187, 199, 209
043 1/E Lubricating oil pump, Smreoliepumpe, kom-

comp. 7-9 cyl. engine plet 7-9 cyl. motor
incl. item 055, 067, 080, inkl. item 055, 067, 080,
092, 102, 114, 138, 163, 092, 102, 114, 138, 163,
175, 187, 199, 209 175, 187, 199, 209
055 3/P Cylindrical pin Cylindrisk stift
067 5/P Screw Skrue
079 1/P Pump housing, Pumpehus,

5-6 cyl. engine 5-6 cyl. motor
080 1/P Pump housing, Pumpehus,

092 1/P Cover Dksel
102 4/P Bush Bsning
114 5/P Screw Skrue
126 1/P Gear wheel, Tandhjul,




175 1/P Cylindrical gear Cylindrisk tandhjul

wheel
187 1/P Washer Skive
199 1/P Screw Skrue
209 5/P Thrust washer Trykskive

08028-0D/H5250/94.08.12
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Filter 51502-15H
L27/38
684
696
539 814 971
672 564
552
540
909
910
922
934
Front end box 946

see plate 51103
958
527
062
755 731 743
013
LEFT VALVE RIGHT
FILTER POSITION FILTER
DRAIN
IN USE EXCHANGE
FILTER
NORMAL
USE
IN USE
FILL, VENT
AND
STANDBY
IN USE
802
FILL, VENT
AND NORMAL
STANDBY USE
DRAIN
EXCHANGE IN USE
FILTER
Lift fixation bolt before turning valve
503
863
887
755
08028-0D/H5250/94.08.12
659 731
826 743
588 755
647 875
576 838 899
635 312 851
169 025
623 037
194
253 049
204
050
055
086
08.25 - ES0
MAN Diesel
Plate
51502-15H Lubricating Oil Filter Page 2 (2)
L27/38
Item Item
013 1/E Filter cartridge Filterindsats 696 19/E Locking spring Lsefjederskiver
washer
025 4/E Lock disc Lseskive
037 4/E Screw Skrue
743 12/E Stud Tapskrue
049 1/E Oil collector tray Oliebakke
755 12/E Nut Mtrik
802 1/E Plate Skilt
062 2/E Safety filter Sikkerhedsfilter
838 1/E Covering plate Dksel
851 1/E Covering plate Dksel
194 1/E Cover Dksel
863 2/E Closing screw Lseskrue
204 3/E Screw Skrue
875 2/E Screw Skrue
253 3/E Locking spring Lsefjederskiver
washer 887 2/E Retaining ring for Spndring for aksel
shafts
312 1/E Latch pin Lsestift
899 6/E Screw Skrue
503 2/E Cover, complete incl. Dksel, komplet inkl.
item 909, 910, 922, 934, item 909, 910, 922, 934, 909 2/F Flange Flange
946, 958, 971 and 983 946, 958, 971 og 983
910 2/F Flange Flange
527 2/E Centering cover Centreret bsning
922 2/F Spring Fjeder
539 2/E Ventilating insert Ventileringsindsats
934 2/F Screw Skrue
540 2/E Valve body Ventilhus
552 2/E Piston insert Stempelindsats
623 2/E O-ring Pakning
635 1/E Switch element Omskifterelement
647 1/E Connecting shaft Transmissionsaksel

08028-0D/H5250/94.08.12
659 1/E Switch element Omskifterelement
672 1/E Plate Plade
Qty/F = Qty/Filter Qty/F = Qty/Filter
08.25 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Pump with El-Motor 51504-05
General
08028-0D/H5250/94.08.12
99.12 - ES0
MAN Diesel
Plate
51504-05 Prelubricating Pump with El-Motor Page 2 (2)
General
Item Item
254 1/P Driving cover Medbringerdksel
266 1/P Gear casing Gearhus
278 1/P End cover, complete, Endedksel, komplet

incl. item 386, 398, 408, inkl. item 386, 398, 408,
421, 433, 445, 457, 469 421, 433, 445, 457, 469
and 470 og 470
291 1/P Driving gear shaft Drivende gearaksel
301 1/P Gear shaft Gearaksel
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 akseltt-

ning
374 1/E Pump, complete Pumpe, komplet uden

without el-motor el-motor
386 1/P End cover Endedksel
398 1/P Piston Stempel
408 1/P Spindle Spindel
421 1/P Dome nut Lukkemtrik
433 1/P Spring Fjeder
445 1/P Pipe nut Rrmtrik
457 2/P Screwed plug Propskrue
469 2/P Sealing ring Ttningsring
470 2/P Sealing ring Ttningsring
482 1/P Coupling, complete Kobling, komplet
494 1/E El-motor, complete El-motor, komplet
504 1/E Pre.lub oil pump, Forsmrepumpe,

complete with el- komplet med el-motor
08028-0D/H5250/94.08.12
motor
516 1/E Ball bearing, rear Kugleleje, bagside
528 1/E Ball bearing, front Kugleleje, forside
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
99.12 - ES0
MAN Diesel
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
MAN Diesel
Plate
51504-08H Prelubricating Pump with El-Motor Page 2 (2)
General
Item Item
014 1/P Driving cover Medbringerdksel
026 1/P Gear casing Gearhus
038 1/P End cover, complete, Endedksel, 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
109 1/P Parallel key Not
122 1/P Rotary shaft seal Roterende akseltt-

ning
134 1/E Pump, complete
without El-motor Pumpe, komplet uden
el-motor
146 1/P End cover
Endedksel
158 1/P Piston
Stempel
171 1/P Spindle
Spindel
183 1/P Dome nut
Lukkemtrik
195 1/P Spring
Fjeder
205 1/P Pipe nut
Rrmtrik
217 2/P Screwed plug
Propskrue
229 2/P Sealing ring
Ttningsring
230 2/P Sealing ring
Ttningsring
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- Forsmrepumpe,
motor komplet med el-motor
08028-0D/H5250/94.08.12
Qty./P = Qty./Pump Antal/P = Antal/Pumpe
02.39 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Cooler 51506-09H
L27/38
064
015
076
375
039 027
409 287
410 052
172 422
184 434
206
218
088
Mandrel,
see plate 52000
111
231
135
243
123
147 446 458
Note: when ordering plates, please state Husk: Ved bestilling af plader angives serienummeret
08028-0D/H5250/94.08.12
the serial numbers of the plates. The serial p pladen. Serienummeret er stemplet i toppen af
numbers of the plates can be found in the top pladen til hjre.
right-hand corner of the plates. (Se arbejdskort 515-06.00).
(see Working Card 515-06.00).
For korrekt samling af kleren henvises
For correct assembling, til arbejdskort 515-06.00.
please see Working Card 515-06.00
07.09 - ES0
MAN Diesel
Plate
51506-09H Lubricating Oil Cooler Page 2 (2)
L27/38
Item Item
015 1/K Plate Plade 446 /I Gasket Pakning
027 8/K O-ring O-ring 458 /I Gasket Pakning
064 1/K Plug screw Propskrue
076 1/K Packing ring Pakningsring
088 1/K Plate Plade
111 1/K Plate Plade
123 12/K Self locking nut Selvlsende mtrik
135 12/K Washer Skive
172 1/E Lubricating oil Smreoliekler,

cooler, 5 cyl. motor,
5 cyl. engine, compl. komplet
184 1/E Lubricating oil

cooler, Smreoliekler,
6, 7 cyl. engine, 6, 7 cyl. motor,
compl. komplet


231 /I Glue Lim
243 /I Cleaning fluid Rensevdske
375 17/K Spring washer Fjederskive
409 /I Oil cooler plate stack Pladestak


08028-0D/H5250/94.08.12


Qty/K = Qty/Cooler Qty/K = Qty/Kler
07.09 - ES0
MAN Diesel
Plate
Page 1 (2) Centrifugal By-pass Filter 51515-03
L27/38
L21/31
266 171
470
110 134
122
470
158
482
278 146
229
242 183
230
109
195 051
038
063
205 026 087
217
08028-0D/H5250/94.08.12
014
469 099
254
457
445
433
03.27 - ES0
MAN Diesel
Plate
51515-03 Centrifugal By-pass Filter Page 2 (2)
L27/38
L21/31
Item Item
014 1/F Body , complete incl. Sokkel, komplet inkl. 313 1/F Valve kit, consisting Ventilkit, indeholdende
item 099, 109, 433, 445, item 099, 109, 433, 445, of item 433, 445, 457, item 433, 445, 457,
457, 469 457, 469 469 469
026 1/F Valve body Ventilsokkel 325 1/F Seals kit, consisting
of item 087, 099, 109, Ttningskit, indehold-
038 1/F Valve handle Ventilhndtag 158, 242 ende item 087, 099,
109, 158, 242
051 1/F Nyloc nut Mtrik 337 1/E Centrifugal by-pass
filter, complete as Centrifugal by-pass
063 1/F Valve adapter Ventiladapter shown on front filter, komplet som vist
page p forsiden
087 1/F Valve seal Ventilttning
433 1/F Plug Prop
099 1/F Flange gasket Flangepakning
445 1/F Washer Skive
109 1/F Filter body O-ring Filtersokkel O-ring
110 1/F Cover, complete incl. Dksel, komplet inkl.
item 122, 134, 146, item 122, 134, 146, 469 1/F Shuttle Spole
158, 171 158, 171
470 2/F Washer Skive
122 1/F Cover Dksel
482 1/F Circlip Lsering
134 1/F Cover nut pin Stift for dkselmtrik
146 1/F Cover fixing nut Dkselmtrik
158 1/F Cover nut O-ring Dkselmtrik O-ring
171 1/F Cover nut collar Dkselmtrik muffe
183 1/F Band clamp Spndering
195 1/F Rotor, complete incl. Rotor, komplet inkl. item

item 205, 217, 229, 205, 217, 229, 230, 242,
230, 242, 254, 266, 254, 266, 482, 470
482, 470
205 2/F Nozzle Dyse
217 1/F Bearing tube Lejerr
229 1/F Stand tube Standrr
230 1/F Circlip Lsering
242 1/F Rotor O-ring Rotor O-ring
254 1/F Pin Stift

08028-0D/H5250/94.08.12
266 1/F Rotor cover nut Rotordkselmtrik
278 1/F Paper insert Papirindsats
301 1/F Cover nut fixing kit, Dkselmtrikskit, inde-

consisting of item 134, holdende item 134, 146,
146, 158, 171 158, 171
Qty/F = Qty/Filter Qty/F = Qty/Filter
03.27 - ES0
MAN Diesel
Plate
Page 1 (2) Crankcase Venting 51531-03H
L27/38
192
202
214
226
238
131
155
179
167
180
143
251
263
275
287
08028-0D/H5250/94.08.12
023
047
06.22 - ES0
MAN Diesel
Plate
51531-03H Crankcase Venting Page 2 (2)
L27/38
Item Item
023 4/E Screw Skrue
047 1/E Packing, square Pakning, firkantet
131 1/E Oil vapour discharge nderr

pipe
143 1/E Bracket Beslag
155 1/E Clamps Klemme
167 2/E Nut Mtrik
179 1/E Oil vapour dischage nderr

pipe
180 /I Glue Lim
192 4/E Screw Skrue
214 4/E Screw Skrue
226 4/E Nut Mtrik

pipe
251 1/E Hexagon nipple Nippel
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
Page 1 (2) Crankcase Venting with Integrated Oil Mist Detector 51531-04H
L27/38
202
214
226
131
238
179
334 180
346 322 309
358 310
155
167 143
371
299
251
263
275
287
08028-0D/H5250/94.08.12
023
047
06.22 - ES0
MAN Diesel
Plate
51531-04H Crankcase Venting with Integrated Oil Mist Detector Page 2 (2)
L27/38
Item Item
023 4/E Screw Skrue

pipe
167 2/E Nut Mtrik

pipe
180 /I Glue Lim
214 4/E Screw Skrue
226 4/E Nut Mtrik

pipe

pipe
310 4/E Screw Skrue
322 1/E Oil mist detector Olietgedetektor
346 8/E Screw Skrue
358 8/E Nut Mtrik
371 1/E Flat steel bars Fladstl

08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
L27/38
202
214 383
226 395
238
179
131
180
192
202
155
167
143 023
047
251
263
08028-0D/H5250/94.08.12
275
287
08.24 - ES0
MAN Diesel
Plate
L27/38
Item Item
023 4/E Screw Skrue

pipe
167 2/E Nut Mtrik

pipe
180 /I Glue Lim
192 4/E Screw Skrue
214 4/E Screw Skrue
226 4/E Nut Mtrik

pipe
383 1/E Packing, oval Pakning, oval
395 2/E Screw Skrue

08028-0D/H5250/94.08.12
08.24 - ES0
MAN Diesel
Plate
L27/38
202
214 383
226 395
405
429
214 238
226
192
202
155 179
430 180
442
454
131
Oil mist detector,
251 see plate 50960
263
023
047
08028-0D/H5250/94.08.12
275
287
08.27 - ES0
MAN Diesel
Plate
L27/38
Item Item
023 4/E Screw Skrue

pipe

pipe
180 /I Glue Lim
192 4/E Screw Skrue
226 12/E Nut Mtrik

pipe
383 1/E Packing, oval Pakning, oval
395 2/E Screw Skrue

pipe
430 2/E Self-locking nut Selvlsende mtrik
442 1/E Flat steel bar Fladstl
454 1/E Angle profile Vinkel profil

08028-0D/H5250/94.08.12
08.27 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-08H
L27/38
08028-0D/H5250/94.08.12
062 086
06.13- ES0
MAN Diesel
Plate
51535-08H Prelubricating Oil Arrangement Page 2 (2)
L27/38
Item Item
062 1/E Straight male Ligeforskruning

stud coupling
086 1/E Pipe Rr
098 1/E Adjustable elbow Justerbar vinkel
121 1/E Reducing adapter Reduktionsadapter
133 1/E Non-return valve Kontaventil
170 1/E Pipe Rr
182 1/E Pipe Rr
241 4/E Screw Skrue
265 1/E Straight male Ligeforskruning

stud coupling
277 1/E Adjustable elbow Justerbar vinkel
289 1/E Pipe Rr
08028-0D/H5250/94.08.12
06.13 - ES0
Cooling water system
516/616
MAN Diesel
Description
Cooling Water System 516.01
L27/38
The cooling water system consists of a low tempe-

rature system and a high temperature system.
Both the low and the high temperature systems are

cooled by fresh water.
The water in the low temperature system passes

through the low temperature circulating pump which
drives the water through the second stage of the
charge air cooler and then through the lubricating
oil cooler before it leaves the engine together with
the high temperature water.
The high temperature cooling water system

passes through the high temperature circulating
pump and then through the first stage of the charge
air cooler before it enters the cooling water jacket
and the cylinder head. Then the water leaves the
engine with the low temperature water.
Both the low and high temperature water leaves the

engine through separate three-way thermostatic
valves which control the water temperature.
Fig. 1 Cooling water system

08028-0D/H5250/94.08.12
99.17 - ES0
MAN Diesel
Description 516.01
Page 1 (1) Cooling Water System (two string) Edition 09
L27/38
Fig 1 Diagram for internal cooling water system.
Cooling water system The engine on the cooling water side only requires
fresh water between 10 and 40C.
The system is designed as a two string circuit with
four flange connections to the external centralized
cooling water system. High Temperature Circuit
The engine is equipped with a self-controlling tem- The built-on engine-driven HT-circulating pump of
perature water circuit. This is a simple solution with the centrifugal type pumps water through the first
low installation costs, which also can be interesting stage of the charge air cooler and then through the
in case of repowering. distributing bore to the bottom of the cooling water
guide jacket. The water is led out through bores at
the top of the cooling water guide jacket to the bore
08028-0D/H5250/94.08.12
Low Temperature Circuit cooled cylinder head for cooling of this, the exhaust
valve seats and the injector valve.
The components for circulation and temperature
regulation are placed in the internal system. From the cylinder heads the water is led through an
integrated collector to the thermostatic valve, and
The charge air cooler and the lubricating oil cooler depending on the engine load, a smaller or larger
are situated in serial order. After the LT water has amount of the water will be led to the external system
passed the lubricating oil cooler, it is let to the ther- or will be re-circulated.
mostatic valve and depending on the water tempe-
rature, the water will either be re-circulated or led to
the external system.
06.06 - ES0
MAN Diesel

Page 1 (2) Check of Cooling Water System Edition 03
L21/31, L27/38

Shut-off fuel oil
Check of cooling water system.
Starting position
Engine is running.
Related procedure

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

Capacity : 1 man
Data

02.20 - ES0
MAN Diesel

Edition 03 Check of Cooling Water System Page 2 (2)
L21/31, L27/38
Checks to be Carried Out 4) Check the condition of the outermost of the

two O-rings (which make up the tightening
1) Examine the cooling water connections for between the water jacket and the combustion
leaks. space) by means of the inspection holes in the
cylinder cover.
2) Check flexible connections for leaks.
Concerning check of the fresh water condition, see
It is important that the flexible connections are free section 504.
3) Check O-rings in water connections between

cylinder covers and also between cylinder
covers and front-end box.
08028-0D/H5250/94.08.12
02.20 - ES0
MAN Diesel
Page 1 (2) Cooling Water, Thermostatic Valve Edition 03H
L27/38

Shut-off fuel oil
Inspection of thermostatic valve and replacement

of elements.
Starting position
Cooling water drained from engine (if neces-

sary).
Related procedure

Capacity : 2 man
08028-0D/H5250/94.08.12
Data

01.30 - ES0
MAN Diesel

Edition 03H Cooling Water, Thermostatic Valve Page 2 (2)
L27/38
The thermostatic valves cannot be adjusted, and 5) Remount a new element (4) by wriggling it
under normal conditions maintenance is not required. somewhat over side.
However, in some cases it is necessary to clean or
replace elements. 6) Mount lock ring (2) in the recess.
7) Clean the sealing surface of the casing.Tighten

Replacement of Elements bolts according to page 500.40.
1) Remove the casing by unscrewing bolts (A),

see fig 2.
2) Remove lock ring (2).
3) Remove element (4) from the casing.
4) Thoroughly clean sleeve (3).
Fig 2 Seen from front end of the engine
Fig 1 Cooling water thermostatic valve

08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Page 1 (2) HT and LT Water Pumps Edition 02H
L27/38

Shut-off fuel oil
Disassembly, overhaul and assembly of HT and

LT pumps.
Starting position
Related procedure

08028-0D/H5250/94.08.12
Capacity : 1 man
51610 010 4/E
51610 022 2/E
Data 51610 095 2/E
51610 250 1/E
99.18 - ES0
MAN Diesel
Edition 02H HT and LT Water Pumps Page 2 (2)
L27/38
After the cooling water thermostat casing is removed, Inspection of the Pump
the cooling water pumps can be dismounted.
6) Inspect the shaft for seizures after removing
1) Remove the screws and pull out the pump by the shaft seal and bearings, also inspect the
means of the spring bolts. impeller for pittings and cavitations. Clean all
parts carefully.
Assembling of the Pump
7) Fit new bearings (13) and (16) together with a

new shaft seal (14).
8) Mount the shaft in the housing and lock it with

the retaining ring (11).
9) Fit the spur gear (4) and washer (3) with

the screw (2) and tight it according to page
500.40.
10) Carefully fit the slide ring joint (10), then fit the
disc (8) and the impeller (9) and tight the nut
(7) according to page 500.40.
11) Mount the cover (6) with the screw (5) and tight
them according to page 500.40.
12) Fit new O-rings on the pump housing and pump

cover, then mount the pump in the front end box
with the screws, and tighten them according
to page 500.40.
HT water pump LT water pump

Fig 1 HT and LT water pumps
Disassembling of the Pump
2) Remove the screw (2), see fig 1 and pull off

the washer (3) and spur gear (4).
08028-0D/H5250/94.08.12
3) Remove the screw (5) and the cover (6).
4) Remove the nut (7) with disc (8), then remove

impeller (9) and the slide ring joint (10).
5) Take out the retaining ring (11), then pull out

the shaft (12) with bearings (13) and (16) and
the shaft seal (14).
Fig 2 HT and LT water pumps
99.18 - ES0
MAN Diesel
Plate
Page 1 (2) High- and Low Temperature Freshwater Pumps 51610-10H
L27/38
08028-0D/H5250/94.08.12
04.14 - ES0
MAN Diesel
Plate
51610-10H High- and Low Temperature Freshwater Pumps Page 2 (2)
L27/38
Item Item
034 1/P Depp groove ball Radialkugleleje

bearing
046 1/P Ball bearing Kugleleje
083 1/P Shaft seal Pakdse
095 1/P Slide ring joint Roterende pakning
105 2/E Freshwater pump, Ferskvandspumpe,

complete as shown komplet som vist
on front page p forside
117 4/P Screw Skrue
129 1/P Pump housing Pumpehus
130* 1/P Impeller Lbehjul
142 1/P Cover Dksel
154 3/P Screw Skrue
166 3/P Lock washer Lseskive
178* 1/P Shaft Aksel
191* 1/P Screw Skrue
201* 1/P Disc Skive
213 1/P Spur gear Cylindrisk tandhjul
225* 1/P Washer Skive
237* 1/P Screw Skrue
453 1/P Kit for upgrading Opgraderingskit

incl. items no 130, inkl. item nr. 130,
178, 191, 201, 225 178, 191, 201, 225
and 237 og 237
08028-0D/H5250/94.08.12
04.14 - ES0
MAN Diesel
Plate
Page 1 (2) Cooling Water Connections 51630-07H
L27/38
224 212 033

021
045
069
021
033
116
128
021 200
212 189
190 212
045
069
045
069
021
08028-0D/H5250/94.08.12
06.43 - ES0
MAN Diesel
Plate
51630-07H Cooling Water Connections Page 2 (2)
L27/38
Item Item
045 4/E Screw Skrue

washer
116 1/E Elbow Vinkel
128 6/E Screw Skrue
200 10/E V-Profile clamp V-profil klemme
212 Seal ring Ttningsring

224 1/E Orifice plate Mleblnde
236 /I Packing-silicone Pakningssilicone

paste
08028-0D/H5250/94.08.12
06.43 - ES0
MAN Diesel
Plate
Page 1 (2) Preheater Unit 51635-02H
L27/38
08028-0D/H5250/94.08.12
00.44 - ES0
MAN Diesel
Plate
51635-02H Preheater Unit Page 2 (2)
L27/38
Item Item
030 4/E Heater element Varmepartron
042 4/E Packiong ring Pakningsring
054 4/E HT pipe HT rr
125 16/E Nut Mtrik
149 1/E HT pipe HT rr
150 1/E Foundation frame Fundamentsramme
162 1/E Freshwater pump Ferskvandspumpe
174 4/E Screw Skrue
186 4/E Nut Mtrik
245 1/E Bleeding screw Afluftningsskrue
269 4/E Screw Skrue
270 1/E Screw Skrue
282 1/E Nut Mtrik
294 1/E Non-return valve Kontraventil
328 4/E Screw Skrue

08028-0D/H5250/94.08.12
00.44 - ES0
Special equipment
517/617
MAN Diesel
Kit
Page 1 (2) Kit for Inspection of Fuel Valve 51701-01
L27/38
See working card 514-01.10
104
033
189
022
046
286
094
298
298
286
08028-0D/H5250/94.08.12
286
06.25
MAN Diesel
Kit
51701-01 Kit for Inspection of Fuel Valve Page 2 (2)
L27/38
Item
033 1/V O-ring Plate 51402
094 2/V Cylindrcal pin Plate 51402
022 1/C O-ring Plate 51404
08028-0D/H5250/94.08.12
Qty/V = Qty/Valve
06.25
MAN Diesel
Kit
Page 1 (2) Kit for Overhaul of Fuel Valve 51702-01
L27/38
104
033
189
022
046
286
094
298
021
298
286
08028-0D/H5250/94.08.12
286
06.25
MAN Diesel
Kit
51702-01 Kit for Overhaul of Fuel Valve Page 2 (2)
L27/38
Item
021 1/V Injection nozzle Plate 51402
094 2/V Cylindrcal pin Plate 51402
08028-0D/H5250/94.08.12
Qty/V = Qty/Valve
06.25
MAN Diesel
Kit
Page 1 (2) Kit for Complete Cylinder Unit Exchange 51703-01
L27/38
045
022 See working card 505-01.55
046
033
043
014
033
027
08028-0D/H5250/94.08.12
363
363
243
135
03.07
MAN Diesel
Kit
51703-01 Kit for Complete Cylinder Unit Exchange Page 2 (2)
L27/38
Item
045 1/C Kit for cylinder unit, complete Plate 50500 Item 045
consisting of:
1/C O-ring Plate 50501 Item 135
4/C Seal ring Plate 51630 Item 033
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
03.07
MAN Diesel
Kit
Page 1 (2) Kit for Cylinder Unit 51704-01
L27/38
021
022
046
095 031
055
104
178
033
076
040 043
237
014 064
250
033
338
111
027
090 172
196
08028-0D/H5250/94.08.12
135
363
363
243
135
02.50 - ES0
MAN Diesel
Kit
51704-01 Kit for Cylinder Unit Page 2 (2)
L27/38
Item
021 1/C Kit for cylinder unit, complete Plate 50500 Item 021
consisting of:
1/C Gasket Plate 50501 Item 338
2/C Circlip Plate 50502 Item 095
4/C Conical ring 2/2 Plate 50502 Item 178
1/C Sealing ring Plate 50610 Item 031

08028-0D/H5250/94.08.12
4/C Seal ring Plate 51630 Item 033
Please Note that this is a kit supply, and that any exceeding
number of o-rings and gaskets are not accepted as return goods.
02.50 - ES0
MAN Diesel
Kit
Page 1 (2) Kit for Overhaul of Rotocap 51705-01
L27/38
536
490-500
512
524
08028-0D/H5250/94.08.12
07.15
MAN Diesel
Kit
51705-01 Kit for Overhaul of Rotocap Page 2 (2)
L27/38
Item
536 1/V Kit for overhaul of rotocap Plate 50502 Item 191
6/V Spring Plate 50502 Item 490
6/V Ball Plate 50502 Item 500
1/V Spring washer Plate 50502 Item 512
1/V Retainer ring Plate 50502 Item 524
08028-0D/H5250/94.08.12
Please Note that this is a kit supply, and that any exceeding number of parts are
not accepted as return goods.
Qty/V = Qty/Valve
07.15
MAN Diesel
Kit
Page 1 (2) Kit for renewal of Piston Rings 51706-01
L27/38
296
306
127

08028-0D/H5250/94.08.12
07.15
MAN Diesel
Kit
51706-01 Kit for renewal of Piston Rings Page 2 (2)
L27/38
Item
306 1/C Set of piston rings and oil scraper ring Plate 50601 Item 306
1/C Oil scraper ring Plate 50601 Item 127
3/C Piston ring Plate 50601 Item 296
08028-0D/H5250/94.08.12
Please Note that this is a kit supply, and that any exceeding number of parts are
not accepted as return goods.
07.15
MAN Diesel
Kit
Page 1 (2) Kit for High- and Low Temperature Freshwater Pumps 51710-01
L27/38
See Working Card 516-10.00
130*
191*
237*
201* 225*
08028-0D/H5250/94.08.12
178*
*Please order item 453
08.02
MAN Diesel
Kit
51710-01 Kit for High- and Low Temperature Freshwater Pumps Page 2 (2)
L27/38
Item
No Qty Designation Where to find in the engine instruction book
453 1/F Kit for upgrading,

incl item 130, 178, 191, 201, 225, 237 Plate 51610
1/F Shaft Plate 51610 Item 178
1/F Screw Plate 51610 Item 191
1/F Disc Plate 51610 Item 201
1/F Washer Plate 51610 Item 225
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/P = Qty/Pump
08.02
MAN Diesel
Kit
Page 1 (2) Kit for Cover, Centrifugal By-pass Filter 51715-01
L27/38
L21/31
171*
134*
110
122*
158*
146*
08028-0D/H5250/94.08.12
* Please order item 110
08.02
MAN Diesel
Kit
51715-01 Kit for Cover, Centrifugal By-pass Filter Page 2 (2)
L27/38
L21/31
Item
110 1/F Cover, complete

incl item 122, 134, 146, 158, 171 Plate 51515
1/F Cover Plate 51515 Item 122
1/F Cover nut pin Plate 51515 Item 134
1/F Cover fixing nut Plate 51515 Item 146
1/F Cover nut O-ring Plate 51515 Item 158
1/F Cover nut collar Plate 51515 Item 171

08028-0D/H5250/94.08.12
Qty/F = Qty/Filter
08.02
MAN Diesel
Kit
Page 1 (2) Kit for Rotor, Centrifugal By-pass Filter 51716-01
L27/38
L21/31
266* See Working Card 515-15.00
470*
482*
229*
242*
230*
195
205*
08028-0D/H5250/94.08.12
217*
254*
08.02
MAN Diesel
Kit
51716-01 Kit for Rotor, Centrifugal By-pass Filter Page 2 (2)
L27/38
L21/31
Item
195 1/F Rotor, complete

incl item 205, 217, 229, 230, 242, 254,
266, 470, 482 Plate 51515
2/F Nozzle Plate 51515 Item 205
1/F Bearing tube Plate 51515 Item 217
1/F Stand tube Plate 51515 Item 229
1/F Circlip Plate 51515 Item 230
1/F Rotor O-ring Plate 51515 Item 242
1/F Pin Plate 51515 Item 254
1/F Rotor cover nut Plate 51515 Item 266
1/F Circlip Plate 51515 Item 482

08028-0D/H5250/94.08.12
Qty/F = Qty/Filter
08.02
MAN Diesel
Kit
Page 1 (2) Kit for Cover Nut, Centrifugal By-pass Filter 51717-01
L27/38
L21/31
171*
134*
301
158*
146*
08028-0D/H5250/94.08.12
08.02
MAN Diesel
Kit
51717-01 Kit for Cover Nut, Centrifugal By-pass Filter Page 2 (2)
L27/38
L21/31
Item
301 1/F Cover nut fixing kit,

incl item 134, 146, 158, 171 Plate 51515
1/F Cover nut pin Plate 51515 Item 134
1/F Cover fixing nut Plate 51515 Item 146
1/F Cover nut O-ring Plate 51515 Item 158
1/F Cover nut collar Plate 51515 Item 171

08028-0D/H5250/94.08.12
Qty/F = Qty/Filter
08.02
MAN Diesel
Kit
Page 1 (2) Kit for Valve, Centrifugal By-pass Filter 51718-01
L27/38
L21/31
08028-0D/H5250/94.08.12
469*
457*
445*
433*
08.02
MAN Diesel
Kit
51718-01 Kit for Valve, Centrifugal By-pass Filter Page 2 (2)
L27/38
L21/31
Item
313 1/F Valve kit,

incl item 433, 445, 457, 469 Plate 51515
1/F Plug Plate 51515 Item 433
1/F Spring Plate 51515 Item 457
1/F Shuttle Plate 51515 Item 469

08028-0D/H5250/94.08.12
Qty/F = Qty/Filter
08.02
MAN Diesel
Kit
Page 1 (2) Kit for Seals, Centrifugal By-pass Filter 51719-01
L27/38
L21/31
158*
242*
109*
087*
08028-0D/H5250/94.08.12
099*
08.02
MAN Diesel
Kit
51719-01 Kit for Seals, Centrifugal By-pass Filter Page 2 (2)
L27/38
L21/31
Item
325 1/F Seals kit,

incl item 087, 099, 109, 158, 242 Plate 51515
1/F Valve seal Plate 51515 Item 087
1/F Flange gasket Plate 51515 Item 099
1/F Filter body O-ring Plate 51515 Item 109
1/F Cover nut ring Plate 51515 Item 158
1/F Rotor O-ring Plate 51515 Item 242

08028-0D/H5250/94.08.12
Qty/F = Qty/Filter
08.02
MAN Diesel
Kit
Page 1 (2) Kit for Lubricating Oil Filter 51725-01
L27/38
971*
983*
909*
910*
922*
934*
946*
958*
FILL, VENT
CHAN
08028-0D/H5250/94.08.12
503*
08.02
MAN Diesel
Kit
51725-01 Kit for High- and Low Temperature Freshwater Pumps Page 2 (2)
L27/38
Item
503 1/E Cover,

incl item 909, 910, 922, 934, 946, 958, 971, 983 Plate 51502
2/F Flange Plate 51502 Item 909
2/F Flange Plate 51502 Item 910
4/F O-ring Plate 51502 Item 958
2/F O-ring Plate 51502 Item 971
8/F Seal Plate 51502 Item 983

08028-0D/H5250/94.08.12
Qty/E = Qty/Engine
Qty/F = Qty/Filer
08.02
Specific plant
information
519/619
MAN Diesel
Description 519.03
Page 1 (2) Resilient Mounting of Generating Sets Edition 08H
L27/38
Resilient Mounting of Generating Sets 1) The support between the bottom flange of the
conical mounting and the foundation is made
On resiliently mounted generating sets, the diesel with a loose steel shim. This steel shim is ad-
engine and the alternator are placed on a common justed to an exact measurement (min 40 mm)
rigid base frame mounted on the ship's/machine for each conical mounting.
house's foundation by means of resilient supports,
type conical. 2) The support can also be made by means of
two steel shims, at the top a loose steel shim
All connections from the generating set to the external of at least 40 mm and below a steel shim of at
systems should be equipped with flexible connections least 10 mm which is adjusted for each conical
and pipes, gangway etc must not be welded to the mounting and then welded to the foundation.
external part of the installation.
Resilient Support
A resilient mounting of the generating set is made

with a number of conical mountings. The number
and the distance between them depend on the size
of the plant. These conical mountings are bolted to
brackets on the base frame (see fig 1).
The setting from unloaded to loaded condition is

normally 5-11 mm for the conical mounting.
The support of the individual conical mounting can

be made in one of the following three ways:
08028-0D/H5250/94.08.12
Fig 1 Resilient mounting of generating sets
Fig 2 Support of conicals.
02.23 - ES1
MAN Diesel
519.03 Description
Edition 08H Resilient Mounting of Generating Sets Page 2 (2)
L27/38
3) Finally, the support can be made by means Adjustment of Engine and Alternatoron
of chockfast. It is necessary to use two steel Base Frame
shims, the top steel shim should be loose
and have a minimum thickness of 40 mm, the The resiliently mounted generating set is normally
bottom steel shim should be cast in chockfast delivered from the factory with engine and Alternator
with a thickness of at least 10 mm. mounted on the common base frame. Eventhough
engine and alternator have been adjusted by the
Irrespective of the method of support, the 40 mm factory with the alternator rotor placed correctly in
steel shim is necessary to facilitate a possible future the stator, and the crankshaft bend of the engine
replacement of the conical mountings, which are within the prescribed tolerances, it is recommended
always replaced in pairs. to check the crankshaft deflection before starting up
the plant.
08028-0D/H5250/94.08.12
02.23 - ES1
MAN Diesel
Working card 519-03.00

Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 27H
L23/30H
L27/38

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, 22 mm

Starting position Allen key, 6 mm
Feeler gauge, 1-2 mm
The foundation should be welded and milled off Measurement tool
on shim surfaces. Hydraulic jack (if necessary)
Related procedure
Check of main beraings alignment

(autolog)
510-01.00
Replacement of conicals 5 1 9 -
03.00
Man power
Working hours : 2 Hours

08028-0D/H5250/94.08.12
Capacity : 2 Men Spare and wearing parts
Plate No. Item No. Qty./
Data 51903 013 1/conical mount.

51903 025 4/conical mount.
03.50 - ES1
MAN Diesel
519-03.00 Working card

Edition 27H Fitting Instructions for Resilient Mounting of GenSets Page 2 (4)
L23/30H
L27/38
Mounting and Adjustment Instructions for 7) Turn all the internal buffers (2), see fig 1, to
New Generating Sets (Method 1) check that they can move freely.
Make Ready for Adjustment of Conical Ele- If all internal buffers Then
ments
Can move freely Let conical elements
If the conical elements have not been mounted by settle for 48 hours.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have Cannot be moved Turn the four jacking
been mounted by the factory, please start with item bolts in the base casting
number 2. clockwise or anticlock-
wise to release the inter
1) Fit the conical elements to the bracket on the nal buffer.
base frame by means of four bolts screwed
into the tapped holes on the top casting (5),
see fig 1. Adjustment of Conical Elements after 48
Hours Settling
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see After the conical elements have been deflected un-
fig 1. der static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the
3) Position the four jacking bolts in the tapped recommended laden height.
holes (9) see fig 1, in the base casting (1).
4) Position the jacking bolts with a through-going

of minimum 40 mm, see fig 2.
5) Lower the generating set until it rests completely

on the foundation.
6) Check that all jacking bolts have full contact

with the foundation.
08028-0D/H5250/94.08.12
Fig 2 Conical mounting.

Fig 1 Conical element
03.50 - ES1
MAN Diesel

L23/30H
L27/38
8) Care must be taken, during levelling of the 12) Lift the generating set with crane or hydraulic
installation, to ensure that individual mountings jack.
are not overloaded.The variation in laden height
should not exceed 2 mm and should ideally 13) Remove all the jacking bolts.
be less. The laden height can be measured
between top and base casting at H, on two 14) Position each completed steel shim.
sides (see fig 1).
15) Lower the generating set until it rests completely
Example: in itself.
H1 + H2 + H3 ----- HN
Average = Number of conical elements 16) Number each steel shim together with each
conical element.
If Then
Adjustment of Internal Buffer
Difference exceeds Level the conical ele-
ment 17) Turn the internal buffer clockwise (downwards)
2 mm. by adjusting the jacking until it makes contact with the steel shim or
bolts - commencing with foundation.
the conical element with
the largest deviation. 18) Turn the internal buffer anticlockwise (upwards)
until it obtains contact with the base casting.
Difference does not ex- The height of the steel
ceed 2 mm shim can be measured. This must be four full turns.
19) Turn the internal buffer two full turns clockwise

The difference between the two sides of a conical (downwards) and check with a feeler gauge
mounting should not be more than 0.6 mm. between the base casting of the conical ele-
ment and the steel shim that the internal buffer
(2), see fig 1, does not touch the steel shim or
Measuring of Steel Shim foundation.
9) Measure the steel shim on several points to 20) Lock the internal buffer by remounting the top
obtain the highest possible accuracy during lock ring (6) and turn it to the nearest thread
preparation. hole - then secure with fixing bolt (7) and spring
washer (8), see fig 1.
Fabricating Steel Shim

Mounting of Conical Elements on the Foun-
10) Make sure that the minimum height of the steel dation
08028-0D/H5250/94.08.12
shim is 40 mm to secure a future replacement

of the conical element. 21) Drill four mounting holes in the foundation for
each conical element, either
Drill the mounting holes in the steel shim according
to the conical base casting dimensions. a) Mark the positions of the mounting holes on
the foundation through the conical element and
the steel shim.
Mounting of the Completed Steel Shim
(Re)move the set completely so that the mark-
11) Turn the internal buffer anticlockwise until it ings can be reached by drilling with conventional
contacts the base casting to secure the laden tools.
height of each conical element.
03.50 - ES1
MAN Diesel

L23/30H
L27/38
Place the set on its former position by aligning The drilling has to be done on beforehand and
it with the drilled holes. the set must be aligned with the foundation
holes before the work starts to avoid further
or removal of the set.
b) Drill the mounting holes in the foundation by 22) Fix all the conical elements and the steel shims
means of the drilling pattern from the installa- to the foundation with four bolts per conical.
tion drawing.
Note! After completion of all works the buffer clear-
ance must be checked, see points 17, 18, 19 and
20.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel

L23/30H
L27/38

Shut-off fuel oil
Description

plants. Hand tools

Related procedure

(autolog)
510-01.00
03.00
Man power

08028-0D/H5250/94.08.12

03.50 - ES1
MAN Diesel

L23/30H
L27/38
Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 2) of minimum 10 mm, see fig 2.
Make Ready for Adjustment of Conical Ele- 6) Lower the generating set until it rests completely
ments on the foundation.
If the conical elements have not been mounted by 7) Check that all jacking bolts have full contact
the factory, they must be mounted on the prepared with the foundation.
brackets on the base frame. In case they have
been mounted by the factory, please start with item 8) Turn the internal buffer (2), see fig 1 to check
number 2. that it can be moved freely.
1) Fit the conical elements to the bracket of the

base frame by means of four bolts screwed If all internal buffers Then
into the tapped holes on the top casting (5),
see fig 1. Can move freely Let conical elements
settle for 48 hours.
A supporting steel shim with a minimum height of 40
mm, to secure a future replacement of the conical Cannot be moved Turn the three jacking
element, complete with tapped holes for three jacking freely bolts in the supporting
bolts and mounting holes drilled according to conical steel shim clockwise, or
base casting dimensions, is required. anticlockwise to release
the internal buffer.
2) Remove fixing bolt (7), spring washer (8) and
top lock ring (6) from the conical element, see
fig 1.
3) Position the supporting steel shim as per fig

2 and locate the conical element by means of
dowel pins.
4) Position the three jacking bolts in the tapped

holes in the supporting steel shim as per fig
2.
08028-0D/H5250/94.08.12

03.50 - ES1
MAN Diesel

L23/30H
L27/38
Adjustment of Conical Elements after 48 Drill the mounting holes in the steel shim according
Hours Settling to the mounting holes in the conical base casting and
the mounting holes in the supporting steel shim.
After the conical elements have been deflected un-
der static load for 48 hours, the laden height (H1)
see fig 2, should be measured and compared to the Mounting of the Completed Steel Shim
recommended laden height.
12) Lift the generating set 1 mm totally be means
9) Care must be taken, during levelling of the of the three jacking bolts.
installation, to ensure that individual mountings
are not overloaded.The variation in laden height 13) Position each completed steel shim.
should not exceed 2 mm and should ideally
be less. The laden height can be measured 14) Re-lower the generating set by means of the
between top and base casting at H, on two three jacking bolts until it rests completely in
sides (see fig 1). itself.
Example:
Adjustment of Internal Buffer
H1 + H2 + H3 ----- HN
Average = Number of conical elements 15) Turn the internal buffer clockwise (downwards)
until it makes contact with the steel shim or
foundation.
If Then
16) Turn the internal buffer anticlockwise (upwards)
Difference exceeds Level the conical ele- until it obtains contact with the base casting.
ment
2 mm. by adjusting the jacking This must be four full turns.
bolts - commencing with
the conical element with 17) Turn the internal buffer two full turns clockwise
the largest deviation. (downwards) and check with a feeler gauge
between the base casting of the conical ele-
Difference does not ex- The height of the steel ment and the steel shim that the internal buffer
ceed 2 mm shim can be measured. (2), see fig 1, does not touch the steel shim or
foundation.
The difference between the two sides of a conical 18) Lock the internal buffer by remounting the top
mounting should not be more than 0.6 mm. lock ring (6) and turn it to the nearest thread
hole - then secure with fixing bolt (7) and spring
washer (8), see fig 1.
Measuring of Steel Shim
08028-0D/H5250/94.08.12
10) Measure the steel shim on several points to Mounting of Conical Elements on the Foun-
obtain the highest possible accuracy during dation
preparation.
19) Remove the dowel pins.
Fabricating Steel Shim 20) Drill four mounting holes in the foundation for
each conical element, either
11) Make sure that the minimum height of the steel
shim is 10 mm. a) Mark the positions of the mounting holes on
the foundation through the conical element and
the steel shims.
03.50 - ES1
MAN Diesel

L23/30H
L27/38
(Re)move the set completely so that the mark- The drilling has to be done on beforehand and
ings can be reached by drilling with conventional the set must be aligned with the foundation
tools. holes before the work starts to avoid further
removal of the set.
Place the set on its former position by aligning
it with the drilled holes. 21) Fix all the conical elements and the supporting
steel shims/steel shims to the foundation with
or four bolts per conical.
b) Drill the mounting holes in the foundation by 22) Weld the lowest steel shim of approx. 10 mm
means of the drilling pattern from the installa- height to the foundation.
tion drawing.
Note! After completion of all works, the buffer clear-
18.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel

L23/30H
L27/38

Shut-off fuel oil
Description

plants. Hand tools

Related procedure

(autolog)
510-01.00
03.00
Man power

08028-0D/H5250/94.08.12

03.50 - ES0
MAN Diesel

L23/30H
L27/38
Mounting and Adjustment Instructions for 5) Position the jacking bolts with a through-going
New Generating Sets (Method 3) of minimum 10 mm plus permitted thickness,
as specified from the chockfast supplier, see
Make Ready for Adjustment of Conical Ele- fig 2.
ments
6) Lowed the generating set until it rests com-
If the conical elements have not been mounted by pletely on the foundation.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have 7) Check that all jacking bolts have full contact
been mounted by the factory, please start with item with the foundation.
number 2.
8) Turn the internal buffer (2), see fig 1, to check
1) Fit the conical elements to the bracket of the that it can be moved freely.
base frame by means of four bolts screwed
into the tapped holes on the top casting (5) If all internal buffers Then
see fig 1.
Can move freely Let conical elements
A supporting steel shim with a minimum height of settle for 48 hours.
40 mm, complete with tapped holes for three jacking
bolts, four mounting holes and four tapped holes, Cannot be moved Turn the three jacking
drilled according to the conical base casting dimen- freely bolts in the supporting
sion, is required see fig 2. steel shim clockwise, or
anticlockwise and
2) Remove fixing bolt (7), spring washer (8) and slacken the four
top lock ring (6) from the conical element, see holddown bolts
fig 1. to release the internal
buffer.
3) Position the supporting steel shim as per fig
2 and locate the conical element by means of
four hold-down bolts.
4) Position the three jacking bolts in the tapped

holes in the supporting steel shim as per fig
2.
08028-0D/H5250/94.08.12

03.50 - ES1
MAN Diesel

L23/30H
L27/38
Adjustment of Conical Element after 48 Fabricating Steel Shim
Hours Settling
Make sure that the minimum height of the steel shim
After the conical elements have been deflected un- is 10 mm.
der static load for 48 hours, the laden height (H1) 11) Drill the mounting holes in the steel shim accord-
see fig 2, should be measured and compared to the ing to the mounting holes in the conical base
recommended laden height. casting and in the supporting steel shim.
9) Care must be taken, during levelling of the

installation, to ensure that individual mountings Adjustment of Internal Buffer
are not overloaded.The variation in laden height
should not exceed 2 mm and should ideally 12) Turn the internal buffer clockwise (downwards)
be less. The laden height can be measured until it makes contact with the steel shim or
between top and base casting at H, on two foundation.
sides (see fig 1).
13) Turn the internal buffer anticlockwise (upwards)
Example: until it obtains contact with the base casting.
H1 + H2 + H3 ----- HN
Average = Number of conical elements This must be four full turns.
14) Turn the internal buffer two full turns clockwise

If Then (downwards) and check with a feeler gauge
between the base casting of the conical ele-
Difference exceeds Level the conical element and the steel shim that the internal buffer
ment 2 mm. by adjusting the jacking (2), see fig 1, does not touch the steel shim or
bolts - commencing with foundation.
the conical element with
the largest deviation. 15) Lock the internal buffer by remounting the top
lock ring (6) and turn it to the nearest thread
Difference does not ex- The height of the steel hole - then secure with fixing bolt (7) and spring
ceed 2 mm shim and the chockfast washer (8), see fig 1.
can be measured.
Mounting of Conical Elements on the Foun-

The difference between the two sides of a conical dation
mounting should not be more than 0.6 mm.
16) Drill four mounting holes in the foundation for
each conical element according to the sup-
Measuring of Steel Shim and Chockfast porting steel shim/steel shim, either
08028-0D/H5250/94.08.12
10) The steel shim should be at least 10 mm a) Mark the positions of the mounting holes on
high. the foundation through the conical element
and the shims.
Check the minimum permitted thickness of chock-
fast for the load and surface of this application with (Re)move the set completely so that the mark-
chockfast supplier. ings can be reached by drilling with conventional
tools.
03.50 - ES1
MAN Diesel

L23/30H
L27/38
Place the set on its former position by aligning The drilling has to be done on beforehand and
it with the drilled holes. the set must be aligned with the foundation
holes before the work starts to avoid further
or removal of the set.
b) Drill the mounting holes in the foundation by Make sure that the mounting bolts are isolated from
means of the drilling pattern. the chockfast.
Note! After completion of all works, the buffer clear-

15.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
Page 1 (2) Replacement of Conicals Edition 03H
L27/38

Shut-off fuel oil
Replacement of conicals. Hydraulic jack.
Starting position
Safety precautions.
Related procedure
Fitting instructions for resilient mounting.
Manpower Spare and wearing parts

08028-0D/H5250/94.08.12
Working hours : - hours Plate no Item no Qty/

Capacity : 2 men
51903 013 4/E
Data

99.20 - ES0
MAN Diesel
Edition 03H Replacement of Conicals Page 2 (2)
L27/38
Replacement of Conicals
1) Loosen all the holding-down bolts for the co- 2) Mount a jack under the base frame, see fig
nicals in one side. 1.
3) Lift the GenSet until the steel shim can be remo-

ved. This will give enough space for removing
damaged conical.
4) Mount the GenSet conical.
Note: Conicals should only be replaced in pairs, see

fig 2 and plate 51903.
5) Lower the GenSet again.
6) Repeat items 1-5 for the other side.
7) Adjust the conicals, please see working card

519-03.00 "Fitting Instructions for Resilient
Mounting of GenSet.
Fig 1 Removal of conicals
08028-0D/H5250/94.08.12
Fig 2 The conicals must be replaced in pairs
99.20 - ES0
MAN Diesel
Page 1 (2) Maintenance of Conicals Edition 03H
L27/38

Shut-off fuel oil
Control and adjustment of conicals. Ring and open-end spanner.

Feeler gauge, 2 mm.
Starting position
Related procedure

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

99.17 - ES0
MAN Diesel
Edition 03H Maintenance of Conicals Page 2 (2)
L27/38
Visual Check Result of Clearance Check
What to Check If Then
everything is OK check is completed

1) Check for oil deposits on the rubber element.
everything is not OK adjust conicals which do not
2) Check for loose mounting bolts. comply with the clearance de-
mands
acc. to item 5-11. Recheck
3) Check for damage in the rubber element. all conicals acc. to item 4.
Result of Visual Check everything is still not OK replace conical acc. to

If Then
everything is OK continue to next conical

Adjustment of Conicals
oil deposits on rubber clean rubber element
element are observed 5) Remove protective cap (10).
loose mounting bolts fasten mounting bolts
6) Remove fixing bolt (9) and top locking ring (7).
damage to conicals replace conical according to
is observed Working Card 519-03.05 7) Turn buffer clockwise until it makes contact
with the steel shim (2).
Clearance Check 8) Turn buffer anti-clockwise until it makes contact

with the conical base casting (3). This must be
What to Check done in four full rotations.
4) Check clearance on all conicals between steel 9) Turn buffer two full rotations clockwise. This will
shim and internal buffer through the slot in the ensure full vertical movement for the buffer.
base casting of the conical (see fig 1) with a
feeler gauge of approx. 2 mm. 10) Check all conicals again.
11) Replace top locking ring, fixing bolt and pro-

tective cap etc.
08028-0D/H5250/94.08.12
Fig 1 Conical
99.17 - ES0S
MAN Diesel
Plate
Page 1 (2) Flexible External Connections 51902-13H
L27/38
Item
Fig. Designation Connection
no
Fuel oil, inlet A1 018
Fuel oil, outlet A2
Waste oil, outlet A3 043
Lubricating oil from separator, C3 079

inlet
Lubricating oil to separator, C4

outlet
Drain from lub. oil sump, C14

outlet
Lub. oil overflow, outlet C15 092
Oil vapour discharge, outlet C13 126
Venting to expansion tank/ F3/F4 163

Fresh water for preheating
08028-0D/H5250/94.08.12
06.18 - ES0
MAN Diesel
Plate
51902-13H Flexible External Connections Page 2 (2)
L27/38
Item
Fig. Designation Connection
no
HT freshwater, inlet F1 209
HT frashwater, outlet F2
LT freshwater/raw water, G1
inlet
outlet
LT freshwater/raw water, G9 222

inlet

outlet
Compressed air, inlet K1 271
Exhaust gas, long, P2 305

outlet (DN450)
Exhaust gas, short, P2 378

outlet (DN450)
Exhaust gas, outlet (DN500) P2 317
Exhaust gas, long, P2 330

outlet (DN600)
08028-0D/H5250/94.08.12
Exhaust gas, short, P2 391

outlet (DN600)
06.18 - ES0
MAN Diesel
Plate
Page 1 (2) Conical Element 51903-03H
L27/38
08028-0D/H5250/94.08.12
99.14 - ES0
MAN Diesel
Plate
51903-03H Conical Element Page 2 (2)
L27/38
Item Item
013 1/M Conical element, Konisk understtning,

complete komplet
025 4/M Screw Skrue
049 1/M Protecting cap Beskyttelseskapsel
050 1/M Fixing ring Fikseringsring
062 1/M O-ring O-ring
08028-0D/H5250/94.08.12
Qty/M = Qty/Conical mounting Qty/M = Qty/Conical montering
99.14 - ES0
MAN Diesel
Plate
Page 1 (2) Conical Element 51903-07H
L27/38
CL - Engine
074
013
025
08028-0D/H5250/94.08.12
Note! When ordering be aware that conical ele- Bemrk! Ved bestilling af conicals elementer skal
ments always should be replaced in pairs. State conicals elementer altid udskiftes parvis. Opgiv
manufacturing No of existing conical elements. fabrikationsnr. p eksisterende conicals elementer.
07.48 - ES0
MAN Diesel
Plate
51903-07H Conical Element Page 2 (2)
L27/38
Item Item
013 1/M Conical element, Konisk understtning,

complete komplet
025 4/M Screw Skrue
074 4/M Screw Skrue
08028-0D/H5250/94.08.12
Qty/M = Qty/Conical mounting Qty/M = Qty/Conical montering
07.48 - ES0
Tools
520/620
MAN Diesel

Page 1 (7) Function of the Hydraulic Tools Edition 02
General

Shut-off fuel oil
Safety hints and function of hydraulic tools.
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

99.43 - ES0
MAN Diesel
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 doesnt
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
MAN Diesel
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
MAN Diesel
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
MAN Diesel

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
MAN Diesel
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 pistons 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
oils 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
MAN Diesel

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 devices 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
MAN Diesel
Page 1 (4) Application of Hydraulic Tools Edition 05H
L27/38

Shut-off cooling water See page 2-4
Shut-off fuel oil
Application of hydraulic tools.
Starting position
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

01.32 - ES0
MAN Diesel
Edition 05H Application of Hydraulic Tools Page 2 (4)
L27/38
This working card gives the information for applica-

tion of hydraulic tools, to be used in connection with
working card 520-01.05.
Fig 1 Contra weight.
08028-0D/H5250/94.08.12
Fig 2 Cross bolt and tierod.
01.32 - ES0
MAN Diesel
Page 3 (4) Application of Hydraulic Tools Edition 05H
L27/38
Fig 3 Cylinder head.

08028-0D/H5250/94.08.12
Fig 4 After main bearing.
01.32 - ES0
MAN Diesel
Edition 05H Application of Hydraulic Tools Page 4 (4)
L27/38
Fig 5 Connection rod.

08028-0D/H5250/94.08.12
01.32 - ES0
MAN Diesel
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

00.45 - ES0
MAN Diesel

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 oils
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
08028-0D/H5250/94.08.12
- Open the tank breather with the square wrench

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.
00.45 - ES0
MAN Diesel
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).
00.45 - ES0
MAN Diesel

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.
00.45 - ES0
MAN Diesel
Plate
Page 1 (13) Standard Tools for Normal Maintenance 52000-02H
L27/38
Supply per Ship

Name Sketch Plate Item no Remarks
Working Spare
Valve spring 1 52000 014

tightening device
Lifting tool for 1 52000 038

cylinder unit
Grinding tool for 1 52000 087

cylinder head/liner
Max. pressure 1 52000 134

indicator
08028-0D/H5250/94.08.12
02.51 - ES1
MAN Diesel
Plate
52000-02H Standard Tools for Normal Maintenance Page 2 (13)
L27/38
Supply per Ship

Working Spare
Handle for 1 52000 146

indicator valve
Removing device 1 52000 021

for flame ring
Guide bush for 1 52000 045

piston
08028-0D/H5250/94.08.12
Fit and removal 1 52000 069

device for conn.
rod bearing, incl.
eye screws (2 pcs)
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Lifting device for 1 52000 082

cylinder liner

piston and connec-
ting rod
Testing mandrel for 1 52000 153

piston ring grooves,
6.43 mm
Testing mandrel for 1 52000 165

piston ring grooves,
8.43 mm
08028-0D/H5250/94.08.12
Plier for piston pin 1 52000 177

lock ring
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Piston ring opener 1 52000 190
Supporting device 1 52000 212

for connecting rod
and piston in the
cylinder liner
Honing brush 1 52000 224
Feeler gauge 1 52000 010

08028-0D/H5250/94.08.12
Dismantling tool for 1 52000 035

main bearing upper
shell
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Tool for fixing of 1 52000 060

marine head for
counterweight
Eye screw for lifting 1 52000 036
Cleaning tool for 1 52000 013

fuel injector
Pressure testing 1 52000 050

tool
Grinding device for 1 52000 074

nozzle seat
08028-0D/H5250/94.08.12
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Extractor device 1 52000 407

for injector valve
Mandrel for 1 52000 012

oil cooler
Eye screw for 1 52000 032

lifting
Fitting device for 1 52000 044

lub. oil cooler
08028-0D/H5250/94.08.12
Pressure pump, 1 52000 011

complete
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Pressure part, 4 52000 059

long M39 x 2
Pressure part, 2 52000 072

short M39 x 2
Pressure part 2 52000 096

M27 x 2

M36 x 2
08028-0D/H5250/94.08.12

M30 x 2
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Tension screw 4 52000 118

M39 x 2
Tension screw 2 52000 131

M24/27 x 2
Distribution piece, 1 52000 143

cylinder head
08028-0D/H5250/94.08.12
Distribution piece, 1 52000 167

main bearing
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Hose with unions 4 52000 180

for cylinder head
Hose with unions 1 52000 202

for connecting of oil
pump and distri-
buting block
Spare parts for hy- Consisting of o-rings, supporting 1 52000 226

draulic tool M39 x 2 rings, hydraulic nipple, sealing
rings.

rings.

rings.

rings.
08028-0D/H5250/94.08.12
Hydraulic tightening 4 52000 263

cylinder M39 x 2
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare

cylinder M36 x 2

cylinder M30 x 2

cylinder M24/27 x 2
08028-0D/H5250/94.08.12
Angle piece 2 52000 358
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Tommy bar 2 52000 334
Container complete 1 51205 318

for water washing
of compressor side
Blowgun for dry 1 51210 136

cleaning of turbo-
charger
08028-0D/H5250/94.08.12
Force-off device 1 52000 424
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Resetting device for 1 52000 436

hydraulic cylinder
Measuring device 2 52000 448
Broad chissel 1 52000 473

08028-0D/H5250/94.08.12
02.51 - ES1
MAN Diesel
Plate
L27/38
Supply per Ship

Working Spare
Broad chissel 1 52000 485
Socket 1 52000 497

08028-0D/H5250/94.08.12
02.51 - ES1
MAN Diesel
Plates
Page 1 (5) Tools for Reconditioning 52001-01H
L27/38
Supply per Ship Drawing Remarks

Name Sketch
Working Spare Plate no Item no
Lifting straps for 1 52001 012

main bearing cap
Lifting handle for 1 52001 036

main bearing cap
Fit and removing 1 52001 073

device for connec-
ting rod bearing
08028-0D/H5250/94.08.12
Support for 1 52001 085

connecting rod
01.16 - ES1
MAN Diesel
Plates
52001-01H Tools for Reconditioning Page 2 (5)
L27/38

Name Sketch
5 Turning device 1 52001 107

for cylinder unit
Grinding machine 1 52001 119

for valve seat rings
08028-0D/H5250/94.08.12
9 Fit and removing 1 52001 120

device for valve
guides
01.16 - ES1
MAN Diesel
Plates
L27/38

Name Sketch
Touching bow for 1 52001 132

inlet valve
Touching bow for 1 52001 144

exhaust valve
Fitting device for 1 52001 156

valve seat rings
08028-0D/H5250/94.08.12
Plate 1 52001 168

(used with item 181)
01.16 - ES1
MAN Diesel
Plates
52001-01H Tools for Reconditioning Page 4 (5)
L27/38

Name Sketch
Extractor for valve 1 52001 181

seat rings

device for fuel
injection pump
Setting device for 1 52001 215

fuel injection pump

device for cooler
insert
08028-0D/H5250/94.08.12
01.16 - ES1
MAN Diesel
Plates
L27/38

Name Sketch
Micrometer screw 1 52001 252

08028-0D/H5250/94.08.12
01.16 - ES1
MAN Diesel
Plates
Page 1 (2) Extra Tools 52002-01H
L27/38

Name Sketch
Fitting and removal of mono- 1 52002 031

block cylinder
Dissambly tools 1 52002 043
Fitting / removing device 1 52002 055

for injection pump
08028-0D/H5250/94.08.12
03.27 - ES1
MAN Diesel
Plates
Page 2 (2) Extra Tools 52002-01H
L27/38

Name Sketch
Crankshaft alignment 1 52002 067

gauge (autolog)

crankshaft bearing
cover
08028-0D/H5250/94.08.12
03.27 - ES1
MAN Diesel
Page 1 (1)
Special Tools for Low Dismantling Height 52003-02H
L27/38

Name Sketch

cylinder unit

piston
40
250

cylinder liner
340
846
Lifting tool for 444.5 1 52003 049

turning bracket
08028-0D/H5250/94.08.12
07.25 - ES1

L2738 Marine

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MAN Diesel

Text Index Drawing No.

Engine data 500/600

Warning Description A500

Operation of engine 501/601

Operation Description 501.01 (11H)

Performance and condition 502/602

Engine performance and condition Description 502.01 (03H)

Trouble shooting 503/603

Starting failures Description 503.01 (02)

Text Index Drawing No.

Media specification 504/604

Cylinder head 505/605

Cylinder head and water jacket Description 505.01 (03H)

Piston/connecting rod 506/606

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

Text Index Drawing No.

Camshaft and camshaft drive Description 507.01 (03H

Operating gear 508/608

Safety, control and monitoring system Description 509.01 (13)

Crankshaft and main bearings Description 510.01 (05H)

Text Index Drawing No.

Flywheel with gear rim Plate 51003-14H

Engine frame/Oil pan 511/611

Engine frame and base frame Description 511.01 (04)

Turbocharger system Description 512.01 (06H)

Compressed air system 513/613

Compressed air system Description 513.01 (09H)

Text Index Drawing No.

Manual turning gear Working card 513-25.00 (02H)

Fuel oil system 514/614

Internal fuel oil system Description 514.01 (05H)

Lubricating oil system 515/615

Internal lubricating oil system Description 515.01 (06H)

Text Index Drawing No.

Crankcase venting Plate 51531-03H

Cooling water system 516/616

Internal cooling water system Description 516.01 (03H)

Special equipment 517/617

Kit for Inspection of fuel valve Kit 51701-01

Specific plant information 519/619

Resilient mounting of generating sets Description 519.03 (08H)

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

(Marine engines only)

It is important that all MAN Diesel engines are oper-

In accordance with Chapter I of the Code of Federal

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

Power range : 1500-2970 kW

Speed : 720/750 rpm

Stroke/bore ratio : 1.4:1

Piston area per cyl. : 572.6 cm2

Swept volume per cyl. : 21.8 ltr.

Compression ratio : 15.9:1

Turbocharging principle : Constant pressure system and intercooling

Fuel quality acceptance : HFO up to 700 cSt/50 C

Firing order : 5 cyl. 1-2-4-5-3

Power lay-out MCR version

Speed rpm 720 750