Man B&W L1624 - Marine Diesel Engine

MAN Diesel
GenSet Index
L16/24
Text Index Drawing No.
Engine data 500/600
Warning Description A500

Main data for engine Description 500.00 (17H)
Introduction Description 500.01 (02)
Safety Description 500.02 (02)
Cross section Description 500.05 (05H)-f
Cross section Description 500.05 (05H)-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 (08H)
Planned maintenance programme, duties during operation Description 500.26 (12H)
Operation data and set points Description 500.30 (57)
Green Passport Description 500.33 (01)
Data for pressure and tolerance Description 500.35 (30H)
Data for tightening torque Description 500.40 (24H)
Declaration of weight Description 500.45 (06H)
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 (03H)

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 (04H)

Evaluation of readings regarding combustion condition Description 502.02 (02)
Condensate amount Description 502.05 (03)
Engine performance data Working card 502-01.00 (03H)
Check of leakage from inspection holes Working card 502-05.00 (01H)
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 (03H)
Ignition in crankcase Description 503.04 (03)
Trouble shooting guide for centrifugal by-pass filter Description 503.05 (02H)
Trouble shooting guide for air starter Description 503.06 (07H)
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 (08)
Media specification 504/604

MAN Diesel
Index GenSet
L16/24
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 (08H)
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 (02H)

Dismantling of cylinder unit from engine Working card 505-01.00 (10H)
Disassembly of cylinder unit Working card 505-01.01 (02H)
Inspection of inlet valve, exhaust valve and valve guide Working card 505-01.05 (07H)
Reconditioning of valve spindle seat and and valve seat ring Working card 505-01.10 (02H)
Valve rotator Working card 505-01.15 (02H)
Replacement of valve guide Working card 505-01.20 (05H)
Replacement of valve guide Working card 505-01.20 (12H)
Replacement of valve seat ring Working card 505-01.35 (05H)
Inspection of cylinder head cooling water space Working card 505-01.45 (02H)
Assembly of cylinder unit Working card 505-01.50 (02H)
Mounting of cylinder unit in engine Working card 505-01.55 (02H)
Cylinder head Plate 50501-11H
Cylinder head Plate 50501-16H
Valve spindles and valve gear Plate 50502-08H
Valve spindles and valve gear Plate 50502-11H
Cylinder head, top cover Plate 50510-02H
Cylinder unit Plate 50515-04H
Piston/connecting rod 506/606
Piston, connecting rod and cylinder liner Description 506.01 (02H)

Separation/assembly of piston, connecting rod and fittings of piston Working card 506-01.05 (07H)
rings
Piston Working card 506-01.10 (03H)
Connecting rod Working card 506-01.15 (06H)
Criteria for replacement of connecting rod big-end and main bearing Working card 506-01.16 (02)
shells
Hydraulic tightening of connecting rod screws Working card 506-01.25 (02H)
In-situ inspection of connecting rod big-end bearing Working card 506-01.30 (02H)
Inspection and honing of cylinder liner Working card 506-01.35 (06H)
Grinding of seal face on cylinder liner and cylinder head Working card 506-01.45 (02H)
Dismantling of piston and cylinder liner at low overhaul height Working card 506-01.50 (02H)
Piston and connecting rod Plate 50601-03H
Piston and connecting rod Plate 50601-08H
Cylinder liner Plate 50610-03H
Camshaft 507/607
MAN Diesel
GenSet Index
L16/24
Camshaft and camshaft drive Description 507.01 (02H)

Check of camshaft and camshaft drive Working card 507-01.00 (02H)
Inspection and replacement of camshaft bearing Working card 507-01.05 (05H)
Adjustment of camshaft for valve and injection timing Working Card 507-01.20 (10H)
Intermediate wheel Plate 50701-02H
Camshaft (valve camshaft) Plate 50705-15H
Camshaft (injection camshaft) Plate 50705-16H
Operating gear 508/608
Operating gear for valves and fuel injection pumps Description 508.01 (02H)
Inspection of valve roller guide Working card 508-01.00 (03H)
Control of valve clearance Working card 508-01.10 (09H)
Safety valve adjustment Working card 508-01.10 (10H)
Roller guide and push rods Plate 50801-02H
Control/safety 509/609
Safety, control and monitoring system Description 509.01 (13)

Lambda controller Description 509.10 (07H)
Communication from the GenSet Description 509.55 (09)
Functional test and adjustment of safety, alarm and monitoring Working card 509-01.00 (02H)
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 analogous temperature transmitter Working card 509-05.04 (04H)
Adjustment and test of tacho and proximity sensors Working card 509-05.06 (01)
Mounting and adjustment of pick-ups on engine Working card 509-08.00 (01H)
Adjustment of lambda controller Working card 509-10.00 (05H)
Governor and governor drive Plate 50901-19H
Governor and governor drive Plate 50901-20H
Regulating device Plate 50902-10H
Instruments Plate 50907-18
Level switch in oil sump (LAL/LAH 28) Plate 50920-12H
Fuel oil leakage alarm (LAH 42) Plate 50925-06H
Monitoring box Plate 50935-18H
Terminal box Plate 50936-16H
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
Prelubricating oil pump starter (4 engines) Plate 50951-01
Prelubricating oil pump starter (1 engine) Plate 50951-04
Converter Plate 50956-01
Oil mist detector Plate 50960-03
Crankshaft 510/610
Crankshaft and main bearings Description 510.01 (02H)

Checking of alternator / crankshaft alignment (autolog) Working card 510-01.00 (15H)
Inspection of main and guide bearing shells Working card 510-01.05 (03H)
Vibration damper Working card 510-04.00 (03H)
Crankshaft Plate 51001-03H
Crankshaft Plate 51001-12H
MAN Diesel
Index GenSet
L16/24
Flywheel with gear rim Plate 51003-16H

Vibration damper/tuning wheel Plate 51004-04H
Engine frame/Oil pan 511/611
Engine frame and base frame Description 511.01 (02H)

Functional test of crankcase safety relief valves Working card 511-01.00 (11H)
Frame with main bearings Plate 51101-23
Front-end box Plate 51103-06H
Front-end box Plate 51103-17H
Covers on frame Plate 51106-21H
Cover on frame Plate 51106-22H
Base frame Plate 51111-09H
Turbocharger 512/612
Turbocharger system Description 512.01 (05H)

Overhaul of charging air cooler Working card 512-01.00 (02H)
Exhaust pipe compensator Working card 512-01.10 (01H)
Cleaning the turbine, dry cleaning Working card 512-10.00 (03H)
Charging air cooler Plate 51201-06H
Charge air cooler with preheating Plate 51201-16H
Charge air cooler without preheating Plate 51201-17H
Exhaust pipe arrangement Plate 51202-17H
Mounting of turbocharger Plate 51203-07H
Connecting pipe Plate 51206-02H
Blowgun for dry cleaning of turbocharger Plate 51210-02
Heat insulation of exhaust pipes Plate 51211-01H
Cover of exhaust pipes Plate 51211-02H
Heat insulation and cover before turbocharger Plate 51211-03H
Charge air pipes Plate 51230-03H
Oil drain from turbocharger Plate 51231-07H
Mounting of charge air cooler Plate 51235-04H
Control air for preheating valve Plate 51236-02H
Compressed air system 513/613
Compressed air system (low pressure) Description 513.01 (16H)

Compressed air system Description 513.01 (17H)
Air filter Working card 513-01.21 (02)
Overhaul, test and inspection of air starter Working card 513-01.30 (03H)
Overhaul, test and inspection of air starter Working card 513-01.30 (06H)
Emergency starting valve Working card 513-01.40 (02H)
Check of compressed air piping system Working card 513-01.90 (03)
Air starter Plate 51309-18H
Air starter Plate 51309-14H
Air starter (supplement for plate 51309-14H) Plate 51309-15H
Air starter (supplement for plate 51309-14H) Plate 51309-20H
Main stop valve Plate 51315-02H
Air filter Plate 51321-03
Pressure reduction valve Plate 51322-08
Pressure reduction valve Plate 51322-09
Turning gear with attachment Plate 51325-02H
Overspeed stop valve Plate 51327-02
Arrangement of jet system Plate 51330-02H
MAN Diesel
GenSet Index
L16/24
Starting air receiver Plate 51335-01
Fuel oil system 514/614
Internal fuel oil system Description 514.01 (02H)

Dismounting/mounting of fuel injection pump (L Orange) Working card 514-01.05 (06H)
Dismounting/mounting of fuel injection pump (Woodward) Working card 514-01.05 (07H)
Disassembly/assembly and repair of fuel injection pump Working card 514-01.06 (05H)
(Woodward)
Disassembly/assembly and repair of fuel injection pump (L Orange) Working card 514-01-06 (06H)
Fuel injection valve (L Orange) Working card 514-01.10 (08H)
Fuel injection valve (Woodward) Working card 514-01.10 (09H)
Check of fuel oil piping system Working card 514-01.90 (04H)
Fuel injection pump (Woodward) Plate 51401-16H
Fuel injection pump (L Orange) Plate 51401-07H
Fuel injection valve (Woodward) Plate 51402-11H
Fuel injection valve (L Orange) Plate 51402-12H
Fuel injection pipe (Woodward) Plate 51404-06H
Fuel injection pipe Plate 51404-07H
Safety filter Plate 51415-03
Fuel oil arrangement Plate 51430-02H
Fuel oil arrangement Plate 51430-19H
Fuel injection pump connections (L Orange) Plate 51435-03H
Fuel injection pump connections (Woodward) Plate 51435-04H
Installation & operation of safety filter Description 2.04.5
Lubricating oil system 515/615
Internal lubricating oil system Description 515.01 (04H)

Lubricating oil pump Working card 515-01.00 (03H)
Prelubricating pump Working card 515-01.05 (03H)
Lubricating oil filter Working card 515-01.10 (02H)
Lubricating oil, thermostatic valve Working card 515-01.20 (03H)
Check of lubricating oil piping system Working card 515-01.90 (02H)
Lubricating oil cooler Working card 515-06.00 (03H)
Centrifugal bypass filter Working card 515-15.00 (03H)
Lubricating oil pump Plate 51501-06H
Lubricating oil filter Plate 51502-12H
Prelubricating pump Plate 51504-04H
Lubricating oil cooler Plate 51506-10H
Centrifugal bypass filter Plate 51515-02H
Lubricating oil separator Plate 51530-02H
Crankcase venting Plate 51531-05H
Prelubricating pump arrangement Plate 51535-02H
Cooling water system 516/616
Internal cooling water system Description 516.01 (04H)

Check of cooling water system Working card 516-01.90 (02H)
Cooling water, thermostatic valve Working card 516-04.00 (02H)
HT and LT water pumps Working card 516-10.00 (01H)
High and low temperature fresh water pumps Plate 51610-11H
Cooling water connections Plate 51630-02H
Special equipment 517/617
Kit for complete cylinder unit exchange Kit 51703-02

MAN Diesel
Index GenSet
L16/24
Kit for cylinder unit Kit 51704-02
Specific plant information 519/619
Resilient mounting of generating sets Description 519.03 (03H)

Fitting instructions for resilient mounting of GenSets Working card 519-03.00 (24)
Replacement of conicals Working card 519-03.05 (02)
Maintenance of conicals Working card 519-03.10 (02)
Flexible external connections Plate 51902-04H
Conical element Plate 51903-02
Tools 520/620
Function of the hydraulic tools Working card 520-01.05 (02)

Application of hydraulic tools Working card 520-01.06 (06H)
Hand lever pump Working card 520-01.07 (01)
Tools for cylinder head Plate 52005-06H
Tools for piston, connecting rod and cylinder liner Plate 52006-08H
Tools for camshaft and camshaft drive plate 52007-03H
Tools for operating gear for inlet and exhaust valves Plate 52008-07H
Tools for crankshaft and main bearings plate 52010-05H
Tools for charge air cooler plate 52012-03H
Tools for fuel oil system and injection equipment Plate 52014-06H
Tools for lubricating oil cooler Plate 52015-04H
Hydraulic tools Plate 52021-09H
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 Data for Engine 500.00
Page 1 (1) Edition 17H
L16/24
Cycle : 4-stroke
Configuration : In-line
Cyl. Nos. available : 5-6-7-8-9
Power range : 450-990 kW
Speed : 1000/1200 rpm
Bore : 160 mm
Stroke : 240 mm
Stroke/bore ratio : 1.5:1
Piston area per cyl. : 201 cm2
Swept volume per cyl. : 4.8 ltr.
Compression ratio : 15.2:1
Turbocharging principle : Constant pressure system and intercooling
Fuel quality acceptance : HFO up to 700 cSt/50° C

(ISO 8217 RMH55 and RMK55)
Power lay-out MCR version
Speed rpm 1000 1200
Mean piston speed m/sec. 8 9.6
Mean effective pressure

5 cyl. engine bar 22.4 20.7
08028-0D/H5250/94.08.12
6, 7, 8, 9 cyl. engine bar 22.4 22.8
Max. combustion pressure bar 170 170
Power per cylinder

5 cyl. engine kW/cyl. 90 100
6, 7, 8, 9 cyl. engine kW/cyl. 90 110
05.45 - 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
L16/24
08028-0D/H5250/94.08.12
99.40 - ES1
MAN Diesel
Description
Cross Section 500.05
Page 1 (1)
Edition 05H
L16/24
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 08H
L16/24
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
6000
12000
24000
50
2000
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

Lubricating of operating gear - Check ............................. ■
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
Camshaft and Camshaft Drive

08028-0D/H5250/94.08.12
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
02.31 - ES0
MAN Diesel
500.25 Description
Edition 08H Planned Maintenance Programme Page 2 (3)
L16/24
overhauled parts
Working
Observations
● = Overhaul to be carried out
3rd month
Description
after - hours
Card
Check new/
Monthly
Weekly
■
200
6000
12000
24000
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 viscodamper - 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* ...................... 200
08028-0D/H5250/94.08.12
Cleaning of the compressor when dismounted* ..............

Cleaning of the silencer when dismounted* ....................
Basic check; all components, bearings, etc.* ..................
* see turbocharger manual
Air starter motor - Dismantling and inspection ................ ■ 513-01.30
02.31 - ES0
MAN Diesel
Description 500.25
L16/24
overhauled parts
Working
Observations
● = Overhaul to be carried out
3rd month
Description
after - hours
Card
Check new/
Monthly
Weekly
■
200
6000
12000
24000
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)....... ■ 516-10.00

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

see 500.26.
08028-0D/H5250/94.08.12
02.31 - ES0
MAN Diesel
Description 500.26
L16/24
Duties during Operation
overhauled parts
Working
Observations
●
3rd month
= Overhaul to be carried out
after - hours
Description
Check new/
Monthly
200
6000
12000
24000
Weekly
50
2000
Card
Daily
■ = Check the condition
No
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
Cylinder Head
Inlet and exhaust valve - check and adjustment of valve

clearance ......................................................................... ■ 508-01.10
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
Cleaning the turbine, dry cleaning .................................. ● 512-10.00

Water washing of compressor side ................................ see TC
manual
Exhaust pipe compensator .............................................. ■ 512-01.10
08028-0D/H5250/94.08.12
07.12
MAN Diesel
500.26 Planned Maintenance Programme Description
Edition 12H Page 2 (2)
L16/24
Duties during Operation

Time Between Overhaul
Overhauled parts
Working
Observations
●
3th month
= Overhaul to be carried out
Description
Check new/
after -hours
50
2000
6000
200
24000
Weekly
12000
Card
Montly
Daily
■ = Check the condition
No
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 - Adjustment of opening pressure .... ■ 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
08028-0D/H5250/94.08.12
Engine Frame and Bedplate
Flexible mounting - Check anti-vibration mountings ........ ■ 519-03.00

Safety cover - Function test ............................................. ■
Alternator - see special instruction book
Major overhaul/inspection, see 500.25
07.12
MAN Diesel
Description
Operation Data & Set Points 500.30
L16/24
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 82° 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) 0.3-1.5 bar <1.0 bar PAL 25 0.1 bar (H) 60
Pressure inlet turbocharger PI 23 1.3 - 2.2 bar >1.3 bar PAL 23 0.25 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
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 30-40°C
HFO TI 40 110-140°C
Press. LT system, inlet engine PI 01 1.5-4.5 bar >1.8 bar PAL 01 0.4 + (B) bar 3
Press. HT system, inlet engine PI 10 1.5-4.0 bar >1.8-<6 bar PAL 10 0.4 + (B) bar 3
Temp. HT system, outlet engine TI 12 75-85°C <85° C TAH 12 90° C 3 TSH 12 95° C
TAH 12-2 93° C 3 (TSH 12) (100° C) (D)
Temp. LT system, inlet engine TI 01 10-45°C
Exhaust Gas and Charge Air
Exh. gas temp. before TC TI 62 500-550° C TAH 62 600° C 10

TAH 62-2 650° C 3
Exh. gas temp. outlet cyl. TI 60 425-490° C TAH 60 525° C 3
Diff. between individual cyl. average TAD 60 average (K) 60
±25° C ± 50° C
Exh. gas temp. after TC TI 61 325-375° C TAH 61 450° C 3
Ch. air press. after cooler PI 31
08028-0D/H5250/94.08.12
1000 rpm 3.0 bar

1200 rpm 2.6 bar
Ch. air temp. after cooler TI 31 35-55° C <55° C
Press. inlet engine (start/stop) PI 70 7-10 bar >7.5-<10 bar PAL 70 6.5 bar 15
08.40 - ES1
MAN Diesel
500.30 Operation Data & Set Points Description

L16/24
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 1200 rpm SAH 81 1380 rpm 0 SSH 81 1356 rpm
(SSH 81) (1380 rpm) (D)
SI 90 1000 rpm SAH 81 1150 rpm 0 SSH 81 1130 rpm
(SSH 81) (1150 rpm) (D)
Turbocharger speed SI 89 (L) SAH 89 (J) 3
Alternator
Winding temperature TI 98 100° C TAH 98 130° C 3

Miscellaneous
Jet system failure SX32 switch 10

Monitoring system failure 24 VDC UX 95-1 switch 120
± 15%
Safety system failure 24 VDC UX 95-2 switch 120
± 15%
Turning engaged ZS75 Engaged (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 1000 rpm SS 90 910 rpm(I) 0
1200 rpm 1130 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
08.40 - ES1
MAN Diesel
Description
Operation Data & Set Points 500.30
L16/24
Remarks to Individual Parameters F. Start Interlock
A. Fuel Oil Pressure, HFO-operation The following signals are used for start interlock/
blocking:
When operating on HFO, the system pressure must
be sufficient to depress any tendency to gasification 1) Turning must not be engaged
of the hot fuel. 2) Engine must not be running
3) "Remote" must be activated
The system pressure has to be adjusted according 4) No shutdowns must be activated.
to the fuel oil preheating temperature. 5) The prelub. oil pressure must be OK, 20 min.
after stop.
B. Cooling Water Pressure, Alarm Set Points 6) "Stop" signal must not be activated
As the system pressure in case of pump failure will G. Start Failure

depend on the height of the expansion tank above the
engine, the alarm set point has to be adjusted to 0.4 If remote start is activated and the engine is in block-
bar plus the static pressure. The static pressure set ing or local mode or turning is engaged the alarm
point can be adjusted on the base module SW3. time delay is 2 sec.
Start failure will be activated if revulutions are below
C. Lub. Oil Pressure, Offset Adjustment 50 rpm within 5 sec. from start or revulutions are
below 210 rpm 10 sec. from start.
At charge air pressure below 1.0 bar the lub. oil pres- Start failure alarm will automatically be released after
sure to turbocharger is normal at 0.6 ±0.1 bar. 30 sec. of activation.
The read outs of lub. oil pressure has an offset H. Alarm Hysterese
adjustment because of the transmitter placement.
This has to be taken into account in case of test and On all alarm points (except prelub. oil pressure) a
calibration of the transmitter. hysterese of 0.5% of full scale are present. On prelub.
oil pressure alarm the hysterese is 0.2%.
D. Software Created Signal
I. Engine Run Signal
Software created signal from PI 22, TI 12, SI 90.
The engine run signal is activated when engine
E. Set Points depending on Fuel Temperature rpm >1130 or lube oil pressure >3.0 bar or TC rpm
>5000 rpm.
If engine rpm is above 210 rpm but below 1130
rpm within 30 sec. the engine run signal will be
activated.
J. Limits for Turbocharger Overspeed Alarm

08028-0D/H5250/94.08.12
(SAH 89)
Engine type 1000 rpm 1200 rpm

5L16/24 / NR 12/S 75,000 75,000
6L16/24 / NR 12/S 75,000 75,000
7L16/24 / NR 12/S 75,000 -
7L16/24 / NR 14/S - 62,200
8L16/24 / NR 14/S 62,200 62,200
9L16/24 / NR 14/S 62,200 62,200
Fig 1 Set point curve.
08.40 - ES1
MAN Diesel
500.30 Operation Data & Set Points Description

L16/24
K. Exhaust Gas Temperatures L. Turbocharger Speed
The exhaust gas temperature deviation alarm is Normal value at full load of the turbocharger is de-
normally ±50° C with a delay of 1 min., but at start- pendent on engine type (cyl. no) and engine rpm.
up the delay is 5 min. Furthermore the deviation The value given is just a guide line. Actual values
limit is ±100° C if the average temperature is below can be found in the acceptance test protocol.
200° C.
08028-0D/H5250/94.08.12
08.40 - 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
Page 1 (1)
Edition 30H
L16/24
Section Description mm. / bar
505 a) Maximum inner diameter, valve guide 12.2 mm

b) For grinding of valve spindle and valve seat ring (see also working card 505-01.10)
c) Minimum height of valve head, inlet valve and exhaust valve, "H" 1 5.0 mm
d) Maximum height of spindle above cylinder head, "H" 2 66.5 mm
506 a) Piston and piston ring grooves (see working card 506-01.10)
b) Clearance between connecting rod bush and piston pin 0.15-0.20 mm

c) Maximum ovalness in big-end bore (without bearing) 0.06 mm
d) Maximum inside diameter cylinder liner, max. ovalness 0.1 mm 160.5 mm
e) Sealing minimum height above the cylinder liner 0.2 mm
507 a) Clearance between camshaft and camshaft bearing
b) Maximum clearance between camshaft and camshaft bearing 0.25 mm

c) Clearance between teeth on intermediate wheel 0.2-0.3 mm
508 a) Valve clearance, Inlet valve (cold engine 15 - 55°C) 0.40 mm

b) Valve clearance, Exhaust valve (cold engine 15 - 55°C) 0.50 mm
c) Maximum clearance between rocker arm bush and rocker arm shaft 0.30 mm
509 a) Free spand between pick-up and band steel (Lambda controller) 1 mm
510 a) Deflection of crankshaft (autolog), (see working card 510-01.00)

08028-0D/H5250/94.08.12
08.17 - ES0
MAN Diesel
Description 500.40
Page 1 (8) Data for Tightening Torque Edition 24H
L16/24
Lubricant
Note: For tightening bolts to a specified torqe,

M Lubricating paste up to 200°C Coefficient of
friction 0.08 - 0.12 only use the specified lubricants. For component
temperatures up to 200°C, e.g. Molykote Pasta d or
MH High temperature lubricating Coefficient of Optiuoly Paste White-T. For component temperatures
paste above 200°C friction 0.08 - 0.12 above 200°C, e.g. Molykote Paste HSC or Copa
Slip.
O Oil
XX Screw in with Loctite 243 until it Re-tightening procedure for hydraulic tool:
sits squarely 1) Pressurize the hydraulic tool to specified
hydraulic pressure.
° Angle when slackening
2) Check if nut is loose. If loose, then tighten.
L Number of holes by which the 3) De-pressurize the hydraulic tool.
nut must be turned back
Tab. 1.
Oil Screw-in Tightening Working

Screw Connection pressure moment torques Card Figure
Bar torsions angle
012 Cylinder Crankcase
012-1
Cap main bearing / 1200 HAND/hand-M M 510-01.05
Cylinder crankcase Loctite 243
012-2
Cap main bearing / 200 HAND/hand-M MH 510-01.05
Cylinder crankcase 1200 HAND/hand-M MH 510-01.05
012-3
Crankcase / 1200 MH 505-01-55
Cylinder head
012-4
Crankcase / Baseframe 340
020 Crankshaft
020-1
08028-0D/H5250/94.08.12
Crankshaft / Counter 1200 45-M

weight
020-2
Gear wheel 100-M
(two parts)
020-3
Gear wheel / 100-M
Crankshaft
08.20 - ES0
MAN Diesel
500.40 Description
Edition 24H Data for Tightening Torque Page 2 (8)
L16/24
Oil Screw-in Tightening Please see

Screw Connection pressure moment torques Working Figure
Bar torsions angle Card
027 Vibration Damper
027-1
Gear wheel / Damper 1. step 210-O 510-04.00
2. step +60°
027-2
Side / Disc 55-O
030 Connecting Rod
030-1
Connecting rod shaft / Con- 1200 M 506-01.25
necting rod cover 506-01.15
506-01.30
034 Piston
034-1
Piston 506-01.10
08028-0D/H5250/94.08.12
034-2
Piston 506-01.10
08.20 - ES0
MAN Diesel
Description 500.40
L16/24

056 Mounting of Fuel Injection Valve
056-1
Clamp / Cylinder head 6-O 32-O 514-01.10
Note: See also working

card 514-01.10
073 Crankcase Casing with Relief Valve
073-1
Crankcase covers / 8-M 511-01.00
Cylinder crankcase
100 Control Drive
100-1
Cylinder crankcase / 1200 HAND/hand-M 507-01.20
Stepped spur gear
101 Camshaft (Valve camshaft)
101-1
Camshaft part piece / 55-M 507-01.00
08028-0D/H5250/94.08.12
Bearing disk
101-2
Bearing plate / Housing 55-M 507-01.00
507-01.05
101-3
Damper (9 cyl.) / Gear wheel 55-M 507-01.00
507-01.05
101-4
Spur gear / Bearing disk 55-M 507-01.05
08.20 - ES0
MAN Diesel
500.40 Description
L16/24

101 Camshaft (injection camshaft)
101-5
Camshaft part piece / 55-M 507-01.00
Bearing disk
Spur wheel / Bearing disk 507-01.05
101-6
Bearing plate / Housing 55-M 507-01.00
507-01.05
101-7
Damper (9L) / Gear wheel 55-M 507-01.00
507-01.05
111 Valve Bridge
111-1
Valve bridge / Settting screws 40-M
111 Rocker arm
111-2
Rocker arm / Setting screws 40-M
112 Tappet
112-1
Housing / Axle 8-M 505-01.05
200 Fuel Injection Pump
200-1
Connection socket / 4-MH 39-MH 514-01.06
Front-end box Loctite 638
08028-0D/H5250/94.08.12

card 514-01.06
08.20 - ES0
MAN Diesel
Description 500.40
Page 5 (8)
Data for Tightening Torque Edition 24H
L16/24

200 Fuel Injection Pump - Cont.
200-2
Plugs on the side of the fuel
injection pump:
Woodward 45 M
L'Orange 100-120 M 514-01.90
Dismounting of pump 514-01.05
289 Exhaust Pipe
289-1
Pipe piece / Compensator 80-MH
289-2
Clamping strap 34-MH 505-01.55
289-3
Cover / Pipe piece 80-MH
289-4
Pipe piece / Turbocharger 34-MH
289-5
Pipe piece 80-MH
311 Casing
311-1
Oil separator (closing cover)
/ Housing 7-MH 68-MH
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
500.40 Description
L16/24

350 Water pump
350-1 350-2
Water pump shaft/spur gear 80-O 350-1
350-2
Water pump shaft/impeller 40-O
434 Fuel Injection Pipe
434-1
2 clamps / Cylinder head 4-MH 28-MH 514-01.05
434-2
3 clamps / Cylinder head
434-1
434-2
447 Cooling Water Pipe
447-1
Flange / Bearing 4-MH 39-MH 505-01.55
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
Description 500.40
L16/24

701 Assembly Flywheel
701-2
Crankshaft / Flywheel 1.step 150-MH
2. step +90°
Lub. Oil Cooler
Lub. oil cooler 515-06.00

card 515-06.00
08028-0D/H5250/94.08.12
08.20 - ES0
MAN Diesel
500.40 Description
L16/24
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 Approximate coefficient of friction:
the lubricant used, the finished condition of
the surfaces and threads, and on the materials μ = 0.08 for lubricants containing molib-de-
paired. It is, therefore, of great importance that num disulphid (MoS2)-(Molycote
all these conditions are met. paste type G-n or HSC and Optimoly
paste White T),
- Tab. 3 lists the tightening torques for various
threads as a function of the coefficient of friction μ = 0.14 for surfaces that are not finish-tre-
μ, i.e. of the lubricant used. The torques are ated, with a thin film of oil or grease
based on bolt material of the strength class 8.8 using Loctite.
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.
Tightening torque in Nm Tightening torque in Nm

Thread Coefficient of friction μ Thread Coefficient of friction μ
nominal size nominal size
0.08 0.14 0.08 0.14
M5 4 6 M 24 475 690
M6 7 10 M 24 x2 500 750
m8 17 25 M 27 700 1020
M 10 34 50 M 27x2 730 1100
M 12 60 85 M 30 950 1380
M 14 95 135 M 30x2 1015 1540
M 14x1.5 100 145 M33 1270 1870
M 16 140 205 M 33x2 1350 2060
M 16x1.5 150 220 M 36 1640 2400
M 18 200 280 M 36x3 1710 2550
08028-0D/H5250/94.08.12
M 18x1.5 215 320 M 39 2115 3120

M 18x2 205 300 M 39x3 2190 3300
M 20 275 400 M 42 2630 3860
M 20x1.5 295 450 M 42x3 2760 4170
M 20x2 285 425 M 45 3260 4820
M 22 370 540 M 45x3 3415 5180
M 22x1.5 395 595 M 48 3950 5820
M 22x2 380 565 M 48x3 4185 6370
Tab. 3. Tightening torques for bolts of the strength class 8.8.
08.20 - ES0
MAN Diesel
Description
Declaration of Weight 500.45
L16/24
Section Component Plate No Item No Weight in Kg
505 Cylinder head, incl. rocker arms 50501 027 85

Cooling water jacket 50501 218 20
Cylinder unit 187
506 Piston, complete 50601 081 8

Connecting rod, complete 50601 068 20
Cylinder liner, complete 50601 018 45
509 Governor, complete 50901 021/104/

116 30
511 Main bearing cap 51101 157 20

Main bearing cap, axial 51101 169 21
Front-end box 51102 019 539
512 Turbocharger, complete 132

Air cooler 51201 162 450
513 Air starter 51309 242 30
514 Fuel injection pump 51401 565 15

Fuel injection valve 51402 116 5
515 Lubricating oil pump 51501 031/043 45

Prelubricating oil pump, incl. el-motor 51504 122 20
Centrifugal filter 51515 337 24
516 HT- and LT-cooling water pump 51610 105 10

08028-0D/H5250/94.08.12
08.05 - 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 μ 1 ft. lbf 1.356 J
106 mega M 10-9 nano n 1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
103 kilo k 10-12 pico p 1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
102 hecto h 10-15 femto f
10 deca da 10-18 atto a * Exact value: 4.1868 J
I.T. = International Steam Table
Area (m2)
1 sq. in (square inch) 0.6452 x 10-3 m2

1 sq. ft (square foot) 92.90 x 10-3 m2
04.37 - ES0
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 25°C 298 K

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

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

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

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

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

** t (°C) = T(K) - T0(K), where T0 = 273.15 K
04.37 - ES0
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 ΔK = temperature difference
r = density in kg/m3 Cp = heat capacity in J/(kg DK)
t ρ Cp t Cp
range
08028-0D/H5250/94.08.12
Water 18 999 4.18 x 103

Lubricating oil (approx.)* 15 900 1.96 x 103
Atmospheric air (dry) (p=1 bar) 0 1.276 998 0-150 1005
Exhaust gas 200-400 1080
* Viscosity: 100-140 cSt at 40°C
750 mm Hg = 1 bar = 105 Pa
1 atm (standard pressure at sea level) = 760 mm Hg = 1013 mbar
Gas constant for air and exhaust gas = 287 J/(kg x K)
Water, heat of evaporation 100°C 1.013 bar 2.256 x 106 J/kg
Fuel oil. Lower calorific value 41-43 x 106 J/kg
ISO 3046/1-1986 standard reference fuel 43 x 106 J/kg
Diesel engine reference fuel (see below)
04.37 - ES0
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
Page 1 (3)
Edition 03H
L16/24
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 60°C 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.
02.49 - ES0
MAN Diesel
501.01 Description
Edition 03H
Operation Page 2 (3)
L16/24
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
9) Check the pressure in the starting air to the data and setpoints sheet.
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

according to the data and setpoints sheet. 17) Check that the turbocharger is running.
18) Check that the prelubricating oil pump stops

Starting automatically.
13) Start the engine by activating the start button 19) Check that all cylinders are firing, see exhaust
on the operation box; push the button until the gas temperatures.
engine ignites, see Fig. 3.
Note: Check the stop cylinder (Lambda controller) for
regulating the shaft works properly, both when stop-
Testing during Running ping normally and at overspeed and shut down.
See Description 509.05 before operating the control

panel.
02.49 - ES0
MAN Diesel
Description
Operation 501.01
Page 3 (3)
Edition 03H
L16/24
Check that all shutdowns are connected and func- 29) To ensure full operational reliability, the con-
tion satisfactory. dition of the engine should be continuously
observed so that order for preventive mainte-
20) Test the overspeed, see Working Card nance work can be carried out before serious
509-01.05. breakdowns occur, see also section 502.
21) Check that all alarms are connected.

Stopping
Operation 30) Before stopping, it is recommended to run the

engine at reduced load, max. 2 min.
The engine should not be run up to more than 50%
load to begin with, and the increase to 100% should 31) The engine is stopped by activating the stop
take place gradually over 5 to 10 minutes. button on the operating box. Please note that
the push button must be activated at least 3
Note: When the engine is running the planned sec. before stop will be activated.
maintenance programme and the following should
be checked:
Starting and Stopping on HFO
22) The lubricating oil pressure must be within the
stated limits and may not fall below the stated Starting and stopping of the engine should take
minimum pressure. The paper filter cartridges place on HFO in order to prevent any incompatibility
must be replaced before the pressure drop problems on changeover to MDO.
across the filter reaches the stated maximum
value, or the pressure after the filter has fallen MDO should only be used in connection with mainte-
below the stated minimum value. Dirty filter nance work on the engine or before a longer period
cartridges cannot be cleaned for re-use. of engine standstill.
23) The lubricating oil temperature must be kept Before starting on HFO the engine must be properly
within the stated limits indicated on the data preheated as described in "Preparations for Starting"
and setpoints sheet. and as described below.
24) The fuel oil pressure must be kept at the stated Stopping the engine on HFO is no problem, but it
value. should be ensured that the temperature of fuel pipes
is not reduced to a level below the pour point of the
25) The cylinder cooling water temperature must fuel. Otherwise reestablishing the circulation might
be kept within the limits indicated on the data cause problems.
and setpoints sheet.
08028-0D/H5250/94.08.12
26) The exhaust gases should be free of visible Starting on MDO

smoke at all loads. For normal exhaust tem-
peratures, see the test report from shop and For starting on MDO there are no restrictions except
sea trials. that lubricating oil viscosity may not be higher than
1500 cSt (10°C SAE 40).
27) Keep the charging air pressure and tempera-
ture under control. For normal values, see the Initial ignition may be difficult if the engine and ambient
test report from shop and sea trials. temperatures are lower than 5°C and 15°C cooling
water temperature.
28) Recharge the starting air receivers to the de-
scribed value.
02.49 - 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
Fig 1 Monitoring of temperature/pressure (MTP). Fig 2 Governor.
02.49 - ES0
MAN Diesel
501.01 Description
Edition 08
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:

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

are running or by means of a preheater (if
installed).

Fig 3 Operation box (OB).

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
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.
28) The cylinder cooling water temperature must
18) Check the cooling water pressure. be kept within the limits indicated on the data
19) Check the fuel oil feed pressure.
29) The exhaust gases should be free of visible
20) Check that the turbocharger is running. smoke at all loads. For normal exhaust tem-
peratures, see the test report from shop and
08028-0D/H5250/94.08.12
21) Check that the prelubricating oil pump stops sea trials.
automatically.
22) Check that all cylinders are firing, see exhaust ture under control. For normal values, see the
gas temperatures. test report from shop and sea trials.
Note: Check the stop cylinder (Lambda controller) for 31) Recharge the starting air receivers to the de-
regulating the shaft works properly, both when stop- scribed value.
ping normally and at overspeed and shut down.
32) To ensure full operational reliability, the con-
Check that all shutdowns are connected and func- dition of the engine should be continuously
tion satisfactory. observed so that order for preventive mainte-
nance work can be carried out before serious
breakdowns occur, see also section 502.
02.49 - ES0
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
preheated as described in "Preparations for Starting"
33) Before stopping, it is recommended to run the and as described below.
Stopping the engine on HFO is no problem, but it
34) The engine is stopped by activating the stop should be ensured that the temperature of fuel pipes
button on the operating box. Please note that is not reduced to a level below the pour point of the
the push button must be activated at least 3 fuel. Otherwise reestablishing the circulation might
sec. before stop will be activated. cause problems.
35) On the governor can be found a manuel emer-

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

nance work on the engine or before a longer period
of engine standstill.
08028-0D/H5250/94.08.12
02.49 - ES0
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
Fig 1 Monitoring of temperature/pressure (MTP). Fig 2 Governor.
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:

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

are running or by means of a preheater (if
installed).


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

Fig 3 Operation box (OB).
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
27) The fuel oil pressure must be kept at the stated
18) Check the cooling water pressure. value.
19) Check the fuel oil feed pressure. 28) The cylinder cooling water temperature must
be kept within the limits indicated on the data
20) Check that the turbocharger is running. and setpoints sheet.
21) Check that the prelubricating oil pump stops 29) The exhaust gases should be free of visible
automatically. smoke at all loads. For normal exhaust tem-
peratures, see the test report from shop and
22) Check that all cylinders are firing, see exhaust sea trials.
gas temperatures.
Note: Check the stop cylinder (Lambda controller) for ture under control. For normal values, see the
regulating the shaft works properly, both when stop- test report from shop and sea trials.
08028-0D/H5250/94.08.12
ping normally and at overspeed and shut down.

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
preheated as described in "Preparations for Starting"
33) Before stopping, it is recommended to run the and as described below.
Stopping the engine on HFO is no problem, but it
34) The engine is stopped by activating the stop should be ensured that the temperature of fuel pipes
button on the operating box. Please note that is not reduced to a level below the pour point of the
the push button must be activated at least 3 fuel. Otherwise reestablishing the circulation might
sec. before stop will be activated. cause problems.
Starting and Stopping on HFO Starting on MDO
Starting and stopping of the engine should take For starting on MDO there are no restrictions except
place on HFO in order to prevent any incompatibility that lubricating oil viscosity may not be higher than
problems on changeover to MDO. 1500 cSt (10°C SAE 40).
MDO should only be used in connection with mainte- Initial ignition may be difficult if the engine and ambient
nance work on the engine or before a longer period temperatures are lower than 5°C and 15°C cooling
of engine standstill. water temperature.
08028-0D/H5250/94.08.12
06.19 - ES0
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 manufacturer’s 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
L16/24
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. 1°C higher charge
tion take place continuously as a result of combustion, air temperature causes about 1.5°C 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
information about the operational and maintenance a corresponding reduction of the compression
condition of the engine. Continuous observation can pressure and max. combustion pressure.
contribute to forming a precise and valuable basis for
evaluation of the optimum operation and maintenance
programmes for the individual plant. Fuel Injection Pump
The amount of fuel injected is equivalent to the

Engine Performance Data supplied energy and is thus an expression of the
load and mean effective pressure of the engine. The
If abnormal or incomprehensible deviations in opera- fuel pump index can therefore be assumed to be
tion are recorded, expert assistance in the evaluation proportional to the mean pressure. Consequently,
thereof should be obtained. it can be assumed that the connected values of the
pump index are proportional to the load.
We recommend taking weekly records of the most
important performance data of the engine plant. Dur- The specific fuel consumption, SFOC (measured by
ing recording (working card 502-01.00 can be used) weight) will, on the whole, remain unchanged whether
the observations are to be compared continuously in the engine is operating on HFO or on MDO, when
order to ascertain alterations at an early stage and considering the difference in calorimetric heat value.
before these exert any appreciable influence on the However, when operating on HFO, the combination
operation of the plant. of density and calorific value may result in a change
of up to 6% in the volumetric consumption at a given
As a reference condition for the performance data, load. This will result in a corresponding change in
the testbed measurements of the engine or possibly the fuel pump index, and attention should be paid to
the measurements taken during the sea trial on the this when adjusting the overload preventive device
delivery of the ship can be used. If considerable de- of the engine.
viations from the normal conditions are observed, it
will be possible, in a majority of cases, to diagnose Abrasive particles in the fuel oil result in wear of fuel
the cause of such deviations by means of a total injection pumps and fuel valve nozzles. Effective
evaluation and a set of measurements, after which treatment of the fuel oil in the purifier can keep the
possible adjustment/overhauls can be decided on content of abrasive particles to a minimum. Worn
and planned. fuel injection pumps will result in an increase of the
index on account of an increased loss in the pumps
due to leakage.
08028-0D/H5250/94.08.12
Evaluation of Performance Data

When evaluating operational results, a distinction
Air Cooler is to be made between changes which affect the
whole engine (all cylinder units) and changes which
Fouling of the air side of the air cooler will manifest occur in only one or a few cylinders. Deviations
itself as an increasing pressure drop, lower charge occuring for a few cylinders are, as a rule, caused
air pressure and an increased exhaust/charge air by malfunctioning of individual components, for ex-
temperature level (with consequential influence on ample a fuel valve with a too low opening pressure,
the overhaul intervals for the exhaust valves). blocked nozzle holes, wear or other defects, an inlet
or exhaust valve with wrongly adjusted clearance,
burned valve seat, etc.
98.48 - ES0
MAN Diesel
502.01 Engine Performance and Condition Description
L16/24
Turbochargers Exhaust Valves
Fouling of the turbine side of the turbocharger will, The overhaul intervals for exhaust valves is one of
in its first phase, manifest itself in increasing turbo- the key parameters when the reliability of the entire
charger revolutions on account of increased gas engine is to be judged. The performance of the ex-
velocity through the narrowed nozzle ring area. In haust valves is therefore extremely informative.
the long run, the charging air quantity will decrease
on account of the greater flow resistance through the Especially under unfavourable conditions, fuel quali-
nozzle ring, resulting in higher wall temperatures in ties with a high vanadium and sodium content will
the combustion chambers. promote burning of the valve seats. Combinations of
vanadium and sodium oxides with a corrosive effect
Service experience has shown that the turbine side will be formed during combustion. This adhesive ash
is exposed to increased fouling when operating on may, especially in the event of increased valve tem-
HFO. peratures, form deposits on the seats. An increasing
sodium content will reduce the melting point and
The rate of fouling and thereby the influence on thereby the adhesive temperature of the ash, which
the operation of the engine is greatest for small will involve a greater risk of deposits. This condition
turbochargers where the flow openings between the will be especially unfavourable when the na weight
va
guide vanes of the nozzle ring are relatively small. ratio increases beyond 1:3.
Deposits occur especially on the guide vanes of the
nozzle ring and on the rotor blades. In the long run, The exhaust valve temperature depends on the actual
fouling will reduce the efficiency of the turbocharger maintenance condition and the load of the engine.
and thereby also the quantity of air supplied for the With correct maintenance, the valve temperature is
combustion of the engine. A reduced quantity of air kept at a satisfactory low level at all loads. The air
will result in higher wall temperatures in the combus- supply to the engine (turbocharger/air cooler) and the
tion spaces of the engine. maximum pressure adjustment are key parameters
in this connection.
Fuel Valves It is important for the functioning of the valves that

the valve seats are overhauled correctly in accord-
Assuming that the fuel oil is purified effectively and ance with our instructions.
that the engine is well-maintained, the operational
conditions for the fuel valves and the overhaul in- The use of rotocaps ensures a uniform distribution
tervals will not normally be altered essentially when of temperature on the valves.
operating on HFO.
If, for any reason, the surface temperature of the fuel Air Inlet Valves
valve nozzle is lower than the condensation tempera-
ture of sulphuric acid, sulphuric acid condensate The operational conditions of the air inlet valves are
can form and corrosion take place (cold corrosion). not altered substantially when using residual fuel.
08028-0D/H5250/94.08.12
The formation of sulphuric acid also depends on the

sulphur content in the fuel oil.
Fuel Injection Pumps
Normally, the fuel nozzle temperature will be higher
than the approx. 180°C at which cold corrosion Assuming effective purification of the fuel oil, the
starts to occur. operation of the fuel injection pumps will not be very
much affected.
Abrasive particles in the fuel oil involve heavier wear
of the fuel valve needle, seat, and fuel nozzle holes.
Therefore, abrasive particles are to the greatest pos-
sible extent to be removed at the purification.
98.48 - ES0
MAN Diesel
Description 502.01
Page 3 (3) Engine Performance and Condition Edition 04H
L16/24
The occurrence of increasing abrasive wear of plunger The fresh air supply (ventilation) to the engine room
and barrel can be a consequence of insufficient should correspond to approximately 1.5 times the
purification of the fuel oil, especially if a fuel which air consumption of the engines and possible boilers
contains residues from catalytic cracking is used. in operation. Sub-pressure in the engine room will
Water in the fuel oil increases the risk of cavitation in involve an increased exhaust temperature level.
connection with pressure impulses occurring at the
fuel injection pump cut-off. A fuel with a high asphalt The exhaust back-pressure measured after the tur-
content has deteriorating lubricating properties and bochargers at full load must not exceed 250-300 mm
can, in extreme cases, result in sticking of the fuel water column. An increase in the exhaust back-pres-
injection pump plungers. sure will also cause an increased exhaust valve tem-
perature level, and increased fuel comsumption.
Engine Room Ventilation, Exhaust System
Good ventilation of the engine room and suitable loca-

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
exhaust valves.
08028-0D/H5250/94.08.12
98.48 - 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 dm³
Temperature in tank (T) 40 °C=313K
Internal press. of tank (p) 30 bar
Draining of Condensation Water = 31 x 105 N/m²(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 03H
L16/24
Safety precautions Special tools
Stopped engine Plate No Item No Note

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

According to scheme "Performance L16/24".
Starting position
Engine is running.
Related procedure
Manpower Replacement and wearing parts

08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty. /

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

Data for torque moment (Page 500.40)
Declaration of weight (Page 500.45)
99.03 - ES0
MAN Diesel MAN Diesel
Performance L16/24
M/V
Eng. type: Eng. No:
T/C type: Serial No:
Fuel type: Viscosity:
Density:
Load
Air temp °C
Date
Time
Run 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. b. filt. bar
LO press. a. filt. bar
LO press. T/C bar
FO temp. °C
FO press. bar
CA temp. °C
CA press. bar
Exh. cyl. 1 °C
Exh. cyl. 2 °C
Exh. cyl. 3 °C
Exh. cyl. 4 °C
Exh. cyl. 5 °C
Exh. cyl. 6 °C
Exh. cyl. 7 °C
Exh. cyl. 8 °C
Exh. cyl. 9 °C
Exh. b. T/C °C
Exh. a. T/C °C
L1 °C
L2 °C
L3 °C
Gov. IDX
IDX 1 mm
IDX 2 mm
IDX 3 mm
IDX 4 mm
IDX 5 mm
IDX 6 mm
IDX 7 mm
IDX 8 mm
IDX 9 mm
Power kW
08028-0D/H5250/94.08.12
Voltage V
Current A
Cos phi / kvAr
Crankcase press. mmWc
Signature:
10029-0EX/H5810/98.07.03
MAN Diesel
Page 1 (3) Check of Leakages from Inspection Holes Edition 01H
L16/24
Stopped engine Plate no Item no Note

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 : ¼ hour Plate no Item no Qty./

Capacity : 1 man
Data

98.22 - ES0
MAN Diesel
502-05.00 Working Card
Edition 01H Check of Leakages from Inspection Holes Page 2 (3)
L16/24
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
Inspection hole for

cooling water or
gas leakage
Fig. 1 Inspection holes in the cylinder unit

08028-0D/H5250/94.08.12
98.22 - ES0
MAN Diesel
Page 3 (3) Check of Leakages from Inspection Holes Edition 01H
L16/24
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
4) Leakages from charge air cooler, see fig. 2.
If Then
Air leaks from the inspection holes The inner O-ring on the charge air cooler has
to be replaced
Water leaks from the inspection hole The O-rings on the cooling water connecting
has to be replaced
08028-0D/H5250/94.08.12
Fig. 2 Inspection holes in the front-end box
98.22 - 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
Disturbances During Running 503.03
Page 1 (3)
Edition 03H
General
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 pres- Check camshaft adjustment, see working card
sure. 507-01.20.
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.
Damaged fuel pump cam. Replace camshaft section, working card 507-01.05.
08028-0D/H5250/94.08.12
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.
98.19 - ES0
MAN Diesel
503.03 Disturbances During Running

Description
Page 2 (3)
Edition 03H
General
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.
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.
Smoky exhaust. Turbine speed lagging behind engine Clean turbine(s), see working card 512-15.00.
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 working card 512-05.05.
Clean turbine, see working card 512-15.00.
Fuel valves or nozzles defective. Check fuel valves, see working card 514-01.10.
Exhaust valve knocking. Adjusting screw for valve setting loose. Inspect and replace defective parts, see working card
Push rod thrust disc damaged. 508-01.00.
08028-0D/H5250/94.08.12
Rising cooling water Thermostatic function Check thermostat.

temperature.
Pump defective Stop the engine and repair the pump.
Decreased flow Check valves.
If Then
The cooling water Open the test cocks (if
fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-100°C.
Cont.
98.19 - ES0
MAN Diesel
Description
Disturbances During Running 503.03
Page 3 (3)
Edition 03H
General
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.

08028-0D/H5250/94.08.12
98.19 - 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 02H
General
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 O ring.
Excessive vibrations. Rotor out of balance owing to un-even

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

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

maged.
Rotor assembly inadequately tight- Tighten and bring to notice of maintenance

ened. 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
98.20 - ES0
MAN Diesel
Description 503.06
Page 1 (1) Trouble Shooting Guide for Air Starter Edition 07H
L16/24
Trouble Possible Cause, see working Trouble Shooting

card
On pressing push-button, starter does - Empty air receiver(s) Charge receiver(s)

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

not respond, although air flows through - Insufficient air pressure Increase pressure in receiver
control circuit. - Push button stuck Remove and clean same
- Excessive length of main air pi- Approach push-button to starter or install a
pework 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 one.
and ring gear Check for distortion of ring gear
Pinion revolves but does not advance. - Push-rod Item 531 inoperative Disassemble, check, smoothen guide dia-
meter, clean or replace if rusted
- Insufficient air pressure Increase pressure in receiver
- Splined shaft Item 511 sticking Disassemble, clean, check spring Item 513
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 revolve. - Pneumatic motor inoperative Disassemble, inspect rotor for foreign mat-
ters between teeth and for possible wear of
gears.
- Check valve Item 578 Clean and reassemble. Replace worn parts
Disassemble, clean and reassemble
Pinion engages gear ring, but will not - Main valve Item 557 blocked Disassemble, clean and reassemble or
turn the engine. replace
- Rotors worn or blocked Disassemble, clean and reassemble or
replace rotors
- Insufficient air pressure Increase pressure in receiver
- Main air pipework restricted or of Check all pipework and replace if necessary
insufficient bore
Starter starts working upon opening - Incorrect connection of control pipes Connect control pipes as per installation
the flow valve of the feed line, although (with separate solenoid- valve) instruction.
push-button (or solenoid valve) are not - Main valve Item 557 blocked and Disassemble, clean and replace joint if
actuated. open needed
08028-0D/H5250/94.08.12
Lack of starter power. - Main pipework choked or bore is Check entire pipework for correct bore and
less than stipulated for the starter replace if incorrect.
- Insufficient air pressure Increase pressure in receiver.
- Badly worn rotors Disassemble, replace and reassemble.
After starting the engine, pinion tries to - Incorrect bore of main pipework Chcek entire pipework for correct bore and
re-engage and hits the ring gear which replace if incorrect.
results in damage to both. - Starting period unnecessarily long Check and adjust timer (if fitted) or press
starter pushbutton for shorter period.
- Idling of main valve item 557 Disassemble, clean, oil and reassemble.
Starter motor will not stop. - Main valve 557 blocked Disassemble, clean, oil and reassemble.
- Check valve 578 keeps open or Disassemble, check for correct closing of
does not seat properly the ball and that plug presses the valve
against is seat.
- Splined shaft 511 sticking Disassemble, clean, check spring 513 and
reassemble.
03.14 - ES0
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 40°C.
If the plate heat exchanger is still leaky,

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

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

start it up again.
Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the gas- plate. Replace defective plates and gaskets,
kets.) if any.
start it up again.
98.20 - ESO
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 08
L16/24
L21/31
Trouble Shooting Safety System
This description is a trouble shooting guide for the The safety system is an independent system and
automation system on the diesel engine type L16/24 consists of maker ABB PLC hardware modules and
and L21/31. MAN B&W software. Fig 1 describes the hardware
modules.
General For wiring of the modules and sensors a reference

is made to the schematic which can be found in the
The following trouble shooting guide is an aid in iso- operation manual, section 509.
lating troubles to the engine built-on safety system
and monitoring system incl. the sensors connected The safety system consists of three ABB PLC mod-
to these systems. ules. The modules named 3P1 is the CPU module,
the module named 4P1 is an input-module, and 5P1
CAUTION! The control system can be damaged is an output module. Indication of individual input and
with the wrong voltage. When replacing a control output can be found on the modules by yellow diodes.
unit, check that the power supply is switched off The reference number for each input and output can
during replacement and check the power supply for be found in the electrical schematic.
the correct voltage before switching-on.
On the operation box individual indication of the shut-
Table 1.1 for the safety system and table 1.2 for the downs (low lub. oil pressure, high cool. water temp.,
monitoring system are general guides for isolating overspeed and emergency stop) can be found.
system problems. Each system check assumes that
the prior checks have been done properly. Table 1.3 If a replacement module is needed, the software ver-
and 1.4 are system error messages which can be a sion must be informed at ordering. Software version
guideline to the problem. can be found by screwing the upper potmeter on 3P1
> half way and then count the numbers of flashes
If the conclusion of a trouble shooting indicates on out 1 on 3P1, ex. vers. 3.3.1.2 = 3 flashes pause
that an exchange of a module is needed, please 3 flashes pause 1 flash pause 2 flashes, remember
fill-in the enclosed inspection report, and return the to put the pot back to zero position after reading
module together with the inspection report to the version number. The pauses between the flashes
engine maker. are approx. 2 sec..
Further, please remember to inform the software no

when ordering a new module.
08028-0D/H5250/94.08.12
Fig 1 Hardware module.
06.22 - ES0
MAN Diesel
503.20 Description
Edition 08 Trouble Shooting / Electrical Failures Page 2 (6)
L16/24
L21/31
Table 1.1
Engine will not start. Supply voltage polarity, or no Check the supply voltage on the green diode on 3P1. If it is alight
Start motor is not engaged. supply voltage. the power supply for the PLC modules are OK.
RUN/STOP change-over switch Put the RUN/STOP change-over switch in RUN position. Check
on 3P1 in wrong position. RUN LED on 3P1.
No software in the module. If all diodes on 3P1 and 4P1 are alight after having switched
on the power supply, the module is without software. The mod-
ule must be replaced with a module incl. software. Note! After
switch-on of the power supply the initialization takes app. 3 sec.
Please wait these seconds before observation.
Output relay on 5P1 out 5 is in Check that diode on 5P1 OUT 5 is alight.
failure or loose connections. If on 5P1 out 5 is not alight check that IN 0 is alight and is
stable (continuous on or continuous off) Check for loose wires
on terminals 5 + C5 on 5P1.
One or several shutdown Reset the shutdowns.

signals are activated on the If one is still activated on the operation box, check that out 2, 3,
monitoring box 4 and 5 on 3P1 are alight. If one is not alight, check the sen-
sor and wiring for short circuit, and check that no shutdowns
are present.
All or some of the shutdown Connector is not correctly Check the connector J29 on the base module. Check the con-
LED are alight on the monitor- connected, internal failure in nector on the 3P1 unit. No red LED must be alight on 3P1.
ing box and the engine is run- 3P1 or connector on 3P1 is not Activate the change-over switch RUN/STOP. Exchange the 3P1
ning without a critical situation, correctly connected. module. Please note that in case that connections from PLC
only LED’s are alight. to base module is in failure it will be possible that the engine
is starting and running even there are one or more indications
of shutdown on the operation box. This observation will only
be possible with base module software version below 2.30 for
engine L16/24 and 4.10 for engine L21/31.
Low lub. oil shutdown oc- Damaged or wrong adjustment Check the pick-up for correct adjustment.
curs when normal stop is of the rpm pick-up. Sensing distance = app. 2 mm.
activated. Check that the connector is plugged correctly. Be aware that
no counternuts prevent from plugging the connector correctly.
Replace the pick-up.
Note! Diode 3 on 4P1 will be alight if actual speed is above
nominal speed. If actual speed is below, it will be dark.
08028-0D/H5250/94.08.12
The alarm „System & Power The internal bus connection Check that the bus connection between 3P1, 4P1, 5P1 is OK.
failure“ is activated. is disconnected or internal Check that power supply is OK. (Green diode must be alight).
Diode 0 or diode 1 are not component failure. Switch on the RUN/STOP change-over switch.The problem could
alight. be related to an internal component failure and the module must
be replaced. Observe that no red diode is alight on 3P1.
The shutdown functions are Wiring or sensor problem. Check the wiring for shutdown sensors.
not working. Internal component failure. Replace the module.
Overspeed set point is not Missing jumper or wrong Check that input 7 is alight for 1000 rpm engines, and OFF for
correct. software. 900 rpm (L21/31) and 1200 rpm (L16/24) engines. Check the
software version (see page 1)
06.22 - ES0
MAN Diesel
Description 503.20
L16/24
L21/31
The Monitoring System Interface to the alarm and monitoring system in the
control room is made by MODBUS or Interlink to the
The monitoring system monitors shows all relevant output module.
pressures, temperatures and rpm on the engine.
The software can be read by pushing the lamp test
The monitoring system consists of four hardware button for 3 seconds. The software version number
modules as standard and a module as option for will be displayed in the operation box display.
bearing temp. monitoring. The monitoring system
hardware and software is developed by MAN B&W. The software for the engine type L21/31 will start
Fig 2 describes the hardware. with 4.xx f.ex. 4.11. Please make sure that the dip
switches SW1, SW2, SW5 and SW3 are in correct
All sensors are connected to the base module and position acc. to the plant related schematic. See
the Operation Box (OB), Monitor for Temp. and section 509.
Pressure Module (MTP) and Monitor for Exh. Gas
Temp. Module (MEG) are connected via interlink
bus connection.
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
Dip Sensor power 0 40

L.T. WATER TEMP.
INLET AIR COOL.

TI01
switches LED
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.
PI22
OVERSPEED INLET ENGINE
Display LOW LUB.

OIL PRESS.
HIGH FRESH
LUB. OIL PRESS.
INLET TC
PI23
WATER TEMP. FUEL OIL TEMP.

TI40
EMERGENCY INLET ENGINE
STOP
FUEL OIL PRESS.
PI40
INLET ENGINE
0 80
Push 3 sec. START STOP

3 SEC. Delay
LAMP TEST CHARGE AIR TEMP.
OUTLET COOL.
TI31
Software version
08028-0D/H5250/94.08.12
0 4
BLOCKING CHARGE AIR PRESS.
REMOTE LOCAL PI31
OUTLET COOL.
RESET
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
L16/24
L21/31
Table 1.2
Engine will not start. Power supply is not correct. Check that the power supply is correct 24 V ± 20%
Start motor is not engaged. Interlock activated. on terminals J3; 132, 133.
Internal component failure. Check that no interlocks are activated
– Turning gear not engaged
– No start failure activated
– No engine run signal
– Remote mode is activated
– No shutdown activated
– Stop valve not activated
– No lub. oil pressure
– Prelub. oil pressure is OK
Check that LED on base module is steadily green
alight. See also table 1.3
Check that wirings from terminals J20; 98, 99 are
correct.
Check the safety system (see table 1.1)
Check that the ON/OFF switch on the base module
is working properly.
Note! After having switched on the power supply,
the system initializes app. 3 seconds. Please wait
with observations until initializing is finished.
Replace the base module.
Start motor engaged and engine Pick-up failure on both safety- and Check monitor pick-up and safety system. If system
started but stopped again after few monitor pick-up. failure or cable failure is activated on safety system
minutes. and the monitor pick-up is out of order the engine
will be stopped again.
Data communication failure. EMC problem or loose connec- Check that the green LED on the base module is
tions. alight. See also table 1.3
Check that all cable screens are connected correctly
in the EMC cable glands.
Check that the data communiation cable (MODBUS)
is the twisted pair type.
No RPM indication Defect pick-up or incorrect adjust- Check the pick-up for correct adjustment.
ment. Sensing distance = app. 2 mm.
Check that the connector is plugged correctly. Be
aware that no counternuts prevent from plugging
the connector correctly.
08028-0D/H5250/94.08.12
Replace the pick-up. Thread for used Dr. Horn

sensor is 1 mm.
The engine suddenly starts or Two or more earth failures on the Check for earth failures on all sensors.
stops. engine and yard installation. Special attention should be made to the exh. gas sen-
sors. Check for earth failures in the yard system.
Replace the base module.
LED flashing green, yellow or red. Internal component failure or EMC See table 1.3. Switch the power ON/OFF.
problem. Exchange the base module.
Cont.
06.22 - ES0
MAN Diesel
Description 503.20
L16/24
L21/31
Cont. Table 1.2
All or some of the red diodes on the No power supply or software in the Check the safety system accoding to table 1.1.
operation box are alight. safety system or bad connection
between safety system and base
module.
Jet system activated under no The band steel on the lambda arm Adjust the band steel to app. 2-3 mm above the
load condition and/or jet alarm is adjusted incorrectly. jet pick-up.
activated.
„Frozen“ operation box, MTP and Internal software failure. See table 1.3. Switch the power supply on/off.
MEG box. Exchange the base module.
Instable behaviour of the output Too high voltage on the output circuit Check that the voltage is below 48 VDC.
signals for start/stop of prelubricat- terminals J20, 108, 109 120 VAC or 220 VAC is not allowed.
ing pump. Note! The voltage must be checked in the prelubri-
cating pump starter panel.
Temp. indication is too high acc. Internal component failure. Replace the base module.
to calibrated values, or values are
abnormal.
Change-over switch between LO- Internal failure in the operation See table 1.3 and 1.4. Replace the operation box.
CAL - REMOTE - BLOCKING is box.
not working. Damaged flat cable between print
card and front panel.
The alarm „System & Power failure“ This alarm consists of different alarm 1) Check diode out 1 on the safety system module
is activated. possibilities 4P1. 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. If it is alight, it is OK. If it is
6) Tacho failure. not alight, check the safety system for cable break
or loose connections.
5) Check if rpm pick-up is OK, and/or lub. oil
08028-0D/H5250/94.08.12
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
06.22 - ES0
MAN Diesel
503.20 Description
L16/24
L21/31
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
MAN Diesel
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
Special Repair / Exchange Price

08028-0D/H5250/94.08.12
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 today’s 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 manufacturer’s 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 paraffin–basic
Behaviour in cold, still flows 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 (filter 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 SAE–Class
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 today’s 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 paraffinbasic
Behaviour in cold, still flows ASTM–D2500 15
°C
Flash point (as per Cleveland) ASTM–D92 > 200
Ash content (oxide ash) ASTM–D482 < 0.02
Weight %
Coke residue (as per Conradson) ASTM–D189 < 0.50
Ageing tendency after being MAN Diesel

heated up to 135 °C for 100 hrs. ageing cabinet *
08028-0D/H5250/94.08.12
n–heptane insolubles ASTM–D4055

Weight % < 0.2
or DIN 51592
Evaporation loss Weight % < 2
Drop test (filter 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 SAE–Class
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 08H
L16/24
Type L16/24 5 cyl. 6 cyl. 7 cyl. 8 cyl. 9 cyl.
Min. level alarm H1 (mm) 285 285 285 285 285
Min. level H2 (mm) 295 295 295 295 295

08028-0D/H5250/94.08.12
Max. level H3 (mm) 370 370 370 370 370
Max. level alarm H4 (mm) 385 385 385 385 385
Min. litre (H2) 342 389 436 483 530
Max. litre (H3) 429 488 547 606 665
99.27 - ES1
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, ρ @ 15°C must be known
The following formula is used to calculate the in order to convert ρ to the present lubricating oil
SLOC: temperature in the base frame. The following formula
is used to calculate ρ:
SLOC [g/kWh] =
ρlubricating oil [kg/m3] =
(lubricating oil added - A1 - A2 [dm ]) * ρlubricating oil [kg/m ]
3 3
run.hrs period * PMCR [kW] ρlubricating oil @15°C [kg/m3] – 0,64 * (tlubricating oil [°C] – 15)
In order to evaluate the correct engine SLOC, The engine maximum continuous design rating (PMCR)
the following circumstances must be noticed and must always be used in order to be able to compare
subtracted from the engine SLOC: the individual measurements, and the running hours
since the last lubricating oil adding must be used
A1: in the calculation. Due to inaccuracy *) at adding
08028-0D/H5250/94.08.12
Desludging interval and sludge amount from the lubricating oil, the SLOC can only be evaluated
lubricating oil separator (or automatic lubricating oil after 1,000 running hours or more, where only the
filters). The expected lubricating oil content of the average values of a number of lubricating oil addings
sludge amount is 30%. are representative.
The following does also have an influence on Note *)

the SLOC and must be considered in the SLOC A deviation of ± 1 mm with the dipstick measurement
evaluation: must be expected, witch corresponds uptill ± 0.1
g/kWh, depending on the engine type.
06.25 - ES0
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] [dm³] [dm³] [°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«
Engine–related 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 low–viscosity 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 specifications 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 ûC 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 ûC
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 specified 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 TBO’s (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
Definition Particle size Quantity
Inorganic foreign particles < 20 mg/kg

< 5 μm
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 mm²/s (cSt) at 50° C

D Density [kg/m³] 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 modifier (hot corrosion)
• Carbon remover (exhaust
Compatibility
system)
The supplier has to guarantee that the heavy fuel Table 4 Additives to heavy fuels Classification/
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 high–residue combustion. From an engine manufacturer‘s 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

Specification 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 specifications:
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 specifications:
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 filter 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/cm³ at a temperature of 15°C
Any catalyst particles are shown by the ash content (59°F).
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 60°F (15.6°C) 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/50°F + 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/50°C 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 60°C (140°F).
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/50°C (1500 sec.
RW/100°F) the highest possible temperature of 98°C
Fuel oils are always contaminated and should there- (208°F) should be maintained in the centrifuge oil
fore be cleaned thoroughly of solid as well as liquid preheater.
contaminants before use. The solid contami-nants
in the fuel are mainly rust, sand, dust and re-finery The fuel is kept in the centrifuge for as long as pos-
catalysts. Liquid contaminants are mainly water, i.e. sible by adjusting the flow rate through the centrifuge
either fresh water or sea water. so that it corresponds to the amount of fuel required
by the engine without excessive re-circulating. Con-
The impurities can cause damage to fuel injection sequently, the centrifuge should operate for 24 hours
pumps and fuel valves, result in increased cylinder a day except during necessary cleaning.
liner wear and cause the exhaust valve seats to
deteriorate. Increased fouling of gasways and tur- Taking today's fuel qualities into consideration the
bocharger blends may also result from the use of need to clean centrifuges ("shooting frequency")
inadequately cleaned fuel oils. should not be underestimated. Correct choice and
adjustment of the regulating screws and/or the grav-
Effective cleaning can only be ensured by means ity discs are of special importance for efficient water
of a centrifuge. We recommend that the capacity removal. The centrifuge manual states the disc or
of the centrifuges installed be at least according to screw adjustment which should be chosen on the
the centrifuge maker's recommendations. To obtain basis of the specific gravity of the fuel.
optimum cleaning it is of the utmost importance to
operate the centrifuge with as low a viscosity of the Normal practice is to have at least two centrifuges
fuel oil as possible and to allow the fuel oil to remain available for fuel cleaning. Results from experimen-
in the centrifuge bowl for as long as possible. tal work on centrifuges, treating today's qualities of
residual fuel, have shown that the best cleaning ef-
fect, especially as regards removal of catalyst fines,
is achieved when the centrifuges are operated in
Cleaning of HFO by Centrifuging
series, in purifier/clarifier mode.
Single centrifuge as purifier.
Operating Therefore series operation of centrifuges to ensure
options Two centrifuges in parallel.
Two centrifuges in series. maximum safety is a fully accepted alternative to the
previously recommended parallel operation, provided
Optimum Operating Configurations the operating capacity of each individual centrifuge
can handle the total amount of fuel required by the
Water content Parallel operation engine, without exceeding the flow rate recommended
below 1 % Purifier / Purifier by the centrifuge maker for the operating mode in
Normal question.
or
conditions
Density at 15°C Series operation
below 0.991 Purifier + Clarifier If the centrifuge capacity installed is on the low side,
corresponding to the specific viscosity of the fuel
08028-0D/H5250/94.08.12
Water content oil used, and if more than one centrifuge is avail-
below 1 % Parallel operation able, parallel operation may be considered in order
to obtain an even lower flow rate. However, in view
Extreme Density at 15°C Purifier / Purifier of the above results and recommendations serious
conditions below 0.991 consideration should be given to installing new equip-
ment in accordance with today's fuel qualities and
High content Series operation flow recommendations.
of catalyst fines Purifier + Clarifier
Table 1. Cleaning of HFO.
97.40 - ES0
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/80°C
Log scales 30 60 80 180 380 600 cST/50°C
200 400 600 1500 3500 6000 sec. RI/100°F
Fig. 1 Flow rate through centrifuge related to nominal capa-

city of centrifuge.
08028-0D/H5250/94.08.12
97.40 - ES0
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 Stenløse
Denmark Cooltreat 652 Liquid 5 l/1000 l
Nalfleet Marine Chemicals Nalfleet EWT Liq

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

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

Marine Chemicals Rocor NB Liquid Liquid 10 l/1000 l
Oslo, Norway
* Initial dosage may be larger
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 505.01
Page 1 (1) Cylinder Head and Water Jacket Edition 02H
L16/24
Cylinder Head The water jacket is bolted to the cylinder head by five
bolts. The five connection bolts to the cylinder head
The cylinder head is of cast iron with an integrated are free accessible from the top side and permit also
charge air receiver, made in one piece. It has a bore- a dismantling of the cylinder head itself.
cooled thick walled bottom. It has a central bore for
the fuel injection valve and 4 valve cross flow design,
with high flow coefficient. Intensive water cooling of Air Inlet and Exhaust Valves
the nozzle tip area made it possible to omit direct
nozzle cooling. The valve pattern is turned about 20° The valve spindles are made of heat-resistant
to the axis and achieves a certain intake swirl. material and the spindle seats are armoured with
welded-on hard metal.
The cylinder head is tightened by means of 4 nuts
and 4 studs which are screwed into the engine All valve spindles are fitted with valve rotators which
frame. The nuts are tightened by means of hydraulic turn the spindles each time the valves are activated.
jacks. The turning of the spindles ensures even tem-pera-
ture levels on the valve discs and prevents deposits
The cylinder head has a screwed-on top cover. It has on the seating surfaces.
two basic functions: oil sealing of the rocker chamber
and covering of the complete head top face to protect The cylinder head is equipped with replaceable
bolts and reduce noise radiation. valve seat rings. The exhaust valve seat rings are
water cooled in order to assure low valve tempera-
The valve guides are identical and therefor inter- tures.
changeable.
The seat rings are made of heat-resistant steel. The
seating surfaces are hardened in order to minimize
Water Jacket wear and prevent dent marks.
The main function of this part is as liner water jacket,

distribution gallery and tappet housing.
08028-0D/H5250/94.08.12
Fig 1 Cylinder head
98.38 - ES0
MAN Diesel
Page 1 (3) Dismantling of Cylinder Unit from Engine Edition 10H
L16/24

Shut-off cooling water 52005 038
Shut-off fuel oil 52006 212
Stopped lub. oil circul. 52005 109
Press Blocking - Reset 52021 011
52021 059
52021 118
Description 52021 143
52021 180
Dismantling of cylinder unit from engine for in- 52021 202
spection and/or overhaul. 52021 275
52021 334
Starting position Hand tools
Engine stopped and cooled down. Unbraco top

Ratchet
Extension
Related procedure
Valve rotator 505-01.15

Disassembly of cyl.head - water
jacket, cyl. liner and piston 505-01.01
Fuel injection valve 514-01.10

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

Capacity : 2 men
Data

07.35 - ES0
MAN Diesel
Edition 10H Dismantling of Cylinder Unit from Engine Page 2 (3)
L16/24
Preparation before Dismantling 9) Remove the 2 clamps securing the charge air
connections by unscrewing the locking bolts
1) Drain off the water from the engine. for the clamps.
2) Remove the top cover. 10) Push the charge air connections, inside the
cylinder head which are to be removed.
3) Remove the side covers on both sides of the
engine. 11) Turn the piston to top position.
4) Remove the exhaust gas cover.

Removal of Bearing Cap
Disassembly of Connections 12) Loosen the connecting rod nuts by means of the
hydraulic jacks, see working card 506-01.25.
5) Remove the clamp for connecting cylinder head
and exhaust gas receiver. 13) Remove the connecting rod nuts and bearing
cap by hand.
6) Remove the fuel oil high pressure pipe.
7) Remove the 4 clamps securing the fresh water

(FW) connection between the cylinder heads by
unscrewing the locking bolts for the clamps.
Lifting tool
8) Push the FW connections inside the cylinder
heads, which are to be removed.
Cylinder unit
Fixing tool
08028-0D/H5250/94.08.12
Fig 1 Push the cooling water connection and charge air

connections inside the cylinder heads, which are be removed.
Fig 2 Mounting of lifting and fixing tool.
07.35 - ES0
MAN Diesel
Page 3 (3) Dismantling of Cylinder Unit from Engine Edition 10H
L16/24
Mounting of Support Tools
14) Mount the fixing part, see plate 52006 item 212
Cylinder unit
for locking the connecting rod to the cylinder
liner.
15) Remove the cylinder head nuts by means of the

hydraulic jacks, see working card 520-01.05.
Work table
Fig. 4 Cylinder unit placed in work table.
16) Mount the lifting tool on the cylinder head, see

plate 52005 item 038.
Removal of Cylinder Unit from Engine
17) Lift the cylinder unit just enough for removing

the upper connecting rod bearing shell by
hand
18) Lift carefully the cylinder unit out of the engine

after the upper connecting rod bearing shell is
removed.
19) Land and fasten the cylinder unit upon the

special work table, or on the floor upon wooden
supports and remove the lifting tool.
Fig 3 Hydraulic tools for dismounting of cylinder head nuts.

08028-0D/H5250/94.08.12
07.35 - ES0
MAN Diesel
Page 1 (3) Disassembly of Cylinder Unit Edition 02H
L16/24

52006 082
Dismounting of cylinder head, water jacket, Measuring tools.

cylinder liner and piston for inspection/overhaul. Allen key, 8 mm.
Ratchet.
Extension.
Serrated fork.
Starting position
Dismantling of cylinder unit 505-01.00
Related procedure
Inlet and exhaust valve - overhaul and

regrinding of spindel and valve seat, 505-01.10
Valve rotator, 505-01.15
Replacement of valve guide, 505-01.20
Replacement of valve seat ring, 505-01.35
Inspection of piston, 506-01.10
Cylinder liner 506-01.35
Separation of piston and
connecting rod 506-01.05

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

Capacity : 1 man
Data

99.03 - ES0
MAN Diesel
Edition 02H Disassembly of Cylinder Unit Page 2 (3)
L16/24
Before starting to dismantle the cylinder unit it must Removal of Cylinder Head
be placed on the grinding table.
4) Remove the five allen screws in the cylinder
head.
Removal of Piston and Connecting Rod
5) Remove the cylinder head by means of the
1) Remove the fixing part (please see plate 52006, lifting tool .
item 212) from the cylinder liner and connecting
rod.
2) Turn the unit 180° in the table.
3) Pull out the piston and connecting rod with the

aid of the tool as shown in fig. 1.
Lifting tool
Cylinder head
Fig 2 Removal of cylinder head
08028-0D/H5250/94.08.12
Fig 1 Removal of piston and connecting rod
99.03 - ES0
MAN Diesel
Page 3 (3) Disassembly of Cylinder Unit Edition 02H
L16/24
Removal of Water Jacket and Cylinder Li-

ner
6) Loosen two positioning pins in the water jacket

and remove the two roller guides.
7) Lift the cylinder liner out of the water jacket by

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

by means of the tool as shown in fig. 4. Use
Fig 4 Removal of flame ring

08028-0D/H5250/94.08.12
Fig 3 Removal of water jacket and cylinder liner
99.03 - ES0
MAN Diesel
Page 1 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 07H
L16/24
Stopped engine Plate no Item no Note.

Shut-off fuel oil
Press Blocking - Reset
Dismounting of inlet and exhaust valve, inspec-

tion of valve guide and mounting of inlet and
exhaust valve.
Starting position
Disassembly of cylinder unit 505-01.01
Related procedure
Reconditioning of valve spindle seat

and valve seat ring 505-01.10
Valve rotator 505-01.15
Replacement of valve guide 505-01.20
Replacement of valve seat ring 505-01.35

08028-0D/H5250/94.08.12

Capacity : 1 man
Data

03.42 - ES0
MAN Diesel
Edition 07H Inspection of Inlet Valve, Exhaust Valve and Valve Guide Page 2 (3)
L16/24
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) Press valve up to access cone ring, see fig 3

*)
6) Remove cone rings, see fig 3.

Fig 3 Removal of cone rings.
7) Release springs again.
8) Loosen nut A and extractor plate B, see fig 10) Repeat point 4 - 9 to remove other valve
1. spindles.
9) Remove a valve rotator and springs.
03.42 - ES0
MAN Diesel
Page 3 (3) Inspection of Inlet Valve, Exhaust Valve and Valve Guide Edition 07H
L16/24
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 spindle guide may cause:
- increased lub. oil consumption.

- fouling up of the spindle guide and thus give
the risk of the sticking of the valve spindle.
11) Clean the valve spindle guide.
12) Inspect and measure for wear.
If the inner diameter of the valve spindle guide Fig 4 Measurement of valve spindle guide for wear.
exceeds the tolerance, please see page 500.35,
the valve spindle guide must be replaced.
Please see working card 505-01.20.
Too much clearance also means insufficient

guidance of the valve spindle, and thus bad
alignment between the spindle head and the
valve seat ring.
Mounting of Valve Spindle
13) For mounting the valve spindle follow the in-

structions in point 3-9 in reverse order.
Note:
Please be aware of the different valve disk diameter
at inlet and exhaust valves.
Inlet valve : Ø57 mm
08028-0D/H5250/94.08.12
Exhaust valve : Ø54 mm
03.42 - ES0
MAN Diesel
Working Card Reconditioning of Valve Spindle Seat 505-01.10
and Valve Seat Ring
L16/24

Shut-off cooling water 52005 408 Grinding machine
Shut-off fuel oil for valve spindle.
Stopped lub. oil circul. (extra tools).
Press Blocking - Reset 52005 350 Grinding machine
for valve seat ring
(extra tools).
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
Mounting of valve spindle 505-01.05

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

98.40 - ES0
MAN Diesel
505-01.10 Reconditioning of Valve Spindle Seat Working Card
Page 2 (3)
Edition 02H and Valve Seat Ring
L16/24
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 inlet
see separate instructions. 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
angel "A" of 30° ± 0
0.1°
0.05°
2) Continue grinding until a clean and uniform
"A" 30 ± 0
surface is obtained.
"R"
"S"
3) Check height "H"1 upon completion the grin-
ding, see fig 2.
"H"1 must be no less than indicated on page

500.35.
If less, the spindle must be scrapped.
08028-0D/H5250/94.08.12
Fig 1 Valve Seat Ring
"A" 30° ± 00.1°

Scraping of Valve Seat Rings "H"1
Normally, the valve seat ring can be reconditioned

several times.
Fig 2 Valve Spindle
98.40 - ES0
MAN Diesel
Working Card Reconditioning of Valve Spindle Seat 505-01.10
and Valve Seat Ring
L16/24
4) After assembling the valves, check by mothing
the valve that distance "H"2 between the up-
per edge of the cylinder head and the upper
edge of the valve spindle, see fig 3, does not
exceed the maximum value, please see page
500.35.
Fig 3 Measurement of distance H2.

08028-0D/H5250/94.08.12
98.40 - ES0
MAN Diesel
Page 1 (2) Valve Rotator Edition 02H
L16/24

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
Mounting of valve spindles 505-01.05
Working time : 1/2 hour Plate no Item no Qty./

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

98.46 - ES0
MAN Diesel
Edition 02H Valve Rotator Page 2 (2)
L16/24
Maintenance and Inspection of Rotocap Note: Having assembled the valve rotator in dry
condition it should be placed in clean lubricating oil
Dirt, especially in the ball pockets due to residues in for a short period of time.
the oil (abrasives, combustion products), can cause
the individual parts to become stuck, and interrupt
the movement of the balls.
Under normal operating conditions rotocap valve

rotators need no servicing.
Rotator performance is satisfactory when the valve

rotates visibly and evenly.
Dismantling of Rotocap
Fig 1 Valve rotator
Please see Working Card 505-01.05, steps 3 to 9.
Overhaul of Rotator Mounting of Rotocap
1) Clean the valve rotator. Please see working card 505-01.05, steps 3 to 9,
opposite direction.
2) Remove the retaining ring and disassemble
the individual parts.
3) Inspect for wear and ball impressions.
4) Replace parts showing wear grooves or de-

pressions formed by the balls.
5) Insert the balls and the tangential springs.
Note: All balls on the inclined races of the ball pockets

must point in the same direction, see fig 1.
The inner ring of the spring washer should rest on

the retainer body.
08028-0D/H5250/94.08.12
98.46 - ESO
MAN Diesel
Page 1 (3) Replacement of Valve Guide Edition 05H
L16/24

Shut-off fuel oil
Dismantling and mounting of valve guide for inlet Hammer / Lead hammer
and exhaust valve. Nitrogen (N2), or similar.
H7 reamer, 12 mm
Starting position
Related procedure

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

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

01.14 - ES0
MAN Diesel
Edition 05H Replacement of Valve Guide Page 2 (3)
L16/24
When to Replace the Valve Guide
If the clearance exceeds the max. limit, please see

page 500.35, the valve guide must be replaced.
Dismounting of Valve Guide
1) Knock the valve guide out from the bottom

of the cylinder head, by means of a mandrel,
which has a shoulder turning that fits into the
valve guide, see fig 1.
2) Clean the bore of the cylinder head carefully.
3) Inspect for marks that can prevent mounting

of new valve guide.
Fig 1 Dismounting of valve guide
Mounting of Valve Guide
4) Before mounting - cool down the new valve

guide to approx. -70°C with nitrogen or si-
milar.
5) Insert the valve guide into the bore.
6) Knock slightly with the mandrel and a hammer,

see fig 2.
Note: The shoulder of the valve guide must bear

against the cylinder head, by knocking slightly with
the mandrel and a hammer.
7) The valve guide must be reamed with a Ø12H7

reamer through the whole guide after guide
temperature is equlized.
Fig 2 Mounting of valve guide
08028-0D/H5250/94.08.12
01.14 - ESO
MAN Diesel
L16/24
8) Insert a new O-ring in the valve guide, before
mounting of the valve spindle.
Correct mounting can easily be done by the

use of two valve spindles as mounting tool,
one spindle to be used as support and the
other spindle to be used for pushing the O-ring
downwards, see fig 3.
Screw-drivers or other sharp tools should never

be used for this purpose.
9) For mounting of valve spindle, please see

working card 505-01.05.
Fig 3 Inserting a new O-ring in the valve guide

08028-0D/H5250/94.08.12
01.14 - ES0
MAN Diesel
L16/24

Shut-off fuel oil
Dismantling and mounting of valve guide for inlet Hammer / Lead hammer
and exhaust valve. Nitrogen (N2), or similar.
Starting position
Related procedure

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

50501 088 4/cyl
Data

08.03 - ES0-ver08
MAN Diesel
505-01.20 Replacement of Valve Guide Working Card
L16/24
When to Replace the Valve Guide
If the clearance exceeds the max. limit, please see

page 500.35, the valve guide must be replaced.
Dismounting of Valve Guide
1) Knock the valve guide out from the bottom

of the cylinder head, by means of a mandrel,
which has a shoulder turning that fits into the
valve guide, see fig 1.
2) Clean the bore of the cylinder head carefully.
3) Inspect for marks that can prevent mounting

of new valve guide.
Fig 1 Dismounting of valve guide
Mounting of Valve Guide
4) Before mounting - cool down the new valve

guide to approx. -70°C with nitrogen or si-
milar.
5) Insert the valve guide into the bore.
6) Knock slightly with the mandrel and a hammer,

see fig 2.
Note: The shoulder of the valve guide must bear

against the cylinder head, by knocking slightly with
the mandrel and a hammer.
Fig 2 Mounting of valve guide

08028-0D/H5250/94.08.12
08.03 - ESO-ver08
MAN Diesel
L16/24
8) Insert a new O-ring in the valve guide, before
mounting of the valve spindle.
Correct mounting can easily be done by the

use of two valve spindles as mounting tool,
one spindle to be used as support and the
other spindle to be used for pushing the O-ring
downwards, see fig 3.
Screw-drivers or other sharp tools should never

be used for this purpose.
9) For mounting of valve spindle, please see

Fig 3 Inserting a new O-ring in the valve guide

08028-0D/H5250/94.08.12
08.03 - ES0-ver08
MAN Diesel
Page 1 (2) Replacement of Valve Seat Ring Edition 05H
L16/24

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
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.

01.32 - ES0
MAN Diesel
Edition 05H Replacement of Valve Seat Ring Page 2 (2)
L16/24
Dismounting of Valve Seat Rings Mounting of Valve Seat Rings
When reconditioning of a valve seat ring no longer is 5) Prior to mounting of a new valve seat ring,
possible due to dimensions exceeding the scrapping the bore must be cleaned thoroughly and
criteria, the seat ring has to be replaced. inspected for marks. Marks that can hinder
mounting of the valve seat ring must be remo-
Dismounting of a valve seat ring is carried out by ved.
means of a special extractor tool set comprising the
components, see fig 1. 6) To facilitate the valve mounting of the seat ring
it must be cooled down, however, a max. of
-25° C otherwise, the O-ring can be dama-
ged.
Coat with
loctite 648
Valve seat ring
O-ring
Coat with oil
Fig 1 Extraction of valve seat ring.
Dismounting of a Valve Seat Ring is Carried Fig 2 Coat with oil/loctite.

out According to the Following Procedure
1) Weld approx. 5 seconds at 3 places around 7) Place the O-ring on the valve seat ring and
the old valve seat with electrode. coat with oil/loctite as shown in fig 2, just before
positioning it in the bore.
2) Wait 60 seconds while the seat is cooling down
and the shrink fit compression is relieved. 8) Prior to mounting of the valve spindle the valve
seat ring must be ground, to ensure correct
3) Mount the extraction tool and pull out the used centering af the valve guide and the valve seat
08028-0D/H5250/94.08.12
valve seat. (If the waiting time is not observed ring. This can be done according to working
the tool might be damaged). card 505-01.10.
4) The valve seat is easy removed by turning the

handle.
01.32 - ESO
MAN Diesel
Page 1 (2) Inspection of Cylinder Head Cooling Water Space Edition 02H
L16/24

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
Replacement and wearing parts

08028-0D/H5250/94.08.12
Manpower
Plate No Item No Qty/
Working time : ¼ hour
Capacity : 1 man
Data

98.38 - ES0
MAN Diesel
Edition 02H Inspection of Cylinder Head Cooling Water Space Page 2 (2)
L16/24
Inspection of Cylinder Head Cooling Water
Space
1) Inspect the cooling water inlet at the bottom 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) Should the cylinder head cooling water space,

contrary to expectation, be blocked with depos-
its, please contact MAN B&W Diesel, Holeby
for further instructions.
Fig 1 Cooling water spaces to be inspected.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
Workinag Card 505-01.50
Page 1 (3) Assembly of Cylinder Unit Edition 02H
L16/24

52006 212
52006 224
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
Working time : 1 1/2 hours Plate no Item no Qty/

08028-0D/H5250/94.08.12

50501 135 1/cyl
50501 196 1/cyl
Data 50610 031 1/cyl
50610 043 1/cyl
Data for pressure and tolerance (Page 500.35) 50610 055 1/cyl
Data for torque moment (Page 500.40) 50610 092 1/cyl
98.47 - ES0
MAN Diesel
Edition 02H Assembly of Cylinder Unit Page 2 (3)
L16/24
Preparing before Mounting
1) Place the water jacket on the table.
2) Place two new o-rings 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.
Fig 2 Marking on the cylinder liner and the water jacket
7) Mount the cylinder head by means of lifting

tool (plate 52005, item no 38)
8) Mount the five allen screws in the cylinder head

and tighten up all the screws, please see page
500.40.
Fig 1 Mounting of new flame ring
Mounting the Piston

Note: Be sure the marking on the cylinder liner cor-
responds to the marking on the water jacket of the Before mounting the piston turn around the cylinder
assembly,see fig 2. unit.
4) Fit a new sealing ring on the cylinder liner. Note: After an overhaul the cylinder liner must always
be honed and the piston must be fitted with new
08028-0D/H5250/94.08.12
5) Mount two roller guides in the water jacket, see piston rings, see Working Card 506-01.35.
Working Card 508-01.00.
9) Mount the piston guide bush around the cylinder
unit.
Mounting of Cylinder Head
10) Lift the piston and connecting rod by means
6) Place two new o-rings at the top of the water of a suspension.
jacket and slightly lubricate with oil.
98.47 - ES0
MAN Diesel
Page 3 (3) Assembly of Cylinder Unit Edition 02H
L16/24
11) Lubricate the piston rings and the cylinder liner
with oil.
12) Slowly lower the piston into the cylinder liner.
Note: Be sure that the "st" mark at the top of the

piston is placed on to the fuel pump side.
13) Place wooden wedges between the connecting

rod and the piston shirt.
14) Remove suspension tool from the connecting

rod.
15) Mount fixing part tool (plate 52006 item 212)

to the connecting rod and the cylinder liner.
08028-0D/H5250/94.08.12
98.47 - ES0
MAN Diesel
Working Card
Mounting of Cylinder Unit in Engine 505-01.55
L16/24

52021 118
52021 334
52021 180
Mounting of cylinder unit after inspection and/or 52021 202
overhaul. 52021 275
52021 059
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

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

Capacity : 2 men
50501 231 1
50501 243 1
Data 51630 033 8
51230 027 4
99.03 - ES0
MAN Diesel

Edition 02H Mounting of Cylinder Unit in Engine Page 2 (4)
L16/24
Preparring before mounting Mounting of the Big-end Bearing
Before the cylinder unit is mounted in the engine, be 3) Make sure the crank throw is in the top posi-
sure to clean the joint faces carefully. tion.
4) Mount the upper part of the big-end bearing

Placing of the Cylinder Unit in Engine shell just before the connecting rod is landed
on the crankshaft.
1) Place an O-ring around the roller guides and
O-rings around the oil connection between the Note: Lubricate the crankshaft with clean lubri-
engine and the water jacket. cating oil.
2) Lower the cylinder unit slowly into the engine 5) Land the connecting rod on the crankshaft.
by means of a lifting tool, (plate 52005 item
038). During this the connecting rod must be guided
by hand to ensure correct approach and landing
in the journal.
6) Remove the fixing part, (plate 52006 item

Lifting tool
212).
7) Mount the bearing cap with the inserted lower

shell of the big-end bearing by hand.
Tightening of the Connecting Rod

Cylinder unit Note:Iden.No. on the connecting rod and on the
bearing cap must always be the same.
Fixing tool
08028-0D/H5250/94.08.12
Fig 1 Lifting tool
Fig 2 Clip on/off
99.03 - ES0
MAN Diesel

Page 3 (4) Mounting of Cylinder Unit in Engine Edition 02H
L16/24
8) Lubricate threads and the contact face of the 13) Place the spacer ring around the nuts with a
connecting rod screws with molycote paste or slot in such a position that the tommy bar can
the like. be used.
9) Mount bolts and nuts and tighten them firmly 14) Tighten the hydraulic jacks and make sure
with a tommy bar. that the cylinder of the jacks bears firmly on
the spacer ring. Tighten up all the nuts, see
For tighting connecting rod bolts, please see description 500.40. For usage of the hydraulic
working card 506-01.25. tools, please see working card 520-01.05.
Note: If new studs or nuts are fit, the nuts must be

Tightening of Cylinder Head Nuts tightened and loosened three times, in order to com-
pensate for deformation of the thread and in order
10) Coat the cylinder stud threads and contact to ensure a safe minimum load of the studs through
faces with copaslip or the like. the tightening.
11) Fit the cylinder head nuts and make sure that
they run easily and that they bear on their entire Assembling of Connections
contact surfaces.
15) Mount the exhaust clamp between the cylinder
12) Tighten the nuts lightly with a tommy bar. 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 4 Correct mounting of clamps.
16) Place new O-rings on water connections and

push the connections into the cylinder head.
17) Secure the water connections with clamps

and tighten bolts on the clamp.
Fig 3 Hydraulic tools for mounting of cylinder head nuts.
99.03 - ES0
MAN Diesel

Edition 02H Mounting of Cylinder Unit in Engine Page 4 (4)
L16/24
18) Place new O-rings on the charge air connection 22) Bleed air from the venting screws on the charge
and push the connections into the next cylinder air cooler.
head.
23) Bleed air from the venting screws on the engine
19) Secure the charge air connection with a clamp top, or by the flange, connection F3, venting to
and tighten the bolt on the clamp. expansion tank.
20) Mount the high pressure fuel oil pipe, please 24) Open connection G2, L.T. fresh water - out-
see working card 514-01.05. let.
25) Check for leakage.

Ventilation
The GenSet is self-ventilating. This means that it Adjustment of Valve Clearance

is not necessary for the engine to vent the system
before start. 26) Adjust the valve clearance, see working card
508-01.10.
However, to avoid problems in the ship's installation,
we recommend to ventilate. This can be done in the 27) Mount the side and top covers.
following way:
21) Open connection G1, L.T. fresh water - inlet.
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Head 50501-11H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
50501-11H Cylinder Head Page 2 (2)
L16/24
Item Item
no Qty Designation Benævnelse no Qty Designation Benævnelse
015 2/C Guide for Styr for

valve bridge ventilbro
027 1/C Cylinder head Cylinderdæksel
039 2/C Plug Prop
040 1/C O-ring O-ring
052 1/C Sleeve Foring
088 4/C Valve guide Ventilstyr
123 2/C Valve seat ring, Ventilsædering,

inlet indstrømning
147 2/C Stop screw Stopskrue
159 /I Loctite Loctite
160 2/C Cylindrical pin Cylindrisk stift

exhaust udstødning
206 5/C Screw Skrue
218 1/C Water guide jacket Kølekappe
255 2/C Bolt Bolt
267 1/C Stud Tap
279 1/C Thrust piece Trykstykke

08028-0D/H5250/94.08.12
When ordering spare parts, see also page 500.50. Ved bestilling af reservedele, se også side 500.50.
* = Only available as part of a spare parts kit. * = Kun tilgængelig som en del af et reservedelssæt.
Qty/C = Qty/Cylinder Qty/C = Qty/Cylinder
Qty/I = Qty/Individual Qty/I = Qty/Individuelt
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Head 50501-16H
L16/24
040
255
015 052
064 076
088
027
039
206
267
111 279
123 172
184
135
147 196
159
160
08028-0D/H5250/94.08.12
218
231
243
See plate 50610
07.27 - ES0 - ver08

MAN Diesel
Plate
50501-16H Cylinder Head Page 2 (2)
L16/24
Item Item
015 2/C Guide for Styr for

valve bridge ventilbro
027 1/C Cylinder head Cylinderdæksel
039 2/C Plug Prop
052 1/C Sleeve Foring
088 4/C Valve guide Ventilstyr

inlet indstrømning
147 2/C Stop screw Stopskrue

exhaust udstødning
206 5/C Screw Skrue
218 1/C Water guide jacket Kølekappe
255 2/C Bolt Bolt
267 1/C Stud Tap

08028-0D/H5250/94.08.12
07.27 - ES0 - ver08

MAN Diesel
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-08H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
50502-08H Valve Spindles and Valve Gear Page 2 (2)
L16/24
Item Item
010 1/C Rocker arm, exhaust Vippearm, udstøds, 274 2/C Valve spindle, inlet Ventilspindel, indsugn.
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 046, 058, 071, 083
083
022 1/C Rocker arm, inlet com- Vippearm, indsugning

plete, incl. item 034, komplet inkl. item 034,
046, 071, 083, 105 046, 071, 083, 105
034 2/C Bolt Bolt
046 2/C Bearing bush Leje
058 1/C Rocker arm, exhaust Vippearm, udstøds
071 4/C Nut Møtrik
083 2/C Adjusting screw com- Justérbar 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
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 Justérbar skrue
166 2/C Valve bridge Ventilbro
178 4/C Conical ring 2/2 Konisk ring 2/2
191 4/C Rotocap Rotationsgiver,

complete komplet
201 4/C Spring Fjeder
213 1/C Screw Skrue
249 1/C Shaft Aksel

08028-0D/H5250/94.08.12
262 2/C Valve spindle, Ventilspindel,

exhaust udstøds
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Valve Spindles and Valve Gear 50502-11H
L16/24
058
010
105 071
022 083
034 095
046 142
117 071
129 154
130
166
178
178 191
191 201
213
201
237
249
250
Cylinder Head,
see plate 50501
08028-0D/H5250/94.08.12
262
274
07.26 - ES0 - ver08

MAN Diesel
Plate
50502-11H Valve Spindles and Valve Gear Page 2 (2)
L16/24
Item Item
010 1/C Rocker arm, exhaust Vippearm, udstøds, 274 2/C Valve spindle, inlet Ventilspindel, indsugn.
complete, incl. item komplet inkl. item 034,
034, 046, 058, 071, 046, 058, 071, 083
083
022 1/C Rocker arm, inlet com- Vippearm, indsugning

plete, incl. item 034, komplet inkl. item 034,
046, 071, 083, 105 046, 071, 083, 105
034 2/C Bolt Bolt
046 2/C Bearing bush Leje
058 1/C Rocker arm, exhaust Vippearm, udstøds
071 4/C Nut Møtrik
083 2/C Adjusting screw com- Justérbar 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
130 2/C Valve bridge com- Ventilbro komplet, inkl.

plete, incl. item 071, item 071, 129, 154,
129, 154, 166 166
166 2/C Valve bridge Ventilbro
178 4/C Conical ring 2/2 Konisk ring 2/2
191 4/C Rotocap Rotationsgiver,

complete komplet
213 1/C Screw Skrue
249 1/C Shaft Aksel

08028-0D/H5250/94.08.12
262 2/C Valve spindle, Ventilspindel,

exhaust udstøds
07.26 - ES0 - ver08

MAN Diesel
Plate
Page 1 (2) Cylinder Head, Top Cover 50510-02H
L16/24
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Plate
50510-02H Cylinder Head, Top Cover Page 2 (2)
L16/24
Item Item
No Qty Designation Benævnelse No Qty Designation Benævnelse
026 5/C Screw Skrue
038 5/C Washer Skive
051 Top cover Topdæksel

3/E 5 cyl. engine 5 cyl. motor
063 8/E Plug Prop
075 2/E Top cover Topdæksel
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine Qty/E = Qty/Motor
98.41 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Unit 50515-04H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
50515-04H Cylinder Unit Page 2 (2)
L16/24
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
03.50 - ES0
MAN Diesel
Plate
L16/24
011
08028-0D/H5250/94.08.12
06.43 - ES0
MAN Diesel
Plate
L16/24
Item

consisting of:
08028-0D/H5250/94.08.12
06.43 - ES0
MAN Diesel
Plate
L16/24
011
08028-0D/H5250/94.08.12
07.27 - ES0 - ver08

MAN Diesel
Plate
L16/24
Item

consisting of:
08028-0D/H5250/94.08.12
07.27 - ES0 - ver08

MAN Diesel
Plate
L16/24
011
08028-0D/H5250/94.08.12
07.46 - ES0 - ver08

MAN Diesel
Plate
L16/24
Item

consisting of:
08028-0D/H5250/94.08.12
07.46 - ES0 - ver08

Piston/connecting rod
506/606
MAN Diesel
Description 506.01
Page 1 (2) Piston, Connecting Rod and Cylinder Liner Edition 02H
L16/24
Piston Connecting Rod
The piston, which is oil-cooled and of the composite The connecting rod is die-forged. The big-end has a
type, has a skirt made of nodular cast iron and a horizontal split. The connecting rod and piston are
crown made of forged deformation resistant steel. It disassembled together with the cylinder liner, thus
is fitted with 2 compression rings and 1 oil scraper ensuring a large bearing diameter and a low bear-
ring in hardened ring grooves. ing pressure.
By the use of compression rings with different bar- The connecting rod has bored channels for supply-
rel-shaped profiles and chrome-plated running suring of oil from the big-end to the small-end.
faces, the piston ring pack is optimized for maximum
sealing effect and minimum wear rate. The big-end bearing is of the bi-metal type coated
with a running layer.
The piston has a cooling oil space close to the piston
crown and the piston ring zone. The heat transfer, The bearing shells are of the precision type and are
and thus the cooling effect, is based on the shaker therefore to be fitted without scraping or any other
effect arising during the piston movement. The kind of adaption.
cooling medium is oil from the engine's lubricating
oil system. The small-end bearing is of the bi-metal type and
is pressed into the connecting rod. The bush is
Oil is supplied to the cooling oil space in the piston equipped with an inner circumferential groove, and
through spray hole in the middle of the connecting a pocket for distribution of oil in the bush itself and
rod to the middle of the piston. Oil is drained from for the supply of oil to the pin bosses.
the cooling oil space through ducts situated dia-
metrically to the inlet channels.
The piston pin is fully floating and kept in position in

the axial direction by two retaining rings.
08028-0D/H5250/94.08.12
08028-0D/H5250/94.08.12
Fig 1 Piston Fig 2 Connecting Rod
98.46 - ES0
MAN Diesel
506.01 Description
Edition 02H
Piston, Connecting Rod and Cylinder Liner Page 2 (2)
L16/24
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
98.46 - ES0
MAN Diesel
Working Card Separation/Assembly of Piston and Connecting Rod 506-01.05
Page 1 (3)
and fitting of Piston Rings Edition 07H
L16/24

Separation of piston and connecting rod for in- Wooden wedge, 2 pieces
spection or/and overhaul. Wooden support
Assembly of the 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 1
50601 103 1
50601 127 1
Data

07.05 - ES0
MAN Diesel
506-01.05 Separation/Assembly of Piston and Connecting Rod Working Card
Page 2 (3)
Edition 07H and fitting of Piston Rings
L16/24
Separation of Piston and Connecting Rod Fittings of Piston Rings
1) Take out the securing ring (seeger circlips) with The piston rings should only be fitted to the piston
the plier (Plate 52006, Item 177). Push out the by the use of a special tool; the socalled piston ring
piston pin and lift the connecting rod away. opener.
If the rings are opened further than necessary there

Assembly of Piston and Connecting Rod is a risk of overstressing, which means that rings will
become permanently distorted and will not confirm
2) Lubricate the piston pin before assembling. to the cylinder inner running surface.
3) For assembly of piston and connecting rod, The piston rings should be installed with the identi-
see point 1, but in the opposite direction. fication mark, which is stamped into the ring close
to the ring joints, facing upwords, see fig 2.
Before fitting the coil spring loaded scraper ring, the

coil spring is dismantled from the ring by removal of
Joint pin for
Joint coil spring to be the joint pin. The coil spring is placed and assembled
coil spring
placed opposite to ring joint in the ring groove then the scraper ring is fitted in
the groove in such a way that the ring joint is ap-
proximately 180° offset to the spring joint.
Ascertain correct assembling by checking the back

clearance.The back clearance is sufficient when the
Ring joint 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

Fig 1 Joint coil spring to be placed opposite to 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
and groove.
Adequate clearance is present so the feeler gauge

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

the piston rings should be turned into positions off-
setting the ring joint 180° to each other.
08028-0D/H5250/94.08.12
07.05 - ES0
MAN Diesel
Working Card Separation/Assembly of Piston and Connecting Rod 506-01.05
Page 3 (3)
and fitting of Piston Rings Edition 07H
L16/24
Piston Ring No 1:
marked with ident.
No "top 1445".
Piston Ring No 2:
marked with ident.
No "top 1461".
Scraper Ring:
marked with ident.
No "top 0254".
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.
07.05 - ES0
MAN Diesel

Page 1 (3) Piston Edition 03H
L16/24

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.
Starting position
Piston has been dismantled from

Related procedure
Assembly of piston and connecting

rod and fitting of piston rings 506-01.05

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

Capacity : 1 man
Data

99.33 - ES0
MAN Diesel

Edition 03H Piston Page 2 (3)
L16/24
Inspection of Piston Mounting of Piston Crown
1) Remove the piston and scraper rings. 8) Lubricate the threads and bearing surface with
"molycote-paste G-n Plus".
2) Clean the piston on the outside and on the
inside. Note: always use new bolts when assembling the
piston
3) Inspect the piston ring and scraper ring grooves
for wear, see page 3. 9) Tighten the bolts crosswise with 20 Nm (cor-
responding to 35° to 90°).
Check of Piston Bolt Tension 10) Loosen the bolts again.
4) Apply a torque spanner to the piston bolts, 11) Tighten the bolts again with a pretighten torque
adjusted to 20 Nm. of 10 Nm.
5) Turn the torque spanner. 12) Turn the bolts 60° further.
Note: It may turn out that the bolts do not turn during 13) Check the piston bolt tension, see "check of
the test: piston bolt tension".
If Then
The bolts do not The tension are ok

turn during the test
The bolts can Loosen the bolts and

turn during the test tighten as described for
the process of "Mounting
of piston crown"
Inspection of Piston Crown
For cleaning and inspection of the piston crown, it

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

crown.
08028-0D/H5250/94.08.12
7) Clean carefully the piston shirt and piston

bolts.
99.33 - ES0
MAN Diesel

Page 3 (3) Piston Edition 03H
L16/24
The piston crow must be scrapped if: Piston and oil New ring
Ring grooves.
scraper ring. grooves.
Max. wear limit.
Nominal size. Tolerances.
A) The wear limit on the testing mandrel is ex- (mm)
(mm) (mm)
ceeded, see fig 1A
Piston ring -0.035 +0.145
5 5 5.38
1 -0.01 +0.130
or
Piston ring -0.035 +0.105
B) The clearance between the new piston/scraper 5 5 5.38
2 -0.01 +0.090
ring and the ring groove is exceeded, see fig
1B. Scraper ring -0.035 +0.035
5 5 5.38
-0.01 +0.020
Note: At each piston overhaul: Table 1. Nominal size, new ring groove tolerance and wear
limit for ring grooves.
- The piston and the scraper ring must be
replaced.
- The cylinder liner must be honed according

to the instructions.
- For position and fittings of piston rings,

please see working card 506-01.05
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.
0.40 mm
Wear limit line.
Maximum vertical clearance

between new piston ring/scraper
ring and ring groove: 0.40 mm.
08028-0D/H5250/94.08.12
The handle is marked

with the nominal size.
Fig 1 Wear limits for ring grooves.
99.33 - ES0
MAN Diesel
Working Card
Connecting Rod 506-01.15
L16/24

52021 275
52021 167
52021 202
Cleaning, inspection and test measurement of 52021 334
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
Assembly of Cylinder Unit 505-01.50
Manpower
08028-0D/H5250/94.08.12
Working time : 1/2 hour

Capacity : 1 man Plate No Item No Qty /
Data

07.17 - ES0
MAN Diesel
506-01.15 Connecting Rod
Working Card
L16/24
Cleaning of Connecting Rod Measurement of Big-end Bore
1) Clean all machined surfaces on the connecting For check of ovalness the bearing cap has to be
rod. mounted onto the big-end bore without bearing
shells.
2) Degrease the joint faces, holes and connecting
rod screws with a volatile solvent and blow dry Note: The ident. No on the connecting rod and the
with working air. bearing cap must always be the same, see fig 3.
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 connecting rod with care. In case

of damaged joint faces caused by improper handling,
the bearing cap can no longer be tightened to the con-
necting rod without ovalness of the big-end bore.
4) Register observed damages in the scheme

"Connecting Rod Inspection" for historic use
only. Please see page 4.
Fig 1 Point of measurement
5) Carefully smooth single raised spots in the
serration caused by pitting and impact marks
with a filesmall. 8) Mount the bearing cap onto the connecting rod
by means of the connecting rod bolts.
Inspection of Connecting Rod bolts
9) Tighten the bolts with the prescribed pressure,
6) Inspect the connecting rod nuts for seizures in please see working card 506-01.25.
the threads and pittings on the contact surfaces
of the screwheads. 10) Measure five different diameters in the groove
08028-0D/H5250/94.08.12
of the boring, see fig 1.

7) Turn the connecting rod nuts onto bottom
position of the bolts. 11) Register the measurements in the scheme
"Connecting Rod Inspection". Please see page
If bolts/nuts Then 4.
have seizures in Renew the bolts/screws 12) Calculate the maximum ovalness as the diffe-
threads or pittings on rence between biggest and smallest diameter
contact surface measured.
cannot be turned onto Renew the bolts/screws 13) Check if maximum ovalness is exceeded,
bottom position by hand please see page 500.35.
07.17 - ES0
MAN Diesel
Working Card
Page 3 (4) Connecting Rod 506-01.15
Edition 06H
L16/24
If Then For connecting rod No 2 in the example the maximum
ovalness is 0.125 mm and therefore the connecting
maximum ovalness is Renew the complete rod is rejected.
exceeded connecting rod, screws
and bearing shells.
Inspection of Connecting Rod Bush
maximum ovalness is Reuse the connecting
not exceeded rod 14) Inspect the surface of the piston pin and the
connecting rod bush.
15) Measure the clearance between the piston pin

and bush.
Connecting Rod Inspection for L16/24
16) Check if max clearance is exceeded, see page

Cylinder No 1 2 3
Connecting rod ident. No
500.35.
Running hours for connecting rod
A
0.01 mm
1/100 mm B
If the specified clearance is exceeded, contact
C MAN B&W Diesel A/S, Holeby for replace-
Nominal
D
diameter
Ø137 mm E
ment.
Ovalness: Diff. between min./max.
Tightening for measurement see

instruction. Wear Wear Wear
Inspection of Bearing Shells for Big-end

Cracks Cracks Cracks
Corrosion/
Pitting
Corrosion/
Pitting
Corrosion/
Pitting
Criteria for replacement of connecting rod big-end
bearing, see working card 506-01.16.
A Impact mark Impact mark Impact mark
B
C
Remarks: Remarks: Remarks:
D
E
Connecting rod
Ident. No
Max ovalness = 0.06 mm
Note! The ident. No on the con-

necting rod and on the bearing
cap must always be the same.
Fig 2. "Connecting rod Inspection".
Example of Measurement Results

08028-0D/H5250/94.08.12
The example, see fig 2, shows measurements and

damage observations for two connecting rods on the
scheme "Connecting Rod Inspection" (in case the
specified maximum ovalness is exceeded, contact
MAN B&W Diesel A/S, Holeby for overhaul).
Fig 3 The ident No on the connecting rod must always be the
same.
For connecting rod No 1 in the example the maximum
ovalness is 0.07 mm and thus reuse is acceptable.
07.17 - ES0
08028-0D/H5250/94.08.12
07.17 - ES0
Working Card
Page 4 (4)
Plant/Ship: Engine Type:

Connecting Rod Inspection for L16/24 Engine No: Running Hours:
Sign.: Insp. Date:
Cylinder No 1 2 3 4 5 6 7 8 9
Connecting rod ident. No
Running hours for connecting rod
A
0.01 mm
1/100 mm B
C
Nominal
diameter D
Ø137 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 Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark Impact mark
B
C
Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks: Remarks:
D
E
Connecting rod
Ident. No
Max ovalness = 0.06 mm
MAN Diesel
506-01.15
Note! The ident. No on the con-
L16/24
Edition 06H
necting rod 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
L16/24, L21/31
Safety precautions: Special tools:
Stopped engine Plate no. Item no. Note.

Shut-off fuel oil
Shut-off cooling 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:

02.26 - ES0
MAN Diesel
506-01.16 Criteria for Replacement of Working Card

L16/24, L21/31
This paper gives information about the evaluation of Bearing Surface

the connecting rod big-end and main bearing shells
when wear appears on the running surface under Standard Miba bimetal bearings have no tin flash.
normal operating conditions.
Oil is used for protective coating.
Bearing damages caused by incorrect running con-
ditions, like In new condition the bearing has a silvery, bright
color.
- Corrosion
- Overloading, overheating a.s.o. The running surface might become dull silvery after
only a short time of operation.
are not described in this paper.
In these cases, the bearing shells must be exchan- Criteria for bimetal bearing replacement
ged, of course, and in order to avoid further bearing
failures, the cause of the failure must be found and Actual wear can be determined by measuring wall
eliminated. thickness or via clearance measurements in com-
parison to the specification for a bearing in new
condition.
New Condition
A bearing should be replaced if the wear limit, as
The running surface has a silvery, bright color, see specified by the engine manufacturer, is reached
fig 1. or can be expected to be reached during the next
period of operation.
Another method is to specify a certain time limit for

the useful service life of the bearing. The individual
time limit (recommended maximum time in operation)
specified by the engine manufacturer is based on the
calculated bearing load, minimum oil film thickness
and load profile.
The useful service life of a bearing is also determined

by the fatigue strength of the lining material under
the respective load profile.
Usual running pattern

Fig 1 Without flash
Typical running pattern after completion of running-
in:
08028-0D/H5250/94.08.12
02.26 - ES0
MAN Diesel

L16/24, L21/31
Bearings to be reused 3. Damage due to foreign particles
Following pictures shows the typical running pattern Shallow scoring and / or imprints that are few in
where bearing shells are reusable. number. See fig 4.
1. Normal wear
Slightly polished zones and symmetrical running

pattern in the most loaded zone of the bearing. Minor
scoring. See fig 2.
Fig 4 Reusable
4. Minor cavitation after long time in opera-

tion
Fig 2 Reusable Minor and shallow material removal outside the most
loaded zone. See fig 5.
2. Minor edge loading
and usual running pattern.

Slightly polished stripes along the side faces. See
fig 3.
08028-0D/H5250/94.08.12
Fig 5 Reusable
Fig 3 Reusable
02.26 - ES0
MAN Diesel
506-01.16 Criteria for Replacement of Working Card

L16/24, L21/31
Bearings to be replaced 7. Damage due to foreign particles
Following pictures shows abnormal wear or dama- Many scores or multiple deep grooves and / or im-
ges that require replacement of bearing shells i.e. prints. See fig 8 and fig 9.
investigation of reasons.
5. Localized heavy smearing of lining mate-

rial
due to local disturbance of the oil film. See fig 6.
Fig 8 Replace
– deep scoring, imprints. Lining material locally smeared
Fig 6 Replace
6. More extensive area of damage with seizure

Locally smeared lining material
caused by a severe disturbance of the oil film. See

fig 7.
Fig 9 Replace
– many deep imprints
08028-0D/H5250/94.08.12
Fig 7 Replace
02.26 - ES0
MAN Diesel

L16/24, L21/31
8. Deep punctual cavitation 10. Fatigue rupture of the lining material
In severe cases the cavitation extends to the steel Mechanism:

shell, spreads along the interface between steel shell - Development of fine cracks in the lining
and lining material, and undermines the AISn20 material
lining. See fig 10. - Network of cracks (crazing)
- Parts of the lining material break out
Fig 10 Replace
Fig 12 Fatigue rupture
9. Deep cavitation
Cavitation at the end of the oil groove.

08028-0D/H5250/94.08.12
Fig 11 Replace
– deep cavitation
02.26 - ES0
MAN Diesel
Page 1 (2) Hydraulic Tightening of Connecting Rod Screws Edition 02H
L16/24

52021 167
52021 180
52021 202
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
Working time : ½ hours Plate No Item No Qty/

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

99.33 - ES0
MAN Diesel
Edition 02H Hydraulic Tightening od Connecting Rod Screws Page 2 (2)
L16/24
1) Mount the connecting rod bolts and tighten the 5) Relieve the hydraulic pressure on the tool.
nuts by hand.
6) Add the hydraulic pressure to the tool once
2) Mount the hydraulic tools, pos. 1, on both con- more.
necting rod bolts.
7) Tighten the nuts again.
Be aware of the max. lifting height of the tool
and adjust the distance between the piston and Note: The point 5 to 7 can be followed in order to
the cylinder before adding pressure to the tool. remove tensions in the bolts, if any.
please see working card 520-01.05.
8) If there still is a distance and the nuts still can
3) Connect the hoses and pressure pump to the be tightened then repeat the point 5 to 7.
hydraulic tool.
9) Release the hydraulic pressure on the tool and
4) Add the prescribed hydraulic pressure, (to both remove the hydraulic nuts.
bolts simultaneously), see description 500.40,
and tighten the nuts by using a handle. Note: General instruction about hydraulic tightening,
please see working card 520-01.05.
1. Hydraulic tools
08028-0D/H5250/94.08.12
Fig 1 Hydraulic tool for tightening of connecting rod screws
99.33 - ES0
MAN Diesel
Page 1 (3) In-situ Inspectioan of Connecting Rod Big-end Bearing Edition 02H
L16/24

52021 275
52021 167
52021 202
In-situ inspection and/or replacement of connec- 52021 334
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

Capacity : 1 man
Data

98.38 - ES0
MAN Diesel
Edition 02H In-situ Inspection of Connecting Rod Big-end Bearing Page 2 (3)
L16/24
1) Turn the crankshaft into the top position. 7) Slowly turn the crankshaft clockwise until the
connecting rod is resting on the inspection
tool.
Removal of the Connecting Rod Bearing
Cap
Removal of the upper Connecting Rod Bea-
2) Loosen the hydraulic bolts by means of the ring Shell
hydraulic tools, please see working card 520-
01.05. 8) Mount the connecting rod on the inspection
tool by means of the connecting rod bolt and
3) Remove the hydraulic tools. a nut.
4) Remove the hydraulic nuts and the bearing Note: Make sure that only one connecting rod bolt is
cap with the lower bearing shell by hand. fit in the connecting rod before the crankshaft turns
any further.
Mounting of the Inspection Tool 9) Turn slowly the crankshaft clockwise until it is
possible to remove the upper connecting rod
5) Turn the crankshaft app. 45° clockwise allowing bearing shell.
the connecting rod bolts be removed.
10) Remove the upper connecting rod bearing
6) Mount the inspection tool acc to fig 1. shell.
08028-0D/H5250/94.08.12
Fig 1 Mounting of the inspection tools.
98.38 - ES0
MAN Diesel
Page 3 (3) In-situ Inspection of Connecting Rod Big-end Bearing Edition 02H
L16/24
Inspection of Bearing Shells 16) Turn slowly the crankshaft anti-clockwise until
it rests in the connecting rod.
11) Inspect the bearing shells, please see working
card 506-01.16. 17) Remove the inspection tool.
Cleaning of Components before Mounting Mounting of Bearing Cap
12) Clean carefully the joint faces, the bore and 18) Lubricate threads and contact face of the con-
the bearing shells. necting rod bolts with Copaslip or the like.
19) Mount the connecting rod bolts.

Mounting of Upper Bearing Shell
20) Turn the crankshaft anti-clockwise until it is in
13) The bearing shell is placed in the bore, the the top position.
contact surfaces of the shells must be parallel
to the contact surface of the connecting rod 21) Mount the bearing cap with the inserted lower
and the bearing cap respectively. big-end bearing shell by hand.
14) Coat the journal with clean lubricating oil. 22) Mount the screws and tighten them by hand.
15) Remove the bolt and nut from the connecting 23) Mount the hydraulic tool and tighten the bolts
rod and inspection tool. according to working card 506-01.25.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel
Page 1 (4) Inspection and Honing of Cylinder Liner Edition 06H
L16/24

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 506-01.05
Related procedure
Grinding of seal face on cylinder

head and cylinder liner 506-01.45

08028-0D/H5250/94.08.12
Working time : ½ hour Plate no Item no Qty/

Capacity : 1 man
Data

04.50 - ES0
MAN Diesel
Edition 06H Inspection and Honing of Cylinder Liner Page 2 (4)
L16/24
Measurement of Cylinder Diameter Honing the Cylinder Liner
While the piston is removed from the cylinder, the Please note:
latter is measured to record the wear. The measure- In order to obtain a round cylindrical cylinder liner
ments are taken by means of an inside micrometer, a factory honing is required. A honing as described
with measuring points at TDC-position for the upper- below can only be regarded as a second best solu-
most piston ring, halfway down, and at the BDC in tion and might have an impact on the time between
the cylinder liner, see fig 1 and page 4. overhaul as well as on the lub. oil consumption.
Renovation is made in the workshop.
Prior to honing, deposits of coke and possible wear

edges at the top of the liner must be removed by
scraping.
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 liner. Fig 2 Flex-honer in cylinder liner
When the wear of a cylinder liner exceeds the value
08028-0D/H5250/94.08.12
indicated on page 500.35, i.e. when it becomes too

troublesome to maintain adequate service conditions, A used flame ring must be used during the honing
the cylinder liner in question should be replaced. process.
The used flame ring must be cleaned in water. Sub-

sequently, the flame ring is remounted in the cylinder
before carrying out the honing process.
04.50 -ES0
MAN Diesel
page 3 (4) Inspection and Honing of Cylinder Liner Edition 06H
L16/24
Note: Upon completion of the honing process
the used flame ring is discarded. A new flame ring
is always mounted in the cylinder when replacing
the piston rings.
The honing is made by means of a flex-honer with

grain fineness 80-120. A revolution speed between 60°
80 and 160 rpm is chosen.
In order to achieve a required angle between honing

grooves, see fig 3, the vertical speed is adjusted to
about 1 m/sec. which corresponds to about 2 sec.
for one double movement (the flex- honer is led from
below up and down in 2 sec.) Fig 3 Angle between honing grooves
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.
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
removed.
08028-0D/H5250/94.08.12
04.50 - ES0
08028-0D/H5250/94.08.12
MAN Diesel
04.50 - ES0
Working Card
Page 4 (4)
Engine type Report No.

Measurement of Cylinder Liner Engine No. Encl. No.
Running hours Insp. date
Plant Fuel Sign.
Cyl. No. 1 2 3 4 5 6 7 8 9
Cyl.liner ident.No.
Running hours
Inspection and Honing of Cylinder Liner
L A
e
n B
g
t C
h
w
45
i
A s
e
135
C A
r B
B o
s C
s
312
w
i
s
e
C Liner
temp.
°C
Remarks...
506-01.35
L16/24
Edition 06H
MAN Diesel
Working Card Grinding of Seal Face on 506-01.45
Cylinder Liner and Cylinder Head
L16/24

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

head and cylinder crankcase by hand with grinding
tool and grinding pasta.
Starting position
Related procedure
Assembling of cylinder unit, 505-01.50

08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty/

Capacity : 1 man
Data

98.38 - ES0
MAN Diesel
506-01.45 Grinding of Seal Face on Working Card
Page 2 (2)
Edition 02H
Cylinder Liner and Cylinder Head
L16/24
Note: The grinding tool is used for both grinding
the groove in the cylinder liner flange (1), the surface
of the cylinder crankcase (2) and the sealing surface
on the cylinder head (3), see fig. 1.
Fig 3 Grinding tool at cylinder crankcase
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 cylinder
crankcase, see fig. 3 and the sealing surface
on the cylinder head, see fig. 4 with the use
of grinding pasta 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 , remove carefully 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 heighth above
the cylinder liner is according to 500.35.
Fig 2 grinding tool at cylinder liner
98.38 - ES0
MAN Diesel
Working Card Dismantling of Piston and Cylinder Liner 506-01.50
Page 1 (2)
at Low Overhaul Height Edition 02H
L16/24

Dismounting of cylinder unit for inspection and/or Inside micrometer (195 mm)
overhaul. Feeler gauge 0.15 - 0.20 mm
Starting position
Engine stopped and cooled down.
Related procedure
Inlet and exhaust valve - overhaul and

regrinding of spindel and valve seat, 505-01.10
Valve rotator, 505-01.15
Replacement of valve guide, 505-01.20
Replacement of valve seat ring, 505-01.35
Inspection of piston, 506-01.10
Cylinder liner 506-01.35
Separation of piston and
08028-0D/H5250/94.08.12

Capacity : 2 men
Data

99.33 - ES0
MAN Diesel
506-01.50 Dismantling of Piston and Cylinder Liner Working Card
at Low Overhaul Heights
L16/24
Removal of Cylinder head Removal of Water Jacket, Cylinder Liner,

Piston and Connectinng Rod
1) Prepare removing of the cylinder head accor-
ding to working card 505-01.55 pos. 1 to 15. 5) Remove the bearing cap and mount the tool
to suport the connecting rod to the cyl. liner,
2) Remove the bolts which hold the cylinder head please see working card 505-01.55
and water jacket together.
6) Lift carefully the water jacket, cylinder liner
Note: This means that the cylinder head now can and piston with connecting rod just enough
be removed from the cylinder unit. for removing the upper connecting rod bearing
shell.
3) Mount the lifting tool on the cylinder head.
7) Lift carefully the water jacket, cylinder liner and
4) Lift the cylinder head and land it carefully in piston with connecting rod out of the engine
wooden support. and land them on wooden support.
Note: The push rods will fall out if they are not sup-
ported by hand.
08028-0D/H5250/94.08.12
99.33 - ES0
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod 50601-03H
L16/24
093
103
127
081
019
032
176
152
056
140
08028-0D/H5250/94.08.12
139
068
164
07.07 - ES0
MAN Diesel
Plate
50601-03H Piston and Connecting Rod Page 2 (2)
L16/24
Item Item
019 1/C Piston pin Stempelpind
032 2/C Retaining ring Sikringsring
056 1/C Bush for connecting Plejlstangsbøsning

rod
068 1/C Connecting rod 2/2 Plejlstang 2/2
081 1/C Piston 2/2, Stempel 2/2,

incl. item 176 inkl. item 176
093 1/C Piston ring Stempelring
127 1/C Oil scraper ring Olieskrabering
139 1/C Connecting rod Plejlstangsleje 2/2

bearing 2/2
152 2/C Screw for connecting Plejlstangsskrue

rod
164 2/C Nut Møtrik
176 4/C Bolt Bolt
08028-0D/H5250/94.08.12
Qty/C = Qty/Cylinder. Qty/C = Qty/Cylinder.
07.07 - ES0
MAN Diesel
Plate
Page 1 (2) Piston and Connecting Rod 50601-08H
L16/24
08028-0D/H5250/94.08.12
01.32 - ES0
MAN Diesel
Plate
50601-08H Piston and Connecting Rod Page 2 (2)
L16/24
Item Item
056 1/C Bush for connecting Plejlstangsbøsning

rod
068 1/C Connecting rod 2/2 Plejlstang 2/2
127 1/C Oil scraper ring Olieskrabering
139 1/C Connecting rod Plejlstangsleje 2/2

bearing 2/2
152 2/C Screw for connecting Plejlstangsskrue

rod
164 2/C Nut Møtrik
223 1/C Piston 2/2, Stempel 2/2,

235 1/C Piston pin Stempelpind
259 4/C Bolt Bolt
08028-0D/H5250/94.08.12
01.32 - ES0
MAN Diesel
Plate
Page 1 (2) Cylinder Liner 50610-03H
L16/24
08028-0D/H5250/94.08.12
97.07 - ES0
MAN Diesel
Plate
50610-03H Cylinder Liner Page 2 (2)
L16/24
Item Item
018 1/C Cylinder liner Cylinderforing
031 1/C Sealing ring Tætningsring
092 1/C Flame ring Flammering
08028-0D/H5250/94.08.12
97.07 - ES0
Camshaft
507/607
MAN Diesel
Description 507.01
Page 1 (1) Camshafts and Camshaft Drive Edition 02H
L16/24
Camshafts and Camshaft Drive The camshafts are located in bearing bushes which
are fitted in bores in the engine frame; each bearing
The inlet and exhaust valves as well as the fuel is replaceable and locked in position in the engine
pumps of the engine are actuated by two cam- frame by means of a locking screw.
shafts.
The gear wheel for driving the camshaft as well as
Due to the two-camshaft design an optimal adjust- a gear wheel connection for the governor drive are
ment of the gas exchange is possible without inter- screwed on to the aftmost section.
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
Fig 1 Twin camshafts, seen from flywheel end
is half that of the crankshaft.
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel
Page 1 (2) Check of Camshaft and Camshaft Drive Edition 02H
L16/24
Stopped engine Plate No Item No Note.

52021 202
Description
Checking of gear wheels, bolted connections and Hand tools

lubricating system.
Unbraco top, 8 mm
Ratchet
Extension
Top, 24 mm
Starting position Serrated fork
Related procedure

08028-0D/H5250/94.08.12
Working time : 3 Hours Plate No Item No Qty./

Capacity : 1 man
51106 142 1/cyl
Data

98.38 - ES0
MAN Diesel
Edition 02H Check of Camshaft- and Camshaft Drive Page 2 (2)
L16/24
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 ena- loose. Tightening torques, please see page
ble inspection allover the circumference of the 500.40.
gear wheels.
4) Start the electrical prelubricating oil pump and

check the oil flow from bearings.
5) Mount the covers.
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel

Page 1 (3) Inspection and Replacement of Camshaft Bearing Edition 05H
L16/24

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

shaft bearing.
Replacement of camshaft bearing.
Starting position
Cover for camshaft and gear wheel has been

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

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

Capacity : 2 men
50705 350 1/eng.
50705 648 1/eng.
Data

01.08 - ES0
MAN Diesel

Edition 05H Inspection and Replacement of Camshaft Bearing Page 2 (3)
L16/24
To Check Roller Path of Cams
1) While turning the engine, examine the cam

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

of the rollers may be blocked, 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, ab-normal wear of one or more
bearings will become apparent in the form of
burrs of white metal at the circumference of the
camshaft journal, and in that case the bearing
will in no doubt be discoloured, as well.
The bearing clearance is measured with a dial

gauge, please see data sheet 500.35. Fig 1 Removing of spur wheel and the bearing plate.
To Replace Camshaft Bearing for Injection Pull the disconnected sections of the camshaft
or valve camshaft so far aft that the bearing which is to be replaced
is free.
If one or several of the camshaft bearings should
be replaced, the camshaft must be wholly or partly 6) Remove the spur wheel and the bearing plate,
dismantled. see fig 1 so the camshaft can be moved toward
the generator.
Note: Before dismantling last bearing and spur gear
wheel the engine has to be turned so marks at gear 7) Push the bearing out of the bore in the engine
wheels are corresponding, please see Working frame.
Card 507-01.20. Engine must be locked in this
position. 8) Check the lubricating oil ducts to the bearing
08028-0D/H5250/94.08.12
for free flow.

3) The camshaft sections are marked in relation
to each other. 9) For fitting of the bearing it must be cooled down
with CO2 to -90°C below crankcase tempera-
4) Disassemble the camshaft for (toward engine ture.
front) of the bearing that is to be replaced.
10) Inspect the camshaft journal for seizures.
5) Dismount all roller guides that are located aft of
the disassembling position, please see working If necessary, the camshaft section must be
card 508-01.00. entirely removed from the engine, and the
journal concerned must be polished.
01.08 - ES0
MAN Diesel
Page 3 (3) Inspection and Replacement of Camshaft Bearing Edition 05H
L16/24
11) 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.
12) Assemble the sections and fit the bolts (coated

with molycote or similar).
13) Tighten the nuts with a torque spanner, please

see data sheet 500.40.
14) Mount all roller guides.

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

Page 1 (4) Adjustment of Camshaft for Valve and Injection Timing Edition 10H
L16/24

Shut-off cooling water 52007 040 Woodward
Shut-off fuel oil 52007 052 L'Orange
Hand tools
Description
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

07.48 - ES0
MAN Diesel

Edition 10H Adjustment of Camshaft for Valve and Injection Timing Page 2 (4)
L16/24
Assembly of gear wheels for valve cam-
shaft and Injection valve camshaft, without
mounted flywheel
Following description is for mounting the gearwheels Upper

in the control drive when alternator, flywheel and cover intermediate
on coupling side are dismantled from the engine. spur wheel
Small
Mounting of intermediate gearwheels holes
1) Turn the crankshaft to top dead centre for the

last cylinder (the cylinder nearest to the coupling Lower
side). intermediate
spur wheel
2) Mount the upper intermediate gearwheel.
3) Mount the lower intermediate gearwheel so the Crankshaft

marks on the lower intermediate gearwheel are
corresponding with the mark on the crankshaft
gearwheel, see fig 1(E2). At the same time turn
the upper intermediate gearwheel so that the
small holes in the circumference of the two
intermediate gearwheels are corresponding,
see fig 2.
Note: The punch mark on the crankshaft gearwheel Fig 2 Position of small holes in the circumference of the two
intermediated gearwheels
is placed on the 13 teeth counting counter clockwise
from the joint of the gearwheel, see fig 3.
08028-0D/H5250/94.08.12
Small
holes
13 teeth
Fig 3 13 teeth counter-clockwise from the joint of the gear-

wheel
Fig 1 Marks on gearwheels
07.48 - ES0
MAN Diesel

Page 3 (4) Adjustment of Camshaft for Valve and Injection Timing Edition 10H
L16/24
4) Tighten up the intermediate gearwheels.Tight- 3) Position the support of the measuring tool
ening torque, please see page 500.40. on the two bolts of the camshaft covering.
Slip on the distance sleeves and fasten to
the cylinder crankcase by means of hexagon
Mounting of gearwheel for valve camshaft nuts.
5) Before mounting the gearwheel, must marks for Note: During attaching, pay attention to the cor-
crankshaft and lower intermediate gearwheel rect fitting position of the contact point.
correspond, see fig 1(E2). Secondly must the
small holes for both intermediate gearwheels 4) Insert the dial gauge into the support.
be corresponding.
5) Turn the engine until the cam base circle is
6) Turn the valve camshaft, until the mark on the reached (approx 40° BTDC).
gearwheel for valve camshaft corresponds with
the 2 marks on upper intermediate gearwheel, 6) Set the dial gauge to "Zero".
see fig 1 (E1).
7) Turn the engine until the TDC mark (ignition
7) Tighten up the gearwheel. Tightening torque, DC) for the actual cylinder is reached.
please see page 500.40. Read the dial gauge and note down the
gauge value in sheet on page 4.
Mounting the gearwheel for injection cam- 8) Determine the values for the other cylinders
shaft in the same way.
8) Before mounting the gearwheel, must marks for Calculate the average value of all measure-
crankshaft and lower intermediate gearwheel ments.
correspond, see fig 1(E2). Secondly must the
small holes for both intermediate gearwheels 9) Compare the calculated value determined
be corresponding. with the value mentioned below.
9) Turn the injection valve camshaft, until the 10) If the values exceeds the limits, an adjust-
mark on the gearwheel for valve camshaft cor- ment must be done in order to correct the
respond with the 2 marks on upper intermediate errors.
gearwheel, see fig 1 (E1).
11) Remove the complete measuring tool.
Note: Adjustment of injection valve camshaft is now
needed, please see separately chapter “Adjustment 12) Mount all camshaft covers.
of Fuel Injection Camshaft / Injection Timing”.
Plunger lift (average value): see Fig 4.

08028-0D/H5250/94.08.12
Measure of fuel pump lead
1) Dismantle covers for fuel camshaft and fuel

pump.
2) Check the mobility of the regulating device.
07.48 - ES0
MAN Diesel

Edition 10H Adjustment of Camshaft for Valve and Injection Timing Page 4 (4)
L16/24
Fig 4
Pump type: Woodward L'Orange
Engine rpm 1000 1200 1000 1200
Engine power rating 90 100 110 90 100 110

(kW/Cyl.) (kW/Cyl.) (kW/Cyl.) (kW/Cyl.) (kW/Cyl.) (kW/Cyl.)
Max plunger lift 5.65 mm 6.5 mm 6.06 mm 5.65 mm 6.5 mm 6.06 mm
08028-0D/H5250/94.08.12
Fixing screws and discs

1. Contact point of enclosing cover used
2 Lever
07.48 - ES0
MAN Diesel
Plate
Page 1 (2) Intermediate Wheel 50701-02H
L16/24
097
085
121 061
120
036
085
107
073 097
085
119
061
048
024
08028-0D/H5250/94.08.12
012
085
107
073
119
07.48 - ES0
MAN Diesel
Plate
50701-02H Intermediate Wheel Page 2 (2)
L16/24
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 Lejebøsning
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 Møtrik
121 1/E Intermediate wheel, Mellemhjul,

complete komplet
08028-0D/H5250/94.08.12
07.48 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft (Valve Camshaft) 50705-15H
L16/24
349
291 291
266 230
278
278 350 254
266 266
301
313*
350
014
014
266 719
278
291 291
5 cyl.
278
026 038
266 038 026
6 cyl.
063 087
Item No for 051 075 099
08028-0D/H5250/94.08.12
7 cyl.
109 122 110
242 110 122 109
8 cyl.
bearing disks 146 075 183
134 158 171 195
9 cyl.
205 087 229 217
217 229 087 205
06.18 - ES0
MAN Diesel
Plate
50705-15H Camshaft (Valve Camshaft) Page 2 (2)
L16/24
Item Item
014 1/C Camshaft part Styreakselsektion, 2/E Bearing disk, Lejesøle,

piece, 6-7-8-9 cyl. 6-7-8-9 cyl. 9 cyl. engine 9 cyl. motor
229
026 2/E Bearing disk, Lejesøle, 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor
230
038 2/E Bearing disk, Lejesøle, 1/E Axial bearing disk Aksial lejesøle
5 cyl. engine 5 cyl. motor 242
1/E Bearing segment Lejesøle, ende
051 1/E Bearing disk, Lejesøle, end
1/E Spur wheel Cylindrisk tandhjul
063 1/E Bearing disk, Lejesøle, 266
6 cyl. engine 6 cyl. motor Screw Skrue
075 Bearing disk Lejesøle 86/E 6 cyl. engine 6 cyl. motor
1/E 6 cyl. engine 6 cyl. motor 100/E 7 cyl. engine 7 cyl. motor
087 Bearing disk Lejesøle 278
1/E 6 cyl. engine 6 cyl. motor Washer Skive
099 1/E Bearing disk, Lejesøle, 98/E 7 cyl. engine 7 cyl. motor
6 cyl. engine 6 cyl. motor 112/E 8 cyl. engine 8 cyl. motor
7 cyl. engine 7 cyl. motor Cylindrical pin Cylindrisk stift
1/E Bearing plate, com- Lejeplade, komplet
134 1/E Bearing disk, Lejesøle, plete incl. item 313 inkl item 313
8 cyl. engine 8 cyl. motor 313*
3/E Expander plug Ekspansionsprop
8 cyl. engine 8 cyl. motor 7/E Screw Skrue
350
158 1/E Bearing disk, Lejesøle, Camshaft bearing Styreakselleje
183 1/E Bearing disk, Lejesøle,
8 cyl. engine 8 cyl. motor 719 1/C Camshaft part Styreakselsektion,
piece, 5 cyl. 5 cyl.
08028-0D/H5250/94.08.12

8 cyl. engine 8 cyl. motor

217
Qty./C = Qty./Cylinder Qty./C = Qty./Cylinder
06.18 - ES0
MAN Diesel
Plate
Page 1 (2) Camshaft (Injection Camshaft) 50705-16H
L16/24
291 266
266 589
278
636
278 648
600
266
648 266
624
362
362
5 cyl.
374 386
590 386 374
6 cyl.
408 433
Item No for 398 421 445
7 cyl.
08028-0D/H5250/94.08.12
457 470 469

469 470 457
291
8 cyl.
278
bearing disks 494 421 528
266 482 504 516 541
9 cyl.
553 433 577 565
565 577 433 553
06.18 - ES0
MAN Diesel
Plate
50705-16H Camshaft (Injection Camshaft) Page 2 (2)
L16/24
Item Item
266 Screw Skrue 482 1/E Bearing disk, Lejesøle,

167/E 5 cyl. engine 5 cyl. motor 8 cyl. engine 8 cyl. motor
227/E 7 cyl. engine 7 cyl. motor 494 1/E Bearing disk, Lejesøle,
278 Washer Skive 8 cyl. engine 8 cyl. motor
291 Cylindrical pin Cylindrisk stift
362 1/C Camshaft part Styreakselsektion 565 2/E Bearing disk, Lejesøle,
piece 9 cyl. engine 9 cyl. motor
374 2/E Bearing disk, Lejesøle, 577 2/E Bearing disk, Lejesøle,
5 cyl. engine 5 cyl. motor 9 cyl. engine 9 cyl. motor
386 2/E Bearing disk, Lejesøle, 589 1/E Axial bearing disk Aksial lejesøle
590 1/E Bearing segment Lejesøle, ende
398 1/E Bearing disk, Lejesøle, end
600 1/E Spur wheel, Cylindrisk tandhjul,
6 cyl. engine 6 cyl. motor 624 1/E Bearing plate, com- Lejeplade, komplet
plete
421 Bearing disk Lejesøle
1/E 6 cyl. engine 6 cyl. motor 636 1/E Ring Ring
648 Camshaft bearing Styreakselleje
433 Bearing disk Lejesøle 6/E 5 cyl. engine 5 cyl. motor

08028-0D/H5250/94.08.12


06.18 - ES0
Operating gear
508/608
MAN Diesel
Description 508.01
Page 1 (1) Operating Gear for Valve and Fuel Injection Pumps Edition 02H
L16/24
Roller Guides for valve clearance.
The valve actuating gear is pressure-feed lubricated
The fuel injection pumps and rocker arms for inlet from the centralized lubricating system, through the
and exhaust valves are operated by the cams on the water chamber part and from there into the rocker
camshafts through roller guides. The roller guides for arm shaft to the rocker bearing.
inlet and exhaust valves are located in bores in the
water jacket for each cylinder.
The roller runs on a bush fitted on a pin that is

pressed into the roller guide and secured by means
of a lock screw.
Operating Gear for Fuel Injection Pumps
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.
The roller is pressed down on to the cam by a

spring, which is fixed between the roller guide and
the foot plate of the fuel injection pump, see also
section 514.
Valve Actuating Gear
The rocker arms are actuated through rollers, roller

guides and push rods. The roller guides for inlet
and exhaust valves are mounted in the water jacket
part. For dismantling, a side cover on the push rod
chamber is provided.
Each rocker arm activates two spindles through a

valve bridge with thrust screws and adjusting screws Fig 1 Valve operating gear
08028-0D/H5250/94.08.12
98.38 - ES0
MAN Diesel

Page 1 (2) Inspection of Valve Roller Guide Edition 03H
L16/24

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

98.47 - ES0
MAN Diesel

Edition 03H Inspection of Valve Roller Guides Page 2 (2)
L16/24
1) Turn the water jacket upside down so the roller
guides can slip out at the water jacket.
2) Examine the surface of the roller and the tap-

pet housing for marks and secures, if any they
must be polished away.
3) Blow clean the lubricating ducts in the tappet

housing and the roller with air.
4) Excamine the push rod, pin and ball cup for

damage and replace if necessary.
Replacement of Roller and Shaft Pin Fig 1 Inspection of roller guide and roller.
5) Remove the lock screw.
6) Push out the axle.
The roller and axle can now be replaced.
7) Mount the lock screw with loctite 275.
Mounting of Roller Guide
8) Mount the tappet housing with roller in the

water jacket.
Note: Be sure that the recess in the tappet

housing is resting on the cylindrical pin in the roller
guide housing. This ensure that the tappet housing
can not turn in the roller guide housing.
08028-0D/H5250/94.08.12
98.47 - ES0
MAN Diesel
Page 1 (2) Control of Valve Clearance Edition 09H
L16/24

Description Hand tols
Control and/or adjusting of valve clearance.
Starting position
Cover for valve cam is removed.

Cover for rocker arm is removed.
Related procedure
Safe valve adjustment 508-01.10 (10H)

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

Capacity : 1 man
Data See also plate 50502.

Data for tightening torque (Page 500.40)
03.43 - ES0
MAN Diesel
Edition 09H Control of Valve Clearance Page 2 (2)
L16/24
1) Turn the engine so that the roller, rests on the 2) Lift rocker arm in order to open the valves.
circular part of the cam, i.e. the inlet valves and Control that the valves start to open at the
the exhaust valves are closed. same time.
If the valves do not open at the same time,

make valve adjustment according to working
card 508-01.10(10H).
3) Verify clearance between valve bridge and

rocker arm, please see page 500.35 for clear-
ance data.
If the valve clearance have to be adjusted,

please see page 508-01.10 (10H)
Fig 1 Control of valve clearance
08028-0D/H5250/94.08.12
03.31 - ES0
MAN Diesel
Working Card 50801.10
Page 1 (3) Safe Valve Adjustment Edition 10H
L16/24

Shutoff starting air
Shutoff cooling water 52008 010
Shutoff fuel oil 52008 034
Press Blocking reset
Description: Hand tools:
Verification and/or adjustement of inlet and Screew driver

exhaust valves clearance. Torque wrench
Marking ink
Starting position:
Cover for valve camshaft is removed.

Cover for rocker arms is removed.
Rocker arms are removed.
Related procedure:
Manpower: Replacement and wearing parts:

08028-0D/H5250/94.08.12
Working time : ½ hours Plate no Item no Qty/

Capacity : 1 man
See also plate 50502
Data:

Data for tightening torque (Page 500.40)
03.43 ESO
MAN Diesel
50801.10 Working Card
Edition 10H Safe Valve Adjustment Page 2 (3)
L16/24
1) Before adjustment the rocker arms must be
removed.
Fig. 1. Cylinder without valve bridge.

Fig.3. The valve bridge in the vice.
2) Loosen the adjusting nut and turn it back one

turn. 5) Apply marking ink on the end of both valve
spindles. Place the valve bridges on the valve
3) Press the valve bridge to the valve spindle on spindles and press gentle.
the nonadjustable end and turn the adjusting
screw until you feel contact. Tighten the nut.
Fig.2. Adjustment of valve bridge.
4) Place the valve bridge in a vice and apply cor-

rect torque on the nut with a torque wrench. Fig. 4. Marking of valve spindles.
08028-0D/H5250/94.08.12
03.43 ESO
MAN Diesel
Working Card 50801.10
Page 3 (3) Safe Valve Adjustment Edition 10H
L16/24
6) If the valve bridge is correctly adjusted there 9) Install the rocker arms and adjust the clearance
will be ink on both contact surfaces and the to specified value.
ink will be clearly touched on both valve spin-
dles.
If the valve bridge do not clearly touch both

valve spindles then clean the marking ink return
to item 3.
Fig.7. Adjustment of rocker arms.
Fig.5. Control of adjustment of valve bridge. 10) Tighten the nut with torque wrench to correct
torque. Check the valve clearance once more
7) Mark the valve bridge adjusting screw and after the nut is tightend with correct torque.
locking nut clearly to indicate it has been The rocker arm adjusting screw and nut to
correctly adjusted and tightened. Mark inlet be marked clearly to indicate it is correct
and exhaust differently to insure they are not adjusted.
interchanged.
Fig.8. Tightening and marking of rocker arms.

Fig.6. Marking after adjustment and tightening.
The valves are now correct adjusted and securely

08028-0D/H5250/94.08.12
8) Turn the engine so that the rollers rest on the

fastened to insure safe operation.
circular part of the cam.
Remark
Item 16 can be performed, without the cylinder

cover mounted on the engine.
03.43 ESO
MAN Diesel
Plate
Page 1 (2) Roller Guide and Push Rods 50801-02H
L16/24
08028-0D/H5250/94.08.12
97.43 - ES0
MAN Diesel
Plate
50801-02H Roller Guide and Push Rods Page 2 (2)
L16/24
Item Item
028 2/C Push rod Stødstang
041 2/C Bolt Bolt
053 2/C Roller Rulle
065 2/C Shaft Aksel
077 2/C Housing for roller Hus for rullestyr

guide
089 2/C Screw Skrue
08028-0D/H5250/94.08.12
97.43 - 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 GenSet’s shutdown at "no fuel" position.
functions.
Each fuel injection pump is connected to the com-
The safety system is based on a programme logic mon, longitudinal regulating shaft by means of a
controller (PLC) which automatically controls the spring-loaded arm.
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 vessel’s 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 vessel’s system cannot oper- ● Indication of:
ate a MODBUS communication unit, MBD-H offers – Engine rpm
an output module (OM) to be installed in the vessel’s – 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 vessel’s 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
Lambda Controller 509.10
Page 1 (1)
Edition 07H
L16/24
V28/32S
Purpose At a 50% load change the system will be activated
for about 3-8 seconds.
The purpose with the lambda controller is to prevent If the system is activated more than 10 seconds,
injection of more fuel in the combustion chamber than the solenoid valve will be shut off and there will be
can be burned during a momentary load increase. a remote signal for "jet system failure".
This is carried out by controlling the relation between
the fuel index and the charge air pressure. The jet system is blocked when engine speed is
below 50 rpm.
The Lambda controller is also used as stop cylin-
der. During the start procedure the jet system is used as
a charge air booster.
Advantages Hereby heavy smoke formation is prevented during

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

den momentary load increases.
- Improved load ability.
- Less fouling of the engine's exhaust gas

ways.
- Limitation of fuel oil index during starting

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

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

08028-0D\H5250\94.08.12
activated, the turbocharger accelerates and increases

the charge air pressure, thereby pressing the piston
(3) backwards in the lambda cylinder (5). When the
lambda ratio is satisfactory, the solenoid valve will
be de-activated.
Fig 1 Principle drawing of lambda controller
Above system is also called jet system.
02.41 - ES0
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 ship’s 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 ship’s
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 02H
L16/24
Stopped engine Plate no. Item no. Note.

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

Analoge pressure transmitter 509-05.03
Analoge temperature transmitter 509-05.04
Working time : hours Plate no. Item no. Qty. /

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

98.38 - ES0
MAN Diesel
509-01.00 Functional Test and Adjustment of Safety, Working Card
Alarm and Monitoring Equipment
L16/24
Maintenance of Monitoring and Safety It is recommended that all functions are tested every
Systems three months according to the mentioned working
cards.
One of the most important parameters of preventive
work is that the alarm system, as well as the shutdown To check these functions use the working cards
and overspeed devices, are functioning 100%. mentioned under related procedure on page 1.
If some of these functions are out of operation,

they must be repaired immediately. If this is not
possible because of the current working situation, the
engine has to be under constant observation until it
can be stopped.
08028-0D/H5250/94.08.12
98.38 - 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
Working time : 1 hour Plate no Item no Qty/

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

alarm and monitoring equipment 509-01.00
Related procedure
Working time : ½ hour Plate no Item no Qty/

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) Analogous Temperature Transmitter Edition 04H
L16/24
Stopped engine Plate no. Item no. Note

Shut-off fuel oil
Adjustment and test of analogous temperature Special testing devices

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

alarm and monitoring equipment, 509-01.00

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

Capacity : 1 man
Data

98.43 - ES0
MAN Diesel
509-05.04 Adjustment and Test of Working Card
Edition 04H Analogous Temperature Transmitter Page 2 (2)
L16/24
The nickel-chrome-nickel sensor, which is used only
for measurement of the exhaust gas temperature, Test
generates a mV signal depending on the tempera-
ture. 2) Functional test of the PT 100 sensor can be
carried out according to the following proce-
The PT 100 sensor consists of a resistance wire dure.
which changes resistance depending on the tem-
perature. 3) Take the sensor out of the pocket.
Look and design vary depending on the place of 4) Test the thermostate by submerging the sen-
measurement and manufacture. sor in the water bath, which is controlled by a
special testing apparatus producing a constant
Adjustment temperature.
1) Since the nickel-chrome-nickel sensor and the If the alarm plant has an instrument unit, the tem-
PT 100 sensor cannot be adjusted the alarm perature can be read on this.
limit must be set on the alarm plant.
Otherwise the test can be carried out by seeing
Set point, see page 500.30. whether the alarm plant gives an alarm when the
alarm limit stated on page 500.30 is exceeded (if
the alarm plant is adjusted).
08028-0D/H5250/94.08.12
Fig 1 PT 100 sensor
98.43 - 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
Working time : 1/4 hour Plate no Item no Qty/

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
Working card 509-08.00
Page 1 (2) Mounting and Adjustment of Pick-ups on Engine Edition 01H
L16/24

Shut-off fuel oil
Stopped lub. oil circulation
Description
Mounting and adjustment of pick-ups on engi-

ne.
Hand tools
Starting position
Related procedure
Man power
Working hours : ½ Hours

Capacity : 1 Man
08028-0D/H5250/94.08.12
Spare and wearing parts

Data
Plate no Item no Qty/
00.12 - ES0
MAN Diesel
509-08.00 Working card
Edition 01H Mounting and Adjustment of Pick-ups on Engine Page 2 (2)
L16/24
Mounting Guidance
Engine rpm pick-up 90-1 and 90-2 and check of

plug for same.
Check to be carried out on stopped engine.
The pick-ups are positioned as indicated on the

enclosure, fig 1.
Fig 2 Placing of pick-up.
Check of Plug
Correct plug, see fig 3, rounded off, black head

and grey wire.
Fig 1 Cover on flywheel, seen from exh. side.
Fig 3 correct plug.
Mounting of Pick-up
Incorrect plug, see fig 4, square, black head and
The pick-up is screwed clockwise until it touches the black wire.
top of a tooth on the gear rim, please see fig 2.
Afterwards, the pick-up is turned one time anti-clock-

08028-0D/H5250/94.08.12
wise and then the groove of the thread (see fig 2) is

put in 3 o'clock or 9 o'clock position seen from the
socket end, still anti-clockwise.
The pick-up is locked with the counternuts.
Fig 4 Incorrect plug.
00.12 - ES0
MAN Diesel

Page 1 (2) Adjustment of Lambda Controller Edition 05H
L16/24

Shut off starting air
Shut off cooling water
Shut off fuel oil
Adjustment of lambda controller. Adjustablle spanner, 8"
Starting position
Related procedure

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

Capacity : 1 man
Data

98.48 - ES0
MAN Diesel
Edition 05H
Adjustment of Lambda Controller Page 2 (2)
L16/24
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 Removal of pipe for charge air pressure.
2) Set the "load limit" control knob at max.
3) Set the pump index to 13 mm by an adjustable

spanner on fuel rack arm.
4) Fit the adjustment screw (4), fig. 2, until the

Fig 1 Check of free space.
piston has contact with the spring without
com-pressing it.
5) Fasten the adjustment screw.
6) Adjustment completed.
Adjustment of the Stop Screw.
7) Set the pump index to 23 mm (spring on gov-

08028-0D/H5250/94.08.12
ernor full pressed) by an adjustable spanner

on fuel rack arm.
8) Adjust the stop screw, see fig 2, to 110% load

according to te 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.
9) Adjustment completed.
Fig 2 Fit the adjustment screw.
98.48 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 50901-19H
L16/24
393
For governor,
see special
instruction book
464
403 415
439
440
452
141
153
165
189
190 177
200 033
045
356 224
212+
344
057
069 236
070 248
082 261
08028-0D/H5250/94.08.12
094 273
285
297
307
332
320
06.32 - ES0
MAN Diesel
Plate
50901-19H Governor and Governor Drive Page 2 (2)
L16/24
Item Item
033 1/E Plug screw Propskrue 403 1/E Governor, Europa Regulator, Europa
(1200 rpm) (1200 rpm)
045 1/E Gasket Pakning
415 4/E Screw Skrue
057 4/E Nut Møtrik
439 1/E Governor, Europa Regulator, Europa
069 2/E Stud Tap (1000 rpm) (1000 rpm)
070 1/E O-ring O-ring 440 1/E Governor, Europa Regulator, Europa
(1000 rpm) (1000 rpm)
082 1/E Castle nut Kronemøtrik
452 1/E Governor, Europa Regulator, Europa
094 1/E Split pin Split (1200 rpm) (1200 rpm)
141 1/E Shim (set 0.1 - Mellemlæg (sæt 0,1 - 464 1/E Shutdown solenoid Shutdown spole
0.3 - 0.5 - 1.0 mm) 0,3 - 0,5 - 1,0 mm)
153 1/E Disc Skive + item 212 require + Item nr. 212 kræver
an individual match- en individuel tilpas-
165 1/E Ball bearing Kugleleje ing (by shims) before ning (med mellemlæg)
moun ting, contact, før montering, kontakt
177 1/E Bevel gear wheel Konisk tandhjul MAN B&W, Holeby. MAN B&W, Holeby
189 1/E Key Feder
200 1/E Split pin Split
212+ 1/E Housing Hus
224 2/E Stud Tap
236 2/E Pin Stift
248 1/E Plug Prop
261 1/E Screw Skrue
273 1/E Axle journal Akseltap
285 1/E Bush Bøsning
297 1/E Bevel gear wheel Konisk tandhjul
307 1/E Gear wheel Tandhjul
320 1/E Wear disc Slidskive
332 1/E Key Feder

08028-0D/H5250/94.08.12
344 1/E Shim, set Mellemlæg, sæt
356 /I Silastene Silastene
393 1/E Synchronizing Synchroniseringsmo-

motor tor
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Governor and Governor Drive 50901-20H
L16/24
For governor,
see special
instruction book
381
128
141
153
165
189
190 177
200 033
368 045
356 224
212+
344
057
069 236
070 248
082 261
094 273
08028-0D/H5250/94.08.12
285
297
307
332
320
06.32 - ES0
MAN Diesel
Plate
50901-20H Governor and Governor Drive Page 2 (2)
L16/24
Item Item
033 1/E Plug screw Propskrue 368 1/E O-ring only valid for O-ring anv. kun til
electronic actuator elektronisk aktuator
381 1/E Actuator, electronic Elektronisk aktuator
057 4/E Nut Møtrik
069 2/E Stud Tap + item 212 require + Item nr. 212 kræver
an individual match- en individuel tilpas-
070 1/E O-ring O-ring ing (by shims) before ning (med mellemlæg)
moun ting, contact, før montering, kontakt
082 1/E Castle nut Kronemøtrik MAN B&W, Holeby. MAN B&W, Holeby
128 4/E Screw Skrue
141 1/E Shim (set 0.1 - Mellemlæg (sæt 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
189 1/E Key Feder
212+ 1/E Housing Hus
224 2/E Stud Tap
236 2/E Pin Stift
248 1/E Plug Prop
261 1/E Screw Skrue
273 1/E Axle journal Akseltap
285 1/E Bush Bøsning
307 1/E Gear wheel Tandhjul
320 1/E Wear disc Slidskive

08028-0D/H5250/94.08.12
332 1/E Key Feder
344 1/E Shim, set Mellemlæg, sæt
356 /I Silastene Silastene
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Regulating Device 50902-10H
L16/24
302
231
184
292
160 159
135
338 375
Pick-up, see
Plate 50907/276 351 231
111
363
196 218
015 255
052 314
326 218 123
172 064
231
135
039 160 111

08028-0D/H5250/94.08.12
231
064 015 280 040 292 206 218 123
06.24 - ES0
MAN Diesel
Plate
50902-10H Regulating Device Page 2 (2)
L16/24
Item Item
015 1/C Bearing bracket, com- Konsol, komplet inkl. 351 1/E Shaft, 8 cyl. engine Aksel, 8 cyl. motor
plete incl. bush bøsning
363 1/E Shaft, 9 cyl. engine Aksel, 9 cyl. motor
039 2/C Screw Skrue
375 1/E Nut Møtrik
040 1/C Lever Arm
052 2/C Clamp screw Skrue
111 1/E Pull rod, complete Trækstang, komplet
123 1/E Lever Arm
135 1/E Governor arm Regulatorarm
159 1/E Screw Skrue
160 2/E Screw Skrue
172 1/C Adjusting screw Justeringsskrue
184 1/E Stop screw Stopskrue
196 1/E Bracket Konsol
218 Spring pin Fjederstift

231 Nut Møtrik

255 1/E Screw Skrue
292 1/E Lever, complete Arm, komplet
302 1/E Cylinder, complete Cylinder, komplet

08028-0D/H5250/94.08.12
06.24 - ES0
MAN Diesel
Plate
Page 1 (5) Instruments 50907-18
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
70 - 120°C 99 82 TSH 12 012

L1
L
Thermostat
0 - 10 bar 90 30 PSL 22 036
-1 - 4 bar PS 31 037
L
08028-0D/H5250/94.08.12
L1
Pressure control
08.08 - ES0
MAN Diesel
Plate
50907-18 Instruments Page 2 (5)
L16/24
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
PT 22
0 - 16 bar 90 30 PT 40 156
L1
0 - 40 bar PT 70 168
Pressure transmitter
Female plug - see item 288
0 - 20 kHz 110 SE 90-1 181

SE 90-2
Pick-up
0 - 1 kHz 129 SE 89 203

08028-0D/H5250/94.08.12
Pick-up
08.08 - ES0
MAN Diesel
Plate
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
0 - 1 kHz 22 ZT 88 227
L
Pick-up
0-160°C 63 174 TE/TI 40 264

L1
Thermometer
(Female plug - see item 288)
0-120°C 90 100 TI 10 311

08028-0D/H5250/94.08.12
Thermometer
08.08 - ES0
MAN Diesel
Plate
50907-18 Instruments Page 4 (5)
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
-50 - 150°C 150 TE 01 335
-50 - 150°C 80 TE 21 384

TE 31
L
Temperature sensor
(Female plug - see item 288)
L1 0 - 800°C 129 9000 TE 60 431
0 - 800°C 69 9000 TE 61 443

L TE 62
Temperature sensor
08028-0D/H5250/94.08.12
08.08- ES0
MAN Diesel
Plate
L16/24
Length Item
Fig. Range Code
L mm L1 mm no
26.5 50 288
L1
Female plug with cable relief
0 - 160°C 63 110 TE/TI 12 240

L1
Thermometer
08028-0D/H5250/94.08.12
08.08 - ES0
MAN Diesel
Plate
Page 1 (2) Level Switch in Oil Sump (LAL/LAH 28) 50920-12H
L16/24
216 241
228 253
265 169
277 157
049 Base frame,
see plate 51111
062
170
050
121
098
182
108 194
182
133
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
50920-12H Level Switch in Oil Sump (LAL/LAH 28) Page 2 (2)
L16/24
Item Item
049 4/E Screw Skrue
050 4/E Nut Møtrik
062 1/E Plate Plade
098 1/E Pipe for level switch Rør for nivaeukontakt
108 1/E Level switch Niveaukontakt
121 1/E Pipe for level switch Rør for nivaeukontakt
157 1/E O-ring O-ring
169 1/E Dipstick, complete Pejlestok, komplet

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

strip
253 2/E Screw Skrue
265 1/E Fitting Fitting
277 1/E Red. adaptor Red. adapter
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Leakage Alarm (LAH 42) 50925-06H
L16/24
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
06.22 - ES0
MAN Diesel
Plate
50925-06H Fuel Oil Leakage Alarm (LAH 42) Page 2 (2)
L16/24
Item Item
No. Qty Designation Benævnelse No. Qty Designation Benævnelse
010 1/E Fuel oil leakage Br.olielækagealarm,

alarm, complete komplet
022 1/E Flange Flange
058 1/E Red. adaptor Red.adapter
178 1/E Repair kit for Reparationssæt for

running in filter indkørselsfilter
286 4/E Screw Skrue
345 1/E Packing ring Pakningsring
357 1/E Plug screw Propskrue
416 /I Glue Lim
08028-0D/H5250/94.08.12
06.22 - ES0
MAN Diesel
Plate
Page 1 (2) Monitoring Box 50935-18H
L16/24
Front view
OB MTP
015 027
To check software
version push “lamp
test” for 3-5 sec.
The display will
indicate the software
version no for BM MEG
module.
483
292
302
135
314 A1
338
351 Diagnose led
Inside view 064

196
375
184
387
399
409
410
08028-0D/H5250/94.08.12
495
471
Fuses
F1 - sensors CPU
363 F2 - output relays
Led sensor
power
07.41 - ES0
MAN Diesel
Plate
50935-18H Monitoring Box Page 2 (2)
L16/24
Item Item
015 1/E Operation box (OB) Operation box (OB)
027 1/E Monitor temp./press. Monitor temp./tryk

(MTP) (MTP)
064 1/E Base module (MB) Basemodul (MB)
135 1/E Panel (A1) Panel (A1)
184 2/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 Møtrik M16
314 1/E Hose connection Rørforskruning
363 1/E Conduit Ledning
471 2/E Fuse Sikring
483 1/E Monitor exh. gas Monitor udst.

temp. (MEG) gastemp. (MEG)
495 1/E 5 pol double 5 pol dobbelt stik

connector
08028-0D/H5250/94.08.12
07.41 - ES0
MAN Diesel
Plate
Page 1 (2) Terminal Box 50936-16H
L16/24
Front view
453
465
477 536
489
490
500
095
Inside view
105
345
24VDC 400mA 0V 24V C 0 1 2 3 4 5 6 7 0 CO 1 C1 2 C2 2 3 C3 3 0 1 2 3 4 5 6 7
SENSOR SUPPLY DC INPUT DC INPUT 0V 24V DC INPUT
POWER RUN ERR 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 SUPPLY 0 1 2 3 4 5 6 7 SUPPLY

IN OUT IN
OUT IN
0 1 2 3 4 5 8 9 10 11 12 13 14 15
MAX
0 07CR41 XO08R2 XI16E1

MAX PLC
1684042-5
07CR41 XO 08 R2
PLC
1684043-7 XI 16 E1
PLC
1684044-9
225
R
Advant Controller 31
Basic Unit EXTENSION
4 RELAY OUTPUT 2A EXTENSION
394
S 8 24VDC INPUTS 4 RELAY OUTPUT NO/NC 3A 16 24VDC INPUTS
6 RELAY OUTPUTS
POWER SUPPLY RELAY OUTPUT DC INPUT 0V 24V DC INPUT

4 C4 5 C5 6 C6 6 7 C7 7
120/230VAC 20VA L1 N 0 C 1 2 3 C 4 5 8 9 10 11 12 13 14 15
404
416
428 250
08028-0D/H5250/94.08.12
142 GRD
GRD
441
-F4.0
-F4.1
-F4.7
-F4.8
GRD
548
274
154
561
07.43 - ES0
MAN Diesel
Plate
50936-16H Terminal Box Page 2 (2)
L16/24
Item Item
095 1/E Safety system Sikkerhedssystem

(CPU) (CPU)
105 1/E I/O module I/O modul
142 3/E Terminal, earth Jordklemme
154 6/E End stop Endestop
225 1/E Conduit Ledningskanal
250 1/E Conduit Ledningskanal
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 26/E Terminal double Klemme, dobbelt

08028-0D/H5250/94.08.12
07.43 - 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/Anlæg
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 Møtrik
225 2/E Cable union Kabel forskruning
237 2/E Nut Møtrik
262 2/E Cable union Kabelforskruning
274 2/E Nut Møtrik
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, blå
035 4/E Lamp holder Lampefatning
047 6/E Glow lamp Glødelampe
059 4/E Head, black Trykknap, sort
060 4/E Body Krop
072 4/E No contact block Sluttekontakt
084 10/E Auxillary relay Hjælperelæ
096 10/E Socket Sokkel
106 1/E Bridge rectifier Ensretterbro
118 1/E Transformer Transformer
131 12/E Fuse terminal Sikringsholder
08028-0D/H5250/94.08.12
98.16 - EO0-ny
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Pump Starter 50951-01
L16/24
024 036 048 012

227
239
240
085
097 1AE1 1AE2 1AE3 1AE4 061
PRELUB. OIL PUMP PRELUB. OIL PUMP PRELUB. OIL PUMP PRELUB. OIL PUMP
ENGINE 1 ENGINE 2 ENGINE 3 ENGINE 4
3H10 3S5 4H7 4S2 5H7 5S2 6H7 6S2

107 PUMP ON
MAN. AUTO.
OFF
PUMP ON
MAN. AUTO.
OFF
PUMP ON
MAN. AUTO.
OFF
PUMP ON
MAN. AUTO.
OFF 144
119 156
120 2S4 2S7 2S10 2S13 168
132 181
193 073
085
097
372
276 252 384
288 396 264 455
3F2 3F3 2F4 2F7 2F10 2F13
311 360
323
3T2 3Q5 4Q2 5Q2 6Q2 3K8 4K5 5K5 6K5
08028-0D/H5250/94.08.12
467
335 3F5 4F2 5F2 6F2 479
347
455
EARTH
EARTH
EARTH
EARTH
EARTH
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
L1
L2
L3
1
2
3
4
5
6
7
8
9
406 431
418 443
455 359 406 455
455
06.39 - ES0
MAN Diesel
Plate
50951-01 Prelubricating Oil Pump Starter Page 2 (2)
L16/24
Item Item
012 1/E Prelubricating oil Forsmøreolie- 359 /I Channel track Kanalspor

pump starter pumpestarter
panel complete komplet 360 /I Conduit Ledning
024 1/E Name plate Navneplade 372 4/E Circuit breaker, Sikkerhedsafbryder,
10 amp 10 amp
036 1/E Name plate Navneplade
384 4/E Auxilliary switch Hjælpekontakt
396 2/E Circuit breaker, Sikkerhedsafbryder,
061 1/E Name plate Navneplade 2 amp 2 amp
073 1/E Name plate Navneplade 406 35/E Terminal Klemme
085 10/E Screw M3 Skrue M3 418 4/E Earth terminal Jordklemme
097 10/E Nut M3 Møtrik M3 431 3/E Terminal Klemme
107 4/E Pilot lamp, green Lampeglas, grøn 443 1/E Earth terminal Jordklemme
119 4/E Lamp holder Lampefatning 455 17/E End angle Endevinkel
120 4/E Glow lamp Glødelampe 467 4/E Auxilliary relay Hjælperelæ
132 4/E Label, PUMP ON Label, PUMP ON 479 4/E Socket Sokkel
144 4/E Head Trykknap
156 4/E Body Krop
181 4/E Label, M-0-A Label, M-0-A
193 4/E Selector switch Omskifter
227 4/E Bracket Beslag
239 4/E Screw M8 Skrue M8

08028-0D/H5250/94.08.12
335 4/E Contactor Kontaktor
347 4/E Thermal relay Terminalrelæ
06.39 - ES0
MAN Diesel
Plate
L16/24
024 036
012
227
239
1AE1 1AE2 1AE3
085 PRELUB. OIL PUMP PRELUB. OIL PUMP PRELUB. OIL PUMP
240
ENGINE 1 ENGINE 2 ENGINE 3
097
3H10 3S5 4H7 4S2 5H7 5S2
PUMP ON
MAN. AUTO.
PUMP ON
MAN. AUTO.
PUMP ON
MAN. AUTO. 048
OFF OFF OFF
107
119 144
2S4 2S7 2S10
120 156
132 168
1AE5 181
193
203 073
215 085
276 252
097
288 264 372
467 384
335 479 396 455
347
3Q5 4Q2 5Q2 3K8 4K5 5K5

3F2 3F3 2F4 2F7 2F10
455 360
3F5 4F2 5F2

08028-0D/H5250/94.08.12
311
EARTH
EARTH
EARTH
EARTH
323 3T2
13
14
15
16
17
18
21
22
23
25
26
27
28
29
30
31
L1
L2
L3
1
2
3
4
5
6
7
8
9
406 406 359 406

418 455 443
455 455
06.39 - ES0
MAN Diesel
Plate
L16/24
Item Item
012 1/E Prelubricating oil Forsmøreolie- 347 3/E Thermal relay Terminalrelæ
panel complete komplet 359 /I Channel track Kanalspor
024 1/E Name plate Navneplade 360 /I Conduit Ledning
10 amp 10 amp
085 8/E Screw M3 Skrue M3 2 amp 2 amp
119 3/E Lamp holder Lampefatning 443 1/E Earth terminal Jordklemme
120 3/E Glow lamp Glødelampe 455 13/E End angle Endevinkel
132 3/E Label, PUMP ON Label, PUMP ON 467 3/E Auxilliary relay Hjælperelæ
144 3/E Head Trykknap 479 3/E Socket Sokkel
156 3/E Body Krop
215 12/E Nut Møtrik

08028-0D/H5250/94.08.12
06.39 - ES0
MAN Diesel
Plate
L16/24
024 036
012
227
239
1AE1 1AE2
085 PRELUB. OIL PUMP PRELUB. OIL PUMP
240
ENGINE 1 ENGINE 2
097
3H10 3S5 4H7 4S2
MAN. AUTO. MAN. AUTO.
PUMP ON PUMP ON
OFF OFF
107
119 144
2S4 2S7
120 156
132 168
1AE5 181
193
203 073
215 085
276 252
097
288 264 372
467 384
335 479 396 455
347
3Q5 4Q2 3K8 4K5

3F2 3F3 2F4 2F7
455 360
3F5 4F2
08028-0D/H5250/94.08.12
311
EARTH
EARTH
EARTH
323
13
14
15
16
21
22
25
26
27
28
29
L1
L2
L3
3T2
1
2
3
4
5
6
406 406 359 406

418 455 443
455 455
06.39 - ES0
MAN Diesel
Plate
L16/24
Item Item
012 1/E Prelubricating oil Forsmøreolie- 359 /I Channel track Kanalspor

panel complete komplet 360 /I Conduit Ledning
10 amp 10 amp
085 6/E Screw M3 Skrue M3 2 amp 2 amp
119 2/E Lamp holder Lampefatning 443 1/E Earth terminal Jordklemme
120 2/E Glow lamp Glødelampe 455 13/E End angle Endevinkel
132 2/E Label, PUMP ON Label, PUMP ON 467 2/E Auxilliary relay Hjælperelæ
144 2/E Head Trykknap 479 2/E Socket Sokkel
156 2/E Body Krop
215 8/E Nut Møtrik

08028-0D/H5250/94.08.12
06.39 - ES0
MAN Diesel
Plate
L16/24
024 012
227
1AE1
239
240
PRELUB. OIL PUMP
ENGINE
085
3H10 3S5
097
PUMP MAN. AUTO
ON OFF
107 144
119 156
120 168
132 2S4
181
193 073
1AE2
085
097
276 276
288 252 288
467 359 264 396
335 479
347 372
384
3F2 3F3 2F4

3Q5
3K8
455
360
08028-0D/H5250/94.08.12
311
EARTH
EARTH
3T2
13
14
15
16
17
18
L1
L2
L3
1
2
3
323
406 406 359 406

418 455 418
455 455
06.39 - ES0
MAN Diesel
Plate
L16/24
Item Item
012 1/E Prelubricating oil Forsmøreolie-

pump starter pumpestarter 384 1/E Auxilliary switch Hjælpekontakt
panel complete komplet
024 1/E Name plate Navneplade 2 amp 2 amp
073 1/E Name plate Navneplade 406 12/E Terminal Klemme
085 4/E Screw M3 Skrue M3 418 2/E Earth terminal Jordklemme
097 4/E Nut M3 Møtrik M3 455 11/E End angle Endevinkel
107 1/E Pilot lamp, green Lampeglas, grøn 467 1/E Auxilliary relay Hjælperelæ
119 1/E Lamp holder Lampefatning 479 1/E Socket Sokkel
120 1/E Glow lamp Glødelampe
132 1/E Label, PUMP ON Label, PUMP ON
144 1/E Head Trykknap
156 1/E Body Krop

08028-0D/H5250/94.08.12
359 /I Channel track Kanalspor
360 /I Conduit Ledning

10 amp 10 amp
06.39 - ES0
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, længde 1.8 m
045 1/E Cable, length 10 m Kabel, længde 10 m
08028-0D/H5250/94.08.12
07.37 - ES0
MAN Diesel
Plate
Page 1 (2) Oil Mist Detector 50960-03H
L16/24
See special instruction book

for oil mist detector
08028-0D/H5250/94.08.12
05.25 - ES0
MAN Diesel
Plate
50960-03H Oil Mist Detector Page 2 (2)
L16/24
Item Item
059 1/E Oil mist detector Olietågedektor
08028-0D/H5250/94.08.12
05.25 - ES0
Crankshaft
510/610
MAN Diesel
Description 510.01
Page 1 (1) Crankshaft and Main Bearings Edition 02H
L16/24
Crankshaft and Main Bearings Vibration Damper
The crankshaft, which is a one-piece forging, is A vibration damper is mounted on the crankshaft
suspended in underslung bearings. The main bea- to limit torsional vibrations. The damper consists of
rings are of the trimetal type, which are coated with a primary and a secondary part. Between these,
a 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 th/e crank-
shaft by means of one 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
98.43 - ES0
MAN Diesel
Page 1 (6) Checking of Alternator / Crankshaft Alignment (Autolog) Edition 15H
L16/24
Stopped engine Plate no. Item no. Note

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

Cover for crankshaft has been removed from
frame.
All indicator valves open.
Related procedure:
Manpower: Replacement and wearing parts:

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

Capacity : 2 men
Data:

08.09 - ES0
MAN Diesel
510-01.00 Checking of Alternator / Crankshaft Alignment (Autolog) Working Card
L16/24
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 Alternator / Crankshaft
Alignment (Autolog), page 5 and 6. 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
08.09 - ES0
MAN Diesel
Working Card
Page 3 (6) Checking of Alternator / Crankshaft Alignment (Autolog) 510-01.00
Edition 15H
L16/24
Deflection of crankshaft in 1/100 mm. (0.01 mm).
Deflection from vertical
misalignment
Cyl. No.
top - bottom
Crank position 1 2 3 4 5 6
or T - B = V 2 -1.5 4 4.5 -2 2
Bottom start X 0 0 0 0 0 0
Fig 4
Left side P 2 0 2 0 -1 2
Top T 3 -2 4 5 -2 3
Deflection from hori-
Right side S 3 -2 2 0 0 1 zontal misalignment
Bottom stop Y 2 -1 0 1 0 2 Right side - left side

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

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

"Closing" of the crankthrow is considered Start in position X.
negative. Turn anti clockwise
Fig 7 Fig 8
08.09 - ES0
MAN Diesel
Edition 15H Checking of Alternator / Crankshaft Alignment (Autolog) Page 4 (6)
L16/24
Measurement of Crank Throw Deflections by Means of Dial Indicator (Autolog)
Crank throw deflection = Difference in dial indicator readings in two diametrically

opposite crank throw positions, i.e. two positions dis-
placed 180°.
Vertical deflection = Difference in top-bottom readings.
Horizontal deflection = Difference in side-side readings.
Check of Crankshaft Alignment after Assembly of Alternator

with Flex-disc Coupling to Engine
For last throw:
Horisontal deflection : max. 5/100 mm
Vertical deflection : max. – 22/100 mm
08028-0D/H5250/94.08.12
08.09 - ES0
MAN Diesel
Page 5 (6) Checking of Alternator / Crankshaft Alignment (Autolog) Edition 15H
L16/24
Process/Proces I.D. no.
Plant/Anlæg Page of/Side af
Engine Type/Motortype Engineer/Operatør Date/Dato
Instruction/Instruktion
Top
Right side Left side
Bottom end/ Bottom start/

1/100 mm Bund slut Bund start
Right side
Cyl. no 1 2 3
Left side
Remarks/Bemærkninger
08028-0D/H5250/94.08.12
08.09 - ES0
MAN Diesel
510-01.00 Checking of Main Bearings Alignment (Autolog)
Working Card
L16/24
Component/Komponent Type I.D. no.
Process/Proces Page of/Side af
Test place/ Test bed/prøvehal Cold/Kold

Condition
On board/Om bord Warm/Varm
Teststed/
Tilstand Plant/Maskinhal
Engine no.:
Motornr.:
Cyl. no. 1 2 3 4 5 6 7 8 9
Bottom X 0 0 0 0 0 0 0 0 0
Left side P
Top T
Right side S
Bottom Y
Bottom
(0.5xY)=B
Deflection from
vertical misalign-
ment.
Top - bottom
or T - B = V
Deflection from
horizontal mis-
alignment.
Left side - Right
08028-0D/H5250/94.08.12
side or P - S = H
Check on gauge
readings.
T+B= C
P+S= D
08.09 - ES0
MAN Diesel

Page 1 (3) Inspection of Main and Guide Bearing Shells Edition 03H
L16/24

52021 275
52021 167
52021 202
Dismantling, inspection and/or replacement and 52021 334
mounting of main and guide bearing shells.
Hand tools
Starting position
Allen key, 12 mm
Socket spanner, 36 mm
Lead hammer
Silastene
Sopaslip
Related procedure
Criteria for replacement of bearings, 506-01.16

08028-0D/H5250/94.08.12

Capacity : 2 man
Data

99.33 - ES0
MAN Diesel

Edition 03H Inspection of Main and Guide Bearing Shells Page 2 (3)
L16/24
Preparing for Dismantling of the Main and Dismantling of the Main and Guide Bearing
Guide Bearing Cap
1) Dismount crankcase covers in front and op- 6) Fit the lifting handle, (Plate 52010, Item 035),
posite the bearing concerned. so as to support the bearing cap.
2) Turn the engine until the crank is in a convenient 7) Work the main bearing cap loose from the
possition for carrying out the work. engine frame with a lead hammer or similar.
3) Mount the hydraulic tool and loosen the brac- 8) Lift the main bearing cap a little and unscrew
ing stud nuts, see fig 1. For operating of the the bearing stud nut.
hydraulic tool, please see working card 520-
01.05, 9) Lift out the bearing cap from the engine.
Note: When the removing the bearing cap for

the guide bearing, be carefull not to loose the thrust
washers down in the oil pan.w
Dismantling of Main and Guide Bearing

Shells
10) Remove the bearing shell from the bearing

cap.
11) Fit the tool for the upper main bearing tool,
for dismantling of upper main bearing shell,
in the lubricating hole in the crankshaft and
turn out the upper bearing shell by turning the
crankshaft, see fig 2.
Fig 1 Mount the hydraulic tool and loosen the bracing stud
08028-0D/H5250/94.08.12
nuts.
4) Mount the hydraulic tools and loosen the main

bearing stud nuts, see fig 1.
5) Dismount the hydraulic tools and slacken the

nuts somewhat.
Fig 2 Tool for removal of upper main bearing shell.
99.33 - ES0
MAN Diesel

Page 3 (3) Inspection of Main and Guide Bearing Shells Edition 03H
L16/24
Cleaning Mounting of the Main and Guide Bearing

Cap
12) Clean all machined surfaces on frame, bearing
cap, stud, nuts and bearing shells. 17) Raise the bearing cap into possition with lift-
ing tool. Coat the bearing studs with molycote
pasta or similar. Fit the bearing stud nuts and
Inspection of Main and Guide Bearing tighten them by hand.
Shells
Note: When mounting the guide bearing cap, re-
13) Inspect the bearing shells according to working member to insert the two thrust washers in the guide
card 506-01.16. bearing cap.
Make sure that the bearing cap and bearing shells

Mounting of Main and Guide Bearing are in the correct possition.
Shells
18) Remove the lifting tool for the bearing cap.
14) Push the upper main bearing shell as far into
possition as possible. 19) Mount the hydraulic bracing screws and tighten
up the first step as prescribed on page 500.40.
Note: Be sure that the shell is turned correct accord- For use of hydraulic tools, please see working
ing to the locking pieces. card 520-01.05.
15) Fit the tool for upper main and guide bearing 20) Tighten the nuts for the bearing cap as pre-
in the lubricating hole in the crankshaft and scribed on page 500.40.
turn in the upper bearing shell by turning the
crankshaft. 21) Tighten up the bracing screw to second step,
please see page 500.40.
Make sure the shell enters its correct position then
remove the tool for upper main and guide bearing. 22) Tighten the bearings one at a time.
16) Insert the lower bearing shell in the bearing

cap according to the locking pieces.
Lubricate the bearing shell and journal with clean

lubricating oil.
Note: never use oil on the outer side of the bearing.

This side must be dry.
08028-0D/H5250/94.08.12
99.33 - ES0
MAN Diesel

Page 1 (3) Vibration Damper Edition 03H
L16/24

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

98.44 - ES0
MAN Diesel
Edition 03H Vibration Damper Page 2 (3)
L16/24
Together with every main revision of the engine Inner Spring Ends and Groove Flanks
the damper is to be inspected as well. Generally
an inspection of this kind is to be carried out every Wear takes place due to lack of oil supply.
28-30.000 hours of service together with service
and the replacement of certain parts, which are Spring packs consisting of two conical spring blades
exposed to wear. only are clamped in the innerstar groove at their
inner spring ends, thus producing a slight preload
Note: Regular inspection and supervision of the of the springs. The allowable wear will be attained
damper allows for preliminary planning and to order as soon as the preload of the springs is not existing
spare parts in time. any more and an additional clearance of "z" mm per
side between spring ends and groove flanks occures
(totalling 2 x z mm if one side of spring end rests on
Allowable Wear groove flank), see fig 2.
Total wear must not exceed 5% of the rope diameter,

see fig 1. Independent from wear all rubber rings
and gaskets should be renewed whenever damper
is taken apart.
Note: Because of leakage problems vulcanized rub-

ber rings do not suit this application. Use seamless
rings only.
Type z
D 56/49/1 0.23
D 56/50 0.18
D 50/4 0.12
Fig 2 Inner spring ends and groove flanks
Fig 1 Rubber seal ring
General Working Conditions

08028-0D/H5250/94.08.12
Oil pressure at oil inlet of damper to be 2,5 bar

minimum (u.o.s.)
Ambient temperature from -20° to + 120° C (unless

otherwise stated).
98.44 - ES0
MAN Diesel

Page 3 (3) Vibration Damper Edition 03H
L16/24
Circularity of Outer Member (correction)
The inner ends of the spring packs or intermediate

pieces might not be exactly circular. An eventuel
divergence from circularity must be corrected to be
less than 0.1 mm in diameter measured between
opposed intermediate pieces. This can be achieved
by hits onto the outside of the clamping ring using a
"soft hammer" or radial hits from the inside. For big
dampers a hydraulic cylinder, applied from inside
will be necessary.
If the lateral plates 5 and 7, fig 3 are without a

centering shoulder (to accommodate clamping ring),
lateral plates 5 and 7, fig 3 and clamping ring 3, fig
3 are to be adjusted concentric with a tolerance of
± 0.1 mm.
Appendix
If water mixes with the engine oil - especially sea-

water - the lubricating properties of the oil will be
reduced rapidly. In case an exceptional amount of
water is detected in the oil supplied to the damper
the remaining oil inside damper is to be replaced
by new oil as well. Even if the damper should be
supplied with an air escape nozzle, which provides a
small oil flow through the damper, this oil circulation
is not suitable to exchange the oil volume inside the
damper. The following procedure is to be followed Fig 3 Damper
for a total oil exchange.
a) To empty the damper totally turn it by 180° a

few times and make sure that the oil outflow
has stopped in any position of the damper.
b) Vent damper before it is put into service

again.
In case that the engine bearings are found to be worn

out because of lub. oil which was or is containing
08028-0D/H5250/94.08.12
water, the damper is to be inspected for wear and

corrosion as soon as possible as well. (Total inspec-
tion). See "Allowable wear".
98.44 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 51001-03H
L16/24
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Plate
51001-03H Crankshaft Page 2 (2)
L16/24
Item Item
021 1/E Crankhaft, Krumtap,





082 2/C Nut Møtrik
094 2/C Bolt Bolt
104 2/C Counterweight Kontravægt
116 Plug screw Propskrue

141 8/E Screw Skrue
165 1/E Cylindrical pin Cylindrisk stift
189 4/E Screw Skrue
190 1/E Gearwheel 2/2 Tandhjul 2/2

08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Plate
Page 1 (2) Crankshaft 51001-12H
L16/24
116
153
141 165
177
189
190
200
190
082
094
104
212
070
116
021
08028-0D/H5250/94.08.12
033
045
057
128 069
06.20 - ES0
MAN Diesel
Plate
51001-12H Crankshaft Page 2 (2)
L16/24
Item Item





082 2/C Nut Møtrik
094 2/C Bolt Bolt
104 2/C Counterweight Kontravægt
116 Plug screw Propskrue

141 8/E Screw Skrue
189 4/E Screw Skrue
190 1/E Gearwheel 2/2 Tandhjul 2/2

08028-0D/H5250/94.08.12
06.20 - ES0
MAN Diesel
Plate
Page 1 (2) Flywheel with Gear Rim 51003-16H
L16/24
010
022 058
034 105
071
046
Crankshaft see plate 51001
083
08028-0D/H5250/94.08.12
095
06.17 - ES0
MAN Diesel
Plate
51003-16H Flywheel with Gear Rim Page 2 (2)
L16/24
Item Item
010 1/E Flywheel, Svinghjul





071 12/E Bolt Bolt
083 1/E Gear rim Tandkrans
095 12/E Screw Skrue
105 12/E Sleeve Afstandsstykke
08028-0D/H5250/94.08.12
06.17 - ES0
MAN Diesel
Plate
Page 1 (2) Vibration Damper / Tuning Wheel 51004-04H
L16/24
173
016 5, 6, 7, 8L16/24-1200 rpm

7, 8, 9L16/24-1000 rpm
100
112
028
041
Crankshaft
053 see plate 51001
124
9L16/24, 1200 rpm

016
136
041
Crankshaft
see plate 51001
053
124
6L16/24, 1000 rpm
148
08028-0D/H5250/94.08.12
028
041
053
124
08.39 - ES0
MAN Diesel
Plate
51004-04H Vibration Damper / Tuning Wheel Page 2 (2)
L16/24
Item Item
No. Qty Designation Benævnelse No. Qty Designation Benævnelse
016 1/E Vibration damper Svingningsdæmper

6 cyl.-1200 rpm eng. 6 cyl.-1200 rpm motor
028 1/E Intermediate ring, Mellemring, undtagen

except 9cyl.-1200 rpm 9cyl.-1200 rpm motor
engine


124 2/E Screw Skrue
136 1/E Intermediate ring, Mellemring,

148 1/E Tuning wheel, Afstemningshjul,

173 1/E Spare part kit for Reservedelssæt for

vibration damper svingningsdæmper
08028-0D/H5250/94.08.12
Qty/E = Qty/Engine. Qty/E = Qty/Motor.
08.39 - ES0
Engine frame/Oil pan
511/611
MAN Diesel
Description
Engine Frame and Base Frame 511.01
Page 1 (1)
Edition 02H
L16/24
Engine Frame On the sides of the frame there are covers for ac-
cess to the camshafts and crankcase. Some covers
The monobloc cast iron engine frame is designed are fitted with relief valves which will operate if oil
to be very rigid. All the components of the engine vapours in the crankcase are ignited (for instance
frame are held under compression stress. The frame in the case of a hot bearing).
is designed for an ideal flow of forces from the cylin-
der head down to the crankshaft and gives the outer
shell low surface vibrations. Base Frame
Two camshafts are located in the engine frame. The engine and alternator are mounted on a rigid
The valve camshaft is located on the exhaust side base frame. The base frame acts as a lubricating
in a very high position and the injection camshaft is oil reservoir for the engine. The alternator is consid-
located on the service side of the engine. ered as an integral part during engine design. This
GenSet is flexible mounted on the foundation with
The main bearings for the underslung crankshaft rubber elements under the base frame.
are carried in heavy supports by tierods from the
intermediate frame floor, and are secured with the
bearing caps. These are provided with side guides
and held in place by means of studs with hydrauli-
cally tightened nuts. The main bearing is equipped
with replaceable shells which have the final toler-
ances.
08028-0D/H5250/94.08.12
Fig 1 Engine Frame
98.41 - ES0
MAN Diesel
Page 1 (2) Functional Test of Crankcase Safety Relief Valves Edition 11H
L16/24

Shut-off fuel oil
Press buttom (Blocking - Reset)
Functional test of crankcase safety relief val-

ves.
Starting position
Related procedure
Working time : 1/4 hour Plate no Item no Qty/

08028-0D/H5250/94.08.12
Capacity : 1 man
51106 237 1/cover
51106 490 4/relief valve
Data 51106 740 1/relief valve

06.46 - ES0
MAN Diesel
511-01.00 Functional Test of Crankcase Safety Relief Valves

Working Card
L16/24
Functional Testing
Functional testing of the crankcase safety relief

valves cannot be performed during operation of the
engine, but it must be checked during overhauls that
Cover
the valve flap is movable.
Relief
valve
When Painting
When painting the engine, take care not to block up

the safety relief valves with paint.
Check of Opening Pressure
To check the proper opening pressure, proceed as

follows:
1) Remove the relief valve cover from the engi-

ne.
Fig 1 Cover with safety relief valve
2) Place the cover on the floor with the pressure
area upwards.
3) Apply a weight at 6 kg on the pressure area.
The relief valve must open under this pres-

sure.
4) Remount the relief valve cover of the engine.
If the safety relief valves are actuated, the

engine must be stopped immediately, and it
must not be restarted until the cause is detected
and the fault is fixed, see also description
503.04, Ignition in Crankcase.
08028-0D/H5250/94.08.12
06.46 - ES0
MAN Diesel
Plate
Page 1 (2) Frame with Main Bearings 51101-23
L16/24
194 037
086
013 098
182 025 108

062
121
074 133
265 145
277
049
241
08028-0D/H5250/94.08.12
241
253 204
204 204
157 216
086 170
228
050 169 086
086
08.41 - ES0
MAN Diesel
Plate
51101-23 Frame with Main Bearings Page 2 (2)
L16/24
Item Item
013 1/E Disk Skive 204 Cylindrical pin Cylindrisk stift

025 1/E O-ring O-ring 8/E 6 cyl. engine 6 cyl. motor
037 4/E Retaining ring Sikringsring 10/E 8 cyl. engine 8 cyl. motor
216 Cross bolt Krydsbolt
050 1/E Cylindrical pin Cylindrisk stift 14/E 5 cyl. engine 5 cyl. motor
062 4/C Tierod Stavbolt 18/E 7 cyl. engine 7 cyl. motor
074 4/C O-ring O-ring 22/E 9 cyl. engine 9 cyl. motor
086 Nut Møtrik 228 Nut Møtrik

098 1/E Frame, 5 cyl. engine Stativ, 5 cyl. motor 241 Main bearing shell Hovedlejeskal 2/2
2/2
108 1/E Frame , 6 cyl. engine Stativ, 6 cyl. motor 7/E 5 cyl. engine 5 cyl. motor
121 1/E Frame, 7 cyl. engine Stativ, 7 cyl. motor 9/E 7 cyl. engine 7 cyl. motor
133 1/E Frame, 8 cyl. engine Stativ, 8 cyl. motor 11/E 9 cyl. engine 9 cyl. motor
145 1/E Frame, 9 cyl. engine Stativ, 9 cyl. motor 253 2/E Thrust bearing ring Tryklejering
157 Main bearing cap Hovedlejedæksel 265 1/I Packing-silicone Silicone

6/E 5 cyl. engine 5 cyl. motor paste
8/E 7 cyl. engine 7 cyl. motor 277 Cylindrical pin Cylindrisk stift
169 1/E Main bearing cap, Hovedlejedæksel, 8/E 8 cyl. engine 8 cyl. motor
axial aksial 9/E 9 cyl. engine 9 cyl. motor
170 2/E Bolt Bolt
182 Tierod Stavbolt

194 Crown nut Kronemøtrik

08028-0D/H5250/94.08.12

08.41 - ES0
MAN Diesel
Plate
Page 1 (3) Front End Box 51103-06H
L16/24
08028-0D/H5250/94.08.12
03.06 - ES0
MAN Diesel
Plate
51103-06H Front End Box Page 2 (3)
L16/24
Item Item
014 1/E Front end box Front end box 349 4/E Screw Skrue
026 5/E Plate Plade 350 8/E Screw Skrue
038 13/E Screw Skrue 362 2/E Flange Flange
051 6/E Washer Skive 374 2/E Gasket Pakning
063 4/E Nut Møtrik 386 16/E Screw Skrue
075 1/E Flange Flange 398 6/E Intermediate piece Mellemstykke
087 3/E Screw Skrue 408 12/E O-ring O-ring
099 3/E Washer Skive 421 1/E Housing for Hus for
lub. oil separator smøreolieseparator
109 1/E Plate Plade
110 4/E Screw Skrue
457 1/E Bracket for by-pass Konsol for centrifugal
134 2/E Packing ring Pakningsring centrifugal filter by-pass filter
146 2/E Thermostatic Termostatelement 469 4/E Screw Skrue

element for lub. oil for smøreolie
158 6/E Sleeve Bøsning
171 6/E Retaining ring Sikringsring
494 1/E Cover Dæksel
183 1/E Plate Plade
195 4/E Stud Tap
516 8/E Screw Skrue
528 8/E Spring washer Fjederskive
217+ 1/E Flange Flange
541 1/E Spring Fjeder
553 1/E Piston Stempel
565 9/E Screw Skrue
266 1/E Housing Hus
278 2/E Thermostatic Termostatelement
element for HT for HT kølevand 612 4/E Screw Skrue
cooling water
08028-0D/H5250/94.08.12
624 1/E Screw Skrue

element for LT for LT kølevand 636 1/E Thrust piece Trykstykke
cooling water
648 1/E Covering plate Dækselplade
03.06 - ES0
MAN Diesel
Plate
Page 3 (3) Front End Box 51103-06H
L16/24
Item Item
661 1/E Setting screw Skrue
673 1/E Nut Møtrik
+ To be used if cen- + Anvendes hvis ikke

trifugal by-pass filter centrifugal by-pass
is not mounted filter er monteret
08028-0D/H5250/94.08.12
03.06 - ES0
MAN Diesel
Plate
Page 1 (3) Front-end Box 51103-17H
L16/24
Centrifugal by-pass filter, 504

see plate 51515
470 494
217+ 482 528
229 516
445 075
099
469 038 087
624 408
026 398
433
457
648 636 Connecting pipe,
see plate 51206
504
661 122
673 553
134
541
Charge air pipes,
see plate 51230
528 612
516 Lubricating oil filter,
see plate 51502
685
386 600 038
Charge air cooler, 014 051 146
see plate 51201
158 171
997 278
205
998
171 109
158
291 110
08028-0D/H5250/94.08.12
687 349 038

051 183
688 Lubricating oil pump,
266 see plate 51501
267 Cooling water pumps,
374 see plate 51610
254
362 Lubricating oil cooler,
see plate 51506
350
08.16 - ES0
MAN Diesel
Plate
51103-17H Front-end Box Page 2 (3)
L16/24
Item Item
014 1/E Front end box Front end box 362 2/E Flange (1-string) Flange (1-streng)
026 5/E Plate Plade 374 2/E Gasket (1-string) Pakning (1-streng)
038 13/E Screw Skrue 386 16/E Screw Skrue
051 6/E Washer Skive 398 1/E Intermediate piece Mellemstykke
075 1/E Flange Flange 408 2/E O-ring O-ring
099 3/E Washer Skive 445 1/E O-ring O-ring
109 1/E Plate Plade 457 1/E Bracket for by-pass Konsol for centrifugal
centrifugal filter by-pass filter
110 4/E Screw Skrue
469 4/E Screw Skrue
element for lub. oil for smøreolie 494 1/E Cover Dæksel
158 6/E Sleeve Bøsning 504 2/E O-ring O-ring
171 6/E Retaining ring Sikringsring 516 8/E Screw Skrue
183 1/E Plate Plade 528 8/E Spring washer Fjederskive
205 1/E Gasket Pakning 541 1/E Spring Fjeder
217+ 1/E Flange Flange 553 1/E Piston Stempel
229 1/E Gasket Pakning 600 15/E Screw Skrue
266 1/E Housing (1-string) Hus (1-streng) 624 1/E Screw Skrue
267 1/E Housing (2-string) Hus (2-streng) 636 1/E Thrust piece Trykstykke
278 2/E Thermostatic ele- Termostatelement 648 1/E Covering plate Dækselplade
ment for HT cooling for HT kølevand
water 661 1/E Setting screw Skrue
291 2/E Thermostatic ele- Termostatelement 673 1/E Nut Møtrik

ment for LT cooling for LT kølevand
water 685 1/E Cover Dæksel
08028-0D/H5250/94.08.12
349 4/E Screw Skrue 687 2/E Seal ring Tætningsring
350 8/E Screw (1-string) Skrue (1-streng) 688 2/E Plug screw Propskrue
08.16 - ES0
MAN Diesel
Plate
Page 3 (3) Front-end Box 51103-17H
L16/24
Item Item
+ To be used if cen- + Anvendes hvis ikke

trifugal by-pass filter centrifugal by-pass
is not mounted filter er monteret
08028-0D/H5250/94.08.12
08.16 - ES0
MAN Diesel
Plate
Page 1 (2) Covers on Frame 51106-21H
L16/24
740 453
490
500
286 357
154 298 369
249 370
250 382
394
166 262 811
225 274 250
441
428
416
345
404
536
250
178 249
237
321
08028-0D/H5250/94.08.12
191
Frame, 201
see plate 51101 250 308
249
06.19 - ES0
MAN Diesel
Plate
51106-21H Covers on Frame Page 2 (2)
L16/24
Item Item
154 1/C Cover Dæksel 370 1/E Cover plate, Dækselplade,

382 1/E Cover plate, Dækselplade,
178 Cover Dæksel 8 cyl. engine 8 cyl. motor
3/E 6 cyl. engine 6 cyl. motor 394 1/E Cover plate, Dækselplade,
5/E 9 cyl. engine 9 cyl. motor 404 1/C Cover Dæksel
191 1/C O-ring O-ring 416 1/E Cover Dæksel
201 1/C Cover Dæksel 428 Stud Tap

225 Cover with Dæksel med 7/E 6 cyl. engine 6 cyl. motor
3/E safety valve sikkerhedsventil 8/E 7 cyl. engine 7 cyl. motor
4/E 5, 6 cyl. engine 5, 6 cyl. motor 9/E 8 cyl. engine 8 cyl. motor
7, 8, 9 cyl. engine 7, 8, 9 cyl. motor 10/E 9 cyl. engine 9 cyl. motor
237 1/C O-ring O-ring 441 1/D Cover Dæksel
249 Screw Skrue 453 1/D Safety valve Sikkerhedsventil

115/E 6 cyl. engine 6 cyl. motor 490 4/D Lock washer Låseskive
150/E 8 cyl. engine 8 cyl. motor 500 4/D Screw Skrue
536 Self locking nut Selvlåsende møtrik
250 Washer Skive 6/E 5 cyl. engine 5 cyl. motor
740 1/D O-ring O-ring
811 4/E Screw Screw

08028-0D/H5250/94.08.12


Qty/D = Qty/Cover Qty/D = Qty/Dæksel
06.19 - ES0
MAN Diesel
Plate
Page 1 (2) Cover on Frame 51106-22H
L16/24
08028-0D/H5250/94.08.12
06.17 - ES0
MAN Diesel
Plate
51106-22H Cover on Frame Page 2 (2)
L16/24
Item Item
034 8/E Screw Skrue
046 8/E Locking spring Låsefjederskive

washer
058 4/E Screw Skrue
071 4/E Thrust washer Fjederskive
105 8/E Screw Skrue
117 8/E Lock washer Låseskive
129 1/E Sealing ring Tætningsring
142 4/E Screw Skrue
08028-0D/H5250/94.08.12
06.17 - ES0
MAN Diesel
Plate
Page 1 (2) Base Frame 51111-09H
L16/24
080
126
138
092
151
163
Level switch in oil sump,

see plate 50920
018
079 031
08028-0D/H5250/94.08.12
043
055
067
06.22 - ES0
MAN Diesel
Plate
51111-09H Base Frame Page 2 (2)
L16/24
Item Item
018 1/E Base frame, Bundramme,





079 7/E Screw Skrue
080 4/E Screw Skrue
092 4/E Nut Møtrik
126 Screw Skrue

138 Disc Skive

08028-0D/H5250/94.08.12
06.22 - ES0
Turbocharger
512/612
MAN Diesel
Description 512.01
Page 1 (2) Turbocharger System Edition 05H
L16/24
Fig. 1. Diagram for Combustion Air System
Turbocharger System The charging air cooler is a compact two-stage tube-

type cooler with a large cooling surface. The high
The turbocharger system of the engine, which is a temperature water is passed through the first stage
constant pressure system, consists of an exhaust of the charging air cooler and the low temperature
gas receiver, a turbocharger, a charging air cooler water is passed through the second stage. At each
and a charging air receiver. stage of the cooler the water is passed two times
through the cooler, the end covers being designed
The turbine wheel of the turbocharger is driven by with partitions which cause the cooling water to
the engine exhaust gas, and the turbine wheel drives turn.
the turbocharger compressor, which is mounted on
the common shaft. The compressor draws air from The cooling water for the low temperature stages of
08028-0D/H5250/94.08.12
the engine room through the air filters. the charge air is controlled by the scavenging pres-
sure to ensure sufficient scavenging temperature
The turbocharger forces the air through the char- for burning HFO.
ging air cooler to the charging air receiver. From the
charging air receiver the air flows to each cylinder From the exhaust valves, the exhaust gas is led
through the inlet valves. through to the exhaust gas receiver where the
pulsatory pressure from the individual cylinders is
equalized and passed on to the turbocharger as a
constant pressure, and further to the exhaust outlet
and silencer arrangement.
99.37 - ES0S
MAN Diesel
512.01 Description
Edition 05H
Turbocharger System Page 2 (2)
L16/24
The exhaust gas receiver is made of pipe sections,
one for each cylinder, connected to each other by
means of compensators to prevent excessive stress
in the pipes due to heat expansion.
To avoid excessive thermal loss and to ensure a

reasonably low surface temperature the exhaust gas
receiver is insulated.
Fig. 2. Constant Pressure Turbocharger System
08028-0D/H5250/94.08.12
99.37 - ES0S
MAN Diesel
Page 1 (4) Overhaul of Charging Air Cooler Edition 02H
L16/24

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 02H Overhaul of Charging Air Cooler Page 2 (4)
L16/24
The charging air cooler is normally cleaned and
overhauled at the intervals indicated in the "Planned
Maintenance Program", or if observations prove that Charge air pipe
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 Assembly of charging air pipe
Lifting hole
Top plate (5)
A-A
A
Screw (1)
A
08028-0D/H5250/94.08.12
Chamber (4)
Gasket (7)
Gasket (6)
Screw (2) End cover (3)
Fig 2 Charging air cooler
01.30 - ES0
MAN Diesel
Page 3 (4) Overhaul of Charging Air Cooler Edition 02H
L16/24
Cleaning and Inspecting
7) Clean the cooler element of the water and air

sides.
After using cleaning agents the manufacturing

recommendation must be followed.
The greatest care must be exercised when

dismantling cleaning and mounting the cooler
element, as the thin fins of the tubes cannot
stand impacts and pressure.
Inevertheless, the metal is bent, it should be

carefully straightened, as bent fins will increase
the pressure drop across the cooler consider-
ably.
Fig 3 Removal of charge air cooler
xxxxxxxxx
Should one or more cooler tubes become leaky
it/they must immediately be made tight, either
3) Mount the lifting tool, see fig 3. by expanding the tube ends into the tube plates
or by blanking of the tube(s) concerned with
4) Attach a tackle hook to the lifting tool bolt and plugs.
tighten the wire.
It is important that the charging air cooler is not
5) Lift and pull the air cooler out of the cooler leaky as any water that leaks in will be carried
housing and place it on a couple of wooden together with the air into the cylinders where it
planks on the floor. will damage valves, piston rings, and cylinder
liners.
6) Remove screws (2) and end cover (3) reversal
chamber (4), and top plates (5), see fig 2. 8) Also clean the end cover and coat it on the
inside with an anti-corrosion agent.
9) Fouling and deposition in the pipes can be

removed with a hand or machine operated
circular steel brush.
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Edition 02H Overhaul of Charging Air Cooler Page 4 (4)
L16/24
Mounting of Charge Air Cooler
1
10) Renew gaskets (6) and (7) before assembling
endcover (3) reversal chamber (4) and top
plate (5). See fig 1.
Note: Before mounting the air cooler the o-ring at

the water connections must be replaced, see fig 4,
pos. 1.
11) Lift the air cooler by the lifting tool and push it
carefully half-way into its housing.
12) Remove the lifting tool and push the air cooler
into place.
13) Mount the screws see fig 2, pos. 1 and the Fig 4 Mounting of charging air cooler
charge air pipe, see fig 1.
Out of Service Periods.
At longer periods out of service, recommendations

for the entire system is followed. Please see section
501.
08028-0D/H5250/94.08.12
01.30 - ES0
MAN Diesel
Page 1 (2) Exhaust Pipe Compensator Edition 01H
L16/24

Shut-off fuel oil
Starting position
Related procedure

08028-0D/H5250/94.08.12
Working time : ½ hour Plate No Item No Qty./

Capacity : 1 man
Data

97.40 - ES0
MAN Diesel
Edition 01H Exhaust Pipe Compensator Page 2 (2)
L16/24
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 smell 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
97.40 - ES0
MAN Diesel
Page 1 (2) Cleaning the Turbine, dry cleaning Edition 03H
L16/24
Stopped engine Plate No Item No Note.

Shut-off fuel oil
Cleaning the turbine.
Starting position
Related procedure

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

Capacity : 1 man
Data

97.50 - ES0
MAN Diesel
Page 2 (2) Cleaning the Turbine, dry cleaning Edition 03H
L16/24
5-7 bar
1 Stop valve
2 Container
3 Valve
4 Working air
1 2 3 4
Fig. 2. Dry cleaning.
Dry cleaning Fill the container (2) with granulate. The amount
depending on the type of turbocharger;
Depending on the type of engine and turbocharger,
the arrangement of items may also differ somewhat NR12, NR14, NR15,
from that shown in the schematic. NR17, NR20 ...................................0.3 liter
Appropriate cleaning materials are granulates from NR24, NR26 ...................................0.4 liter
nut shells or activated charcoal of a grain size of 1
mm (max. 1.5 mm). NR29, NR34 ...................................0.5 liter
Connect to the working air system (4).

Cleaning sequence
Connect the "blow gun" to valve (1) and open valve
Please also consult the data plate. (3). Then open valve (1) slowly until a hissing sound
indicates that the granulate is being injected. Injection
The cleaning is to be carried out at high engine load, period: approx 2 min.
min. 75 % MCR.
Dry cleaning must be performed at all injection con-
Before connecting the "blow gun" open the stop valve nections (if more than one).
(1) and check that the passage is not blocked. Close
08028-0D/H5250/94.08.12
the valve again.
97.50 - ES0
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler 51201-06H
L16/24
08028-0D/H5250/94.08.12
97.43 - ES0
MAN Diesel
Plate
51201-06H Charging Air Cooler Page 2 (2)
L16/24
Item Item
017 2/K Top plate Topplade
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
091 16/K Washer Skive
101 16/K Screw Skrue
113 1/K Gasket end cover Pakning endedæksel
125 1/K End cover Endedæksel
137 1/K Cooler block Kølerblok
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
08028-0D/H5250/94.08.12
Qty/K = Qty/Cooler Qty/K = Qty/Køler
Qty./E = Qty./Engine Qty./E = Qty./Motor
97.43 - ES0
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler with Preheating 51201-16H
L16/24
101
174
091
125
113
186
029
198
030
017
186
137 042
198
066
150
054
149
08028-0D/H5250/94.08.12
066
054
078
08.39 - ES0
MAN Diesel
Plate
51201-16H Charging Air Cooler with Preheating Page 2 (2)
L16/24
Item Item
017 2/K Side plate Sideplade
029 8/K Screw Skrue
042 8/K Screw Skrue
078 5/K Screw Skrue
149 1/K Reversing chamber Vendekammer

reversing chamber vendekammer

complete komplet
174 1/K Screw Skrue
186 2/K Parallel pin Cylindrisk stift
08028-0D/H5250/94.08.12
08.39 - ES0
MAN Diesel
Plate
Page 1 (2) Charging Air Cooler without Preheating 51201-17H
L16/24
101
174
091
125 113
186
029
198
030
017
186
042
137 198
066
150 054
149
066
08028-0D/H5250/94.08.12
054
078
07.47 - ES0
MAN Diesel
Plate
51201-17H Charging Air Cooler without Preheating Page 2 (2)
L16/24
Item Item
017 2/K Side plate Sideplade
029 8/K Screw Skrue
042 8/K Screw Skrue
078 5/K Screw Skrue
149 1/K Reversing chamber Vendekammer

reversing chamber vendekammer

complete komplet
174 1/K Screw Skrue
186 2/K Parallel pin Cylindrisk stift
08028-0D/H5250/94.08.12
07.47 - ES0
MAN Diesel
Plate
Page 1 (2) Exhaust Pipe Arrangement 51202-17H
L16/24
08028-0D/H5250/94.08.12
06.24 - ES0
MAN Diesel
Plate
51202-17H Exhaust Pipe Arrangement Page 2 (2)
L16/24
Item Item
024 Gasket Pakning

036 Screw Skrue

048 Nut Møtrik

061 1/C Exhaust manifold Udstødsmanifold
073 1/C Compensator Kompensator
097 1/C Clamping strap 2/2 Holder 2/2
107 2/C Screw Skrue
119 2/C Nut Møtrik
08028-0D/H5250/94.08.12
06.24 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Turbocharger 51203-07H
L16/24
08028-0D/H5250/94.08.12
99.06 - ES0
MAN Diesel
Plate
51203-07H Mounting of Turbocharger Page 2 (2)
L16/24
Item Item
018 4/E Screw Skrue
043 4/E Screw Skrue
067 1/E Pipe piece for Rørstykke for

5 cyl. 1200 rpm 5 cyl. 1200 rpm
6 cyl. 1000/1200 rpm 6 cyl. 1000/1200 rpm
7 cyl. 1000 rpm 7 cyl. 1000 rpm
080 4/E Screw Skrue
092 4/E Nut Møtrik
102 1/E Socket Muffe
126 1/E Turbocharger foot for Turboladerfod for

7 cyl. 1200 rpm 7 cyl. 1200 rpm
8 cyl. 1000/1200 rpm 8 cyl. 1000/1200 rpm
9 cyl. 1000/1200 rpm 9 cyl. 1000/1200 rpm
138 4/E Bolt Bolt
151 4/E Spring ring Fjederring
163 1/E Casing Hus
175 1/E Closing cover Dæksel
187 /I Sealing compound Tætningsmiddel

(Silastene) (Silastene)
199 1/E Pipe piece for Rørstykke for

7 cyl. 1200 rpm 7 cyl. 1200 rpm
8 cyl. 1000/1200 rpm 8 cyl. 1000/1200 rpm
9 cyl. 1000/1200 rpm 9 cyl. 1000/1200 rpm
210 8/E Screw Skrue
222 8/E Nut Møtrik

08028-0D/H5250/94.08.12
99.06 - ES0
MAN Diesel
Plate
712 L16/24
724
665
677
653
S2 S2
S3 S3
665
S2 : S2
690
S3 : S3
700
700
712
724 653
785
748
797
773 736
665
761
08028-0D/H5250/94.08.12
690
807
819
665
689
07.18 - ES0
MAN Diesel
Plate
L16/24
Item Item
653 1/E Foot for Fod for turbolader

turbocharger
665 13/E Lock spring washer Låseskive
677 7/E Screw Skrue
689 4/E Screw Skrue
690 2/E Screw Skrue
712 2/E Screw Skrue
748 4/E Screw Skrue
761 1/E Exhaust pipe before Udstødsrør før TC

TC
773 4/E Screw Skrue
785 8/E Nut Møtrik
819 1/E Seal ring Tætningsring
08028-0D/H5250/94.08.12
07.18 - ES0
MAN Diesel
Plate
712 L16/24
724 665
677
653
S2 S2
S3 S3
665
S2 : S2
690
S3 : S3
700
700
712
724 653
785
748
797
773 736
665
761
08028-0D/H5250/94.08.12
690
807
819
665
689
07.18 - ES0
MAN Diesel
Plate
L16/24
Item Item
653 1/E Foot for Fod for turbolader

turbocharger
677 7/E Screw Skrue
689 4/E Screw Skrue
690 2/E Screw Skrue
712 2/E Screw Skrue
748 4/E Screw Skrue
761 1/E Exhaust pipe before Udstødsrør før TC

TC
773 6/E Screw Skrue
785 6/E Nut Møtrik
08028-0D/H5250/94.08.12
07.18 - ES0
MAN Diesel
Plate
Page 1 (2) Connection Pipe 51206-02H
L16/24
08028-0D/H5250/94.08.12
99.17 - ES0
MAN Diesel
Plate
51206-02H Connection Pipe Page 2 (2)
L16/24
Item Item
051 4/E Screw Skrue
229 1/E Connecting pipe Forbindelsesrør
08028-0D/H5250/94.08.12
99.17 - ES0
MAN Diesel
Plate
Page 1 (2) Blowgun for Dry Cleaning of Turbocharger 51210-02
L16/24
197
161 256 173 185 268 207 219
281
220 315
0.2 L
232
0.3 L
303
244
0.4 L
293
08028-0D/H5250/94.08.12
08.26 - ES0
MAN Diesel
Plate
51210-02 Blowgun for Dry Cleaning of Turbocharger Page 2 (2)
L16/24
Item Item
No. Qty. Designation Benævnelse No. Qty. Designation Benævnelse
161 1/E Snap coupling Snapkobling
173 1/E Nipple Nippel
185 1/E Tee T-stykke
197 1/E Ball valve Kugleventil
232 1/E Pipe Rør
244 1/E Container, complete Beholder, komplet
268 1/E Nipple Nippel
281 1/E Restriction Restriktion
293 1/E Spray nozzle Forstøverdyse
303 1/E Blowgun, complete Rensepistol, complete
315 /I Granulate Granulat
08028-0D/H5250/94.08.12
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
08.26 - ES0
MAN Diesel
Plate
Page 1 (2) Heat Insulation of Exhaust Pipes 51211-01H
L16/24
S1
S1
011 047 059
011 023 035 047 059
060
S1
08028-0D/H5250/94.08.12
06.50 - ES0
MAN Diesel
Plate
51211-01H Heat Insulation of Exhaust Pipes Page 2 (2)
L16/24
Item Item
011 1/E Heat insulation on Varmeisolering

rear end (bagende)
023 1/E Intermediate heat Varmeisolering

insulation for (mellemstykke) for
035 1/E Intermediate heat Varmeisolering

insulation for (mellemstykke) for
8 and 9 cyl. engine 8 og 9 cyl. motor

front end for (forreste ende) for
5, 7 and 8 cyl. engine 5, 7 og 8 cyl. motor

front end for (forreste ende) for
060 1/E Connecting wire Samlingstråd
08028-0D/H5250/94.08.12
06.50 - ES0
MAN Diesel
Plate
Page 1 (2) Cover of Exhaust Pipes 51211-02H
L16/24
084 096 106
A3 A2
084 118 131 096 106
A3 A2
08028-0D/H5250/94.08.12
143
A2 A3
167
155
06.50 - ES0
MAN Diesel
Plate
51211-02H Cover of Exhaust Pipes Page 2 (2)
L16/24
Item Item
084 1/E Cover on rear end Dæksel (bagende)
096 1/E Cover on front end for Dæksel (forreste ende)

5, 7 and 8 cyl. engine for 5, 7 og 8 cyl. motor
106 1/E Cover on front end for Dæksel (forreste ende)

6 and 9 cyl. engine for 6 og 9 cyl. motor
118 1/E Intermediate cover for Mellemdæksel for

131 1/E Intermediate cover for Mellemdæksel for

143 Cyl. screws Cylinderskrue

155 Cyl. screws Cylinderskrue

167 Self drilling screw Selvskærende skrue

08028-0D/H5250/94.08.12
06.50 - ES0
MAN Diesel
Plate
Page 1 (2) Heat Insulation and Cover before Turbocharger 51211-03H
L16/24
180
179
192
202
08028-0D/H5250/94.08.12
214
226
06.50 - ES0
MAN Diesel
Plate
51211-03H Heat Insulation and Cover before Turbocharger Page 2 (2)
L16/24
Item Item
179 1/E Heat insulation Varmeisolering
180 1/E Heat insulation Varmeisolering
192 1/E Connecting wire Samlingstråd
202 1/E Insulation plate cover Isoleringsdækplade
214 2/E Hexagon screw Skrue
226 2/E Washers Skive
08028-0D/H5250/94.08.12
06.50 - ES0
MAN Diesel
Plate
Page 1 (2) Charge Air Pipes 51230-03H
L16/24
08028-0D/H5250/94.08.12
02.36 - ES0
MAN Diesel
Plate
51230-03H Charge Air Pipes Page 2 (2)
L16/24
Item Item
015 1/E Flange Flange 302 4/E Screw, 5-6 cyl. Skrue, 5-6 cyl.
7 cyl. 1000 rpm 7 cyl. 1000 rpm
027 Seal ring Tætningsring
11/E 5 cyl. engine 5 cyl. motor 326 1/E Covering sheet Dækplade
15/E 7 cyl. engine 7 cyl. motor 338 17/E Screw Skrue
19/E 9 cyl. engine 9 cyl. motor 483 1/C Screw Skrue
040 Lock washer Låseskive 505 1/E Screw Skrue

052 1/C Intermediate piece Mellemstykke
064 1/C Safety clamp Sikkerhedsring
088 1/E Pipe piece Rørstykke
111 8/E Screw Skrue
123 1/E Pipe piece Rørstykke
135 2/E Screw Skrue
147 1/E Flange, 5-6 cyl. Flange, 5-6 cyl.

7 cyl. 1000 rpm 7 cyl. 1000 rpm

7 cyl. 1200rpm 7 cyl. 1200rpm
172 3/E Screw Skrue
184 5/E Screw Skrue
206 8/E Screw Skrue
218 1/E Compensator Kompensator
231 1/E Diffuser Diffusor

7 cyl. 1000 rpm 7 cyl. 1000 rpm
267 1/E Plate, 8-9 cyl. Plade, 8-9 cyl.

08028-0D/H5250/94.08.12
280 4/E Screw, 8-9 cyl. Skrue, 8-9 cyl.

02.36 - ES0
MAN Diesel
Plate
Page 1 (2) Oil Drain from Turbocharger 51231-07H
L16/24
View with turbocharger NR14/S
345
500
512
345
453 357
465
369 404
428 394
489 416
477
370
490
382
441
477
585 548
573
597 561
View with turbocharger NR12/S

08028-0D/H5250/94.08.12
08.27 - ES0
MAN Diesel
Plate
51231-07H Oil Drain from Turbocharger Page 2 (2)
L16/24
Item Item
357 1/E Adjustable elbow Justerbar vinkelkobling,

coupling, complete komplet
369 1/E Drain for TC Dræn for TC
370 1/E Straight male stud Tap
394 1/E Pipe clamp Rørklemme
404 1/E Plate Plade
416 2/E Screw Skrue
453 2/E Screw Skrue
465 2/E Packing Pakning
489 2/E Screw Skrue
490 2/E Nut Møtrik
500 1/E Reducing stand Reduktionsrør

pipes
512 1/E Straight male stud Kobling

coupling
548 2/E Screw Skrue
573 1/E Guard Skærm
585 5/E Screw Skrue
597 1/E Screw Skrue

08028-0D/H5250/94.08.12
08.27 - ES0
MAN Diesel
Plate
Page 1 (2) Mounting of Charge Air Cooler 51235-04H
L16/24
S1 : S1
S1 S2 S3 S4 S5
S2
S1
360 S3 S5
charge air cooler,

S4
see plate 51201
S2 : S2
479 480 492 502
S4 : S4
443
467
347 384 372 359

S5 : S5
538 406 396 418 455 431

08028-0D/H5250/94.08.12
575
526 551 563 514
07.46 - ES0
MAN Diesel
Plate
51235-04H Mounting of Charge Air Cooler Page 2 (2)
L16/24
Item Item
347 1/E Valve Ventil
359 3/E Intermediate piece Mellemstykke
396 1/E Bushing Bøsning
443 4/E Screw Skrue
455 1/E Valve Ventil
467 4/E Screw Skrue
479 1/E Pipe Rør
492 1/E Plate Plade
502 1/E Pipe Rør
514 1/E Slider Glider
526 2/E Bushing Bøsning
538 1/E Actuator Aktuator
563 1/E Sealing ring Tætningsring
575 8/E Screw Skrue

08028-0D/H5250/94.08.12
07.46 - ES0
MAN Diesel
Plate
Page 1 (2) Control Air for Preheating Valve 51236-02H
L16/24
474 450 258 401 258

462 271 437 271 354 378
366 342 391 413
A-A
317
329
295
305
401
425
234
246
258
271
222
210
234
283
330
342
08028-0D/H5250/94.08.12
474 401 258 354 342 378 401 391

449 437 271
07.48 - ES0
MAN Diesel
Plate
51236-02H Control Air for Preheating Valve Page 2 (2)
L16/24
Item Item
210 1/E Straight male stud Ligeforskruning

coupling
222 1/E Pipe Rør
234 1/E Pipe Rør
246 1/E Straight coupling Ligeforskruning
258 16/E Pipe clamp Rørholder
283 1/E Adjustable T-coupling Justerbar T-samling
295 1/E Support Støtte
305 2/E Screw Skrue
317 1/E Solenoid valve Magnetventil
329 2/E Screw Skrue

coupling
342 1/E Pipe Rør
354 1/E Male stud elbow Vinkelforskruning

coupling

coupling
378 1/E Pipe Rør

coupling
413 1/E Pipe Rør
425 1/E Pipe Rør
437 1/E Pipe Rør
449 1/E Pipe Rør
450 1/E Pipe Rør

08028-0D/H5250/94.08.12
462 1/E Adjustable elbow Justerbar vinkelforskru-

coupling ning
474 1/E Solenoid valve Magnetventil
07.48 - ES0
Compressed air system
513/613
MAN Diesel
Description
Compressed Air System (low pressure) 513.01
Page 1 (2)
Edition 16H
L16/24
Main starting valve

(with push button for
emergency / local start)
On-off valve
for jet system
SS
32 K1
Strainer
SS
83
SA SSH
On-off valve for shutdown 99 81-1
(with push button for Air starter
SS SX SX SSH
84 84 83 81-2
emergency stop)
UX
95
Cyl. 1 Monito- Safety
ring system SS
system 86
SX
ZS ZS SX ZS 86
SS 75 96 32 97
Compressed air to TC, 82
(see combustion air diagram) Cylinder for Stop solenoid
lambda controller on governor
and overspeed stop Charging air inlet,
(see combustion air diagram)
Fig. 1 Diagram for compressed air system.
General Starting System
The compressed air system on the engine consists The engine is started by means of a built-on air
of a starting system, starting control system and starter, which is a turbine motor with safety clutch
safety system. Further, the system supplies air to and drive shaft with pinion. Further, there is a main
the jet assist system. starting valve.
The compressed air is supplied from the starting

air receivers (max. 10 bar). If needed an additional Control System
air reduction station can be supplied for external
08028-0D/H5250/94.08.12
instal-lation. The air starter is activated electrically with a pneumatic

solenoid valve. The valve can be activated manually
To avoid dirt particles in the internal system, a strainer from the starting box on the engine, and it can be
is mounted in the inlet line to the engine. arranged for remote control, manual or automatic.
05.05 - ES1
MAN Diesel
513.01 Compressed Air System (low pressure)

Description
Page 2 (2)
Edition 16H
L16/24
For remote activation the starting coil is connected Pneumatic Start Sequence
so that every starting signal to the starting coil goes
through the safe start function which is connected to When the starting valve is opened, air will be supplied
the basemodule mounted on the engine. to the drive shaft housing of the air starter.
Further, the starting valve also acts as an emergency The air supply will - by activating a piston - bring the
starting valve which makes it possible to activate the drive pinion into engagement with the gear rim on
air starter manually in case of power failure. the engine flywheel.
As shown in fig. 2.
When the pinion is fully engaged, the pilot air will
flow to, and open the main starting valve, whereby
Safety System air will be led to the air starter, which will start to
turn the engine.
As standard the engine is equipped with a pneuma-
tic/mechanic stop cylinder, which starts to operate if When engine rpm exceeds approx. 158 and firing
the safety system is activated.The system is activated has taken place, the starting valve is closed whereby
electrically or mechanically by 3/2-way valve on top the air starter is disengaged.
of engine, behind regulator.
Air supply must not be interrupted when the engine

is running.
08028-0D/H5250/94.08.12
Fig. 2 Emergency start.
05.05 - ES1
MAN Diesel
Description
Compressed Air System 513.01
Page 1 (2)
Edition 17H
L16/24
Fig. 1 Diagram for compressed air system.
General Starting System
The compressed air system on the engine consists The engine is started by means of a built-on air
of a starting system, starting control system and starter, which is a turbine motor with safety clutch
safety system. Further, the system supplies air to and drive shaft with pinion. Further, there is a main
the jet assist system. starting valve.
The compressed air is supplied from the starting air

receivers (16-30 bar) through a reduction station, from Control System
where compressed air is supplied to the engine.
The air starter is activated electrically with a pneumatic
To avoid dirt particles in the internal system, a strainer 3/2-way solenoid valve. The valve can be activated
08028-0D/H5250/94.08.12
is mounted in the inlet line to the engine. manually from the starting box on the engine, and
it can be arranged for remote control, manual or
automatic.
05.05 - ES1
MAN Diesel
513.01 Compressed Air System Description
Page 2 (2)
Edition 17H
L16/24
For remote activation the starting coil is connected Pneumatic Start Sequence
so that every starting signal to the starting coil goes
through the safe start function which is connected to When the starting valve is opened, air will be supplied
the basemodule mounted on the engine. to the drive shaft housing of the air starter.
Further, the starting valve also acts as an emergency The air supply will - by activating a piston - bring the
starting valve which makes it possible to activate the drive pinion into engagement with the gear rim on
air starter manually in case of power failure. the engine flywheel.
As shown in fig. 2.
When the pinion is fully engaged, the pilot air will
flow to, and open the main starting valve, whereby
Safety System air will be led to the air starter, which will start to
turn the engine.
As standard the engine is equipped with a pneuma-
tic/mechanic stop cylinder, which starts to operate if When engine rpm exceeds approx. 158 and firing
the safety system is activated.The system is activated has taken place, the starting valve is closed whereby
electrically or mechanically by 3/2-way valve on top the air starter is disengaged.
of engine, behind regulator.
Air supply must not be interrupted when the engine

is running.
08028-0D/H5250/94.08.12
Fig. 2 Emergency start.
05.05 - ES1
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 (4) Overhaul, Test and Inspection of Air Starter Edition 03H
L16/24

Shut-off fuel oil
Check of air starter 1 flex. male key 4 mm

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

Capacity : 1 man
08028-0D/H5250/94.08.12
51309 278 1 (spare part kit)
Data

98.48 - ES0
MAN Diesel
Edition 03H Overhaul, Test and Inspection of Air Starter Page 2 (4)
L16/24
It is not nessesary to disassemble the air starter
for inspection, only if overhaul is necessary due to
worn parts.
Inspection
1) Check the drive pinion.
Note: This should be shiny and no special wear must

appear on both side of the teeth.
2) Check with a torque spanner the tighten of the

drive pinion screw. This must be 54-61 Nm.
3) Check the flange cover screw are tighten to

4-5 Nm.
08028-0D/H5250/94.08.12
Fig 1 Air starter
98.48 - ES0
MAN Diesel
L16/24
Disassembly 11) Remove the drive housing seal (16) from the
flange cover.
Always wear eye protection when performing any
maintenance on this air starter. 12) Turn the air starter over and secure it vertically
in a fixture.
Always turn off the air supply and disconnect the air
supply before installing, removing or adjusting any Note: Use care when removing the housing cover
accessory on this air starter or before performing bolts (12) holding the housing cover (11) to the air
any maintenance on this air starter. starter. The liner (9) is spring loaded and will pro-
trude approximately one inch beyong the housing
1) Do not disassemble the air starter any further when released.
than necessary to replace worn parts.
13) To remove the housing cover, slowly loosen
2) When grasping a part in a vise, always use the four housing cover bolts while holding the
leather-covered or copper-covered vise jaws to housing cover in place.
protect the surface of the part and help prevent
distortion. This is paritcularly true of threaded 14) Slide the liner assembly out of the housing.
members.
15) Remove the return spring (8).
3) Do not remove any part which is a press fit in
or on a subassembly unless the removal of that
part is necessary for replacement or repairs. Assembly
4) Always have a complete set of seals and o-rings 16) Always press on the inner ring of a ball-type
on hand before starting any overhaul of the air bearing when installing the bearing on a
starter. Never reuse old seals or gaskets. shaft.
5) When disassembling, always mark adjacent 17) Always press on the outer ring of a ball-type
parts so the members can be located in the bearing when pressing the bearing into a bear-
same relative position when the air starter is ing recess.
reassembled.
18) Whenever grasping an air starter or part in a
6) Never wash the liner assembly (9) in a sol- vise, always use leather-covered or copper-
vent. covered vise jaws. Take extra care with treaded
parts or housings.
Disassembly of the Air Starter

Assembly of the Air Starter
7) Remove the drive pinion screw (1) from the
drive shaft and remove the drive pinion (2). 19) Place the housing (13), front end down so that
the return spring (8) can be placed into the
8) Remove the six flange cap screws (3) from the housing.
housing (13).
08028-0D/H5250/94.08.12
20) Slide the liner assembly (9) into the housing.

9) Remove the flange cover (4) and flange (5) Orient the liner so that the notch aligns correctly
simultaneously by pulling up on the flange. with the housing inlet port and liner air inlet
port aligns with the housing inlet port. Attach
10) Remove the front drive shaft bearing (15) from housing cover gasket (10) to housing cover.
the flange cover.
98.48 - ES0
MAN Diesel
L16/24
21) Attach the housing cover (11) to the housing 29) Attach the drive pinion (2) to the drive shaft
with just one housing cover bolt (12). Engage using the drive pinion screw (1) and Locktite,
only a few threads so that the housing cover tighten to 40-45 ft-lb (54-61 Nm) torque, fig
can be easily rotated. 1.
22) While pushing the liner assembly down against

the return spring, rotate the housing cover over Test and Inspection
the liner to hold it down.
Warning ! When 6 bar air pressure is applied to the
23) Tighten the housing cover cap screws to 5-6 air starter, the drive pinion will be rotating at 2,800
ft-lb (6.7-8 Nm) torque. rpm and drive shaft and drive pinion will move forward
30-32 mm. Keep face and hands away from rotating
24) Press the drive housing seal (16) into the flange drive pinion.
cover (4) with the sealing lip pointed down.
30) Orientation: Mounting flange must be oriented
25) Press the front drive shaft bearing (15) into the per the customer's order or engineering draw-
flange cover. ing. If orientation is not specified by customer,
standard orientation will be supplied.
26) Fit the flange (5) onto the flange cover so that
the counterbore of the flange slides over the 31) Free speed (all models): Install air starter
shoulder of the flange cover correctly. on a test fixture. Apply 6 bar to the air starter
motor. Minimum free speed is 2,800 rpm.
27) Carefully slide this assembly over the drive
shaft. Be careful not to tear the seal lip. Orient 32) Confirm overrunning of clutch: Turn the drive
the flange correctly. pinion by hand in the direction of rotation. The
clutch should ratchet smoothly.
28) Tighten the six flange cap screws (3) to 3-4
ft-lb (4-5.4 Nm) torque. 33) Confirm drive rotation: Turn the drive pinion
by hand in the direction of rotation. The clutch
should ratchet smoothly.
08028-0D/H5250/94.08.12
98.48 - ES0
MAN Diesel
L16/24

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

Capacity : 1 man
08028-0D/H5250/94.08.12
51309 614 1
(set of seals, air starter)
Data
51309 615 1
Data for pressure and tolerance (Page 500.35) (repair kit, air starter)
03.14 - ES0
MAN Diesel

L16/24
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 3.500 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
03.14 - ES0
MAN Diesel

Page 1 (2) Emergency Starting Valve Edition 02H
L16/24

Shut-off fuel oil
Lubricating, disassembly and reassembly of Small screwdriver

emergency starting valve in starting system.
Starting position
Related procedure

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

Capacity : 1 man
Data

98.45 - ES0
MAN Diesel
Edition 02H Emergency Starting Valve Page 2 (2)
L16/24
Emergency Starting Valve
The emergency starting valve is placed on the tur-

bine starter and should be tested according to the
planned maintenance programme.
1) Switch the engine to "local" on the operating

box panel.
2) Push the emergency start button with a small

screwdriver, as shown in fig 1, until the engine
ignites.
3) Release the button. The button is springloaded

and will automatically return to the start posi-
tion.
Fig 1 Emergency starting valve.
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel

Page 1 (2) Check of Compressed Air Piping System Edition 03
General

Shut-off fuel oil
Shut-off nozzle cooling 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
Plate
Page 1 (2) Air Starter 51309-18H
L16/24
08028-0D/H5250/94.08.12
08.04 - ES0
MAN Diesel
Plate
51309-18H Air Starter Page 2 (2)
L16/24
Item Item
014 1/S Drive pinion screw Tandhjulsskrue 624 1/S Spare parts kit for Reservedelskit for
air starter, incl. item startemotor, inkl. item
026 1/S Drive pinion, Tandhjul, 014, 038, 051, 063, 014, 038, 051, 063,
incl item 291 inkl. item 291 087, 291 087, 291
038 1/S Gasket for housing Pakning for 648 1/S Spare parts kit for Reservedelskit for
cover motorhusdæksel item 325, consisting item 325, indeholder
of element, gasket element, pakning
051 1/S Front drive shaft Forreste
bearing drivakselleje 673 1/S Straight male stud Ligeforskruning
coupling
063 1/S Drive housing seal Tætning for drivgear
685 1/S Reducing stand Reduktionsrør
087 6/S Flange cap screw Dækselskrue for pipe
flange
697 1/S Adjustable Justerbar
099 1/S Flange cover Flangedæksel T-coupling T-forskruning
109 1/S Flange Flange 707 1/S Nipple Nippel
134 1/S Return spring Fjeder
158 1/S Housing cover Motorhusdæksel
171 4/S Bolt for housing Bolt for motorhus-

cover dæksel
183 1/S Housing Motorhus
195 1/S Vent plug Afluftningsskrue
217 4/S Mounting bolt Bolt for montering
230 1/S O-ring O-ring
242 1/E Air starter com- Startemotor komplet

plete
254 3/S Screw Skrue
266 3/S Washer Skive
291* 1/S Shaft collar Støttering
325 1/S Strainer complete Vandsi komplet
337 1/S Adj. straight male Justerbar

stud coupling ligeforskruning
349 1/S Adjustable Justerbar

08028-0D/H5250/94.08.12
elbow vinkelforskruning
408 1/S Solenoid valve Magnetventil
Qty/S = Qty/Air starter Qty/S = Qty/Startemotor
08.04 - ES0
MAN Diesel
Plate
L16/24
215 222
232 229 209
220 214 216 210
201 230 221
234
208
209
210
211
231
202 226
233 227
Pinion see, 1½
plate 51309 217 228

item 613
218 224 225
218 235
235 219
617
232
213
207
206
All valves and fittings
has to be approved by
classification society.
223
08028-0D/H5250/94.08.12
212 209
210
For details for serial no. q 04-0118, see plate 51309-15H
For details for serial no. d 04-0118, see plate 51309-20H
09.41 - ES0
MAN Diesel
Plate
L16/24
Item Item
201 1/S Flange Flange 232 2/S Cutting ring Skærering
202 4/S Screw Skrue 233 4/S Washer Skive
206 1/S Distributor block Fordelerblok 234 1/S Connector Forskruning
207 1/S O-ring O-ring 235 2/S Male connector Forskruning
208 3/S Screw Skrue 617 1/S Filter insert Filterindsats
210 7/S Nut Møtrik
211 1/S Threaded pin Gevindtap
212 1/S Solenoid valve Magnetventil
213 1/S Elbow male Vinkelforskruning

connector
214 1/S Connecting tube Forbindelsesrør
215 1/S Swivel connector Forskruning
217 1/S Male connector Forskruning
218 2/S Elbow union Vinkelforskruning
219 1/S Strainer Filter
220 1/S Holder Holder
221 1/S Protective hood Beskyttelsesskærm
222 2/S Screw Skrue
223 1/S Cap nut Dækselmøtrik
224 1/S Bracket Konsol
225 2/S Nut Møtrik
226 1/S Spacer plate Afstandsplade
227 2/S Cap nut Dækselmøtrik

08028-0D/H5250/94.08.12
229 1/S Screw plug Propskrue
230 1/S Male connector Forskruning
231 1/S Elbow union Vinkelforskruning
08.41 - ES0
MAN Diesel
Plate
Serial no. ≤ 04-0118 L16/24

08028-0D/H5250/94.08.12
08.41 - ES0
MAN Diesel
Plate
L16/24 Serial no. ≤ 04-0118

Item Item
500 1/E Air starter, Startemotor, 568 1/S Inlet nozzle Indstrømningsdyse
complete komplet
574 1/S Silencer Lyddæmper
501 1/S Front cover Fordæksel
502 1/S Outer bearing ring Udvendig lejering
578 1/S Non-return valve Kontraventil
504 1/S Needle bearing Nåleleje
582 1/S Silencer Lyddæmper
506 1/S Circlip Sikringsring
583 4/S Nut Møtrik
507 1/S Hauling crown Rotordæksel
584 1/S Air tube Luftrør
508 25/S Cylinder roller Cylinderrulle
586 1/S Membrane plug Membranprop
510 1/S Bearing disc Lejeskive
591 4/S Plug Prop
511 1/S Splined shaft Fjedrende aksel
592 4/S Nut Møtrik
512 1/S Plug Prop
596 1/S Flange Flange
513 1/S Spring Fjeder
514 8/S Allen screw Stiftskrue
601 1/S Air tube Lufttrør
516 1/S Lock nut Låsemøtrik
603 1/S Set ring Låsering
517 1/S Protection Beskyttelses-
cover dæksel 604 1/S Valve body Ventilhus
519 1/S Motor body Motorhus 605 1/S Distributor Fordeler
526 4/S Stud Tap 612 1/S Servo valve Servoventil
531 1/S Tappet with Styreknast 613 1/S Pinion Drev

guidance
614 1/S Seals kit complete Tætningssæt kom-
536 2/S Screw Skrue for air starter plet for luftstarter
539 1/S Secondary Sekondær 615 1/S Repair kit complete Reparationssæt
rotor rotor for air starter, con- komplet for luftstar-
sisting of item 539, ter, bestående af
544 1/S Primary rotor Primær rotor 544, 614 item 539, 544, 614
549 2/S Stud Tap
553 2/S Lock nut Låsemøtrik

08028-0D/H5250/94.08.12
554 1/S Plug Prop
557 1/S Main valve Hovedventil
565 1/S Spring Fjeder
566 1/S Elastic pin Elastisk tap
08.41 - ES0
MAN Diesel
Plate
Serial no. > 04-0118 L16/24

4 6 79 3 1 7 8 9 16 17
10 12 13 14 15
80
26 27 28 30
32
72
103 106 105
102
101 104
A
34
A
Clean air filter
34 periodically
39
40
71 75
23 86 87 89 25
24
81 82 84 85
76
46
18 19 74
83 92 44 88
47 48 71
21 73 20
90 91 93
45
94 41 42 43 95 96 97 98
08028-0D/H5250/94.08.12
77
63
78
61
66
50 51 52 53 54 55 56 57 58 59 60
67
64
69 70
68
08.38 - ES0
MAN Diesel
Plate
L16/24 Serial no. > 04-0118

Item Item
1 1/S Tension washer Tilspændingsskive 39 1/S Pipe Rør
3 1/S Needle bearing Nåleleje 40 1/S Silencer Lyddæmper
4 4/S Allen screw Skrue 41 4/S Stud Tap
6 1/S Front cover Fordæksel 42 4/S Special washer Skive
7 1/S Special joint Speciel samling 43 4/S Special nut Møtrik
8 1/S Outer ring bearing Yderleje 44 1/S Secondary rotor Sekundær rotor
9 25/S Roller bearing Rulleleje 45 1/S Check valve Checkventil
10 1/S Bearing disc Lejeskive 46 1/S Sleeve Bøsning
12 1/S Special nut Møtrik 47 1/S Membrane Membran
13 1/S Washer Skive 48 1/S Plug Prop
14 1/S Supporting ring Støttering 50 1/S Lip seal Tætningsring
15 1/S Hauling crown Rotordæksel 51 1/S Main valve Hovedventil
16 1/S Spring Fjeder 52 1/S O-ring O-ring
17 1/S Splined shaft Fjedrende aksel 53 1/S Distributor Fordeler
18 1/S Plug Prop 54 1/S Bushing Bøsning
19 1/S O-ring O-ring 55 1/S O-ring O-ring
20 1/S Follower Medfølger 56 1/S O-ring O-ring
21 2/S Screw Skrue 57 1/S Join shell Samlingskappe
23 1/S Motor body Motorhus 58 1/S Special washer Skive
24 1/S Primary rotor Primær rotor 59 1/S Nut Møtrik
25 1/S Valve body Ventilhus 60 1/S Spring Fjeder
26 1/S Silencer Lyddæmper 61 4/S Stud Tap
27 1/S Elbow Bøjning 63 4/S Nut Møtrik
28 1/S Nut Møtrik 64 1/S Stud Tap
30 2/S Nut Møtrik 66 1/S O-ring O-ring

08028-0D/H5250/94.08.12
32 2/S Stud Tap 67 1/S Inlet nozzle Indstrømningsdyse
34 1/S Servo-limiter unit Servo-limiter unit 68 1/S O-ring O-ring
08.38 - ES0
MAN Diesel
Plate
Serial no. > 04-0118 L16/24

Item Item
69 4/S Special washer Skive 96 1/S O-ring O-ring
70 4/S Allen screw Skrue 97 1/S Needle bearing Nåleleje
71 1/S Pipe for stop signal Rør 98 1/S O-ring O-ring
72 1/S Elastic pin Elastisk tap 101 1/S O-ring O-ring
73 1/S Flange Flange 102 1/S Electro valve Ventil
74 1/S O-ring O-ring 103 1/S Connector Forbindelsesstykke
75 1/S O-ring O-ring 104 1/S O-ring O-ring
76 1/S O-ring O-ring 105 1/S Filter Filter
77 1/S Flange Flange 106 2/S O-ring O-ring
78 1/S Sleeve Bøsning 107 1/S Set of seals com- Tætningssæt inde-
prising item 7, 14, holdende item 7, 14,
79 1/S Locker ring Låsering 19, 47, 50, 52, 55, 56, 19, 47, 50, 52, 55,
66, 68, 74, 75, 76, 79, 56, 66, 68, 74, 75,
80 1/S Locker ring Låsering 80, 82, 84, 87, 89, 76, 79, 80, 82, 84,
90, 92, 96, 98, 101, 87, 89, 90, 92, 96,
81 1/S Front locker Tætning 104, 106 98, 101, 104, 106
82 1/S O-ring O-ring 108 1/S Repair kit compris- Reparationskit inde-
ing item 24, 44 and holdende item 24, 44
83 1/S Needle bearing Nåleleje a set of seals og et tætningssæt
85 1/S Big retainer Holder
86 1/S Big retainer Holder
93 1/S Small retainer Holder

08028-0D/H5250/94.08.12
94 2/S Pin Stift
95 1/S Retainer Holder
08.38 - ES0
MAN Diesel
Plate
Page 1 (2) Main Stop Valve 51315-02H
L16/24

08028-0D/H5250/94.08.12
99.03 - EO0
MAN Diesel
Plate
51315-02H Main Stop Valve Page 2 (2)
L16/24
Item Item
017 1/V Gland flange Ters
029 1/V Stem with disc Spindel med skive
030 1/V Gasket Pakning
042 1/E Stop valve, complete Stopventil, komplet
08028-0D/H5250/94.08.12
Qty./E = Qty./Engine. Antal/E = Antal/Motor.
Qty./C = Qty./Valve. Antal/V = Antal/Ventil.
99.03 - EO0
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 Reparationssæt

(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 51322-08
L16/24
L21/31
483 483
495 458 495
505 517 409 387 471 505
529 410 422 530 399 446 529
434
08028-0D/H5250/94.08.12
07.04 - EO0
MAN Diesel
Plate
51322-08 Pressure Reduction Valve Page 2 (2)
L16/24
L21/31
Item Item
387 1/E Pressure reduction Reduktionsventil

valve
399 1/E Pressure gauge Manometer
409 1/E Pipe section Rørstykke
410 1/E Strainer Filter
422 1/E Adj. straight male Justerbar lige

coupling samling
434 1/E Straightway valves, Ligeløbsventil, komplet

complete
458 1/E Safety valve Sikkerhedsventil
471 1/E Protective device Beskyttelsesanordning
483 2/E Packing ring Pakning
505 8/E Nut Møtrik
517 1/E Pressure reduction Reduktionsventil,

valve, complete komplet
530 1/E Repair kit for reduction Reparationssæt til

valve reduktionsventil
08028-0D/H5250/94.08.12
07.04 - EO0
MAN Diesel
Plate
Page 1 (2) Pressure Reduction Valve 51322-09
L16/24
L21/31
483
495 458
517 505 409 387 471
410 422 530 399 446
434
08028-0D/H5250/94.08.12
07.04 - EO0
MAN Diesel
Plate
51322-09 Pressure Reduction Valve Page 2 (2)
L16/24
L21/31
Item Item
387 1/E Pressure reduction Reduktionsventil

valve
399 1/E Pressure gauge Manometer
410 1/E Strainer Filter
422 1/E Adj. straight male Justerbar lige

coupling samling
434 1/E Straightway valves, Ligeløbsventil, komplet

complete
471 1/E Protective device Beskyttelsesanordning
483 1/E Packing ring Pakning
505 4/E Nut Møtrik
517 1/E Pressure reduction Reduktionsventil,

valve, complete komplet
530 1/E Repair kit for reduction Reparationssæt til

valve reduktionsventil
08028-0D/H5250/94.08.12
07.04 - EO0
MAN Diesel
Plate
Page 1 (2) Turning Gear with Attachment 51325-02H
L16/24
08028-0D/H5250/94.08.12

99.03 - ES0
MAN Diesel
Plate
51325-02H Turning Gear with Attachment Page 2 (2)
L16/24
Item Item
023 1/E Shaft Aksel
035 1/E Pressure spring Trykfjeder
047 2/E Screw Skrue
059 2/E Screw Skrue
060 1/E Position swich Position switch
084 1/E Spur gear Cylindrisk tandhjul
096 1/E Shaft, complete incl. Aksel, komplet inkl. item

item 023, 035, 072, 023, 035, 072, 084
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Plate
Page 1 (2) Overspeed Stop Valve 51327-02
General
08028-0D/H5250/94.08.12
04.50 - ES0
MAN Diesel
Plate
51327-02 Overspeed Stop Valve Page 2 (2)
General
Item Item
012 1/E Solenoid valve, Magnetventil,

complete komplet
024 1/E Coil Spole
08028-0D/H5250/94.08.12
04.50 - ES0
MAN Diesel
Plate
Page 1 (2) Arrangement of Jet System 51330-02H
L16/24

08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Plate
51330-02H Arrangement of Jet System Page 2 (2)
L16/24
Item Item
019 1/E Pipe Rør
032 1/E Pipe Rør
044 1/E Pipe Rør

coupling
140 1/E Solenoid valve 2/2, Magnetventil 2/2,

complete komplet
164 1/E Coil Spole
176 1/E Housing Hus
188 2/E Screw Screw
08028-0D/H5250/94.08.12
99.03 - 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 Påfyldningsventil
077 1/E Air relief valve Afluftningsventil
089 1/E Auxiliary valve Hjælpeventil
090 1/E Drain valve Drænventil
08028-0D/H5250/94.08.12
99.15 - EO0
Fuel oil system
514/614
MAN Diesel
Description 514.01
Page 1 (2) Internal Fuel Oil System Edition 02H
L16/24
Fig 1 Diagram for fuel oil system
Fuel Oil System The fuel injection valve is located in a valve sleeve
in the centre of the cylinder head. The opening of
The built-on fuel oil system consists of inlet pipes for the valve is controlled by the fuel oil pressure, and
fuel oil, mechanical fuel pump units, high-pressure the valve is closed by a spring.
pipes as well as return pipes for fuel oil.
The high pressure pipe which is led through a bore
Waste oil and fuel oil leakages are led to a leakage in the cylinder head is surrounded by a shielding
alarm which is heated by means of the inlet fuel tube.
oil.
The shielding tube also acts as a drain channel in
order to ensure any leakage from the fuel valve and
Fuel Injection System the high pressure pipe will be drained off.
The engine is provided with one fuel injection pump The complete injection equipment including injec-
08028-0D/H5250/94.08.12
unit, an injection valve, and a high pressure pipe for tion pumps and high pressure pipes is well enclosed
each cylinder. behind removable covers.
The injection pump unit is mounted on the engine

frame. The pump unit consists of a pump housing
embracing a roller guide, a centrally placed pump
barrel and a plunger. The pump is activated by the
fuel cam, and the volume injected is controlled by
turning the plunger.
98.41 - ES0
MAN Diesel
514.01 Description
Edition 02H
Internal Fuel Oil System Page 2 (2)
L16/24
Running-in Filter
The running-in filter has a fineness of 50 mm and is

placed in the fuel inlet line as an integrated part of
the fuel oil leaking alarm box. Its function is to remove
impurities in the fuel pipe between safety filter and
the engine in the running-in period.
Note: The filter must be removed before ship delivery

or before handling over to the customer.
It is adviced to install the filter every time the ex-

tern fuel pipe system has been dismantled, but it
is important to remove the filter again when the
extern fuel oil system is considered to be clean for
any impurities.
08028-0D/H5250/94.08.12
98.41 - ES0
MAN Diesel
Working Card Dismounting/Mounting of 514-01.05
Fuel Injection Pump (L'Orange)
L16/24

Shut-off fuel oil
Dismounting/mounting of fuel injection pump. Open-end spanner, 36 mm

Unbraco top and ratchet, 10 mm
Plier for lock ring, outer
Unbraco top, 8 mm
Torque wrench
Tools for cleaning.
Starting position Clean kerosene or gas oil.
Antiseizure product.
Cover for fuel injection pump has been (Copaslip, Molykote GN Plus or similar)
dismounted.
Related procedure

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

01.08 - ES0
MAN Diesel
514-01.05 Dismounting/Mounting of Working Card
L16/24
Dismounting of Fuel Injection Pump
Dismounting of fuel injection pipe.
1) Unscrew the sleeve piece (1).
2) Remove the high pressure pipe.
Fig 1 Dismounting of fuel injection pipe.
Dismounting of Fuel and Drain Pipes
4) The lock ring (1), see fig 2 must be shifted into

the groove in the center of the pipe. Fig 2 Dismounting of fuel and drain pipes.
5) Push the fuel and drain pipes into the adjacent

pump until the injection pump is free, see fig
2. pointer.The pointer position for the adjustment value,
the "adjustment point", is a 18 mm and can be read
from the scale on the control rack.
Removal of Fuel Injection Pump
8) Attach the injection pump to the engine frame,
6) Separate the spring loaded lever from the tighten the 5 screws with a torque, according
regulating rod on the fuel injection pump. to description 500.40.
7) Remove the screws in the bottom flange and 9) Reconnect the regulating rod to the spring
take the fuel injection pump away. loaded lever.
08028-0D/H5250/94.08.12
Mounting of Fuel Injection Pump Assembly of the Pressure Pipe
New pumps: Remove preserving agents. 10) Renew O-ring (pos 2, fig. 4), and coat the high-
pressure connecting threds at the pump and
The injection pumps are adjusted by the manufacturer at the pressure piece including the O-rings.
to a uniform delivery quantity of 75% by means of a
01.08 - ES0
MAN Diesel
L16/24
11) Screw the pressure pipe manually to the pres- Mounting of Fuel and Drain Pipes
sure piece.
15) Check the fuel and leakage pipes, they must
12) The correct positioning of the sealing cone not have any sharp bores on the outer circum-
from the pressure pipe has to be checked. The ference, the inner circumference must be free
sealing cone must be completely ummersed of any residuals.
into the pressure nozzle of the injection pump
(approx. 3.6 mm). The sleeve nut has to be 16) Rub the O-rings in the injection pump with
screwed manually to the pressure socket of paste for lip-type packing.
the injection pump.
17) Mount the pipes opposite order of dismantling
13) Tighten the sleeve nut at the pressure piece point 4-5.
with 65 + 5 Nm.
14) Tighten the sleeve nut at the connecting socket

of the pump with 65 + 5 Nm.
08028-0D/H5250/94.08.12
01.08 - ES0
MAN Diesel
Page 1 (3)
Fuel Injection Pump (Woodward) Edition 07H
L16/24

Shut-off fuel oil
Dismounting/mounting of fuel injection pump. Open-end spanner, 36 mm

Unbraco top and ratchet, 10 mm
Plier for lock ring, outer
Unbraco top, 8 mm
Torque wrench
Tools for cleaning.
Starting position Clean kerosene or gas oil.
Cover for fuel injection pump has been (Copaslip, Molykote GN Plus or similar)
dismounted.
Related procedure

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

01.05 - ES0
MAN Diesel
514-01.05 Dismounting/Mounting of Working Card
Fuel Injection Pump (Woodward)
L16/24
Dismounting of Fuel Injection Pump
Dismounting of fuel injection pipe.
1) Unscrew the sleeve piece (1).
2) Remove the high pressure pipe.
Fig 1 Dismounting of fuel injection pipe.
Dismounting of Fuel and Drain Pipes
4) The lock ring (1), see fig 2 must be shifted into

the groove in the center of the pipe. Fig 2 Dismounting of fuel and drain pipes.
5) Push the fuel and drain pipes into the adjacent

pump until the injection pump is free, see fig
2.
8) Attach the injection pump to the engine frame,
tighten the 5 screws with a torque, according
Removal of Fuel Injection Pump to description 500.40.
6) Separate the spring loaded lever from the 9) Reconnect the regulating rod to the spring
regulating rod on the fuel injection pump. loaded lever.
7) Remove the screws in the bottom flange and

take the fuel injection pump away. Assembly of the Pressure Pipe
08028-0D/H5250/94.08.12
10) Renew O-ring (pos 2, fig. 4), and coat the high-
Mounting of Fuel Injection Pump pressure connecting threds at the pump and
at the pressure piece including the O-rings.
New pumps: Remove preserving agents.
11) Screw the pressure pipe manually to the pres-
The injection pumps are adjusted by the manufacturer sure piece.
to a uniform delivery quantity of 75% by means of a
pointer.The pointer position for the adjustment value,
the "adjustment point", is a 18 mm and can be read
from the scale on the control rack.
01.05 - ES0
MAN Diesel
L16/24
12) The correct positioning of the sealing cone Mounting of Fuel and Drain Pipes
from the pressure pipe has to be checked. The
sealing cone must be completely ummersed 15) Check the fuel and leakage pipes, they must
into the pressure nozzle of the injection pump not have any sharp bores on the outer circum-
(approx. 3.6 mm). The sleeve nut has to be ference, the inner circumference must be free
screwed manually to the pressure socket of of any residuals.
the injection pump.
16) Rub the O-rings in the injection pump with
13) Tighten the sleeve nut at the pressure piece paste for lip-type packing.
with 65 + 5 Nm.
17) Mount the pipes opposite order of dismantling
14) Tighten the sleeve nut at the connecting socket point 4-5.
08028-0D/H5250/94.08.12
01.05 - ES0
MAN Diesel
Working Card Disassembly/assembly and Repair of 514-01.06
L16/24

Disassembly/assembly and repair of fuel injection Adjustable spanner 12"

pump Unbraco top and ratchet 5, 8 mm
Torque wrench
Aluminium arbor
Tools for cleaning.
Clean kerosene or gas oil.
Starting position (Copaslip, Molykote GN Plus or similar)
Dismounting of fuel injection pump 514-01.05
Related procedure
Mounting of fuel injection pump 514-01.05

Capacity : 1 man
08028-0D/H5250/94.08.12
51402 033 2/valve

51402 104 1/valve
Data

01.05 - ES0
MAN Diesel
514-01.06 Disassembly/assembly and Repair of Working Card
L16/24
If damages occur at the injection pump during the
warranty period the service of the manufacturer or
of a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.
Note! It must be cared during the disassembly of the

injection pump that the workplace is free of chips
and contaminations. It is recommended to clean
all parts with diesel fuel oil, and to place them on a
non-fuzzing cloth.
The complete injection pump must not be placed on

hard or metallic surfaces by the roller. Do not use the
extractable control rack as a handle!
The Following Guidelines shall be

Considered
⇒ Do not mix up parts of the pump element and

of the constant-pressure release valve.
⇒ High-pressure surfaces must be protected

against damage, and cleaned with clean Diesel
fuel and a non-fuzzing cloth or paper when they
are installed again.
⇒ O-rings on demounted parts shall generally

be replaced by new O-rings before parts are
installed again.
⇒ Only original 0-rings of the manufacturer shall

be used. Apply paste for lip-type sealings to
the 0-rings before installation.
⇒ Cylindrical screws must be coated by graphite

paste on the bearing surface and on the thread;
tighten them crosswise and step by step (in
three steps of equal torque) to the required
tightening torque.
⇒ The cylindrical screws shall be loosened cross-

Fig. 1 Fuel injection pump.
wise and step by step (in three steps of equal
08028-0D/H5250/94.08.12
torque), too.
Caution! The holding screw (24), see fig 1 and the Exchange of Pressure Valve
cylindrical screw (12) are provided with a TufLok
bolt protection. The bolts can be re-used. If there is 1) Loosen the cylindrical screws (25), see fig 1.
no TufLok (blue medium in the thread) in the thread
any more a new screw must be used. 2) Remove the delivery socket (1), the stroke lim-
iter (17) and the pressure valve spring (15).
01.05 - ES0
MAN Diesel
L16/24
3) Exchange the pressure valve (The pressure 7) Screw off the sliding block (10).
valve can be exchanged as a component group
only). 8) Loosen the springforce and demount the instal-
lation device.
4) Assembly in reciprocal order.
Tightening torque 45 Nm. 9) Take off the roller (22) and the roller pin (23).
Caution! Installation of the pressure-valve housing 10) Loosen the 2 nbs. cylindrical screws (12)
(16) with an aluminum arbor and a non-fuzzing cloth M5x14, and take off the roller tappet (13).
to protect the high-pressure surface.
11) Pull out the thrust piece (11) with the plunger
(18), afterwards the pump spring (9), the spring
Disassembly of the Pump Element plate (8), and control sleeve (19).
5) Loosen the 4 nbs. holding screws (24) M6x35, 12) Turn the injection pump vertically by 180 de-
see fig 1. grees.
6) Press in the roller tappet (14) by means of the 13) Further disassembly as under "Exchange of
installation device, see fig 2. pressure valve".
14) Screw off the blocking screw (2).
15) Carefully press out the barrel (7) with an alu-

minum arbor.
Installation
16) Pump elements can be exchanged as compo-

nent groups only. (plunger and barrel).
17) Insert the barrel (7), see fig 1 carefully into the
injection-pump casing (4) with an aluminum
arbor and a non-fuzzing cloth to protect the
high-pressure surface, and screw in the block-
ing screw (2).Tightening torque 5 Nm.
18) Further assembly see under "Exchange of

pressure valve".
19) Turn the injection pump vertically by 180 de-

grees.
08028-0D/H5250/94.08.12
20) Install the control sleeve (19) - care for the mark-
ing! - control sleeve (19) milled tooth, control
rack (3) groove around circumference.
21) The further assembly is carried in reciprocal

order of disassembly (driving pin of the plunger
Fig 2 Dismounting of roller tappet. in the direction of the slot of the control sleeve).
Tightening torque: (24) 10 Nm + tuflok, (10) 20
Nm, (12) tuflok.
01.05 - ES0
MAN Diesel
L16/24
22) Marking on the driving pin, installed towards Caution! Secure the countersunk screws (20) by
the boring of the control rack. Loctite 601 - tightening torque 4 Nm
If a pump element is exchanged it is recommended

to check the pre-stroke. Proceed as follows: Pump-element Sticking
The injection pump is assembled without pump spring In case a pump-element sticking has occurred, utilize
(9) and cavitation screws (6). the service of the manufacturer or of a contracted
workshop. If this is not possible the following proce-
The plunger (18) is fixed in the control boring by the dure is recommended:
measuring pin, see fig 3.
23) Loosen the holding screws (24) M6x35, see
The span between the measuring sleeve and the fig 1.
roller is measured by a depth micrometer.
24) Remove the roller (22) with the roller pin
The difference to the required dimension of 10 ± 0.05 (23).
mm has to be newly adjusted by the thrust piece
(21), if necessary. 25) Attach the installation device, see fig 2 and
locate it in such a way that it acts as a secur-
If the pre-stroke is not correct, the max firing pressure ing element of the roller tappet which is under
of the mentioned cylinder will be wrong. pre-tension by the spring.
If the pre-stroke is correct then reassembly the pump 26) Remove the sliding block (10)
with spring (9) and cavitation screws (6) and tighten
with correct torque acc. to description 500.40. 27) Turn the injection pump vertically by 180 de-
grees.
28) further as under "Exchange of pressure

valve".
29) Hit down the plunger (18) by an aluminum

arbor and a hammer, in interaction with the
installation device, until the spring pre-tension
has been overcome.
30) Demount the installation device.
31) Proceed as described under "Disassembly of

the pump-element"
32) Installation and check-up of the pre-stroke see

under "Installation".
08028-0D/H5250/94.08.12
Preservation
The main functional components of each injection

pump supplied by the manufacturer has been pre-
served during its check-up in the test stand.
Fig 3 Check of pre-stroke.
01.05 - ES0
MAN Diesel
L16/24
P3 gero cut S 102 having a viscosity of 3.5 mm2/sec The suction chamber of the injection pump is filled
at 20°C according to DIN 53015 is used as preser- with preserving agent through the fuel discharge
ving agent. boring, and closed.
All external surfaces are primed. By moving the plunger, the hollows are filled with
preserving agent.
The processed external surfaces are coated with
anti-rust grease or preserved with preserving oil All external surfaces coated with anti-rust agent must
Castrol Rustilo DWX31 having a specific gravity of be preserved once more.
820 kg/m3 at 15°C according to DIN 51757.
The control rack has to be moved in regular inter-
This preservation is effective for 2 years. vals of approx. 3 months to avoid a sticking of the
plunger.
Re-preservation
If the injection pump has not been put into operation

within 2 years after its delivery a re-preservation
has to be carried out. For that purpose, a protective
cap must be removed from the fuel discharge (upper
connection) at the injection pump.
08028-0D/H5250/94.08.12
01.05 - ES0
MAN Diesel
L16/24

Disassembly/assembly and repair of fuel injection Adjustable spanner 12"

pump Unbraco top and ratchet 5, 8, 10 mm
Plier for lockring, inner
Torque wrench
Aluminium arbor
Tools for cleaning.
Starting position Antiseizure product.
(Copaslip, Molykote GN Plus or similar)
Dismounting of fuel injection pump 514-01.05
Related procedure
Mounting of fuel injection pump 514-01.05

Capacity : 1 man
08028-0D/H5250/94.08.12
51402 033 2/valve

51402 104 1/valve
Data

01.05 - ES0
MAN Diesel
L16/24
If damages occur at the injection pump during the
warranty period the service of the manufacturer or
of a contracted workshop shall be utilized, otherwise
you lose your rights under the guarantee.
Note! It must be cared during the disassembly of the

16
injection pump that the workplace is free of chips
5 15
and contaminations. It is recommended to clean
all parts with diesel fuel oil, and to place them on a 6 17
non-fuzzing cloth. 7 18
20
8
The complete injection pump must not be placed on 21
9
hard or metallic surfaces by the roller. Do not use the 19
extractable control rack as a handle!
10
The Following Guidelines shall be
11
Considered
12 22
⇒ Do not mix up parts of the pump element and 13
of the constant-pressure release valve. 14
⇒ High-pressure surfaces must be protected

against damage, and cleaned with clean Diesel 1 Connection socket 7 Barrel
2 Cylindrical screw 8 Spring plate
fuel and a non-fuzzing cloth or paper when they 3 Regulating rod 9 Pump spring
are installed again. 4 Pump casing 10 Guiding screw
5 Sealing ring 11 Thrust piece
⇒ O-rings on demounted parts shall generally 6 Cavitation screw 12 Shim
13 Tappet insert
be replaced by new O-rings before parts are 14 Roller tappet
installed again. 15 Pressure valve spring
2
16 Valve spring
⇒ Only original 0-rings of the manufacturer shall 1
17 Plunger (1.5-20 cSt)
18 Plunger (< 1.5 cSt)
be used. Apply paste for lip-type sealings to 19 Regulating sleeve
the 0-rings before installation. 23 20 Lockring
21 Guide pin
⇒ Cylindrical screws must be coated by graphite 3 22 Roller
23 Plug screw
paste on the bearing surface and on the thread;
tighten them crosswise and step by step (in
4
three steps of equal torque) to the required
tightening torque.
⇒ The cylindrical screws shall be loosened cross-

Fig 1 Fuel injection pump.
wise and step by step (in three steps of equal
08028-0D/H5250/94.08.12
torque), too.
2) Screw off the sliding block (10).

Disassembly of Fuel Pump
3) Loosen the spring force and demount the
1) Press in the roller tappet (14) by means of the installation device.
installation device, see fig 2.
01.05 - ES0
MAN Diesel
L16/24
4) Take out the tappet insert (13), roller tappet Installation
(14), roller (22), thrust piece (11), pump spring
(9) and plunger (17/18). 8) Pump elements can be exchanged as compo-
nent groups only. (plunger and barrel).
Caution! Be sure not to damage the plunger.
9) Insert the barrel (7), see fig. 1 carefully into the
5) If necessary remove the lockring (20), guide injection-pump casing (4) with an aluminum
pin (21) and take out the regulating rod (3) as arbor and a non-fuzzing cloth to protect the
well as the plug screw (23) in the opposite end high-pressure surface.
of the regulating rod (3).
10) Mount the connection socket tighten the 4
6) Loosen the 4 cylindrical screws (2) and remove cylindrical screws. Tighten torque 40 Nm.
the connection socket (1) and barrel (7). Pres-
sure valve is included in connection socket (1) 11) Turn the injection pump vertically by 180 de-
and can be exchanged as a component group grees.
only.
12) Install the control sleeve (19) - care for the
7) Carefully press out the barrel (7) with an alu- marking!
minum arbor.
13) The further assembly is carried in reciprocal
order of disassembly (driving pin of the plunger
in the direction of the slot of the control sleeve).
Guiding screw has to be mounted with loctite
0577.
14) Marking on the driving pin, installed towards

the boring of the control rack.
08028-0D/H5250/94.08.12
Fig 2 Dismounting of roller tappet.
01.05 - ES0
MAN Diesel
L16/24
If a pump element is exchanged it is recommended Preservation
to check the pre-stroke. Proceed as follows:
The main functional components of each injection
The injection pump is assembled without pump spring pump supplied by the manufacturer has been pre-
(9) and cavitation screws (6). served during its check-up in the test stand.
The plunger (18) is fixed in the control boring by the P3 gero cut S 102 having a viscosity of 3.5 mm2/sec
measuring pin, see fig. 3. at 20°C according to DIN 53015 is used as preser-
ving agent.
The span between the measuring sleeve and the
roller is measured by a depth micrometer. All external surfaces are primed.
The difference to the required dimension of 10 ± 0.05 The processed external surfaces are coated with
mm has to be newly adjusted by the thrust piece anti-rust grease or preserved with preserving oil
(21), if necessary. Castrol Rustilo DWX31 having a specific gravity of
820 kg/m3 at 15°C according to DIN 51757.
If the prestroke is not correct, the max firing pressure
of the mentioned cylinder will be wrong. This preservation is effective for 2 years.
If the pre-stroke is correct then reassembly the pump

with spring (9) and cavitation screws (6) and tighten Re-preservation
with correct torque acc. to description 500.40.
If the injection pump has not been put into operation
Caution! Secure the guiding screws (10) by Loctite within 2 years after its delivery a re-preservation
0577. has to be carried out. For that purpose, a protective
cap must be removed from the fuel discharge (upper
connection) at the injection pump.
The suction chamber of the injection pump is filled

with preserving agent through the fuel discharge
boring, and closed.
By moving the plunger, the hollows are filled with

preserving agent.
All external surfaces coated with anti-rust agent must

be preserved once more.
The control rack has to be moved in regular inter-

vals of approx. 3 months to avoid a sticking of the
plunger.
08028-0D/H5250/94.08.12
Fig 3 Check of pre-stroke.
01.05 - ES0
MAN Diesel
Page 1 (5) Fuel Injection Valve (L'Orange) Edition 08H
L16/24

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
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
(Copaslip, Molykote GN Plus or similar).
Related procedure
Manpower
Working time : 2 hours
Capacity : 1 man Plate no Item no Qty/
08028-0D/H5250/94.08.12
51402 116 3/valve

Data

01.44 - ES0
MAN Diesel
Edition 08H Fuel Injection Valve (L'Orange) Page 2 (5)
L16/24
The fuel injection valve is the single component that 6) Loosen the nozzle nut (5). If it is jammed, then
has the greatest influence on the diesel engine condi- heat the nozzle nut up in hot oil.
tion. Various forms of operation and quality of fuel oil
affect the overhaul intervals. In some cases it may be 7) Remove the injector nozzle (6). Be careful that
necessary to shorten the prescribed intervals. the the injector needle does not fall out.
Dismounting and Cleaning Attention
1) Dismount the fuel injection valve from the Do not damage the lapped surface.
cylinder head by means of the special tool as
shown in fig 1. 8) Dismount all other components.
2) Mount the fuel injection valve on the pressure 9) All parts must be cleaned with kerosene or gas
testing pump. oil and a hard brush (not a steel brush).
Note: Utmost cleanliness and care are required dur- 10) Clean the nozzle holes of charred coke by
ing the disassembly of fuel injection valve. means of the supplied special drill please see
plate 52014 with holder.
3) Loosen the nut, see fig 2, pos 2.
11) Clean carefully the injector body by placing
4) Then release the pressure spring (3). these in a cleaning liquid and then blow through
the parts with dry air.
5) Clean the lower part of the nozzle from carbon-
ized oil disposits.
08028-0D/H5250/94.08.12
Fig 1 Tool for dismounting of fuel injection valve. Fig 2 Fuel injection valve.
01.44 - ES0
MAN Diesel
L16/24
Inspection of the Parts c. Renew the O-rings (pos 4, fig 2).
12) Nozzles are matched by lapping and are there- d. Tighten torque for lock nut (2): 100 Nm.
fore only interchangeable as units.
13) The injector needle, which has been previ- Pressure Testing of Fuel Injection Valve
ously cleaned, wetted by test oil P3 gero cut
S 102 or diesel fuel and inserted into nozzle 19) The most effective checking of the fuel injection
body, is pulled out to approx. one third of its valves is obtained through pressure testing,
sliding surface. At an almost vertical position, preferably carried out after each overhaul and
the injector needle must quickly slide onto the also in case of irregularities in operation. The
tight seat by its deadweight. This check-up has pressure testing is carried out in the following
to be carried out for three almost uniformly way by means of the pressure testing apparatus
distributed turning position of the needle. supplied.
14) If the holes are oval worn, which is checked by 20) Mount the fuel injection valve in the test tool
means of a magnifying glass, the nozzle must again. The bracket to be in such a position
be scrapped. that the nozzle of the injector is pointing down-
wards.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the 21) To flush off possibly existing dirt particles in the
nozzle which, in general, only can be made fuel system of the injection valve, it is recom-
at the manufacturer's works on a special test mended to pump through fuel several times,
stand. while the released pressure spring (3) of the
nozzle holder is increase pressure by means
16) Every effort to refurbish will result in alterations of the lever on the test pump, and adjust the
of these values and malfunction of the noz- opening pressure to 450 bar, by the adjusting
zle. If heavy abrasion symptoms, respectively screw (1), see fig. 2, then tighten lock nut (2)
damages are observed at the visual inspec- and check opening pressure again.
tion of the parts, the parts in question must be
replaced. 22) The fuel injection valve shall properly spray
at a pumping frequency of approx. 1 to 2
strokes/second, do not expect chattering. The
Reassembling fuel (MDO) must be atomized by uniform jets.
After the jets are cut off, no fuel (MDO) drop
17) When all parts have been overhauled, found shall fall down from the bottom of the spraying
in good order and carefully cleaned, assemble ball during 10 seconds when the injector nozzle
the fuel injection valve again. is vertically placed. Do not expect a nozzle tip
with more than 1000 running hours to perform
18) When assembling the fuel injection valve, like a new nozzle in the test pump.
proceed in the opposite order compared to the
disassembly. Pay attention to the following: 23) All connecting and attached points of the fuel
injection valve must not leak during this check-
08028-0D/H5250/94.08.12
a. Lubricate the threads on the adjusting screw, up.

fig. 2, pos. 1, with lub. oil, and the threads of the
nozzle holder for the nozzle nut. The shoulder If the test conditions are not fulfilled it is necessary
of the nozzle which is in contact with the noz- to demount the fuel injection valve to determine the
zle nut, must be lubricated with an antiseizure causes. For that purpose, check the slidability of the
product. injector needle and that the injection nozzle is not
jammed in the nozzle holder.
b. The sealing plane surface of body and nozzle
must be wiped dry with paper.
01.44 - ES0
MAN Diesel
514-01.10 Fuel Injection Valve (L'Orange) Working Card

L16/24
No Jamming Assembly of the Injection Valve
If the injector nozzle is deformed by the tightening of 25) Coat the O-rings at the injection valve with
the nozzle nut (5), the injector needle will be jammed graphite paste.
in the nozzle body. Then fuel will be leaving the spray
holes as not or only partially atomized straight jet only. 26) The injection valve has to be inserted into the
Tightening torque for nozzle nut (5) 120 Nm. cylinder head. Care for the alignment of the
high-pressure cone connection.The alignment
of the injection valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
Assembly of the Pressure Piece
27) Pull off the immosion-melting coating from the

pressure piece. Blow the fuel borehole clean
by air to remove dirt. Renew and coat the O-
ring (pos 1, fig 4) for the sealing in the cylinder
head with graphite paste.
28) Carefully insert the pressure piece together

with spring lock washers into the cylinder
head. Press the pressure piece thoroughly by
hand down to the sealed seat of the injection
valve.
29) The nut including the guiding gasket has to be

screwed on the stud bolt. The pressure piece
must be turned clockwise up to the stop of the
spring lock washer. Tighten the nut with 28 Nm.
Care that the wrench is not pressed against the
Fig 3 Grinding tool for seat and liner for fuel injection valve. pressure piece. The tightening torque is then
to small in this case and leakages will be the
consequence.
Conditions of Labour Safety
The fuel jets must not be touched under any cir-

cumstances as they hit through the skin tissue, and
cause blood poisoning. Urgently comply with the
regulations on fire prevention when handling inflam-
mable liquids.
08028-0D/H5250/94.08.12
Mounting of the Fuel Injection Valve in Cyl-

inder Head
24) Before mounting the fuel valve, clean and

inspect the valve sleeve in the cylinder head.
If necessary, grind the seating face with the Fig 4 Fuel injection pipe.
grinding tool, see fig 3.
01.44 - ES0
MAN Diesel

L16/24
30) When the pressure piece has been tightened, 32) Screw the pressure pipe manually to the pres-
the fixing flange for the injection valve must be sure piece.
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve 33) The correct positioning of the sealing cone
is pressed to the sealed seat by an alternate from the pressure pipe has to be checked at
tightening of the nuts. The nuts shall be tight- the pump.The sealing cone must be completely
ened with 9 Nm and with use of antiseizure ummersed into the pressure nozzle of the in-
products. jection pump (approx. 3.6 mm). The sleeve nut
has to be screwed manually to the pressure
socket of the injection pump.
Assembly of the Pressure Pipe
34) Tighten the sleeve nut at the pressure piece
31) Renew O-ring (pos 2, fig. 4), and coat the high- with 65 + 5 Nm.
at the pressure piece including the O-rings. 35) Tighten the sleeve nut at the connecting socket
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
Page 1 (5) Fuel Injection Valve (Woodward) Edition 09H
L16/24

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
Fuel injection pipe dismounted 514-01.05 Socket spanner 24 mm
Socket spanner 30 mm
Tools for cleaning.
(Copaslip, Molykote GN Plus or similar).
Related procedure
Manpower
Capacity : 1 man Plate no Item no Qty/
08028-0D/H5250/94.08.12
51402 116 3/valve

Data

01.44 - ES0
MAN Diesel
Edition 09H Fuel Injection Valve (Woodward) Page 2 (5)
L16/24
The fuel injection valve is the single component that 6) Loosen the nozzle nut (5). If it is jammed, then
has the greatest influence on the diesel engine condi- heat the nozzle nut up in hot oil.
tion. Various forms of operation and quality of fuel oil
affect the overhaul intervals. In some cases it may be 7) Remove the injector nozzle (6). Be careful that
necessary to shorten the prescribed intervals. the the injector needle does not fall out.
Dismounting and Cleaning Attention
1) Dismount the fuel injection valve from the Do not damage the lapped surface.
cylinder head by means of the special tool as
shown in fig 1. 8) Dismount all other components.
2) Mount the fuel injection valve on the pressure 9) All parts must be cleaned with kerosene or gas
testing pump. oil and a hard brush (not a steel brush).
Note: Utmost cleanliness and care are required dur- 10) Clean the nozzle holes of charred coke by
ing the disassembly of fuel injection valve. means of the supplied special drill please see
plate 52014 with holder.
3) Loosen the nut, see fig 2, pos 2.
11) Clean carefully the injector body by placing
4) Then release the pressure spring (3). these in a cleaning liquid and then blow through
the parts with dry air.
5) Clean the lower part of the nozzle from carbon-
ized oil disposits.
08028-0D/H5250/94.08.12
Fig 1 Tool for dismounting of fuel injection valve. Fig 2 Fuel injection valve.
01.44 - ES0
MAN Diesel
L16/24
Inspection of the Parts c. Renew the O-rings (pos 4, fig 2).
12) Nozzles are matched by lapping and are there- d. Tighten torque for lock nut (2): 50 Nm.
fore only interchangeable as units.
13) The injector needle, which has been previ- Pressure Testing of Fuel Injection Valve
ously cleaned, wetted by test oil P3 gero cut
S 102 or diesel fuel and inserted into nozzle 19) The most effective checking of the fuel injection
body, is pulled out to approx. one third of its valves is obtained through pressure testing,
sliding surface. At an almost vertical position, preferably carried out after each overhaul and
the injector needle must quickly slide onto the also in case of irregularities in operation. The
tight seat by its deadweight. This check-up has pressure testing is carried out in the following
to be carried out for three almost uniformly way by means of the pressure testing apparatus
distributed turning position of the needle. supplied.
14) If the holes are oval worn, which is checked by 20) Mount the fuel injection valve in the test tool
means of a magnifying glass, the nozzle must again. The bracket to be in such a position
be scrapped. that the nozzle of the injector is pointing down-
wards.
15) The best way, however, to check if the holes
are worn out is to control the flow rate of the 21) To flush off possibly existing dirt particles in the
nozzle which, in general, only can be made fuel system of the injection valve, it is recom-
at the manufacturer's works on a special test mended to pump through fuel several times,
stand. while the released pressure spring (3) of the
nozzle holder is increase pressure by means
16) Every effort to refurbish will result in alterations of the lever on the test pump, and adjust the
of these values and malfunction of the noz- opening pressure to 450 bar, by the adjusting
zle. If heavy abrasion symptoms, respectively screw (1), see fig. 2, then tighten lock nut (2)
damages are observed at the visual inspec- and check opening pressure again.
tion of the parts, the parts in question must be
replaced. 22) The fuel injection valve shall properly spray
at a pumping frequency of approx. 1 to 2
strokes/second, do not expect chattering. The
Reassembling fuel (MDO) must be atomized by uniform jets.
After the jets are cut off, no fuel (MDO) drop
17) When all parts have been overhauled, found shall fall down from the bottom of the spraying
in good order and carefully cleaned, assemble ball during 10 seconds when the injector nozzle
the fuel injection valve again. is vertically placed. Do not expect a nozzle tip
with more than 1000 running hours to perform
18) When assembling the fuel injection valve, like a new nozzle in the test pump.
proceed in the opposite order compared to the
disassembly. Pay attention to the following: 23) All connecting and attached points of the fuel
injection valve must not leak during this check-
08028-0D/H5250/94.08.12
a. Lubricate the threads on the adjusting screw, up.

fig. 2, pos. 1, with lub. oil, and the threads of the
nozzle holder for the nozzle nut. The shoulder If the test conditions are not fulfilled it is necessary
of the nozzle which is in contact with the noz- to demount the fuel injection valve to determine the
zle nut, must be lubricated with an antiseizure causes. For that purpose, check the slidability of the
product. injector needle and that the injection nozzle is not
jammed in the nozzle holder.
b. The sealing plane surface of body and nozzle
must be wiped dry with paper.
01.44 - ES0
MAN Diesel
514-01.10 Fuel Injection Valve (Woodward) Working Card

L16/24
No Jamming Assembly of the Injection Valve
If the injector nozzle is deformed by the tightening of 25) Coat the O-rings at the injection valve with
the nozzle nut (5), the injector needle will be jammed graphite paste.
in the nozzle body. Then fuel will be leaving the spray
holes as not or only partially atomized straight jet only. 26) The injection valve has to be inserted into the
Tightening torque for nozzle nut (5) 200 Nm. cylinder head. Care for the alignment of the
high-pressure cone connection.The alignment
of the injection valve is ensured by tightening
the pressure piece before tightening the injec-
tion valve.
Assembly of the Pressure Piece
27) Pull off the immosion-melting coating from the

pressure piece. Blow the fuel borehole clean
by air to remove dirt. Renew and coat the O-
ring (pos 1, fig 4) for the sealing in the cylinder
head with graphite paste.
28) Carefully insert the pressure piece together

with spring lock washers into the cylinder
head. Press the pressure piece thoroughly by
hand down to the sealed seat of the injection
valve.
29) The nut including the guiding gasket has to be

screwed on the stud bolt. The pressure piece
must be turned clockwise up to the stop of the
spring lock washer. Tighten the nut with 28 Nm.
Care that the wrench is not pressed against the
Fig 3 Grinding tool for seat and liner for fuel injection valve. pressure piece. The tightening torque is then
to small in this case and leakages will be the
consequence.
Conditions of Labour Safety
The fuel jets must not be touched under any cir-

cumstances as they hit through the skin tissue, and
cause blood poisoning. Urgently comply with the
regulations on fire prevention when handling inflam-
mable liquids.
08028-0D/H5250/94.08.12
Mounting of the Fuel Injection Valve in Cyl-

inder Head
24) Before mounting the fuel valve, clean and

inspect the valve sleeve in the cylinder head.
Fig 4 Fuel injection pipe.
If necessary, grind the seating face with the
grinding tool, see fig 3.
01.44 - ES0
MAN Diesel

L16/24
30) When the pressure piece has been tightened, 32) Screw the pressure pipe manually to the pres-
the fixing flange for the injection valve must be sure piece.
plugged on. The washers and nuts have to be
attached or screwed on. The injection valve 33) The correct positioning of the sealing cone
is pressed to the sealed seat by an alternate from the pressure pipe has to be checked at
tightening of the nuts. The nuts shall be tight- the pump.The sealing cone must be completely
ened with 9 Nm and with use of antiseizure ummersed into the pressure nozzle of the in-
products. jection pump (approx. 3.6 mm). The sleeve nut
has to be screwed manually to the pressure
socket of the injection pump.
Assembly of the Pressure Pipe
34) Tighten the sleeve nut at the pressure piece
31) Renew O-ring (pos 2, fig. 4), and coat the high- with 65 + 5 Nm.
at the pressure piece including the O-rings. 35) Tighten the sleeve nut at the connecting socket
08028-0D/H5250/94.08.12
01.44 - ES0
MAN Diesel
Page 1 (2) Check of Fuel Oil Piping System Edition 04H
L16/24

Shut-off fuel oil
Description
Hand tools
Check of fuel oil piping system.
Starting position
Engine is running.
Related procedure
Working time : ½ hour Plate no Item no Qty. /

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

01.08 - ES0
MAN Diesel
Edition 04H Check of Fuel Oil Piping System Page 2 (2)
L16/24
Fuel Oil System 4) Move all valves in the piping system.
Lubricate valve spindles with graphite or simi-
Important for starting up new engines or newly lar.
overhauled engines!
5) Check flexible connections for leaks and dam-
The system includes all parts in the internal fuel oil ages.
system, ie main components as pumps, high pressure
pipes, pressure piece, injection valve and all types It is important that the flexible connections are free
of connections, all types of pipes as well as leakage from paint and grease and in healthy condition.
alarm and safety filter.
6) Check for any leak of the O-ring for the fuel
These components have to be checked at intervals ac- injection pipe.
cording to the "Planned maintenance programme".
When the engine has reached normal working
1) Dismount the covers to the injection pumps. temperature and no later than 24 operating hours
Blow through drain pipes. after starting up, the complete fuel oil system has
to be checked according to the above-mentioned
2) Examine the piping system for leaks. No outer instruction book working card "Check of the fuel oil
leaks can be permitted. piping system".
3) Retighten all bolts, nuts and plugs in the pip- If the above instructions are not followed carefully,
ing system. Especially does all high pressure there is a risk of oil leakage that can result in danger-
parts have to be tightened correctly. Please, ous vaporised fuel emission into the engine room.
see working cards in section 514 "Fuel Oil
system". Concerning fuel oil condition, see section 504.
08028-0D/H5250/94.08.12
01.08 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump (Woodward) 51401-16H
L16/24
08028-0D/H5250/94.08.12
06.27 - ES0
MAN Diesel
Plate
51401-16H Fuel Injection Pump (Woodward) Page 2 (2)
L16/24
Item Item
014 1/P Roller guide, com- Rullestyr, komplet inkl. 278 1/P Spring plate Fjederplade
plete incl. item 026, item 026, 038, 051,
038, 051, 063, 075, 063, 075, 408 291 1/P Pump spring Pumpefjeder
408
301* 1/P pressure valve Fjeder for
026* 1/P Roller Rulle spring trykventil
038* 1/P Roller pin Rulletap 313* 1/P Stroke limiter Begrænser
051* 1/P Roller guide Rullestyr 325 1/P Blocking screw Skrue
063 4/P Holding screw Skrue 337 1/P Guiding screw Styreskrue
075 1/P Cylindrical pin Cylindrisk stift 349 1/P Locking screw Låseskrue
087 1/P Pump element, com- Pumpeelement, kom- 350 2/P Throttle screw Skrue
plete incl. item 099, plet inkl. item 099,
109, 110 109, 110 362 1/P Pointer Viser
099* 1/P Barrel Cylinder 374 1/P Stop plate Stopplade
109* 1/P Plunger Stempel 386 1/P Sealing Tætning
110* 2/P O-ring O-ring 398 2/P Cylindrical screw Cylindrisk skrue
122 1/P Pressure valve, com- Trykventil, komplet inkl. 408 1/P Cylindrical screw Cylindrisk skrue
146, 158, 301, 313 301, 313 421 6/P Cylindrical screw Cylindrisk skrue
134* 1/P Pressure valve Hus for trykventil 433 1/P Pan head screw Skrue
housing
445 4/P O-ring O-ring
146* 1/P Constant pressure Konstant trykventil
valve 457 1/P O-ring O-ring
158* 1/P O-ring O-ring 469 2/P O-ring O-ring
171 1/P Pressure piece, com- Trykstykke, komplet 470 2/P Seal ring Tætningsring
plete incl. item 183, inkl. item 183, 195,
195, 205, 217 205, 217 482 2/P Seal ring Tætningsring
183 1/P Slotted disk Skive 494 1/P Seal ring Tætningsring
195 1/P Spacer plate Afstandsplade 504 1/P Seal ring Tætningsring
205 1/P Thrust piece Trykstykke 516 1/P Fitting disk Skive
217 3/P Countersunk screw Skrue 528 1/P Fitting disk Skive
229 1/P Pump casing Pumpehus 541 1/P Fitting disk Skive
08028-0D/H5250/94.08.12
230 1/P Connecting piece Forbindelsesstykke 553 1/P Fitting disk Skive
242 2/P Buffer bolt Bolt 565 1/C Fuel Injection Pump, Brændselspumpe,
complete as shown komplet som vist på
254 1/P Control rack Reguleringsstang on front page forsiden
266 1/P Control sleeve Kontrolbøsning 984 1/C O-ring O-ring
Qty/P = Qty/Pump Qty/P = Qty/Pumpe
06.27 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump (L'Orange) 51401-07H
L16/24
08028-0D/H5250/94.08.12
01.09 - ES0
MAN Diesel
Plate
51401-07H Fuel Injection Pump (L'Orange) Page 2 (2)
L16/24
Item Item
014 1/P Roller guide, com- Rullestyr, komplet inkl. 482* 1/P Seal ring Tætningsring
038, 051, 063 063 516 1/P Shim, Mellemlæg,
set of 4 pcs sæt af 4 stk
026* 1/P Roller Rulle 565 1/C
Fuel Injection Pump, Brændselspumpe,
038* 1/P Roller pin Rulletap complete as shown komplet som vist på
on front page forsiden
051* 1/P Roller guide Rullestyr
577 1/P Cylindrical pin Cylindrisk stift
063* 1/P Bolt Bolt
600 4/P Screw Skrue
087 1/P Pump element, com- Pumpeelement, kom-
plete incl. plunger plet inkl. stempel og 697* 2/P Support ring Støttering
and barrel cylinder
707* 1/P O-ring O-ring
756* 1/P Circlip Snapring
768* 6/P Seal ring Tætningsring
183 1/P Shim Skive
781* 1/P Lock ring Låsering
205 1/P Piston spring plate Stempelfjederplade
793 1/P Screw plug Propskrue
229 1/P Pump casing Pumpehus
803* 1/P Seal ring Tætningsring
230 1/P Connecting socket Forbindelsesstykke
complete incl. valve komplet, inkl. ventil- 827 /I Loctite 0577 Loctite 0577
cones, springs and spindler, fjedre og item
item 577 577 839 1/P Seal kit for fuel in- Pakningssæt for
jection pump, incl. brændselspumpe,
242 1/P Buffer bolt Bolt item110, 158, 457, inkl. item 110, 158,
469, 482, 697, 707, 457, 469, 482, 697,
254 1/P Control rack Reguleringsstang 756, 768, 781, 803, 707, 756, 768, 781,
984 803, 984
266 1/P Regulating sleeve Reguleringsbøsning
incl. clamping sle- inkl. xxxxx 984 1/P O-ring O-ring
eve
278 1/P Spring plate Fjederplade
291 1/P Pump spring Pumpefjeder
337 1/P Arresting bolt Bolt
349 1/P Blocking screw Låseskrue
362 1/P Pointer Viser
421 6/P Cylindrical screw Cylindrisk skrue

08028-0D/H5250/94.08.12
433 1/P Countersunk screw Skrue
01.09 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve (Woodward) 51402-11H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
51402-11H Fuel Injection Valve (Woodward) Page 2 (2)
L16/24
Item Item
021 1/V Injection nozzle, Dyse,

1200 rpm engine 1200 omdr. motor
033 2/V O-ring O-ring
045 1/V Nozzle nut Dysemøtrik
057 1/V Pressure bolt Bolt
069 1/V Adjusting spindle Justebar spindle
070 1/V Pressure spring Trykfjeder
082 1/V Nut Møtrik
094 2/V Cylindrical pin Cylindrisk stift
116 1/C Fuel injection valve, Brændselsventil, kom-

complete for 1200 rpm plet for 1200 omdr.
engine, incl. item 021, motor, inkl. item 021,
033, 045, 057, 069, 070, 033, 045, 057, 069, 070,
082, 094, 104, 128 082, 094, 104, 128
128 1/V Nozzle holder Dyseholder
141 1/V Pressure piece Spændestykke
153 2/V Nut Møtrik
165 2/V Sperical disc Skive


045, 057, 069, 070, 082, 045, 057, 069, 070, 082,
094, 104, 128, 273 094, 104, 128, 273 08028-0D/H5250/94.08.12
Qty/V = Qty/Valve Qty/V = Qty/Ventil
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Valve (L'Orange) 51402-12H
L16/24
08028-0D/H5250/94.08.12
03.50 - ES0
MAN Diesel
Plate
51402-12H Fuel Injection Valve (L'Orange) Page 2 (2)
L16/24
Item Item

045 1/V Nozzle nut Dysemøtrik
057 1/V Pressure bolt Bolt
069 1/V Adjusting spindle Justebar spindle
070 1/V Pressure spring Trykfjeder
082 1/V Nut Møtrik
094 2/V Cylindrical pin Cylindrisk stift

033, 045, 057, 069, 070, 033, 045, 057, 069, 070,
082, 094, 104, 128 082, 094, 104, 128
128 1/V Nozzle holder Dyseholder
141 1/V Pressure piece Spændestykke
153 2/V Nut Møtrik
165 2/V Sperical disc Skive


045, 057, 069, 070, 082, 045, 057, 069, 070, 082,
094, 104, 128, 273 094, 104, 128, 273 08028-0D/H5250/94.08.12
Qty/V = Qty/Valve Qty/V = Qty/Ventil
03.50 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pipe (Woodward) 51404-06H
L16/24
08028-0D/H5250/94.08.12
00.48 - ES0
MAN Diesel
Plate
51404-06H Fuel Injection Pipe (Woodward) Page 2 (2)
L16/24
Item Item
010 1/C Pressure piece Trykstykke
034 1/C Pressure pipe Højtryksrør
083 1/C Holder, complete Holder, komplet

incl. sleeve inkl. bøsning
095 1/C Nut Møtrik
08028-0D/H5250/94.08.12
Qty/E = Qty./Engine Qty/E = Qty./Motor
00.48 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pipe (L'Orange) 51404-07H
L16/24
08028-0D/H5250/94.08.12
00.48 - ES0
MAN Diesel
Plate
51404-07H Fuel Injection Pipe (L'Orange) Page 2 (2)
L16/24
Item Item
010 1/C Pressure piece Trykstykke
034 1/C Pressure pipe Højtryksrør
083 1/C Holder, complete Holder, komplet

incl. sleeve inkl. bøsning
095 1/C Nut Møtrik
08028-0D/H5250/94.08.12
Qty/E = Qty./Engine Qty/E = Qty./Motor
00.48 - ES0
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 Benævnelse Qty. Designation Benævnelse
1 1/E Fuel oil filter duplex, Brændselsoliespalte-

complete filter, komplet
2 2/F Screw plug Propskrue
3 2/F Gasket Pakning
10 6/F Bolt Bolt
11 2/F Cover Dæksel
12 2/F O-ring O-ring
13 8/F Nut Møtrik
16 1/F Ball valve Kugleventil
18 1/F Cock Hane
19 2/F O-ring O-ring
20 1/F Circlip ring Sikringsring
21 1/F Plug key Prop
22 2/F Filter element Filterelement
37 8/F Bolt Bolt
38 8/F Nut Møtrik
70 2/F Screw Skrue
72 2/F Nut Møtrik
73 2/F Spring washer Fjederskive

08028-0D/H5250/94.08.12
Qty./E = Qty./Engine Qty./E = Qty./Engine
Qty./F = Qty./Filter Qty./F = Qty./Filter
03.18 - EO0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Arrangement 51430-02H
L16/24
08028-0D/H5250/94.08.12
97.40 - ES0
MAN Diesel
Plate
51430-02H Fuel Oil Arrangement Page 2 (2)
L16/24
Item Item
012 2/E Screw Skrue
036 1/E Pipe Rør
048 1/E Housing for Hus for

thermofeeler termoføler

coupling
073 2/E Reduction Reduktion
097 1/E Screw Skrue
107 1/E Pipe Rør

coupling
120 1/E Pipe Rør
132 1/E Pipe holder Rørholder
144 2/E Screw Skrue
156 1/E Equal elbow coupling Vinkelforskruning
168 1/E Pipe Rør
181 1/E Adjustable elbow Justerbar

coupling vinkelforskruning
193 1/E Equal elbow coupling Vinkelforskruning
203 1/E Pipe Rør

coupling
227 1/E Pipe Rør
240 4/E Slotted cheese head Kærvskrue

screw
08028-0D/H5250/94.08.12
97.40 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Oil Arrangement 51430-19H
L16/24
061 193
073
360 107
264 119
156
085 168
097
181 203
443
036 120
264 132
288 144
311 252 215
012 239
024 240
276
227
323
384 239
335
240
347
431
359
372
406
467
Loop expansion joint, see plate 51902
418
Fuel oil leakage alarm, see plate 50925
08028-0D/H5250/94.08.12
07.21 - ES0
MAN Diesel
Plate
51430-19H Fuel Oil Arrangement Page 2 (2)
L16/24
Item Item
012 1/E Screw Skrue 288 3/E Gasket Pakning
024 2/E Washer Skive 311 12/E Screw Skrue
036 1/E Pipe, Rør, 323 3/E Packing ring Pakningsring

fuel oil outlet afgang brændolie
335 8/E Screw Skrue
coupling 347 4/E Screw Skrue
073 2/E Reduction Reduktion 359 12/E Nut Møtrik
085 1/E Pipe clamp Rørholder 360 1/E Pipe, Rør,

fuel oil outlet afgang brændolie
097 1/E Screw Skrue
372 1/E Pipe, Rør,
107 1/E Pipe, Rør, fuel oil inlet tilgang brændolie
fuel oil inlet tilgang brændolie
384 1/E Pipe, Rør,
119 1/E Straight male stud Ligeforskruning fuel oil outlet afgang brændolie
coupling
120 1/E Pipe, drain Rør, dræn
418 3/E Screw Skrue
431 1/E Drain pipe Rør, dræn
144 2/E Screw Skrue
443 1/E Flat steel bars Fladståljern
156 1/E Adjustable elbow Justebar
coupling vinkelforskruning 467 3/E Nut Møtrik
168 1/E Pipe Rør


203 1/E Pipe Rør
215 1/E Straight coupling, Ligeforskruning,

complete komplet
227 1/E Pipe Rør
240 5/E Slotted cheese head Kærvskrue

screw
08028-0D/H5250/94.08.12
252 1/E Non-return valve Kontraventil
264 5/E Straight male stud Forskruning

coupling
276 1/E Screw Skrue
07.21 - ES0
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump Connections (L'Orange) 51435-03H
L16/24
08028-0D/H5250/94.08.12
07.17
MAN Diesel
Plate
51435-03H Fuel Injection Pump Connections (L'Orange) Page 2 (2)
L16/24
Item Item
021 5/C Screw Skrue
057 1/C Spring pin Fjederstift
069 Insert pipe Rør


104 2/E Plug Prop
116 1/E Plug Prop
141 1/E Screw Skrue
153 1/E Cover plate Dækselplade
165 2/E Screw Skrue
177 2/E Stud Tap
189 1/E Connecting socket Forbindelsesstykke
190 2/E Nut Møtrik

08028-0D/H5250/94.08.12
07.17
MAN Diesel
Plate
Page 1 (2) Fuel Injection Pump Connections (Woodward) 51435-04H
L16/24
08028-0D/H5250/94.08.12
00.50 - ES0
MAN Diesel
Plate
51435-04H Fuel Injection Pump Connections Page 2 (2)
L16/24
Item Item
021 5/C Screw Skrue
057 1/C Spring pin Fjederstift


104 2/E Plug Prop
116 1/E Plug Prop
128 1/E Sheet Plade
141 1/E Screw Skrue
153 1/E Cover plate Dækselplade
165 2/E Screw Skrue
177 2/E Stud Tap
189 1/E Connecting socket Forbindelsesstykke
190 2/E Nut Møtrik

08028-0D/H5250/94.08.12
00.50 - ES0
Lubricating oil system
515/615
MAN Diesel
Description 515.01
Page 1 (2) Internal Lubricating Oil System Edition 04H
L16/24
Fig 1 Diagram for Internal Lubricating Oil System
Lubricating Oil System The main groups of components to be lubricated

are:
All moving parts of the engine are lubricated with oil
circulating under pressure. 1 - Turbocharger.
2 - Main bearings, big-end bearing etc.
3 - Camshaft drive.
System Flow
4 - Governor drive.
The lubricating oil pump draws oil from the oil sump 5 - Rocker arms.
and pushes the oil through the cooler and filter to 6 - Camshaft.
the main lubricating oil bore, from where the oil is
distributed to various lubricating points. From the ad 1) For priming and during operation the turbo-
lubricating points the oil returns by gravity to the oil charger is connected to the lub. oil circuit of the
sump.The oil pressure is controlled by an adjustable engine. The oil serves for bearing lubrication
spring-loaded relief valve built into the system. and also for dissipation of heat.
ad 2) Lubricating oil for the main bearings is sup-

08028-0D/H5250/94.08.12
plied through holes in the engine frame. From

the main bearings it passes through bores in
the crank-shaft to the connecting rod big-end
bearings.
98.50 - ES0
MAN Diesel
515.01 Description
Edition 04H
Internal Lubricating Oil System Page 2 (2)
L16/24
Channels have been bored into the connecting Lubricating Oil Cooler
rods for supply of oil from the big-end bearings
to the small-end bearings, which has an inner The lubricating oil cooler is of the plate type. The
circumferential groove, and a pocket for distri- cooler is mounted on the front-end box.
bution of oil in the bush itself. For supply of oil
to the pin bosses and the piston cooling.
Thermostatic Valve
From the front main bearings channels have
been bored in the crankshaft for lubricating of The thermostatic valve is a fully automatic 3-way
the pump drive. valve with thermostatic elements set at fixed tem-
perature.
ad 3) The camshaft drive gear wheels are being
lubricated via the oil-mist principle. Oil-mist is
being generated by oil, which is led out from Lubricating Oil Filter
the bearing in the intermediate wheels.
The lubricating oil filter is a full-flow depth filter of
ad 4) From bores in the engine frame the governor the duplex paper car tridge type, with a fineness of
drive is being pressure lubricated. 10-15 microns, and a safety filter with a fineness of
60 microns.
ad 5) The lubricating oil to the rocker arms is led
through bores in the engine frame to each cy-
linder head. The oil continues through bores in Pre-lubricating
the cylinder head to lubricate the rocker arms
and valve bridges. Further, lub oil is led to the The engine is equipped with an electric-driven prelub.
movable parts in need of lubrication. pump mounted parallel to the main pump. The pump
is arranged for automatic operation, ensuring stand-
ad 6) Lubrication to the fuel pump is supplied via still of the prelubricating pump when the engine is
the fuel camshaft bearing. running, and running during engine stand-still in
stand-by position by the engine control system.
Lubricating Oil Pump
The lubricating oil pump, which is of the helical gear

type, is mounted in the front-end box of the engine
and is driven by the crankshaft.
08028-0D/H5250/94.08.12
98.50 - ES0
MAN Diesel
Page 1 (3) Lubricating Oil Pump Edition 03H
L16/24

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

06.51 - ES0
MAN Diesel
515-01.00 Lubricating Oil Pump
Working Card
L16/24
Preparing before Dismounting Mounting
For access to the lubricating oil pump it is neces- 8) Change the O-rings on the pump.
sary to remove the lubricating oil cooler. Please see
worcking card 515-06.00. 9) Mount the pump by the bolts and tighten these
according to description 500.40.
Dismounting 10) Re-new 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 1
5
3) Remove the bolt (1) and the spur gear (2), see
fig 1.
2 Spur gear
4) Remove the bolt (3) and the cover (4), see fig
1. 4
Take out the pinion spindles (5) and clean all parts
in gas oil and with a hard bush, (never use a steel 5 Axle for spur gear
bush). The parts are blown clean with working air. Must be placed correctly
in relation to guide pin
Guide pin
5) Check the wear of the bearing bush.
Fig 1 Lubricating oil pump
6) If the bearing bush is to be removed the existing
bearing bush is plugged out by means of a
mandrel, the bores are cleaned, see fig 2, and
new bearing bush is mounted.
The bush is cooled down to -130°C, the housing
or cover has room temperature.
Note: criteria for replacement of bearing bush, see

A, fig 3.
7) Mount the pinion spindels (5) the cover (4) and

the bolt (3), the spur gear (2) and the bolt (1),
see fig 1.
08028-0D/H5250/94.08.12
Note: be aware that axle for spur gear is pla-

ced correctly in relation to guide pin on pump
housing.
Fig 2 Bores to be cleaned
Tighten the bolts according to page 500.40.
Note: check that the oil pump can run easily when
the pump is assembled.
06.51 - ES0
MAN Diesel
Page 3 (3) Lubricating Oil Pump Edition 03H
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

can not 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
06.51 - ES0
MAN Diesel

Page 1 (4) Prelubricating Pump Edition 03H
L16/24
L23/30H

Shut-off fuel oil
Dismantling, replacement of the mechanical seals Ring and open end spanner, 13 mm.
and assembly of prelubricating pump. Ring and open end spanner, 15 mm.
Socket spanner, 15 mm.
Adjustable spanner.
Screw driver.
Lubricating light oil and grease.
Starting position Vessels for cleaning.
Related procedure
Working time : 2-3 Hours Plate no Item no Qty. /

Capacity : 1 man
08028-0D/H5250/94.08.12
See Plate 61504
Data

98.47 - ES0
MAN Diesel
Edition 03H
Prelubricating Pump Page 2 (4)
L16/24
L23/30H
Periodic Overhauls 2) Shut off the suction to the pump and block the
electric motor starting button.
Periodic overhauls for the purpose of avoiding func-
tional trouble are not normally necessary for the 3) Loosen the screws which hold the motor and
prelubricating pumps. When properly used, there is pump together and lift away the motor.
very little wear on the pump screws.
4) Remove the front end cover of the pump (1).
If oils and other liquids with abrasive properties are Do not damage the joint (2) between front end
pumped periodic overhauls may nevertheless be cover and pump body.
carried out so that worn parts can be replaced in
good time. The intervals between such overhauls are 5) Press the stationary seal with o-ring (27 and
determined by experience in each individual case. 23) see fig. 2, out of the front cover.
Impurities in the pumped liquid or careless handling

during dismantling and reassembly can result in
damage to the lapped sealing surfaces. Dismantling
and reassembling the seal should therefore be car- 23 24
ried out in conditions of scrupulous cleanliness and
carefulness and every effort must be made to avoid
touching the sealing surfaces with the fingers. The
25
carbon ring must be carefully handled.
Warning: It must not get in touch with grease.
Dismantling
1) Turn the motor, using the fan beneath the

fan casing, until the set screw (20) see fig. 1, 27
which locks the pump shaft to the motor shaft 18
is accessible in one of the inspection holes in
the pump body back off the stop screw all the
way.
Fig 2. Shaft seal
1 2 3 6) Remove the power rotor (17) fig. 1, from the

pump body. If only the seal is to be replaced,
4 the idlers can remain in the pump body.
5
6 7) Remove the rotary seal ring (24) fig. 1.
7
22 8) Press the rotating seal (18) out of the power
8
08028-0D/H5250/94.08.12
21 9
rotor (17). Due to the rubber bellows (25) fig.
20 2, the necessary press-off power may be
comparatively big.
10
11
12
19 18 17 16 15 14 13
Fig 1. Prelubricating pump.
98.47 - ES0
MAN Diesel

Page 3 (4) Prelubricating Pump Edition 03H
L16/24
L23/30H
Reassembly
The fit of the rotary seal on the pump shaft is rather

hard. To prevent damage of the bellows (25) it is
advisable to clean the pump shaft from possible
coating like particles of coke from oil etc.
Polish the pump shaft by means of an emery or

cleaning cloth to get a smooth finish.This preparation
facilitates the mounting of the rotary seal.
The reassembly will take place in reverse order: Fig. 3.
9) After cleaning wipe the shaft over with light oil

(not grease). Press the rotating seal (18) with 17) The power rotor shall be forced up on the mo-
removed rotary seal ring (24) onto the rotor tor shaft by means of a screw driver put into
shaft. the groove of the power rotor shaft, see fig.
3. Thereafter screw the set screw (20) firmly
10) Check that the bellows are pressed against against the motor shaft. This is necessary to
the locating ring of the spring. Keep the seal ensure a correct play of the idler rotors.
pressed in that position for half a minute until
the bellows stick. 18) Check that the pump rotates freely when the
motor is rotated by hand.
11) Mount the rotary seal ring (24) with its smaller
surface turning upwards, taking care that the Open the valves in the pipe lines and re-establish the
grooves in the seal ring are in line with the electric supply to the motor. Proceed in accordance
dimples of the retaining sleeve. with the instructions "Starting-up".
12) Insert the power rotor in the pump casing Note: Do not let the pump run for more than one
(3). minute without working.
13) Wipe over the outside of the stationary seat

with its o-ring gasket (27 and 23) with light oil Maintenance
and press the seat into the front cover.
The seal is self-adjusting and requires no subsequ-
14) Mount the front cover (1) to the pump casing ent tightening.
(3) making sure not to forget the joint (2) which
seal between the pump casing and the front If copious leakage occurs, this is the usual sign of
cover. wear, which may be due to such causes as incau-
tious starting, dirty oil, poor alignment or running
15) Screw the set screw (20) into the power rotor without oil.
far enough to be guided into the keyway in the
motor shaft.
08028-0D/H5250/94.08.12
Starting
16) Mount the electric motor on the pump so that the
set screw (20) enters the motor-shaft keyway. Starting should always take place with fully open
Tighten the screws joining pump and motor valves in the suction and delivery lines.
flanges.
98.47 - ES0
MAN Diesel

Edition 03H
Prelubricating Pump Page 4 (4)
L16/24
L23/30H
As the prelubricating pump is self-priming it carries off If the pump refuses to work properly after having
the air in the suction line and the noise reveals when been started, it must not be allowed to run for more
the pump begins to work. It is essential for the air to than about half a minute. Fresh attempts to make
be led off without any appreciable counter-pressure the pump go may be made at intervals of about a
in the delivery line. minute and in conjunction with these attempts the
bypass valve tension should be increased slightly. If
As soon as the pump has started to work normally, thes does not help, something must be wrong and
the by-pass valve must be set by means of a pres- the fault must be located and remedied before the
sure gauge at the required pressure. pump is put into operation.
Set the by-pass valve, with the screw (10) fig 1, on

the end cover of the pump body. Turning to the right Direction rotation
increases the opening pressure. Do not set the valve
at pressures higher than necessary. When the pump is ready to be started, check that
the dive motor rotates in the correct direction as indi-
This pressure setting should be maintained while cated on the pump by briefly switching it on and by
the pump is in operation. watching the fan impeller of the electric motor.
Note: Do not check the direction of rotation without

prior filling the pump with oil.
08028-0D/H5250/94.08.12
98.47 - ES0
MAN Diesel
Page 1 (3) Lubricating Oil Filter Edition 02H
L16/24

Shut-off fuel oil
Description
Hand tools
Replacement of paper filter element(s).
Cleaning of safety filter and filter housing. Open-end ring spanner, 19"
Allen key, 6 mm
Allen key, 10 mm
Starting position
Related procedure
Working time : 1 hour Plate no Item no Qty. /

Capacity : 1 man
51502 013 2x3/E
08028-0D/H5250/94.08.12
51502 049 2x1/E

Data

98.45 - ES0
MAN Diesel
Edition 02H Lubricating Oil Filter Page 2 (3)
L16/24
Please note: Never open the filter while it is in use. 9) Remove the outer elements.
The filter to be cleaned must be out of operation.
Note: Our filter elements are of the disposable type.
Always change to new original filter.
Normal Running
10) Clean the filter housing and the cap.
1) The valve is in position 2 or 4, see fig 2, and
the element not in use is vented and ready to 11) Check the seal in the cap. Change if needed.
use (standby).
12) Assemble the filter in reverse order.
Changing the Filter 13) Switch to position 2 or 4 and vent the exchanged
element by means of the vent screw.
2) Switch to position 3, fig 2, and wait 5 minutes.
Then continue to position 1 or 5, fig 2.
Vent screws
3) Wait 2 minutes.
4) Open the vent screw on the filter out of ser-

vice.
5) Wait 20 minutes
6) Dismantle the cover.
7) Dismantle the filter housing cap.
8) Remove the inner safety element. Clean the

element with detergent. Check that it is in-
tact. Fig 1 Vent screws
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel
Page 3 (3) Lubricating Oil Filter Edition 02H
L16/24
Pos.
Fig 2 Name plate for lubricating oil filter.

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

Page 1 (2) Lubricating Oil, Thermostatic Valve Edition 03H
L16/24

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

98.47 - ES0
MAN Diesel

Edition 03H Lubricating Oil, Thermostatic Valve Page 2 (2)
L16/24
Adjustment and Maintenance Check the Element
The thermostatic valve cannot be adjusted and un- 10) Place the element in a bucket of water -12°
der 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

glycol may be used.
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).

Fig 2 Placing of lubricating oil thermostatic valve.
9) Renew the gasket and mount the cover
(2). Tighten the bolt (1) according to page
500.40.
98.47 -ES0
MAN Diesel
Page 1 (2) Check of Lubricating Oil Piping System Edition 02H
L16/24

Shut-off fuel oil
Check and examination of the lubricating oil

piping system.
Starting position
Engine is running.
Related procedure
Working time : ½ hour Plate no Item no Qty /

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

98.41 - ES0
MAN Diesel
Edition 02H Check of Lubricating Oil Piping System Page 2 (2)
L16/24
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 con-

nections 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
98.41 - ES0
MAN Diesel

Page 1 (5) Lubricating Oil Cooler Edition 03H
L16/24

Shut-off fuel oil
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
Plate No Item No Qty./
08028-0D/H5250/94.08.12
Capacity : 1 man
Data

98.43 - ES0
MAN Diesel
Edition 03H Lubricating Oil Cooler Page 2 (5)
L16/24
Introduction Upon completion of the procedure “Cooling and
Pressure Relief”, separate the frame by retaining
Cleaning of the cooler must take place, when the two or four diagonally placed bolts.
pressure drop on the oil and water side exceeds an
allowable value and/or if oil cannot be sufficiently Note: Take care that the pressure plate does not
cooled. 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.
Separation of Edge-clamped Frame

Manual Cleaning
Mount the bolts, see fig. 1.
Clean the plates with a soft brush and a suitable
detergent. In the case of dense coating of scale or
organic materials, the plates must be put in a bath
with detergent.
Note: Never use a steel brush, metal scraper or

the like.
A high-pressure cleaner can be used with care, how-

ever, never with sand or other abrasives added.
Detergents
A detergent is suitable, if it removes any coating

on the plates without causing any damage to plates
08028-0D/H5250/94.08.12
and gaskets.
Note: It is of great importance that decomposi-

Fig 1 Mounting of oil cooler in front-end box. tion of the protective film on the stainless steel does
not take place - the film preserves the corrosion
resistance of steel.
Do not use chlorine-containing agents such as hy-

drochloricacid (HCI)!
98.43 - ES0
MAN Diesel
L16/24
Oil and fats are removed by using a water emulsify- Replacement of Plates and Gaskets
ing oil solvent, e.g. BP-system cleaner.
Marking
Organic and greasy coatings are removed by using
sodium hydroxide (NaOH): The plates are marked with material codes and refer-
ence numbers at each end, plus codes for non-glued
- max. concentration 1.5% gaskets, if any, and stamped with letters V and H
(1.5% concentration corresponds to 3.75 at either end (fig 1).
l 30% NaOH per 100 l water).
- max. temperature 85o C. When facing the gasket, the plate is designated as
a left plate, when letter V turns upwards - and as a
Stone and lime/calcareous deposits are removed by right plate when letter H turns upwards. Inlets and
using nitric acid (HNO3): outlets of the V-plates are taking place through the
corner holes Nos 1 and 4. Inlets and outlets of the
- max. concentration 1.5% H-plates take place through corner holes Nos 2
(1.5% concentration corresponds to 1.75 l and 3.
62% HNO3 per 100 l water).
- max. temperature 65o C.
Replacement of Plates
Note: The nitric acid has an important constructive
effect on the protective film of stainless steel. Before mounting a spare plate in the plate stack,
please make sure that the spare plate is identical
with the faulty one.
Control of Cleaning Fluid Concentrations
Note: The same corner holes must be opened and
Sodium hydroxide (NaOH) solution is titrated with letters V and H must be placed properly.
0.1 n hydro-chloric acid (HCI) with methyl orange
or methyl red as an indicator.
Replacement of Glued Gaskets
Nitric acid (HNO3) solution is titrated with 0.1 n
sodium hydroxide (NaOH) with phenolphtalin as an On Plate 51506 stated are gasket and glue quan-
indicator. tity.
The concentration of the cleaning fluid in % can be Please use a degreasing agent on the new gas-
calculated from the titration result with of the follow- kets.
ing formula:
The first plate after the end cover and the connector
Concentration = bxnxm % grid must have gaskets in all grooves. The gaskets
a x 10 must be cut according to the existing gaskets.
a : ml cleaning fluid taken out for titration

b : ml titration fluid used as a cover
n : the molecular concentration of titration fluid
08028-0D/H5250/94.08.12
m : The molecular weight of the cleaning fluid

(NaOH) the molecular weight 40, HNO3
molecular weight 63)
98.43 - ES0
MAN Diesel
Edition 03H Lubricating Oil Cooler Page 4 (5)
L16/24
Loosen the glued gaskets by heating the plate in The plates with the gaskets are mounted in the frame
water at 100o C. Clean the plates and remove the which is lightly clamped. In the case of using rubber
coatings, if any. grooves, they are assembled to the minimum measure
stated on the engine sign plus 0.2 mm per plate.
Cleaning of New Gaskets and Plates Heat up the plate heat exchanger to 90-100° C by
means of water or steam.
New gaskets and gasket grooves of the plates are
cleaned with a cloth moistened with degreasing Please note:
agent. The glued surfaces must be absolutely clean
- without finger prints etc. - The temperature must be kept for 1 1/2-2
hours.
Please use our cleaning fluid, which conforms to - The liquid pressure must be kept as low as
suppliers recommendations. possible.
Alternatively, please use: If there is no possibility of heating the plate heat

exchanger, it must be placed in a place as warm as
- Trichloroethylene possible with connections dismounted.
- Chlorothene VG
- Acetone At 20° C the drying time will be approx. 48 hours. At
- Methyl ethyl ketone 40° C, the drying time is approx. 24 hours.
- Ethylacetat
It is important that all degreasing agent be evapo- Assembling

rated, before glue is applied. This will normally take
approx. 15 min. at 20o C. If the plates are dismounted, they must be properly
assembled according to plate item numbers.
Clean the new gaskets on the glued surfaces with The fixed cover has number 1 and serial numbers
fine-grained sandpaper instead of the degreasing for the subsequent plates, and intermediate frames,
agent supplied. if any, are numbered 2, 3, 4, 5 etc.
Gluing
Serial number
(please state when
Pliobond 25, which is a solvent-based nitrile rubber Material Code ordering single plates)
glue (25% solids).The glue is applied with a brush in a
thin layer on the backs of the gaskets and the gaskets
must be dried in a clean place free of dust.
1 2
Apply a thin layer of glue on the gasket grooves
of the plates and press the gaskets down into the
gasket grooves.
08028-0D/H5250/94.08.12
The insertion of the gaskets starts at both ends of

the plate - and continues with the straight sections Four last digits Four last digits are ref.
H number of the plate.
along the edges. are ref. number
or (only on plates for non-
of plate
V glued gasket)
The gluing process is most easily performed by
placing the gaskets and the plates on a table. After
Fig 2 Plate with serial no etc.
pressing the gaskets into the grooves of the plate,
it is stacked.
98.43 - ES0
MAN Diesel

L16/24
Serial numbers are stamped in the right top corner Fastening
of the plates. Further, please note that the gasket
side must face the fixed cover. Fasten the nuts crosswise until the movable cover
to the measure x at each nut.
Cyl x
5 82.5 mm
6 86.3 mm
7 100.0 mm
8 117.3 mm
9 131.1 mm
Fig 3 Measuring x
08028-0D/H5250/94.08.12
98.43 - ES0
MAN Diesel

Page 1 (3) Centrifugal Bypass Filter Edition 03H
L16/24

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

98.47 - ES0
MAN Diesel

Edition 03H Centrifugal Bypass Filter Page 2 (3 )
L16/24
Cleaning Procedure 5) Remove stand tube (075) and clean.
6) Remove sludge from inside the rotor by means

1) Isolate the filter by closing the valve for lubrica- of a spatula and wipe clean. Ensure that all
ting oil inlet to the filter. rotor components are throughly cleaned and
free from deposits of dirt before reassembling
2) Slacken cover clamp ring (266). Unscrew cover the rotor.
fixing nut and lift off cover.
Note: Failure to do so could cause an out-of-
3) Lift off rotor assembly having allowed oil to balance condition which will accelerate bearing
drain from nozzles. The rotor should be remo- and spindle wear.
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 and
not damaged. bottom bearings in tube assembly. If damaged
or worn - replace tube assembly complete.
4) Unscrew rotor cover nut (026) and separate Examine O-ring and renew if damaged.
cover (038) from body.
8) Replace paper insert (if mounted).
9) Reassemble rotor complete and tighten top

026 nut.
038 Note: Ensure that rotor cover and rotor body are
always matched by balance number and pin location.
Do not interchange rotor cover.
10) Examine spindle journals. If damaged or worn

- replace with body assembly complete.
075
11) Reassemble filter complete checking that rotor
revolves freely. Then replace filter body cover
266
Tighten cover nut and secure safety clamp.
The clamp ring should be securely 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.

026 Cover nut Check for excessive vibration.
038 Cover
075 Stand tube
266 Cover clamp ring
Maintenance - Bearings and Spindle
08028-0D/H5250/94.08.12
Fig 1 Centrifugal bypass filter All rotors are correctly balanced before leaving the
factory. An out-of-balance condition can occur as a
result of an uneven build up of sludge in the rotor or
as a result of excessive bearing or spindle wear.
Dependent on the conditions, wear will eventually take

place on the spindle and bearings and these should
be replaced with factory fitted assemblies only.
98.47 - ES0
MAN Diesel

Page 3 (3 ) Centrifugal Bypass Filter Edition 03H
L16/24
To Check Bearing Clearances Spindle top journal diameter 14.98 mm Min.
Spindle bottom journal diameter21.63 mm Min.
This is most easily done by applying a dial gauge Top bearing bore diameter 15.06 mm Max.
to the outside of the rotor opposite each bearing in Bottom bearing bore diameter 21.69 mm Max.
turn and measuring the total play thus:
The spindle and body assembly and the rotor bear-
14) Apply dial gauge and measure play. ing tube assembly are factory assembled items and
should only be replaced with complete assemblies.
15) Turn rotor 90° and repeat measurement.
16) Re-apply dial gauge at 90° to previous posi-

tion and repeat.
17) Turn rotor 90° and repeat.
The highest reading is the play in the bearing.
The maximum clearances when new are 0.08 mm at

top and 0.06 mm at bottom bearing. If the clearance
exceeds 0.25 mm top or 0.2 mm bottom then check
the sizes of the individual components and replace
as necessary.
08028-0D/H5250/94.08.12
98.47 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Pump 51501-06H
L16/24
08028-0D/H5250/94.08.12
06.32 - ES0
MAN Diesel
Plate
51501-06H Lubricating Oil Pump Page 2 (2)
L16/24
Item Item
031 1/E Lubricating oil pump, Smøreoliepumpe, kom-

comp. 5-6 cyl. engine plet 5-6 cyl. motor
incl. item 055, 079, 092, incl. item 055, 079, 092,
102, 114, 126, 151, 175, 102, 114, 126, 151, 175,
187, 199 187, 199
043 1/E Lubricating oil pump, Smøreoliepumpe, kom-

comp. 7-9 cyl. engine plet 7-9 cyl. motor
incl. item 055, 080, 092, inkl. item 055, 080, 092,
102, 114, 138, 163, 175, 102, 114, 138, 163, 175,
187, 199 187, 199
055 3/P Cylindrical pin Cylindrisk stift
067 6/P Screw Skrue
079 1/P Pump housing, Pumpehus,

complete komplet
5-6 cyl. engine 5-6 cyl. motor
080 1/P Pump housing, Pumpehus,

complete komplet
092 1/P Cover Dæksel
102 4/P Bush Bøsning
114 6/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

08028-0D/H5250/94.08.12
06.32 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Filter 51502-12H
L16/24
050
037 025
216
049
Front-end box,
see Plate 51103
049
216
025
204
170
182
133
145
169
194
300
157 312
062 182
013 204 324
074 013
062 074 289
013 013 265
074 277 086
013 290 253
08028-0D/H5250/94.08.12
074 108
013 049 241
289 253
265
277 228
086 098
098 241
108 228 121
06.25 - ES0
MAN Diesel
Plate
51502-12H Lubricating Oil Filter Page 2 (2)
L16/24
Item Item
013 6/E Filter cartridge Filterindsats 312 1/E Latch pin Låsestift
025 2/E Cover Dæksel 324 1/E Spring pin Fjederstift
037 8/E Screw Skrue
050 2/E Cover, complete incl. Dæksel, komplet inkl.

item 216 item 216
062 2/E Safety filter Sikkerhedsfilter
074 4/E Spacer ring Afstandsring
086 2/E Cover, complete Dæksel, komplet
098 8/E Screw Skrue
108 2/E Covering, complete Skærm for dæksel,

incl. item 228, 241, komplet inkl. item 228,
253 241, 253
121 6/E Screw Skrue
133 1/E Shaft Aksel
145 1/E Shaft Aksel
170 1/E Plate Plade
194 1/E Plate Plade
204 6/E Screw Skrue
216 2/E Guide ring Styrering
228 2/E Cover Skærm
241 2/E Screw Skrue
253 2/E Retaining ring Sikringsring
265 2/E Filter guide with safety Filterstyr med sikker-

valve hedsventil
08028-0D/H5250/94.08.12
289 2/E Screw Skrue
300 1/E Lever Arm
06.25 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Pump 51504-04H
L16/24
99.07 - ES0
MAN Diesel
Plate
51504-04H Prelubricating Pump Page 2 (2)
L16/24
Item Item
014 1/P Front cover Fordæksel 516 1/E Ball bearing, rear Kugleleje, bagside
026 1/P Joint Pakning 528 1/E Ball bearing, front Kugleleje, forside
038 1/P Pump casing Pumpehus
051 8/P Screw Skrue
063 1/P Socket Muffe
075 1/P Set screw Sætskrue
087 2/P Counter flange, Modtryksflange,

complete komplet
099 2/P Joint Pakning
109 1/P Joint Pakning
110 1/P Rear cover Endedæksel
122 2/P Idler rotor, only avai- Friløbsrotor, kun tilgæn-

lable together with gelig sammen med
item 217 item 217
134 1/P Regulating screw Reguleringsskrue
146 1/P Retaining ring Låsering
158 1/P Valve cover Ventildæksel
171 1/P Sealing washer Pakning
195 1/P Valve spring Ventilfjeder
205 1/P Valve piston Ventilstempel
217 1/P Power rotor, only Drivrotor, kun tilgæn-

available together gelig sammen med
with item 122 item 122
229 1/P Drip ring Dræn
230 1/P Shaft seal, Akseltætning,

complete komplet
242 1/E Pump, complete Pumpe, komplet

with el-motor med el-motor
08028-0D/H5250/94.08.12
374 1/E Pump, complete Pumpe. komplet

without el-motor uden el-motor
494 1/E El-motor, El-motor,

complete komplet
99.07 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Cooler 51506-10H
L16/24
064 015
076 027
172 039
184 040
196 052
206
218
040
088
111
Mandrel, 159
see plate 52015
231 135
123 147 160
243 483 529
495 530
505 542
517 554
08028-0D/H5250/94.08.12
Note: when ordering plates, please state the

serial numbers of the plates. The serial numbers
of the plates can be found in the top right-hand
corner of the plates. (See working card 515-06.00)
Husk: Ved bestilling af plader angives serienum-

meret på pladen. Serienummeret er stemplet I
toppen af pladen til højre. (Se arbejdskort 515-06.00)
06.48 - ES0
MAN Diesel
Plate
51506-10H Lubricating Oil Cooler Page 2 (2)
L16/24
Item Item
015 1/K Plate Plade 495 10/K Screw Skrue

7 cyl. engine 7 cyl. engine
039 14/K Screw Skrue 8 cyl. engine 8 cyl. motor
040 4/K O-ring, oval O-ring, oval 517 10/K Screw Skrue
052 8/K Screw Skrue
529 /I Plate Plade
064 1/K Plug screw Propskrue 6 cyl. engine 6 cyl. motor
076 1/K Packing ring Pakningsring 530 /I Plate Plade

088 1/K Plate Plade
542 /I Plate Plade
111 1/K Plate Plade 8 cyl. engine 8 cyl. motor
123 10/K Self locking nut Selvlåsende møtrik 554 /I Plate Plade

159 /I Gasket Pakning
160 /I Plate Plade

172 1/E Lubricating oil Smøreoliekøler,

cooler, 5 cyl. motor
5 cyl. engine

6 cyl. engine

7 cyl. engine

8 cyl. engine

9 cyl. engine
231 /I Glue Lim

08028-0D/H5250/94.08.12
243 /I Cleaning fluid Rensevædske

06.48 - ES0
MAN Diesel
Plate
Page 1 (2) Centrifugal By-pass Filter 51515-02H
L16/24
171
266 110 134
291 195
278 122
158
337
146
229
183
242
109
230
075
205
217
08028-0D/H5250/94.08.12
014
254 026 099
051 087
038 063
07.27 - ES0
MAN Diesel
Plate
51515-02H Centrifugal By-pass Filter Page 2 (2)
L16/24
Item Item
014 1/F Body , complete incl. Sokkel, komplet inkl. 291 1/F Stiffner plate Plade
item 026, 038, 051, 063, item 026, 038, 051, 063,
075, 087, 099, 109 075, 087, 099, 109 301 1/F Cover nut fixing kit, Dækselmøtrikskit, inde-
consisting of item 134, holdende item 134, 146,
026 1/F Valve body Ventilsokkel 146, 158, 171 158, 171
038 1/F Valve handle Ventilhåndtag 313 1/F Valve kit, consisting Ventilkit, indeholdende
of item 026, 038, 051, item 026, 038, 051, 063,
051 1/F Nyloc nut Møtrik 063, 075, 087 075, 087
063 1/F Valve adaptor Ventiladapter 325 1/F Seals kit, consisting Tætningskit, indehold-
of item 087, 099, 109, ende item 087, 099,
075 1/F Valve stop Ventilstop 158, 242 109, 158, 242
087 1/F Valve seal Ventiltætning 337 1/E Centrifugal by-pass Centrifugal by-pass fil-
filter, complete as ter, komplet som vist på
099 1/F Flange gasket Flangepakning shown on front page forsiden
109 1/F Filter body O-ring Filtersokkel O-ring
110 1/F Cover, complete incl. Dæksel, komplet inkl.

item 122, 134, 146, item 122, 134, 146,
158, 171 158, 171
122 1/F Cover Dæksel
134 1/F Cover nut pin Stift for dækselmøtrik
146 1/F Cover fixing nut Dækselmøtrik
158 1/F Cover nut O-ring Dækselmøtrik O-ring
171 1/F Cover nut collar Dækselmøtrik muffe
183 1/F Band clamp Spændering
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, 278, 291
278, 291
205 1/F Nozzle Dyse
217 1/F Bearing tube Lejerør
229 1/F Stand tube Standrør
230 1/F Circlip Låsering
242 1/F Rotor O-ring Rotor O-ring

08028-0D/H5250/94.08.12
254 1/F Pin Stift
266 1/F Rotor cover nut Rotordækselmøtrik
278 1/F Paper insert Papirindsats
Qty/F = Qty/Filter Qty/F = Qty/Filter
07.27 - ES0
MAN Diesel
Plate
Page 1 (2) Lubricating Oil Separator 51530-02H
L16/24
08028-0D/H5250/94.08.12
99.06 - ES0
MAN Diesel
Plate
51530-02H Lubricating Oil Separator Page 2 (2)
L16/24
Item Item
041 4/E Nut Møtrik
053 4/E Stud Tap
077 2/E Screw Skrue
089 2/E Screw Skrue
090 1/E Bow Bøjning
112 8/E Screw Skrue
136 1/E Insert Indsats
148 1/E Housing Hus
161 1/E Lubricating oil separa- Smøreolieseparator,

tor, complete as shown komplet som vist på
on front page forsiden
08028-0D/H5250/94.08.12
99.06 - ES0
MAN Diesel
Plate
Page 1 (2) Crankcase Venting 51531-05H
L16/24
011
08028-0D/H5250/94.08.12
07.44 - ES0
MAN Diesel
Plate
51531-05H Crankcase Venting Page 2 (2)
L16/24
Item Item
011 1/E Venting pipe Udluftningsrør
08028-0D/H5250/94.08.12
07.44 - ES0
MAN Diesel
Plate
Page 1 (2) Prelubricating Oil Arrangement 51535-02H
L16/24
08028-0D/H5250/94.08.12
00.14 - ES0
MAN Diesel
Plate
51535-02H Prelubricating Oil Arrangement Page 2 (2)
L16/24
Item Item
037 1/E Adjustable straight Justerbar

male stud coupling ligeforskruning
049 1/E Male stud coupling Vinkelforskruning
062 1/E Straight male Ligeforskruning

stud coupling
074 1/E Equal tee coupling, T-forskruning,

complete komplet
086 1/E Pipe Rør
098 2/E Adjustable elbow Justerbar vinkel
108 1/E Non-return valve Kontraventil
121 1/E Reducing adaptor Reduktionsadapter
133 1/E Non-return valve Kontaventil
145 2/E Threaded sleeve Bøsning
169 1/E Bleeding screw Skrue
170 1/E Pipe Rør
182 1/E Pipe Rør
194 1/E Pipe Rør
204 2/E Screw Skrue
08028-0D/H5250/94.08.12
00.14 - ES0
Cooling water system
516/616
MAN Diesel
Description 516.01
Page 1 (1) Internal Cooling Water System Edition 04H
L16/24
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 treated 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.
It should be noted that there is no water in the en-

gine frame.
Fig 1 Integral cooling water system.
Thermostatic Valves
The thermostatic valves are fully automatic three-

way valves with thermostatic elements set at fixed
temperatures.
08028-0D/H5250/94.08.12
99.03 - ES0
MAN Diesel
Page 1 (2) Check of Cooling Water System Edition 02H
L16/24

Shut-off fuel oil
Check of cooling water system.
Starting position
Engine is running.
Related procedure

08028-0D/H5250/94.08.12
Working time : ½ hour Plate no Item no Qty./

Capacity : 1 man
Data

98.41 - ES0
MAN Diesel
Edition 02H Check of Cooling Water System Page 2 (2)
L16/24
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.
from paint and grease and in healthy condition.
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
98.41 - ES0
MAN Diesel
Page 1 (2) Cooling Water, Thermostatic Valve Edition 02H
L16/24

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

98.41 - ES0
MAN Diesel
Edition 02H Cooling Water, Thermostatic Valve Page 2 (2)
L16/24
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 recees.
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 (1),

see fig 1.
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
98.41 - ES0
MAN Diesel
Page 1 (2) HT and LT Water Pumps Edition 01H
L16/24

Shut-off fuel oil
Disassembly, overhaul and assembly of HT and

LT pumps.
Starting position
Related procedure
Working time : 1 hours Plate No Item No Qty /

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
98.41 - ES0
MAN Diesel
Edition 01H HT and LT Water Pumps Page 2 (2)
L16/24
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 (1), see fig. 1 and pull out the shaft seal and bearings, also inspect the
the pump by means of the spring bolts. impeller for pittings and caviations. Clean all
parts carefully.
Assembling of the Pump
7) Fit new bearings (13) and (14) together with a

new shaft seal (15).
8) Mount the shaft in the housing and lock it with

the lock ring (11).
9) Fit the spur wheel (4) and washer (3) with

the screw (2) and tight it according to page
500.40.
10) Fit carefully the slide ring joint (10), then fit the
washer (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 (1), see fig. 1 and tight
them according to page 500.40.
Fig 1 HT and LT water pumps
Disassembling of the Pump
2) Remove the screw (2), see fig 2 and pull of the

washer (3) and spur wheel (4).
08028-0D/H5250/94.08.12
3) Remove the bolt (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 lock ring (11), then pull out the
shaft (12) with bearings (13) and (14) and the
shaft seal (15).
Fig 1 HT and LT water pumps
98.41 - ES0
MAN Diesel
Plate
Page 1 (2) High- and Low Temperature Freshwater Pumps 51610-11H
L16/24
129
022 010
095
130
250
105
201 117
191 237
142
166
154
225
213
071
08028-0D/H5250/94.08.12
058
046
178
034
083
07.06 - ES0
MAN Diesel
Plate
51610-11H High- and Low Temperature Freshwater Pumps Page 2 (2)
L16/24
Item Item
034 1/P Depp groove ball Radialkugleleje

bearing
046 1/P Ball bearing Kugleleje
058 1/P Retaining ring Sikringsring
071 1/P Retaining ring Sikringsring
083 1/P Shaft seal Pakdåse
095 1/P Slide ring joint Roterende pakning
105 2/E Freshwater pump, Ferskvandspumpe,

complete as shown komplet som vist
on front page på forside
117 4/P Screw Skrue
129 1/P Pump housing Pumpehus
130 1/P Impeller Løbehjul
142 1/P Cover Dæksel
154 4/P Screw Skrue
166 4/P Lock washer Låseskive
178 1/P Shaft, Aksel,

incl. item 191 and 201 inkl. item 191 og 201
191 1/P Self locking nut Selvlåsende møtrik
201 1/P Disc Skive
213 1/P Spur gear Cylindrisk tandhjul
225 1/P Washer Skive
237 1/P Screw Skrue

08028-0D/H5250/94.08.12
Qty./P = Qty./Pump Qty./P = Qty./Pumpe
Qty./I = Qty./Individual Qty./I = Qty./Individuelt
07.06 - ES0
MAN Diesel
Plate
Page 1 (2) Cooling Water Connections 51630-02H
L16/24
08028-0D/H5250/94.08.12
98.45 - ES0
MAN Diesel
Plate
51630-02H Cooling Water Connections Page 2 (2)
L16/24
Item Item
033 Seal ring Tætningsring

045 Screw Skrue

069 Lock washer Låseskive

070 2/C Intermediate piece Mellemstykke
082 2/C Safety clamp Sikkerhedsring
094 2/E Stud Tap
104 2/E Nut Møtrik
08028-0D/H5250/94.08.12
98.45 - ES0
Special equipment
517/617
MAN Diesel
Kit
Page 1 (2) Kit for Complete Cylinder Unit Exchange 51703-02
L16/24
045
022 See working card 505-01.55

457
274
046
104
033a
014
033b
027
08028-0D/H5250/94.08.12
033b
243
231
04.43 - ES0
MAN Diesel
Kit
51703-02 Kit for Complete Cylinder Unit Exchange Page 2 (2)
L16/24
Item
No Qty Designation Where to find in the engine instruction book
045 1/C Kit for cylinder unit, complete Plate 50500 Item 045
consisting of:
1/C O-ring Plate 50501 Item 231
2/C O-ring Plate 51402 Item 033a
8/C Seal ring Plate 51630 Item 033b
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
04.43 - ES0
MAN Diesel
Kit
Page 1 (2) Kit for Cylinder Unit 51704-02
L16/24
021
08028-0D/H5250/94.08.12
04.17 - ES0
MAN Diesel
Kit
51704-02 Kit for Cylinder Unit Page 2 (2)
L16/24
Item
No Qty Designation Where to find in the engine instruction book
021 1/C Kit for cylinder unit, complete consisting of:
1/C Sealing ring Plate 50610 Item 031
1/C O-ring Plate 51401 Item 457*
2/V O-ring Plate 51402 Item 033
1/V O-ring Plate 51402 Item 104
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.
* = Only available as part of a spare parts kit.

08028-0D/H5250/94.08.12
Qty/V = Qty/Valve
Qty/I = Qty/individual
04.17 - ES0
Specific plant
information
519/619
MAN Diesel
Description
Page 1 (2) Resilient Mounting of Generating Sets 519.03
Edition 03H
L16/24
Resilient Mounting of Generating Sets 1) The support between the bottom flange of the
conical mounting and the foundation is made
On resiliently mounted generating sets, the diesel with a loose steel shim. This steel shim is ad-
engine and the alternator are placed on a common justed to an exact measurement (min. 75 mm)
rigid base frame mounted on the ship's/machine for each conical mounting.
house's foundation by means of resilient supports,
Conical type. 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 75 mm and below a steel shim of at
systems should be equipped with flexible connections least 10 mm which are 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
the top flange of the base frame (see fig 1).
The setting from unloaded to loaded condition is nor-

mally between 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.
99.44 - ES1
MAN Diesel
519.03 Resilient Mounting of Generating Sets

Description
Page 2 (2)
Edition 03H
L16/24
3) Finally, the support can be made by means Adjustment of Engine and Alternator on
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 75 mm and the The resiliently mounted generating set is normally
bottom steel shim should be cast in chockfast delivered from the factory with engine and alternator
with a thickness of at least 10 mm. mounted on the common base frame. Eventhough
the engine and alternator have been adjusted by the
Irrespective of the method of support, the 75 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 is
replacement of the conical mountings, which are within the prescribed tolerances.
always replaced in pairs.
08028-0D/H5250/94.08.12
99.44 - ES1
MAN Diesel
Page 1 (4) Fitting Instructions for Resilient Mounting of GenSets Edition 24
L16/24
L21/31

Shut-off fuel oil
Mounting and adjustment instruction for new Ring and open-end spanner, 19 mm
GenSet and adjustment instruction for existing Ring and open-end spanner, 24 mm
plants. Ring and open-end spanner, 41 mm
Feeler gauge, 1-2 mm
Measurement tool
Hydraulic jack (if necessary)
Starting position
The foundation should be welded and milled off

on shim surfaces.
Related procedure
Replacement of conicals 519-03.05
Manpower Spare and wearing parts

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

Capacity : 2 men
Data

03.50 - ES1
MAN Diesel
519-03.00 Fitting Instructions for Resilient Mounting of GenSets

Working card
L16/24
L21/31
Mounting and Adjustment Instructions for 5) Position the jacking bolt with a through-going
New Generating Sets (Method 1) of minimum 75 mm.
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 the 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 4. 8) Loosen the nut (7).
1) Remove nut (7) and ring (6) from the conical 9) Turn all the internal buffers by applying a span-
element. ner to the hexagon (S = 19) to check that they
can move freely.
2) Fit the conical element to the bracket on the
suspended equipment by means of fixing the
central buffer (2), the ring (6) and nut (7). If all internal buffers Then
3) Tighten the nut (7) by hand and simultane- Can move freely Let conical elements
ously block the central buffer (2) by applying settle for 48 hours.
a spanner to the hexagon (S = 19) on the top
of the central buffer (2). Cannot be moved Turn the jacking bolts
freely clockwise to release the
4) Position the four jacking bolts in the tapped internal buffer.
holes (8) in the bottom flange.
08028-0D/H5250/94.08.12
Fig 2 Conical element.
Fig 1 Conical mounting.
03.50 - ES1
MAN Diesel
Working card
Page 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 24
L16/24
L21/31
Adjustment of Conical Elements after 48 Drill the mounting holes in the steel shim according
Hours Settling to the conical base casting dimensions.
After the conical elements have been deflected un-

der static load for 48 hours, the loaded height (H1) Mounting of the Completed Steel Shim
see fig 1, should be measured and compared to the
recommended loaded height. 13) Turn the internal buffer anticlockwise until it
contacts the base casting to secure the loaded
10) Care must be taken, during levelling of the height of each conical element.
installation, to ensure that individual mountings
are not overloaded.The variation in laden height 14) Lift the generating set with crane or hydraulic
should not exceed 2 mm and should ideally jack.
be less. The laden height can be measured
between top and base casting at H, on two 15) Remove all the jacking bolts.
sides (see fig 1).
16) Position each completed steel shim.
H1 + H2 + H3 ----- HN
Ex:Average = Number of conical elements 17) Lower the generating set until it rests completely
in itself.
If Then 18) Number each steel shim together with each

conical element.
Difference exceeds Level the conical element
2 mm. by adjusting the jacking
bolts - commencing with Adjustment of Internal Buffer
the conical element with
the largest deviation. 19) Turn the internal buffer clockwise (downwards)
until it makes contact with the steel shim or
Difference does not ex- The height of the steel foundation.
ceed 2 mm shim can be measured.
20) Turn the internal buffer anticlockwise (upwards)
until it obtains contact with the base casting.
The difference between the two sides of a conical
mounting should not be more than 0.5 mm. This must be four full turns.
21) Turn the internal buffer two full turns clockwise

Measuring of Steel Shim (downwards) and check with a feeler gauge
between the base casting of the conical ele-
11) Measure the steel shim on several points to ment and the steel shim that the internal buffer
obtain the highest possible accuracy during (2), see fig 1, does not touch the steel shim or
08028-0D/H5250/94.08.12
preparation. foundation.
22) Tighten the nut (7) with a torque of 300 Nm

Fabricating Steel Shim and block the central buffer (2) with a spanner
(S = 19) at the same time.
12) Make sure that the minimum height of the steel
shim is 75 mm to secure a future replacement
of the steel shim.
03.50 - ES1
MAN Diesel

Working card
Page 4 (4)
Edition 24
L16/24
L21/31
Mounting of Conical Elements on the Foun- or
dation
b) Drill the mounting holes in the foundation by
23) Drill four mounting holes in the foundation for means of the drilling pattern from the installa-
each conical element, either tion drawing.
a) Mark the positions of the mounting holes on The drilling has to be done on beforehand and
the foundation through the conical element. the set must be aligned with the foundation
holes before the work starts to avoid further
(Re)move the set completely so that the mark- removal of the set.
ings can be reached by drilling with conventional
tools. 24) Fix the conical element and the steel shim to
the foundation with four bolts.
Place the set on its former position by aligning
it with the drilled holes. Note! After completion of all works the buffer clear-
ance must be checked, see points 19, 20, 21 and
22.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
L16/24
L21/31

Shut-off fuel oil
Measurement tool
Starting position

on shim surfaces.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 2 men
Data

03.50 - ES1
MAN Diesel

Working card
Page 2 (4)
Edition 25
L16/24
L21/31
Mounting and Adjustment Instructions for for four jacking bolts and mounting holes drilled
New Generating Sets (Method 2) according to conical base casting dimensions, is
required.
Make Ready for Adjustment of Conical Ele-
ments 4) Position the supporting steel shim as per fig
1 and locate the conical element by means of
If the conical elements have not been mounted by dowel pins.
the factory, they must be mounted on the prepared
brackets on the base frame. In case they have been 5) Position the jacking bolts in the tapped holes
mounted by the factory, please start with item 4. in the supporting steel shim as per fig 1.
1) Remove nut (7) and ring (6) from the conical 6) Position the jacking bolts with a through-going
element. of minimum 10 mm, see fig 1.
2) Fit the conical element to the bracket on the 7) Lowed generating set until it rests completely
suspended equipment by means of fixing the on the foundation.
central buffer (2), the ring (6) and nut (7).
8) Check that all jacking bolts have full contact
3) Tighten the nut (7) by hand and simultane- with the foundation.
ously block the central buffer (2) by applying
a spanner to the hexagon (S = 19) on the top 9) Loosen the nut (7).
of the central buffer (2).
10) Turn all the internal buffers by applying a span-
A 75 mm supporting steel shim, complete with holes ner to the hexagon (S = 19) to check that they
can move freely.
08028-0D/H5250/94.08.12
Fig 1 Conical mounting. Fig 2 Conical element.
03.50 - ES1
MAN Diesel
Working card
Page 3 (4) Fitting Instructions for Resilient Mounting of GenSets 519-03.00
Edition 25
L16/24
L21/31
If all internal buffers Then Measuring of Steel Shim
Can move freely Let conical elements 12) Measure the steel shim on several points to
settle for 48 hours. obtain the highest possible accuracy during
preparation.
Cannot be moved Turn the three jacking
freely bolts in the supporting
steel shim clockwise, or Fabricating Steel Shim
anticlockwise to release
the internal buffer. 13) Make sure that the minimum height of the steel
shim is 10 mm to secure the future replacement
of the supporting steel shim.
Adjustment of Conical Elements after 48
Hours Settling Drill the mounting holes in the steel shim according
to the conical base casting dimensions.
After the conical elements have been deflected un-
der static load for 48 hours, the loaded height (H1)
see fig 1, should be measured and compared to the Mounting of the Completed Steel Shim
recommended loaded height.
14) Lift the generating set 1 mm totally be means
11) 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 15) Position each completed steel shim.
should not exceed 2 mm and should ideally
be less. The laden height can be measured 16) 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.
H1 + H2 + H3 ----- HN
Ex:Average = Adjustment of Internal Buffer
Number of conical elements
17) Turn the internal buffer clockwise (downwards)
If Then until it makes contact with the steel shim or
foundation.
Difference exceeds Level the conical element
2 mm. by adjusting the jacking 18) Turn the internal buffer anticlockwise (upwards)
bolts - commencing with until it obtains contact with the base casting.
the conical element with
the largest deviation. This must be four full turns.
08028-0D/H5250/94.08.12
Difference does not ex- The height of the steel 19) Turn the internal buffer two full turns clockwise
ceed 2 mm shim can be measured. (downwards) and check with a feeler gauge
between the base casting of the conical ele-
ment and the steel shim that the internal buffer
The difference between the two sides of the conical (2), see fig 1, does not touch the steel shim or
mounting should not be more than 0.5 mm. foundation.
20) Tighten the nut (7) with a torque of 300 Nm

and block the central buffer (2) with a spanner
(S = 19) at the same time.
03.50 - ES1
MAN Diesel

Working card
Page 4 (4)
Edition 25
L16/24
L21/31
Mounting of Conical Elements on the Foun- b) Drill the mounting holes in the foundation by
dation means of the drilling pattern from the installa-
tion drawing.
21) Remove the dowel pins.
The drilling has to be done on beforehand and
22) Drill four mounting holes in the foundation for the set must be aligned with the foundation
each conical element, either holes before the work starts to avoid further
removal of the set.
a) Mark the positions of the mounting holes on
the foundation through the conical element. 23) Fix the conical element and the supporting
steel shim/steel shim to the foundation with
(Re)move the set completely so that the mark- four bolts.
ings can be reached by drilling with conventional
tools. 24) Weld the lowest steel shim to the foundation.
Place the set on its former position by aligning Note! After completion of all works, the buffer clear-
it with the drilled holes. ance must be checked, see points 17, 18, 19
and 20.
or
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel
L16/24
L21/31

Shut-off fuel oil
Measurement tool
Starting position

on shim surfaces.
Related procedure

08028-0D/H5250/94.08.12

Capacity : 2 men
Data

03.50 - ES0
MAN Diesel

Working card
Page 2 (4)
Edition 26
L16/24
L21/31
Mounting and Adjustment Instructions for A 75 mm supporting steel shim, complete with tapped
New Generating Sets (Method 3) holes for three jacking bolts, four mounting holes and
four tapped holes, drilled according to the conical
Make Ready for Adjustment of Conical Ele- base casting dimension, is required see fig 1.
ments
4) Position the supporting steel shim as per fig
If the conical elements have not been mounted by 1 and locate the conical element by means of
the factory, they must be mounted on the prepared four hold-down bolts.
brackets on the base frame. In case they have been
mounted by the factory, please start with item 4. 5) Position the jacking bolts in the tapped holes
in the supporting steel shim as per fig 1.
1) Remove nut (7) and ring (6) from the conical
element. 6) Position the jacking bolts with a through-going
of minimum 10 mm plus permitted thickness,
2) Fit the conical element to the bracket on the as specified from the chockfast supplier, see
suspended equipment by means of fixing the fig 1.
central buffer (2), the ring (6) and nut (7).
7) Lowed the generating set until it rests com-
3) Tighten the nut (7) by hand and simultane- pletely on the foundation.
ously block the central buffer (2) by applying
a spanner to the hexagon (S = 19) on the top 8) Check that all jacking bolts have full contact
of the central buffer (2). with the foundation.
08028-0D/H5250/94.08.12
Fig 2 Conical element.
Fig 1 Conical mounting.
03.50 - ES1
MAN Diesel
L16/24
L21/31
If all internal buffers Then Measuring of Steel Shim and Chockfast
Can move freely Let conical elements 10) The steel shim should be at least 10 mm
settle for 48 hours. heigh.
Cannot be moved Turn the three jacking Check the minimum permitted thickness of chock-
freely bolts in the supporting fast for the load and surface of this application
steel shim clockwise, or with chockfast supplier.
anticlockwise and
slacken the four hold-
down bolts to release Fabricating Steel Shim
the internal buffer.
Make sure that the minimum height of the steel shim
is 10 mm to secure a future replacement of the sup-
Adjustment of Conical Element after 48 porting steel shim.
Hours Settling
11) Drill the mounting holes in the steel shim ac-
After the conical elements have been deflected un- cording to the mounting holes in the supporting
der static load for 48 hours, the loaded height (H1) steel shim.
see fig 1, should be measured and compared to the
recommended loaded height.
Adjustment of Internal Buffer
9) Care must be taken, during levelling of the
installation, to ensure that individual mountings 12) Turn the internal buffer clockwise (downwards)
are not overloaded.The variation in laden height until it makes contact with the steel shim or
should not exceed 2 mm and should ideally foundation.
be less. The laden height can be measured
between top and base casting at H, on two 13) Turn the internal buffer anticlockwise (upwards)
sides (see fig 1). until it obtains contact with the base casting.
H1 + H2 + H3 ----- HN This must be four full turns.

Ex:Average = Number of conical elements
14) Turn the internal buffer two full turns clockwise
(downwards) and check with a feeler gauge
If Then between the base casting of the conical ele-
ment and the steel shim that the internal buffer
Difference exceeds Level the conical element (2), see fig 1, does not touch the steel shim or
2 mm. by adjusting the jacking foundation.
bolts - commencing with
the conical element with 15) Tighten the nut (7) with a torque of 300 Nm and
08028-0D/H5250/94.08.12
the largest deviation. blocking the internal buffer (2) with a spanner
at the same time, see fig 1.
Difference does not ex- The height of the steel
ceed 2 mm shim and the chockfast
can be measured. Mounting of Conical Elements on the Foun-
dation
The difference between the two sides of the conical 16) Drill mounting holes in the foundation accord-
mounting should not be more than 0.5 mm. ing to the supporting steel shim/steel shim and
chockfast, either
03.50 - ES1
MAN Diesel

Working card
Page 4 (4)
Edition 26
L16/24
L21/31
a) Mark the positions of the mounting holes on b) Drill the mounting holes in the foundation by
the foundation through the supporting steel means of the drilling pattern.
shim.
The drilling has to be done on beforehand and
(Re)move the set completely so that the mark- the set must be aligned with the foundation
ings can be reached by drilling with conventional holes before the work starts to avoid further
tools. removal of the set.
Place the set on its former position by aligning Make sure that the mounting bolts are isolated from
it with the drilled holes. the chockfast.
or Note! After completion of all works, the buffer clear-

ance must be checked, see points 13, 14, 15 and
16.
08028-0D/H5250/94.08.12
03.50 - ES1
MAN Diesel

Page 1 (2) Replacement of Conicals Edition 02
L16/24
L21/31

Shut-off fuel oil
Replacement of conicals. Hydraulic jack
Starting position
Safety precautions.
Related procedure
Fitting instructions for resilient mounting.

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

Capacity : 2 men
51903 013 4/E
Data

98.41 - ES0
MAN Diesel
519-03.05 Working card

Edition 02 Replacement of Conicals Page 2 (2)
L16/24
L21/31
Replacement of Conicals
1) Loosen all the holding down-bolts for the co- 3) Lift the GenSet until the steel shim can be remo-
nicals in one side. ved. This will give enough space for removing
damaged conical.
2) Mount a jack under the base frame, see fig
1. 4) Mount the GenSet conical.
Note: Conicals should only be replaced in pairs, see

fig 2 and plate 51903.
Nut
Conical mounting 5) Lower the GenSet again.
Adjusting screw
Holding down bolts
6) Repeat items 1-5 for the other side.
Steel shim
7) Adjust the conicals, please see working card
Foundation 519-03.00 "Fitting Instructions for Resilient
Bracket Mounting of GenSet.
Deck
Jack
Fig 1 Removal of conicals
08028-0D/H5250/94.08.12
One pair
Fig 2 The conicals must be replaced in pairs
98.41 - ES0
MAN Diesel
Page 1 (2) Maintenance of Conicals Edition 02
L16/24
L21/31

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

98.41 - ES0
MAN Diesel
Edition 02 Maintenance of Conicals Page 2 (2)
L16/24
L21/31
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
demands acc. to item 5-10.
Recheck all conicals acc. to
3) Check for damage in the rubber element. 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 by loosen the nut (1).
loose mounting bolts fasten mounting bolts
6) Turn internal buffer (2) clockwise until it makes
damage to conicals replace conical according to contact with the steel shim (4).
is observed Working Card 519-03.05
7) Turn internal buffer (2) anti-clockwise until it
makes contact with the conical base casting
Clearance Check (3). This must be done in four full rotations.
What to Check 8) Turn internal buffer (2) two full rotations clock-
wise. This will ensure full vertical movement for
4) Check clearance on all conicals between steel the buffer.
shim and internal buffer through the slot in the
base casting of the conical (see fig 1) with a 9) Check all conicals again.
feeler gauge of approx. 2 mm.
10) Tighten the nut (1), see page 500.40 and at
the same time block the internal buffer (2) with
a spanner.
1. Nut
2. Internal buffer
08028-0D/H5250/94.08.12
2
3. Conical base casting
4. Steel shim
3
Fig 1 Conical
98.41 - ES0S
MAN Diesel
Plate
Page 1 (2) Flexible External Connections 51902-04H
L16/24
Item
Fig. Designation Connection
No
Fuel oil, inlet A1 018
Fuel oil, outlet A2 031
Waste oil, outlet A3 043
Lubricating oil from separator, C3 079

inlet
Lubricating oil to separator, C4 080

outlet
Lub. oil overflow, outlet C15 092
Oil vapour discharge, outlet C13 126

08028-0D/H5250/94.08.12
Venting to expansion tank/ F3/F4 163

Fresh water for preheating
99.09 - ES0
MAN Diesel
Plate
51902-04H Flexible External Connections Page 2 (2)
L16/24
Item
Fig. Designation Connection
No
HT freshwater, inlet F1 209
HT freshwater, outlet F2 210
LT freshwater/raw water, G1 222

inlet
LT freshwater/raw water, outlet G2 234
Compressed air, inlet K1 271
Exhaust gas, outlet (DN 250) P2 305
Exhaust gas, outlet (DN 400) P2 329
08028-0D/H5250/94.08.12
99.09 - ES0
MAN Diesel
Plate
Page 1 (2) Conical Element 51903-02
L16/24
L21/31
08028-0D/H5250/94.08.12
97.49 - ES0
MAN Diesel
Plate
51903-02 Conical Element Page 2 (2)
L16/24
L21/31
Item Item
013 1/M Conical element, Konisk understøtning,

complete komplet
025 4/M Screw Skrue
08028-0D/H5250/94.08.12
Qty/M = Qty/Conical mounting. Qty/M = Qty/Conical montering.
97.49 - 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
Application of hydraulic tools 520-01.06
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 doesn´t
4. Make sure that the components to be tensioned show the right pressure leads to overstressing
do not exceed the admissible strain. of the parts and to an incorrect bolt connec-
tion. Apart from damaged parts an incorrect
5. In order to use the device, the thread has to bolt connection can also cause conditions that
be sufficiently exceeding in order to avoid that are danger to life. Therefore take care that
the turn of a thread cracks, see item 4. the manometer shows the right value or the
tensioning force is checked in an other way
08028-0D/H5250/94.08.12
6. During the pressurization the people involved (for example by using a master manometer).
have to remain in an appropriate distance. Tensioning forces can be checked for example
Staying in direction towards the bolt axis is by measuring the linear deformation. Damaged
forbidden. manometers have to be exchanged immedi-
ately.
7. Tensioning pressures or tensioning forces are
to be given or changed by authorized personnel
only while considering the admissible compo-
nent loads, see item 4.
99.43 - ES0
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 piston’s uncontrolled outlet.
connections must be done. After removal of the piston, the seals and the backup
rings can be removed from the piston and the cyl-
The piston return stroke is done by a screw-down at inder.
the bolt itself before the device is taken off.
Carefully clean the components with fluff-free mate-
Hint: When using fast lock coupling elements, the rial and check them for damages. If necessary, use
oil’s running out and thus a piston return stroke in compressed air for the cleaning, but never aggres-
an uncoupled condition is impossible! sive cleaning liquids. After that, slightly oil these
components with hydraulic oil and assemble new
backup rings as well as new seals to the piston and
the cylinder according to the drawing.
08028-0D/H5250/94.08.12
Fig. 4. Piston return stroke.
Fig. 5. Exchange of the seals.
99.43 - ES0
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 device’s operation, repair possible dam-

ages and clean the device.
08028-0D/H5250/94.08.12
Check the components of the device and its acces-

sories for completion.
The operating manual has to be read by all users.
99.43 - ES0
MAN Diesel
Page 1 (4) Application of Hydraulic Tools Edition 06H
L16/24

Shut-off cooling water See page 2-4
Shut-off fuel oil
Application of hydraulic tools.
Starting position
Function of hydraulic tools 520-01.05
Related procedure

08028-0D/H5250/94.08.12

Capacity : men
Data

01.35 - ES0
MAN Diesel
Edition 06H Application of Hydraulic Tools Page 2 (4)
L16/24
This working card gives the information for applica-

tion of hydraulic tools, to be used in connection with
Fig 1 Spur gear.
08028-0D/H5250/94.08.12
Fig 2 Cross bolt and tierod.
01.35 - ES0
MAN Diesel
Page 3 (4) Application of Hydraulic Tools Edition 06H
L16/24
Fig 3 Connection of hydraulic tools.

08028-0D/H5250/94.08.12
Fig 5 After main bearing.
Fig 4 Main bearing
01.35 - ES0
MAN Diesel
Edition 06H Application of Hydraulic Tools Page 4 (4)
L16/24
Fig 6 Counter weight and connection rod.

08028-0D/H5250/94.08.12
01.35 - 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 oil’s
Disregard leads to danger to life. Please see working running out.
card 520-01.06.
Attention - Danger on injuries Pressurization

Loads being lifted by the pump may never be held
by the pump valves alone. Use additional non-return
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 (4) Tools for Cylinder Head 52005-06H
L16/24
Dimensions Item
S/E
Illustration of Tools Designation
A B C No
Valve spring S 014

tightening device
Lifting tool for S 038

cylinder unit
Grinding machine for valve

seat ring incl. wooden box,
complete E 051
Mandrel E 122
Cutting tool E 158

08028-0D/H5250/94.08.12
S = Standard E = Extra
02.22 - ES0
MAN Diesel
Plate
52005-06H Tools for Cylinder Head Page 2 (4)
L16/24
Dimensions Item
S/E
A B C No

spindle incl wooden box,
complete E 063
Grinding stone E 075
Grinding tool for S 087

cylinder head/liner
Mandrel for dismounting/

mounting of valve guide E 120
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 3 (4) Tools for Cylinder Head 52005-06H
L16/24
Dimensions Item
S/E
A B C No
Turning table for cylinder unit E 107
Extraction tool for valve

seat ring E 181

seat ring incl. wooden box,
complete E 119
Grinding stone E 183

08028-0D/H5250/94.08.12
Guide E 195
02.22 - ES0
MAN Diesel
Plate
52005-06H Tools for Cylinder Head Page 4 (4)
L16/24
Dimensions Item
S/E
A B C No
Tool for mounting of

fuel insert E 205
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 1 (4) Tools for Piston, Connecting Rod and Cylinder Liner 52006-08H
L16/24
Dimensions Item
S/E
A B C No
Removing device for S 021

flame ring
Guide bush for piston S 045
Fit and removal device for S 069

connecting rod bearing
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
52006-08H Tools for Piston, Connecting Rod and Cylinder Liner Page 2 (4)
L16/24
Dimensions Item
S/E
A B C No
Lifting device for S 082

cylinder liner
Lifting device for piston S 104

and connecting rod
08028-0D/H5250/94.08.12
Testing mandrel for S 153

piston ring grooves
02.22 - ES0
MAN Diesel
Plate
Page 3 (4) Tools for Piston, Connecting Rod and Cylinder Liner 52006-08H
L16/24
Dimensions Item
S/E
A B C No
Plier for piston pin lock ring S 177
Piston ring opener S 190
Supporting device for S 212

connecting rod and piston in
the cylinder liner (2 pcs)
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
52006-08H Tools for Piston, Connecting Rod and Cylinder Liner Page 4 (4)
L16/24
Dimensions Item
S/E
A B C No
Honing brush,
incl. wooden box S 224
Micrometer screw for

connecting rod E 236
Micrometer screw for

cylinder liner E 248
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Camshaft and Camshaft Drive 52007-03H
L16/24
Dimensions Item
S/E
A B C No
Adjusting tool for

injection timing, Woodward E 040
Adjusting tool for

injection timing, L'Orange E 052
08028-0D/H5250/94.08.12
07.50 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Operating Gear for Inlet and Exhaust Valves 52008-07H
L16/24
Dimensions Item
S/E
A B C No
Feeler gauge, 0.4-0.5 mm S 010

(exhaust valve)
Feeler gauge, 0.5-0.6 mm S 034

(inlet valve)
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Crankshaft and Main Bearings 52010-05H
L16/24
Dimensions Item
S/E
A B C No
Removal device for main

bearing cap E 011
Dismantling tool for S 035

main- and guide bearing
upper shell
Crankshaft alignment E 059

gauge (autolog)
150
210
08028-0D/H5250/94.08.12
08.03 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Charge Air Cooler 52012-03H
L16/24
Dimensions Item
S/E
A B C No
Eye screw for lifting S 036
Lifting tool for

charge air cooler E 239
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 1 (3) Tools for Fuel oil and injection equipment 52014-06H
L16/24
Dimensions Item
S/E
A B C No
Cleaning tool for S 013

fuel injector
Extractor device for S 407

injector valve
Grinding device for S 074

nozzle seat
08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
52014-06H Tools for Fuel oil and injection equipment Page 2 (3)
L16/24
Dimensions Item
S/E
A B C No
Pressure testing tool,

incl. bow S 050
Bow E 098
Tool for dismantling of

roller tappet E 108
08028-0D/H5250/94.08.12
Measuring pin E 121
02.22 - ES0
MAN Diesel
Plate
Page 3 (3) Tools for Fuel oil and injection equipment 52014-06H
L16/24
Dimensions Item
S/E
A B C No
Measuring sleeve E 133

08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 1 (1) Tools for Lubricating Oil Cooler 52015-04H
L16/24
Dimensions Item
S/E
A B C No
Mandrel for oil cooler S 012

08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
Page 1 (4) Hydraulic Tools 52021-09H
L16/24
Dimensions Item
S/E
A B C No
Pressure pump, complete, with

wooden box S 011
Manometer 023
Gasket for Item 405 395
Quick coupling 405
Distributor 417
Hydraulic tools with wooden

box, complete S 633
consisting of the following:

08028-0D/H5250/94.08.12
02.22 - ES0
MAN Diesel
Plate
52021-09H Hydraulic Tools Page 2 (4)
L16/24
Dimensions Item
S/E
A B C No
Distributing piece for cylinder

head, complete. S 143
Gasket 155
Quick coupling 179
Distributing piece for main bea-

ring, complete. S 167
Gasket 155
Quick coupling 179
Hydraulic tools for connecting

rod, complete S 299
Piston for hydraulic jack* 704
Set of O-rings with back-up ring 716
Cylinder for hydraulic jack* 741
Spacer piece 096
Angle piece complete 358

08028-0D/H5250/94.08.12
Hydraulic jack as item nos. 704,

716, 741 586
Spare parts for hydraulic tools for

connecting rod E 251
*not available as a single part
02.22 - ES0
MAN Diesel
Plate
Page 3 (4) Hydraulic Tools 52021-09H
L16/24
Dimensions Item
S/E
A B C No
Hydraulic tools for cylinder

head, complete S 275
Piston for hydraulic jack* 429
Set of O-rings with back-up ring 430
Cylinder for hydraulic jack* 442
Spacer piece, long 059
Hydraulic jack as Item Nos. 429,

430, 442 454
Angle piece, complete 358
Spacer piece, short 072
Tension screw 118
Spare parts for hydraulic tools for

cylinder head E 226
Spare parts kit for angle

piece E 322
Spanner S 310
08028-0D/H5250/94.08.12
Tommy bar S 334
*not available as a single part
02.22 - ES0
MAN Diesel
Plate
52021-09H Hydraulic Tools Page 4 (4)
L16/24
Dimensions Item
S/E
A B C No
Hose with unions for cylinder

head, 4 pieces complete 500 ø27 S 180
Hose with unions for connection

of oil pump and distributing
block, 1 pieces complete 3000 ø27 S 202
Hose 3000 537
Quick coupling with protecting

cap 549
Hose 500 525
Adapter 836
Air-driven high pressure pump

for hydraulic tools 367 256 326 E 608
08028-0D/H5250/94.08.12
02.22 - ES0

Man B&W L1624 - Marine Diesel Engine

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Man B&W L1624 - Marine Diesel Engine

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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 (03H)

Performance and condition 502/602

Engine performance and condition Description 502.01 (04H)

Trouble shooting 503/603

Starting failures Description 503.01 (02)

Media specification 504/604

Text Index Drawing No.

Cylinder head 505/605

Cylinder head and water jacket Description 505.01 (02H)

Piston/connecting rod 506/606

Piston, connecting rod and cylinder liner Description 506.01 (02H)

Text Index Drawing No.

Camshaft and camshaft drive Description 507.01 (02H)

Operating gear 508/608

Safety, control and monitoring system Description 509.01 (13)

Crankshaft and main bearings Description 510.01 (02H)

Text Index Drawing No.

Flywheel with gear rim Plate 51003-16H

Engine frame/Oil pan 511/611

Engine frame and base frame Description 511.01 (02H)

Turbocharger system Description 512.01 (05H)

Compressed air system 513/613

Compressed air system (low pressure) Description 513.01 (16H)

Text Index Drawing No.

Starting air receiver Plate 51335-01

Fuel oil system 514/614

Internal fuel oil system Description 514.01 (02H)

Lubricating oil system 515/615

Internal lubricating oil system Description 515.01 (04H)

Cooling water system 516/616

Internal cooling water system Description 516.01 (04H)

Special equipment 517/617

Kit for complete cylinder unit exchange Kit 51703-02

Text Index Drawing No.

Kit for cylinder unit Kit 51704-02

Specific plant information 519/619

Resilient mounting of generating sets Description 519.03 (03H)

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 : 450-990 kW

Speed : 1000/1200 rpm

Stroke/bore ratio : 1.5:1

Piston area per cyl. : 201 cm2

Swept volume per cyl. : 4.8 ltr.

Compression ratio : 15.2:1

Turbocharging principle : Constant pressure system and intercooling

Fuel quality acceptance : HFO up to 700 cSt/50° C

Power lay-out MCR version

Speed rpm 1000 1200

Mean piston speed m/sec. 8 9.6

Mean effective pressure

6, 7, 8, 9 cyl. engine bar 22.4 22.8

Max. combustion pressure bar 170 170

Power per cylinder